intership final fkl
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INTRODUCTION
Textile and garments sector is the biggest and fastest growing sector in Bangladesh. It is also the highest foreign currency earning sector in Bangladesh. Among this sector, Knit garment is growing very rapidly due to smaller investment requirement, greater backward linkage facility & higher profit than woven garments. Thats why export of knit garments is increasing steadily for last few years and up to now.
Textile education cant be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at FAKIR KNITWEARS LIMITED, which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing.
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GENEREL INFORMATION ABOUT THE FACTORY
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LAYOUT FOR GOING TO THE FKL FROM DHAKA
WorkshopHIGHWAY ROAD
Shivo market
Mosque
CHASARAFakir KnitwearsLimited
Nature of Company:Privet Limited Company
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Nature of business:100% export oriented fabrics+garmentsmanufacturer and exportersYear of establishment:1995.
Name of the contact persons:Mr. Khan Mohammad AmeerChief Executive Officer
:Khalid Hosaain KhanDirector Production
Total employees:4500 persons
Turnover:US$ 30 million/year (2004)Factory land & building:Own property(8 storied dye House+Finishing area )Factory area:43,558 square metersFinanced By:Sonali Bank ,Local OfficeMotojheel Commercial Area Dhaka -1000,Bangladesh Fax:880-02-9561410 Swift: BSONBDDHXXX
VISION AND MISSION OF THE PROJECT
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They strive to provide the best quality garments to their buyers. They practice advanced technology in all aspects of our operation to attain excellence concerning quality, dependability and commitment for apparel industry and society.
Other facilities & achievement:
Facilities
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Certificate:ISO 9001: 2000SRM (Compliance) & Oeko-Tex
Membership :
BGMEA
BKMEA
Oeko-Tex
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Product Range
Men Women Kids
ITEM OF PRODUCT
Knit fabric:Single jersey, Heavy jersey, Pique, LacosteInterlock, Rib & pleated design rib, French Terry, Fleece, Collar & cuff made of cotton, Viscose, Modal, Cotton/modal, Polyester, Cotton/polyester, CVC etc are also made.
Garments:T-shirt, Polo shirt, Sweat-shirt,Tank Tops, Children wear, Jogging suits, under wear, Runners pant, Functional wear, Fashion Dresses and Sports wear etc.
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PRODUCTION CAPACITY
SectionCapacityKnitting37 Tons /DayDyeing45 Tons/DayFinishing40 Tons / DayGarments80,000 Pcs / DayGarments washing25000 Pcs /DayPrinting25000 Pcs /Day (upto 8 colors )Embroidery92 Heads (Total)
MAJOR BYRES
1. H & M (HENNES & MAURITZ)-SWEDEN 2. PRIMARK - UK 3. PENNYES - IRELAND 4. PEACOCKS -UK 5. TEMA 6. TOP GRADE-USA 7. COMPECT- O- STYLE
SISTER CONCERN OF FKL
1. Knitivo Knitwears ltd. 2. Zaman Knitwears ltd. 3. Fakir Apparels Ltd. 4. KnitivoFashion Ltd. 5. Fakir Dyes & Chemicals 6. ZamanPackaging Industries 7. Zaman Label Industrie 8. Sunshine Knitting Fashion
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SECTION WISE MANPOWER
DepartmentOfficeOfficePieceProductionProductionGrandExecutivestuffrateExecutivestuffWorkeTotalworkerrAccounts1616Audit347Commercial33Compliance44GPQ1919HRD2810617142IE & planning221739IT1010P&M11Planning11Purchase44Quality1680533629AssuranceSample193949Knitting2910195234Dyeing+13951460551finishingGarments126476Cutting58611304379Sewing356104310721481G-Finishing103520281409Sweater11516Printing1321533567Embroidery233944Merchandising2323Inventory25324198
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Maintenance214465Grand total9010651723428336374867
a) knitting Section: Knitting Inspection b) Dyeing section: Batch section Dye house Dyeing lab. Quality control Finishing Different Departmentsc) Garments section: Merchandising Sample Cutting Section Sewing Section Finishing Section d) Maintenance section: Electrical Mechanical e) Store Section f) Administration Section g) Security Section h) Marketing Section i) Production Planning & Control
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MANAGEMENT SYSTEM Intercom telephone Fax E-mail Written letters Oral
ORGANIZATIONAL STRUCTURE OF DIFFERENT DEPARTMEN
CHAIRMAN
MANAGING DIRECTOR
DIRECTOR
GMGM(Personal & management)(Operation)
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ORGAN GRAM OF KNITTING SECTION
DGM
Knitting Manager
Production officer
Knitting Master
Astt. Knitting Master
Shift Incharge
Floor In charge
Supervisor
Operator
Helper
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ORGAN GRAM OF DYEING AND FINISHING
General Manager (GM)
Manager
ManagerManager
Senior production officerAsst.Manager
Production officerIn charger
Dyeing masterSupervisor
Shift in chargeOperator
Floor in chargeHelperSupervisor Operator Helper
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Raw Materials
Raw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric.
Raw material Types
1.Yarn2.Fabric3.Dye stuff4.Chemical and auxiliaries
Name and source:
Yarn:
Sudhan combed, SSM Combed, Precot Combed, Maral, Srimatha, Nahar Comb Slave, Sohag, Faisal Sluv, Maral Sluv, Delta Viscos etc are purchased from India and local market.
Lycra:
Roica from Taiwan. Texlon Korea.
Remarks: The price of the product is most secret matter of the Industry.
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MACHINE DESCRIPTION OF KNITTING SECTION
Circular Knitting Machine
Single JerseyDouble JerseyAuto StriperJacquard (S/J)Total no of M/CNo. of line KNITTING SECTION: Single Jersey, Double Jersey,Auto Striper & Jacquard.
: 62: 30: 03: 02: 97.: 07(A-G)
OTHER MACHINE IN KNITTING SECTION
Flat Bed Knitting Machine: (No of M/C: 07)
Brand name: Stoll (Jacquard). Origin: Germany Gauge: 12 & 14
01. Gray Fabric Inspection M/c, Brand: Uzu cloth inspection machine Manufacturer: AATPR INDUSTRY CO.LTD. Model: UZ - 900-3 Origin: Thailand. No. of Machine: 02 pcs for open fabric and 03 pcs for tube fabric.
02. Electric Balance for Fabric Weight.
03. Electric Balance for GSM check.
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04. Winding machine (01 pcs)
05. LAYOUT PLAN OF KNITTING FLOOR OF FKL:
YARN STIRETABLEGAITEYARN STORE
G-1F-1E-1D-1C-1B-1A-1G-2F-2E-2D-2C-2B-2A-2G-3F-3E-3D-3C-3B-3A-3G-4F-4E-4D-4C-4B-4A-4G-5F-5E-5D-5C-5B-5A-5G-6F-6E-6D-6C-6B-6A-6G-7F-7E-7D-7C-7B-7A-7G-8
RAWFABRICINSPECTIONMACHINE F-8
F-9 E-8D-8C-8B-8A-8E-9D-9C-9B-9A-9E10
LIFT
RAWFABRICSTORE
F10E11D10
F11E12D11
F12E13D12
F13E14D13
F14E15D14
GAITE
C10B10A10
C11B11A11
C12B12A12
C13B13A13
C14B14A14
YARN STORE
51
52
53
A15
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LINE NO. - A SLM/CS/JBrandOriginModelDiaNo ofGaugeNo ofNoNo.ornameinfeederNeedleD/Jinch01A-1D/JJIUNNTAIWANJLR363672224973LONG 02A-2D/JJIUNNTAIWANJLR3636108184069LONG 03A-3S/JJIUNNTAIWANJLS3434102241921LONG 04A-4S/JJIUNNTAIWANJLS3434102242562LONG 05A-5S/JJIUNNTAIWANJLS-F3296242411LONG 06A-6S/JJIUNNTAIWANJLS-C28112242110LONG07A-7JacquardJIUNNTAIWANJLSMJ3672242712LONG08A-8JacquardJIUNNTAIWANSSMJ-3072242260LONG7209A-9S/JJIUNNTAIWANJLS-C3296202009LONG 10A-10S/JJIUNNTAIWANJLSF34102282989LONG 11A-11S/JJIUNNTAIWANJLS-C34102242562LONG 12A-12S/JJIUNNTAIWANJLS-C40120243014LONG 13A-13S/JJIUNNTAIWANJLS-C40120243014LONG
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14A-14S/JMASATAIWANJLS-C4012024301415A-15Multi fitterMASATAIWANMS/S4225224316620
LINE NO. -BSLM/CS/JBrandOriginModelDiaNo ofGaugeNo ofNoNo.ornameinfeederNeedleD/Jinch01B-1D/JJIUNNTAIWANJLR363672163618LONG02B-2D/JJIUNNTAIWANJLR363666163618LONG03B-3S/JDONGTAIWANDH-36108242712HOCV04B-4S/JDONGTAIWANK-S4F26104241959HO05B-5S/JDONGTAIWANDH-26104241959HO45J06B-6S/JDONGTAIWANDH-25100241884HO45J07B-7S/JDONGTAIWANDH-2493241808HO45J08B-8S/JJIUNNTAIWANJLS20-2080241507LONG409B-9S/JJIUNNTAIWANJLS20-2080241507LONG410B-10S/JDONGTAIWANDH-218424182HO45J11B-11S/JDONGTAIWANDH-2288241657HO45J12B-12S/JDONGTAIWANDH-2496241808HO45J13B-13S/JDONGTAIWANDH-24100241808HO45J
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14B-14S/JJIUNNTAIWANJIS-C42128243165LONG
LINE NO: C
SL NoM/CS/JBrandOriginModelDia inNo ofGaugeNo ofNo.ornameinchfeederNeedleD/J 01C-1D/JJIUNNTAIWANJLR-383872163818LONG02C-2D/JJIUNNTAIWANJLR-383872245727LONG03C-3S/JMASATAIWANMSS903296242411
04C-4S/JMASATAIWANMSS90329624241105C-5S/JMASATAIWANMSS9034102242562
06C-6S/JMASATAIWANMSS9034102242562
07C-7S/JJIUNNTAIWANJIS-C34102242562LONG08C-8S/JJIUNNTAIWANJIS-C3296282813LONG09C-9S/JMASATAIWANMS/SC3296242411
10C-10S/JMASATAIWANMS/SC349024256211C-11S/JMASATAIWANMS/SC36102242412
12C-12S/JMASATAIWANMS/SC3610824271213C-13S/JMASATAIWANMS/SC40120243014
14C-14S/JJIUNNTAIWANJIS-C36108242712LONG
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LINE NO: D
SLM/CS/JBrandOriginModelDiaNo ofGaugeNo ofNoNo.ornameinfeederNeedleD/Jinch
01D-1D/JJIUNNTAIWANJLR343472163416LONG 02D-2D/JJIUNNTAIWANJLD303072163014LONG 03D-3S/JMASATAIWANMS-44132243315S13 04D-4S/JMASATAIWANMS-42128243166S13 05D-5S/JMASATAIWANMS-401202430144S13 06D-6S/JMASATAIWANMS-401202430144S13 07D-7S/JMASATAIWANMS-38114242864S13 08D-8S/JMASATAIWANMS-36104242712S1309D-9S/JMASATAIWANMS-3090242260S1310D-10S/JMASATAIWANMS/SC38114242864
11D-11S/JMASATAIWANMS/SC3811424286412D-12S/JMASATAIWANMS/SC3610824271213D-13S/JMASATAIWANMS/SC42126243166
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14D-14S/JJIUNNTAIWANJLD-C3296242411LONG
LINE NO. -E
SL NoM/CS/JBrandOriginModelDia inNo ofGaugeNo ofNo.ornameinchfeederNeedleD/J 01E-1D/JJIUNNTAIWANJLS343472183844LONG02E-2D/JJIUNNTAIWANJLS343472224698LONG03E-3S/JMASATAIWANMS/S66226624165704E-4S/JMASATAIWANMS/S66226624165705E-5S/JMASATAIWANMS/S66236924173406E-6S/JMASATAIWANMS/S66236924173407E-7S/JMASATAIWANMS/S662472241808
08E-8S/JMASATAIWANMS/S66267824195909E-9S/JMASATAIWANMS/S66288424211010E-10S/JMASATAIWANMS/S66288424211011E-11S/JMASATAIWANMS/S663811424286412E-12S/JJIUNNTAIWANJLS3438114242864LONG 13E-13S/JJIUNNTAIWANJLS3436108242712LONG 14E-14S/JJIUNNTAIWANJLS3434102244698LONG 15E-15S/JJIUNNTAIWANJLS3438114242864LONG
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LINE NO:-F
SLM/CS/JBrandOriginModelDiaNo ofGaugeNo ofNoNo.ornameinfeederNeedleD/Jinch01E-1D/JJIUNNTAIWANJLS343472183844LONG02E-2D/JJIUNNTAIWANJLS343472224698LONG03E-3S/JMASATAIWANMS/S66226624165704E-4S/JMASATAIWANMS/S66226624165705E-5S/JMASATAIWANMS/S66236924173406E-6S/JMASATAIWANMS/S66236924173407E-7S/JMASATAIWANMS/S66247224180808E-8S/JMASATAIWANMS/S66267824195909E-9S/JMASATAIWANMS/S66288424211010E-10S/JMASATAIWANMS/S66288424211011E-11S/JMASATAIWANMS/S663811424286412E-12S/JJIUNNTAIWANJLS3438114242864LONG 13E-13S/JJIUNNTAIWANJLS3436108242712LONG 14E-14S/JJIUNNTAIWANJLS3434102244698LONG 15E-15S/JJIUNNTAIWANJLS3438114242864LONG
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LINE NO: - G
SLM/CS/JBrandOriginModelDia inNo ofGaugeNo ofNoNo.ornameinchfeederNeedleD/J01G-1D/JMASATAIWANMSSC3296242411
02G-2D/JJIUNNTAIWANJLD323272222210LONG03G-1D/JMASATAIWANMSSC3296242411
04G-2D/JJIUNNTAIWANJLD323272222210LONG05G-1D/JMASATAIWANMSSC3296242411
06G-2D/JJIUNNTAIWANJLD323272222210LONG07G-1D/JMASATAIWANMSSC3296242411
08G-2D/JJIUNNTAIWANJLD323272222210LONG
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WITHOUT LINE
SLM/CS/J orBrand nameOriginModelDiaNo ofGaugeNo ofNo.No.D/JinfeederNeedleinchAuto151StriperFUKAHARAJAPANV-3348244974(D/J)NY2Auto252StriperFUKAHARAJAPANVX-3848242836(S/J)RSYAuto353StriperFUKAHARAJAPANVX-3848242836(S/J)RSY
FLAT BED KNITTING SECTION
Machine no.01~02:
Machine name: Flat knit jacquard machine.Brand name: STOLLNo. of Gage: 12Model: CMS 411 TCOrigin: Germany
Machine no.03~04:
Machine name: Flat knit jacquard machine.Brand name: STOLLNo. of Gage: 12Model: CMS 311 TC- LOrigin: Germany
Machine no.05~07:
Machine name: Flat knit jacquard machine.Brand name: STOLLNo. of Gage: 14Model: CMT 211 TCOrigin: Germany24Pg25Pg25
DIFFERENT PARTS OF KNITTING MACHINE
Creel: Creel is used to place the cone. Feeder: Feeder is used to feed the yarn. Tensioning device: Tensioning device is used to give proper tension to the yarn. VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length. Guide: Guide is used to guide the yarn. Sensor: Sensor is used to seen & the machine stops when any problem occurs. Spreader: Spreader is used to spread the knitted fabric before take up roller. Take up roller: Take up roller is used to take up the fabric Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger. Rethom: These devise are used in Electrical Auto Striper Knitting machine
PROCESS FLOW CHART OF KNITTING:
Yarn in cone form
Feeding the yarn cone in the creel
Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension device.
Knitting
Withdraw the rolled fabric and weighting
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Inspection
Numbering
END PRODUCTS OF CIRCULAR KNITTING MACHINE
Single Jersey M/C: a) S/J Plain b) Single lacoste c) Double lacoste d) Single pique e) Double pique f) Mini jacquard g) Terry
Interlock M/C: a) Interlock pique b) Eyelet fabric c) Mash fabric d) Honeycomb fabric e) Face/Back rib
Rib M/C: a)1*1 Rib fabricb)2*2 Rib fabricc) Separation fabric d) Honeycomb
END PRODUCTS OF FLAT BED KNITTING MACHINE
a) Tipping
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b) Plain c) Emboss
CONSIDERABLE POINTS TO PRODUCE KNITTED FABRICS
When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows- Type of Fabric or design of Fabric. Finished G.S.M. Yarn count Types of yarn (combed or carded) Diameter of the fabric. Stitch length Color depth.
RAW MATERIALS FOR KNITTING
Type of yarnCountCotton16s ,20s, 24s, 26S, 28S, 30S, 34S, 40SPolyester75D, 72D,100DSpandex yarn20D,40DGrey Mlange (C-90% V-10%)24S, 26SPC (65%Polyester & 35% cotton)24S, 26S, 28S, 30SCVC24S, 26S, 28S, 30S
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PRODUCTION CALCULATION
A. Production/shift in kg at 100% efficiency
RPM No of Feeder No of Needle SL ( mm )3527 80 Yarn count
B. Production/shift in meter
Course / minCourse / cmRPM No of Feeder 60 12 EfficiencyCourse / cm 100
C. Fabric width in meter:
Total no of walesWales / cm 100Total no of Needles used in knittingWales cm /100
PRODUCTION PARAMETER 1. Machine Diameter; 2. Machine rpm (revolution per minute); 3. No. of feeds or feeders in use; 4. Machine Gauge; 5. Count of yarn; 6. Required time (M/C running time);
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7. Machine running efficiency
CONSIDERABLE POINTS TO PRODUCE KNITTED FABRICS
When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors must need to consider. Those are as follows-- Type of Fabric or design of Fabric. - Finished G.S.M. - Yarn count - Types of yarn (combed or carded) - Diameter of the fabric. - Stitch length - Color depth.
FAULTS & THEIR CAUSES IN KNITTING
1. Hole Mark
Causes: Holes are the results of yarn breakage or yarn cracks. During loop formation the yarn breaks in the rejoin of the needle hook. If the yarn count is not correct on regarding structure, gauge, course and density. Badly knot or splicing. Yarn feeder badly set. Remedies: Yarn strength must be sufficient to withstand the stretch as well as uniform. Use proper count of yarn. Correctly set of yarn feeder. Knot should be given properly.
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2. Needle Mark
Causes: When a needle breaks down then needle mark comes along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics.
Remedies: Needle should be straight as well as from broken latch.
3. Sinker Mark
Causes: When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes. If sinker head bend then sinker mark comes.
Remedies: Sinker should be changed.
4. Star
Causes: Yarn tension variation during production. Buckling of the needle latch. Low G.S.M fabric production. Remedies: Maintain same Yarn tension during production. Use good conditioned needles.
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5. Drop Stitches
Causes: Defective needle. If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook. Take-down mechanism too loose. Insufficient yarn tension. Badly set yarn feeder. Remedies: Needle should be straight & well. Proper feeding of yarn during loop formation. Correct take up of the fabric & correct fabric tension. Yarn tension should be properly.
6. Oil stain
Causes: When oil lick through the needle trick then it pass on the fabrics and make a line.
Remedies: Ensure that oil does not pass on the fabrics. Well maintenance as well as proper oiling.
7. Rust stain
Causes: If any rust on the machine parts.
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Remedies: If any rust on the machine parts then clean it. Proper maintenance as well as proper oiling.
8. Pin hole Causes: Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies: Change the needle 9. Grease stain Causes: Improper greasing Excess greasing
Remedies: Proper greasing as well as proper maintenance
10. Cloth fall- out Causes: Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles.
Remedies: Make sure all the latches of needle are closed with feeding yarn after a drop stitch.
11. Barre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) Stripe. Causes: This fault comes from yarn fault. If different micro near value of fiber content in yarn. Different lustier, dye affinity of fiber content in yarn.
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During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics. In draw fame different similar classes sliver is mixed and make one sliver.
Remedies: We can use this fabric in white color.
12. Fly dust: Causes: In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production.
Remedies: Blowing air for cleaning and different parts after a certain period of time. By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor. Over all ensure that lint does not attach to the fabric.
13. Yarn contamination Causes: If yarn contains foreign fiber then it remains in the fabric even after finishing, If lot, count mixing occurs.
Remedies: By avoiding lot, count mixing. Fault less spinning.
14. Yarn Faults: Neps. Slubs. Yarn count variations. Thick/Thin place in yarn.
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Hairiness.
PICTURES OF KNITTING MACHINARY OF FKL
S/J Circular knitting machine(Open form)
S/J Circular knitting machine(Tube form)
Auto-stripe circular knitting machine
Cone Winding machine
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Flat knit jacquard machine
Flat Knit Jacquard Machine Batching
Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.
Function or Purpose of Batch Section - To receive the grey fabric roll from knitting section or other source. - Turn the grey fabric if require. - To prepare the batch of fabric for dyeing according to the following criteria - Order sheet (Received from buyer) Dyeing shade (color or white, light or dark) M/C capacity M/C available Type of fabrics(100% cotton, PE, PC, CVC) Emergency - To send the grey fabric to the dyeing floor with batch card. - To keep records for every previous dyeing.
Proper batching criteria
- 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 management
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Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency. M/c s in batch section No. of M/c: 02Machine Name: Air turning m/cOrigin: Local
No. of M/c: 01Machine name: Air turning machineOrigin: KOREA
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DYEING LAB Central Laboratory: Labs dip Development: Lab Dip Development means the sample which is dyed according to buyers requirements (similar shade and so on).The following sequence need to produce a Lab Dip.
Merchandisers sent Swatch or Sample or Color Code
Received Sample by Central Laboratory
Compare Swatch with Self Shade or Spectroflash Machine
Take Recipe for Sample dyeing (More than one Recipe)
Take dyeing auxiliaries automatically and manually
Sample Dyeing
Hydro Extractor
Dryer
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Compare Dyeing Sample with Light Box and Spectroflash machine
If need Take correction for required shade manually and automatically
Sample Dyeing
Compare Dyeing sample with Swatch.
If Approved Sample
Bulk production
Knit Dyeing Lab:
The main objective in Knit lab is as follows. To calculate the recipe for sample dyeing. To compare dyed sample with swatch by light Box or Spectroflash. To calculate revise recipe for sample dyeing. Finally approved Lab Dip
Self Shade Compare: Self shade compare is very important in knit lab section. To get appropriate shade it takes many responsible. To better understand one self shade is given bellow.
Spectro flash: Company: Data color. Light box: Types of light: 04 types. - TL 83
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- D65 - Florescent. - Ultra violet.
Machine no.01: Name of the machine: Dyeing machine.Manufacture of the machine: ATAC LAB DYE H.T (TURKEY)Temperature: (34 C-130C)Number of put: 16 pcs. (One is for cooling).
Machine no 02:Name of the machine: Dyeing machine.Manufacture of the machine: RAPID LABORTEX COMPANY LTD.(TAIWAN)Temperature: (34 C-130C)Number of put: 12 pcs.Model no.: 11-120Electricity Consumption:06 volt; 03 KW.
Machine no. 03(Number of the machine 2 pcs)Name of the machine: dyeing machine.Manufacture of the machine: IR DRYER (Low temperature m/c)Temperature: (34 C-98C )Number of put: 24 pcs.(one is for cooling).Speed of the machine: 50 rpm.
Machine no.05:Name of the machine: Drying machine.Manufacture of the machine: ATAC FT (TURKEY)
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Temperature: 120CNo. of tray: 05Drying time: (5-7.5 min).Drying system: Fabric hanged by tray pin.Machine no.-06:Name of the machine:Squizzer machine.Manufacture of the machine: ATAC F-350 (TURKEY)Number of roller: 02pcs.Pressure system: Air.
Machine no.-07:Name of the machine: HYDRO EXTRACTORMACHINE.Manufacture of the machine: ATAC SFJ-10 (TURKEY)Model: SFJ-10Serial no.: 003Product year: 2003Rotation: clock wise.Capacity: 01 kg.
Machine no.-08:Name of the machine: Dryer machine.Manufacture of the machine: ATAC (TURKEY)Serial no.: 036Model no.: GK 40Product year: 2002Temperature: 120CSample capacity: (4-5) pcs.No. of tray: 01 pc
Size of pipette used in dyeing lab:A.0.01 ccB.0.1 cc
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C.1 ccD.5 ccE.10 ccF.20 cc
Dyeing Section
Responsibility of production officer
Overall supervision of dyeing & finishing. Dyes & chemicals requisition issue & check. Program making, sample checking color measurement. Control the supervisors operators & helpers of machines. To give dye-line or the program slip according to daily production plan, batch preparation & PH check. To rectify the finished fabric which rejected from quality control department To check daily production report. To study dye & chemicals nature delivery by the manufacture & applied them correctly to the production to get best product.
Job Description Title: Production officer. Dept: Dyeing Report to: Senior production officer. Job summary: To plan execute & follow up the production activities & control the quality production with related activities.
Title: Senior production officer.
41 Pg42Pg42
Dept: Dyeing. Report to: Dyeing manager. Job summary: To plan execute & follow up the production activities & control the quality production with related activities. Dyeing Machine
Sample No. of Atmospheric dyeing machine= 02 pcsNo. of High temperature dyeing machine= 12 pcs
No. of Total samples dyeing machine=14 pcsTotal machine capacity of sample m/c=220 kgsTotal production capacity of sample m/c=520 kgs
Bulk Production
No. of Atmospheric temperatures dyeing machineNo. of High temperatures dyeing machineNo. of Total productions dyeing machinesTotal Machine capacity on dyeing floorTotal Production capacity on dyeing floor = 15 pcs= 08 pcs= 22 pcs= 36 ton= 28 ton
42 Pg43Pg43
Machine no. -01:
Machine nameCompany given name ModelMax. Temperature OriginsManufacturer : Fongs (Atmospheric temperature machine).: FKL-01.: FC28ADCapacity: 400 kg: 98CNumber of nozzle : Two (02): china: Fongs national Engineering (SHENZHEN) Company limited.
Machine no-02:Machine nameCompany given name ModelMax. Temperature OriginManufacturer : Fongs (Atmospheric temperature machine).: FKL-02.: FC28ADCapacity: 600 kg: 98CNumber of nozzle : Three (03): china: Fongs national Engineering (SHENZHEN) Company limited.
Machine no-(03~04):Machine nameCompany given name ModelMax. Temperature OriginManufacturer : Fongs (Atmospheric temperature machine).: FKL-(03~04): FC28ADCapacity: 800 kgs: 98CNumber of nozzle : Four (04).: china: Fongs national Engineering (SHENZHEN) Company limited
Machine no. - (05~06):
43 Pg44Pg44
Machine nameCompany given name ModelLoadNumber of nozzleManufacturer
: Fongs (Atmospheric temperature machine.).: FKL-(05~06): FC28ADCapacity: 1200 kgs.: 950 kgsMax. Temperature: 98C: six (06).Origin: china: Fongs national Engineering (SHENZHEN) Company limited
Machine no. - (07~08)
Machine nameCompany given name ModelLoading capacityNumber of nozzleManufacturer : Fongs (Atmospheric temperature machine.).: FKL-(07~08): FC28ADCapacity: 200 kgs.: 150 kgsMax. Temperature: 98C: Single (01)Origin: china: Fongs national Engineering (SHENZHEN)Company limited
Machine no. -09:
Machine nameCompany given name ModelLoading capacityNumber of nozzleManufacturer : Fongs (Atmospheric temperature machine.).: FKL-09.: FC28ADCapacity: 1500 kgs.: 1000 kgs Max. Temperature: 98C : Six (06) Origin : China: Fongs national Engineering (SHENZHEN) Company limited
Machine no. - (10~11)
Machine nameCompany given name ModelLading capacityNumber of NozzleManufacturerlimited : Fongs (Atmospheric temperature machine.).: FKL-(10~11): FC28ADCapacity: 1000 kgs: 750 kgMax. Temperature: 98C: Four (04)Origin: China: Fongs national Engineering (SHENZHEN) Company
44 MNumine no. -16:Pg45Pg45
Machine no. -12:
Machine nameCompany given name ModelLoading capacityNumber of NozzleManufacturer : Fongs (High temperature machine.).: FKL-12.: FC28ADCapacity: 1000 kgs.: 800 kgsMax. Temperature: 130C: Four (04)Origin: china: Fongs national Engineering (SHENZHEN) Company limited.
Machine no. -13:
Machine nameCompany given name ModelLoading capacityNumber of NozzleManufacturer : Fongs (High temperature machine).: FKL-13: FC28ADCapacity: 1500 kgs: 1200 kgsMax. Temperature: 130C: Six (6)Origin: china: Fongs national Engineering (SHENZHEN) Company limited
Machine no. -14:
Machine name
Company given name CapacityMax. Temperature Origin : Moon light atmospheric dyeing(Atmospheric temperature machine) : FKL-14: 750 kgs.Loading capacity : 500 kgs: 98CNumber of Nozzle : Five (05): China
Machine no. -15:
Machine nameCompany given name ModelLoading capacityber of NozzleManufacturer
: Fongs (High temperature machine.).: FKL-15: FC28ADCapacity: 500 kgs.: 400 kgsMax. Temperature: 130C: Single (01).Origin: China: Fongs national Engineering (SHENZHEN) Company limited.
45 Pg46Pg46
Machine no.-16:
Machine nameCompany given name ModelLoading capacityNumber of NozzleManufacturer : Fongs (High temperature machine.).: FKL-16: FC28ADCapacity: 1500 kgs.: 400 kgsMax. Temperature: 130C: Six. (06)Origin: China: Fongs national Engineering (SHENZHEN)Company limited.
Machine no. -17:
Machine nameCompany given name ModelLoading capacityNumber of NozzleManufacturer : Fongs (High temperature machine.): FKL-17: FC28ADCapacity: 1500 kgs: 1200 kgsMax. Temperature: 130C: Six (06)Origin: China: Fongs national Engineering (SHENZHEN)Company limited.
Machine no. -18Machine nameCompany given name ModelLoading capacityNumber of loopManufacturer : Fongs (Atmospheric temperature machine).: FKL-18: FC28ADCapacity: 250 kgs.: 200 kgsMax. Temperature: 98C: Single (01)Origin: china.: Fongs national Engineering (SHENZHEN) Company limited.
Machine no. -19:
Machine nameCompany given name ModelLoading capacityNumber of NozzleManufacturer : Fongs (Atmospheric temperature machine).: FKL-19: FC28ADCapacity: 400 kgs.: 200 kgsMax. Temperature: 98C: Four (04)Origin: china: Fongs national Engineering (SHENZHEN)Company limited.
Machine no. -20:
46 Pg47Pg47
Machine nameCompany given name ModelLoading capacityNumber of NozzleManufacturer
: Fongs (Atmospheric temperature machine.).: FKL-20: FC28ADCapacity: 400 kgs.: 350kgsMax. Temperature: 98C: Four (04)Origin: China: Fongs national Engineering (SHENZHEN)Company limited.
Machine no. -21 & 22:
Brand nameCompany given name Loading capacityNumber of NozzleManufacturer
: ACME (): FKL-21 & 20Capacity: 500 kgs.: 400kgsMax. Temperature: 130C: Double (02)Origin: TAIWAN: ACME machineries industries Company limited.
SAMPLE SECTION
Machine no.-(01~04):
47 Pg48Pg48
Machine name: Sample dyeing machine. (High temperature machine)Brand name: FONGOrigin: ChinaSerial number: 31019683-6Model: FC28ADMachine no.: ALLIFI-30Capacity: 25 kgs.Loading capacity: 20 kgsMax. Temperature: 130CNumber of Nozzle: Single (01)Company given name: FKL-S-(01~04) Manufacturer : Fongs national Engineering (SHENZHEN) Company limited.
Machine no. - (05~08 & 11):
Machine name: Sample dyeing machine. (High temperature machine)Brand name: FONGModel: FC28ADSerial number: 31019685Origin: China.Machine no.: ALLIFIT-30Capacity: 60 kgs.Loading capacity: 50 kgsMax. Temperature: 130CNumber of Nozzle : Single (01) Company given name: FKL-S-(05~08) & FKL-S-11 Manufacturer : Fongs national Engineering (SHENZHEN) Company limited.
Machine no. -09:
Machine name: Sample dyeing machine. (High temperature machine)Brand name: ACMECompany given name: FKL-09Capacity: 125 kgLoading capacity:100 kgNumber of Nozzle: 01 (one) pcsMax. Temperature: 98COrigin: TAIWANManufacturer: ACME machinery co.ltd
Machine no.-10:
48 Pg49Pg49
Machine name: Sample dyeing machine. (High temperature machine)Brand name: FONGCompany given name: FKL-S-10Model: FC28ADCapacity: 120 kgs.Loading capacity: 100 kgsMax. Temperature: 130CNumber of Nozzle : Single (01)Origin: ChinaManufacture: Fongs national Engineering (SHENZHEN) Company limited.
Machine no. - 12:
Machine nameBrandCompany given nameLoading capacityMachine no. - 13:Number of NozzleManufacture
: Sample dyeing machine. ((Atmospheric temperature)): FONGModel: FC28AD: FKL-S-12Capacity: 120kgs.: 100 kgsMax. Temperature: 98C: Single (01)Origin: China: Fongs national Engineering (SHENZHEN) Company limited.
Machine no. - 13:
Machine name: Sample dyeing machine. (Atmospheric temperature)Brand name: FONGCompany given name: FKL-S-13Model: FC28ADCapacity: 50 kgs.Loading capacity: 40 kgsMax. Temperature: 98CNumber of Nozzle : Single (01)Origin: ChinaManufacture: Fongs national Engineering (SHENZHEN) Company limited.
Machine no. - 14:
Machine name: Sample dyeing machine. (Atmospheric temperature)Brand name: FONGCompany given name: FKL-S-14Model: FC28ADCapacity: 50 kgs.49Loading capacity: 40 kgsMax. Temperature: 98CNumber of Nozzle : Single (01)Origin: ChinaManufacture: Fongs national Engineering (SHENZHEN) Company limited.Pg50Pg50
OF DIFFERENT PARTS OF DYEING MACHINARY
DOSING TANK
DOSING TANK HEAT EXCHANGER
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DRAINAGE LINE FILTER OF HEAT EXCHANGER
FABRIC LOADING
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RAW MATERIALS FOR DYEING
Raw materials used in the dyeing section are: 1. Grey fabrics 2. Dyes 3. Chemicals.
GREY FABRICS
Following types of gray fabrics are dyed: Single jersey Single jersey with lycra Polo pique Back Pique Single lacoste Double Lacoste Fleece Interlock Terry
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Mini Terry Interlock with lycra Rib Rib with lycra 11 rib22 rib Different types of collar & cuff.
RECIPE AT DIFFERENT STAGE IN DYEING:
Recipe for machines heavy wash:
Detergent (Assist SL-2F)= 0.5 gm/LCaustic= 1 gm/L60 minutes at 98 CHydrous= 2 gm/L
For machine neutralization:
Acetic acid= (As required) gm/L
Recipe for scouring and bleaching: :( For cotton)
Wetting agent (Assist SL-2F)=1.0 %Anti creasing agent (Texport D - 600)=0.4 %Sequestering agent (Neocrystal-150)=0.8 %60 minutes at 98 CCaustic= 2 %Stabilizer (Neocrate PH-150/Neocrate PH-55 FN )=0.8 %Hydrogen per oxide (H2O2)=3.2 %
53 Pg54Pg54
Recipe for hot (cotton black):Wetting agent (Assist SL - 2F)= 0.5gm/LSequestering agent (Neocrystal-DNBF)= 0.75 gm/LCaustic= 1 gm/L
Recipe for enzyme treatment: :( For cotton)[Wetting agent (Assist SL-2F)=0.1 gm/LAcid (acetic acid)=0.8 gm/LEnzyme (Bio-Touch C-30/ Biopolish B-12/ Bio touch 37) =05-1.0 gm/LRecipe for leveling :( For cotton)
Anti creasing agent(Texport D - 1044F/ Texport D - 600/ Nice pole D-1044F) =1 -1.5 gm/L Neocrystal-150 =1-1.5 gm/L
Recipe for leveling :( For polyester)
Anti creasing agent(Texport D - 1044F/ Texport D - 600/ Nice pole D-1044F) =1 .0 gm/L Wetting agent (Assist SL-2F) =1.0 gm/LSequestering agent (Neocrystal-DMBF)=1.0 gm/L
Recipe for softening:
Sapamine CWS (Anionic)=0.5% (For color) 30minutes at98 C
40 minutes at 62C
10 minutes at 60C
20 minutes at 60CSapamine FPG (Non ionic)Nicepole PR
Recipe for Reduction (POLYESTER): 10minutes at 40C=0.5% (For white)=0.5 %( For polyester)
54 Pg55Pg55
Ekaline-F = 0.2 gm/LCaustic=2 gm/LHydross=4 gm/L
SODA AND DYES USED IN DYEING AND TOPPING
% dyeSumifixCibaLivafixBezaktiveSumifix0.0001-3101510 gm/L10 gm/L0.1 %gm/Lgm/Lgm/L0.-0.55-72015-2020 gm/L10 gm/L%gm/Lgm/Lgm/L0.5-1 %10-1540203530 gm/L15 gm/Lgm/Lgm/Lgm/L1-2 %15-205035-5040 gm/L20 gm/Lgm/Lgm/Lgm/L2-3 %20-406050-605020 gm/Lgm/Lgm/Lgm/Lgm/L3-4 %40-607060-8060 gm/L20 gm/Lgm/Lgm/Lgm/L4-10 %40-608070-802020gm/Lgm/Lgm/Lgm/Lgm/L
CibaLivafix65gm/Lgm/L86-7gm/Lgm/L107-10gm/Lgm/L1510-13gm/Lgm/L1513-15gm/Lgm/L1815-20gm/Lgm/L2020gm/Lgm/L
20 minutes at 80C
Bezaktive5 gm/L
10 gm/L
10-15gm/L15 gm/L
25 gm/L
25 gm/L
25 gm/L
55 Pg56Pg56
DYEING PROCESS OF COTTON FABRIC
Method: All in method Dyeing Procedure:
-Liquor ratio for cotton fabric is 1:8.5.-Add auxiliaries + dyes + salt + soda at room temperature.-Set temperature gradient 30c/min up to 600c (for cold brand dyes).-Set temperature gradient 3c/min up to 800c (for hot brand dyes).-At 60/800c run for 60 min.-Cool down the m/c at 400c with 30c/min.-Dyeing Scheme:
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800C
Grade 30C/ min600 C
300C
60 min
30C / min
60 min
400CCooling Manually 400C Cooling Manually Water+Dye+Salt+Soda+Auxilaries
Washing off:
-Cold wash (manual). Fig: Dyeing process of cotton fabric -Hot wash by boiling water with detergent (1/2) gm/l. Hold time 10 min. -Cold wash (manual). -Then after treatment.
Dyeing sequence for white shade:
Fabric Loading
57 Pg58Pg58
Wetting agent (Assist SL-2F)Anti creasing Agent (Texport D-1044FSequestering Agent (Neocrystal-DMBF)
Caustic dosing (10 min at 60C) Dosing at 50 C
Stabilizer (Neorate PH -55 FN) (Dosing time 5 min at 70C)
H2O2 (Dosing 30 min at 70 C) (Run time 10 min) Temperature rise 90C (2C/min) (Run time 60 min)
Cooling 80C
Brightener dosing 30 min
Temps raise 98C (2C/min) (Run time 40 minutes)
Cooling 80C
Rinsing wash
Soaping (Sample cutting)
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Acid (Enzyme if need)
Softener
Unload
Dyeing sequence Black shade:
Hot wash (Detergent + caustic + Neocrystal -150)
Temperature: 95C; Run time: 30 minutes
Over flow
Drain
Acid forNeutralization
Overflow
Drain
Leveling agent
(Dosing at normal temperature)Run time 20 minutes at the temperature 80 C
(Dosing at60 C temperature)Run time 5 minutes at the temperature 60 C
59 Pg60Pg60
Salt dosing
Color dosing (before dosing individual mixed properly) 30 min at 60C
Soda dosing 50 min at 60C
Color steam required time at 80C
Color wash
Acid
Soaping
Fixing 10 min at 80C
Softener 10 min at normal temperature
UN load
Sequence for Grey mlange (white):
Water load in the dyeing machine (L: R=1:10)
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Fabric load in the machine
Dosing (1-5) At 50 C
Dosing hydrogen per oxide At 70C 5 min
Steam to 80 C
Run time 10 min
Shade check (if not ok)
Steam 90 C (10+10) minutes
Shade check ok
Dosing croaks NF at 80 10 min (H2O2 killer)
Over flow and drain
Softener dosing at 62 C, 70%; 30minutes.
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Then rest 30% dosing at the same temperature 15 minutes
Steam 80 C
Over flow and drain.
Color (OBA) dosing at 60 C required minutes to match.
Shade check ok
Over flow and drain.
Dyeing Sequence for topping: Fabric load
Scouring (at 60 min at 95 C)
Peroxide killer (20 min at 80 C)
Acid (20 min at 60 C)
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Leveling (60 min)
Salt (dosing at 15 min+ 15min+20min)
Color (dosing 30 min at 60 C)
Soda (dosing 45 min)
Color steam (required time and temperature)
Colors wash (at 50C)
Acid (20 min at normal temperature)
Acid wash (20 minutes)
Soaping (by as required quantity)
Soaping wash (20 minutes)
Leveling (10 minutes)
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Salt (quantity dependent on shade % colors brand)
Color (quantity depend on deference between dyed fabric and counter sample)
Soda (quantity dependent on shade % colors brand)
time and temperature)
Color wash
Soaping with soaping agent (liptol ps)
Soaping wash
Acid
Acid wash
Softener
Unload
64 Pg65Pg65
DYEING PROCESS OF POLYESTER FABRIC
Method: All in method. Dyeing Procedure:
-Liquor ratio for polyester fabric is 1:10.-Add dyes+ dispersing agent + leveling agent + buffer solution.-Set temperature gradient 20c/min up to 1300c.-Run time 30 min at 1300c temperature.-Cool down the m/c at 400c with 30c/min.
Dyeing Curve:
65 Pg66Pg66
30 min 130 C
2C/min
2C/min
40C 300CCoolingManually And Unload Water+Dye+Buffer soln +Dispersing agent +Leveling AgentFig: Dyeing process of Polyester fabric
Washing off:
-Cold wash (manual).-Hot wash by boiling water containing with 2 g/l hydrose & 2 g/l caustic soda for10 min.-Neutralized with 1 g/l acetic acid for 2 min.-Rinse with cold water.-Then after treatment.
Process Flow Chart of P/C Blend Fabric(65/35):
66 Pg67Pg67
Color: BlackM: L -1:10
Polyester Part
Sequence of polyester dyeing with curve:
Dosing detergent
Formic acid (for maintained PH =4.5)Dosing at 60C
Leveling agent
Buffer solution
Dyes
Color steam at 130C
Shade check at 80C
If not ok
Color add at 60C
67 Pg68Pg68
Color steam at 130C
Shade check
If ok
Cotton Part
Hot wash (Detergent + caustic + Neocrystal -150)
Temperature: 95C; Run time: 30 minutesOver flow
Drain
Acid forNeutralization
Overflow
Drain
(Dosing at normal temperature)Run time 20 minutes at the temperature 80
(Dosing at60 C temperature)Run time 5 minutes at the temperature 60 CLeveling agent
68 Pg69Pg69
Salt dosing at 60C 10 min
Color dosing at 25 min at 60
Soda dosing 30 min in 3 steps
Color steam 60C (For normal brand dyes)
Color wash
Acid at normal temperature
Soaping (at 70C 25 min)
Soaping wash (20 min)
Fixing if buyers requirement 10min at 80C
Fixing wash 15 minutes [ Softener (10 minutes)
UN load Sequence of polyester dyeing with curve:
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Dosing detergent
Formic acid (for maintained PH =4.5)
Dosing at 60CLeveling agent
Buffer solution
Dyes
Color steam at 130C
Shade check at 80C
If not ok
Color add at 60C
Color steam at 130C
Shade check
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If ok
Dyeing curve:
20
Reduction cleaning
Neutralization by acetic acid (PH=5.5)
Unload
130C 40 minHeating2C/min2 C/min
Ekaline-F=0.2 gm/LCaustic=2 gm/LHydross=4 gm/L
Coaling 60C
Color- Leveling - Buffer soln -Acid
Reduction cleaning 20 min at 80C
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Heating 60 C Coaling
-Ekaline-F -caustic -Hydrous
Neutralization: 10 min at 60C
HeatingCoaling60 CUN load
Acetic acid
Special parameter maintained for viscose dyeing:
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1.Wetting Agent= 0.5 gm/LLeveling agent= 0.4 gm/LAnti creasing Agent=1 gm/LSoda ash= 3 gm/L
Drop and neutralization 20 min at 80C/ 90C
Check pH and dyeing like cotton process. (L: R=1:9/10/11)
2. Reel speed kept less as much as possible (150 m/min)
3. During color addition in dye bath or 1/3 water Drop and add color
Dyeing sequence for100% viscose: (For white)
Detergent (Assist SL-2F)Ant creasing agent (Nicepole D -1044Visco BleachH2O2BYB
Cooling 2C / min to 75CPH Check
Drop Run time 45 minutesat 98C(L: R=1:12)
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Normal hot
Neutralization 0.5 gm/L
PH check
Bath drop
Dyeing sequence for100% viscose any color (Except white)
1. Sequestering2. Peroxide3. Stabilizer
Detergent (Assist SL-2F)Ant creasing agent (Nicepole D -1044Visco Bleach
Drop
Normal hot 60C 10 min
Neutralization 0.5 gm/L
Peroxide killer 0.5 gm/L 80C 20 min
Run time 45 minutesat 98C(L: R=1:12)
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Normal wash
Lavelling 60C 10 min
Salt dosing
Color dosing 60C 30 min
Soda dosing
Color steam (isothermal)
Color wash
Hot
Bath drop
DYEING PARAMETERS
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PH Levels for Different Stages of Cotton Dyeing:
1. Initial Bath pH2. Before Enzyme, bath pH3. After Enzyme & Aquachoron ,pH4. Before Scouring & Bleaching, pH (With Enzyme) 5. Before Scouring & Bleaching, pH (Without Enzyme) 6. Scouring & Bleaching, bath pH7. After Scouring & Bleaching, pH8. Before Leveling Chemicals, pH9. After Leveling Chemicals, pH10. After Adding Dyes, pH11. After Addition of Salt, pH12. After Addition of Soda, pH13. Before Hot Wash, Bath pH14. Hot Wash, bath pH15. Before Softener, bath pH16. After Softener Addition, bath pH
PH Levels for Different Stages of Polyester Dyeing:
1. Initial bath pH2. Scouring, bath pH3. After Scouring, bath pH4. Before Addition of Leveling Chemicals, pH 5. After Addition of Leveling Chemicals, pH6. After Addition of Colors, bath pH7. During Reduction Clearing, bath pH8. Before Softener, bath pH9. After Softener Addition, bath pH
COMMON DYEING FAULTS WITH THEIR REMEDIES:
6.5~7.0. 4.5~4.7. 5.5~6.0. 5.5~5.8. 5.5~5.8. 10.0~10.5. 8.5~9.0. 6.5~7.0. 6.7~7.0. 6.2~6.35. 7.5~8.0. 10.5~11.0. 6.8~7.2. 8.5~8.7. 7.2~7.8. 6.5~6.8.
6.5~7.0. 10.0~11.5. 8.5~9.0. 6.0~6.5. 4.5~4.7. 4.2~4.3. 10.5~11.5. 6.3~6.8. 5.8~6.2
76 Pg77Pg77
1. Uneven dyeing: Causes: - Uneven pretreatment (uneven scouring & bleaching). - Improper color dosing. - Using dyes of high fixation property. - Uneven heat-setting in case of synthetic fibers. - Lack of control on dyeing m/c
Remedies: - By ensuring even pretreatment. - By ensuring even heat-setting in case of synthetic fibers. - Proper dosing of dyes and chemicals. - Proper controlling of dyeing m/c
2. Batch to Batch Shade variation: Causes: - Fluctuation of Temperature. - Improper dosing time of dyes & chemicals. - Batch to batch weight variation of dyes and chemicals. - Dyes lot variation. - Improper reel speed, pump speed, liquor ratio. - Improper pretreatment. Remedies: - Use standard dyes and chemicals. - Maintain the same liquor ratio. - Follow the standard pretreatment procedure. - Maintain the same dyeing cycle. - Identical dyeing procedure should be followed for the same depth of the Shade. - Make sure that the operators add the right bulk chemicals at the same time and temperature in the process. - The pH, hardness and sodium carbonate content of supply water should check daily. 2. Patchy dyeing effect:
77 Pg78Pg78
Causes: - Entanglement of fabric. - Faulty injection of alkali. - Improper addition of color. - Due to hardness of water. - Due to improper salt addition. - Dye migration during intermediate dyeing. - Uneven heat in the machine, etc Remedies: - By ensuring proper pretreatment. - Proper dosing of dyes and chemicals. - Heat should be same throughout the dye liquor. - Proper salt addition. 4. Roll to roll variation or Meter to Meter variation: Causes: - Poor migration property of dyes. - Improper dyes solubility. - Hardness of water. - Faulty m/c speed, etc
Remedies: - Use standard dyes and chemicals. - Proper m/c speed. - Use of soft water
5. Crease mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - If pump pressure & reel speed is not equal - Due to high speed m/c running Remedies:
78 Pg79Pg79
- maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature - Reducing the m/c load - Higher liquor ratio
6. Dye spot: Causes: - Improper Dissolving of dye particle in bath. - Improper Dissolving of caustic soda particle in bath. Remedies: - By proper dissolving of dyes & chemicals - By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the large un-dissolved particles are removed
7. Wrinkle mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - High temperature entanglement of the fabric Remedies: - Maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature - Higher liquor ratio 8. Softener Mark: Causes: - Improper mixing of the Softener. - Improper running time of the fabric during application of softener. - Entanglement of the fabric during application of softener Remedies: - Maintaining proper reel sped & pump speed. - Proper Mixing of the softener before addition. - Prevent the entanglement of the fabric during application of softener MACHINE SPECIFICATION: FINISHING SECTION
79 Pg80Pg80
MachineryNo. of machineManufacturerBrandcountrySqueezer01SwedenAir CalatorSqueezer01SwedenSystem CalatorSqueezer01Dryer01FranceObermayerDryer01TurkeyAMSCompactor (tube)01ItalySperroto RimarCompactor (tube)01ItalyFebconCalendar01ItalyFerraroCompactor01ItalyFerraro(Open width)Compactor02ItalyLafer(Open width)Squizer and slitter01ItalyERHARD(for open width+LEMER S.R.fabric)Stenter -101ACCStenter -201GermanyBruknerStenter-301Brushing06TaiwanI-KUANGShearing02TaiwanI-KUANGSwedding/ peach01TurkeylaferfinishSinging machine01Backswinging01ItalyRimomachine
LAY OUT OF FINISHING UNIT
80 Pg81Pg81
FLOOR (1STUNIT)
GREY FABRIC STORE
Garments store
DYED FABRIC STORE
C- 3C- 2C- 1FINISHE FABRICT-5T-4STORE
T-3T-2T-1
FINISHE FABRIC STORE (TEMPORARY)
COMPECTOR
SLITER T-6
NWES
LAY OUT OF FINISHING FLOOR (2ND UNIT)
81 Pg82Pg82
YARN STORE LIFT
SINGING MACHINE
SH-1PICH FINISH
SH-2
B-6
B-5
B-4
B-3
B-2
B-1
GATE
F-UNIT -1= 1ST UNIT OF FINISHING FLOOR.
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B (1-4) = BRUSHING MACHINE. SH (1-2) = SHEARING MACHINE. T (1-5) = DYED FABRIC INSPECTION TABLE. (PRODUCTION) C (1-2) = CALENDERING MACHINE (FERRARO) C 3 = CALENDERING MACHINE (LAFER) T-6 = DYED FABRIC INSPECTION TABLE. (SAMPLE)
Machine no. -01: Machine name: Squeezer-1Brand name: System calatorOrigin: SwedenPressure: 50 psiSpeed: (60-70) m/min
Machine no.-02:
Machine name: Squeezer-2Brand name: KromsonOrigin: SwedenPressure: 50 psiSpeed: (60-70) m/min
Machine no.-03:
Machine name: Squeezer-3Brand name: Air Tex (AB CALATOR)Origin: SwedenSpeed: (60-70) m/min
Working principle of Squeezer:
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After completing the dyeing process from the dyeing m/c then the fabrics are ready for de-watering. In de-watering m/c tubular fabrics are mainly processed. There is a magnetic sensor which scene the twist of the fabric and its direction and turn the fabric in opposite direction to remove twist automatically. Here dewatering is performed De-watering is the process to remove the water from the fabric completely by squeezing and it is done by the padder. A suitable expander is used before the fabric is passed through the nip of the padders, which expands the fabric flat wise and adjust the width. The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%, Lacoste-40% wider than the required width. There is a pair of rubber coated padder, where water is removed from fabric when passed through the nip of it. Normally squeezer contain single or double padders where, - One for removing water and - Other for applying finishing chemicals such as softener. But this finishing is done only for the tubular fabric. Open width knitted fabrics are applied finishing treatment later in stenter. Here present the compressor which given compress air to form ballooning before passing through the padder. This balloon remove crease mark but not form the maximum balloon otherwise shrinkage increase . Infeed & Out feed traverses which present in albatros control the following functions by over feeding system.
-To control the width (dia) of the fabric.-To control the spirality of the fabric.-To control the crease mark of the fabric.-To control the length of the fabric.
Operational parameter
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-Speed: As much as possible (40-60 m/min). Higher the GSM lower the speed.-Over feed: As required. Higher the GSM higher the over feed.-Padder pressure: 3-7 bar as required. Higher the GSM lower the padder pressure.-Width: Fabric width is adjusted as per required width.
Machine no. 04
Machine name: Compactor.Brand name: FERRAROOrigin: ITALYModel: COMPTEX-RE 2500 Temperature (set) : 120CMinimum speed: 14 m/minworking speed: 20 m/minMaximum Overfeed %: +35%Capacity: 7 ton /day.Heating source: Direct gas heating system. Maximum speed: 40 m/minManufacture: FERRARO CONSTRUZIONI MACHINE
Machine no. 05:
Machine name: Compactor.Brand name: LAFER SPAOrigin: ITALYModel:Temperature (set): 150CMaximum speed: 45 m/minMinimum speed: 14 m/minWorking speed: 20 m/minMaximum:Overfeed %: +100%Capacity: 7 ton /day.Heating source: Direct gas heating system.Manufacture: TEXEN S.R.I FACTORY AUTOMATION.
Important parts
85 Pg86Pg86
- Over feed roller. - Expander. - Blanket(2) Operational parameter
-Set the temperature at 120 C (as required) -Set the speed as much as possible (15-25 m/min).GSM m/c speed. -Set the overfeed % as required; to increase GSM, overfeed need to increase to a certain limit. Function - Shrinkage control. - GSM control. - Width control.
PICTURE: OPEN COMPACTOR MACHNE
Machine no. - 6:
86 Pg87Pg87
Machine name: SlittingBrand name: Erh ardf + Leimer (EL)Working Speed: 80-85 m/minMax. Over feed % : +10%Working over feed : + 7 %manufactur year: 2003Type: SZ-2005Origin: ITALY + GERMANYManufacture: VIA SILVIO PELLICO 20 24040 STEZZANO (BG) ITALY.
Working principle
The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After dyeing completed and falling of water from fabric the fabric is fed in slitting m/c. So it is necessary to remove some water initially for the case of further processing in this m/c. The initial squeezer does this work. The de-twisting unit removes twists that may present in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2 feeler rollers with sensors. By these rollers it detects twist in fabric and removes by rotating rope fabric in opposite direction. Before slitting there is a blower which blows air to open the tubular fabric & makes it easy to pass over cigger. The cigger can be extended in circumference and opens the tubular fabric in full circumference. Slitting is done by using open mark detecting golden eye by around knife. Then the fabric passes through the padder where washing or chemical treatment is done. Squeezer is used to remove 60-70% of water. After removing water width is controlled by stretcher and fabric is delivered by folding device.
Operational parameter
-Set the padder pressure as required (3-7bar) -Set the speed as much as possible (30-80m/min).
Function of the Machine
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Used to remove excess water after pretreatment and dyeing To slit the tube fabric by the knife for opening of the fabric and ready for stentering Delivered fabric in crease free state Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism
Different parts of slitting m/c
Fig: Feed zone of Slitting M/CFig: Fabric Pass through Detwister
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Cutting Knife (round)
Fig: Fabric Pass through KnifeFig: Delivery zone of Slitting M/C
Machine no. 07:
Machine name: Stenter.Manufacture: ACC (GARMANY)Model: IPG/2400-6Serial no.: /039Power: 140 KWProduct: 2004/06Electricity: 380 volt; 50 HZAir pressure: 6 BARMaximum Speed: 100 m/minMaximum temperature: 200C Minimum speed: 7 m/ minMinimum temperature: 100C working speed: 18-28 m/minNo of Burner: 12No of nozzle: 48Over feed %: +10%; - 5%Lower feed % : +60%; -5%Working temperature: (110-200) C No of Chamber: 06 Heating source: Direct gas heating system.
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Burner: Ratio matic burner Model: RMHPL-02-CUKType: RM - 100Serial: 00 4095063 71Capacity: 150KWFuel: Natural gas.
Machine no. 07
Machine name:Stanter.Brand name:Chang FuSerial no.: NO.960Maximum temperature:200CPower: 250HPMinimum temperature: 100CModel: STENTER 2500-B Product: 2006-07Electricity: 380 V 50HZWorking temperature: (110-200) COver feed %: 300+%; -100 % Maximum Speed: 80m/minLower feed %: +1120%;No of Burner:16 No ofChamber: 08Minimum speed: 6 m/minNo of nozzle:128working speed(8-10) m/minHeating source: Direct gas heating system.Manufacture: Chang Fu machinery and industry co.ltd
Machine no. 08
Machine name: Stenter.Brand name: BRUCKNER Maximum temperature:200COrigin: GERMANYMinimum temperature: 110CModel:Working temperature: (110-200) CSerial no.: 00409506370Maximum Speed: 60 m/minPower:Minimum speed: 7 m/ minProduct:Working speed: 18-25 m/minElectricity:No of Chamber: 06Air pressure:No of Burner: 12Over feed %: +%; - %C-cNo of nozzle: 60Lower feed %: +%; -%Type: RM - 100Capacities: 150KWHeating source: Direct gas heating system.
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SOME PICTURES OF STENTER MACHINE
PICTURES OF STENTER MACHINE (BRUCKNER)
Fig: Weft StraighterFig: Softener Application tank
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S-tank
SL-F
123456C-c
U-F Fig: Flow path of Stenter (BRUCKNER)
(1-6) = Heating chamber.S-tank = Softener tankU-F = Upper feeder rollerL-F = Lower feeder roller.C-c = Cooling chamber.= Direction of fabric path.S = Squeezer roller
Burner:Ratio matic -burnerModel: RM-100VER -310Type: RMPH-150-BSerial no.: 00 4095559 53 - EFuel: Natural gasPressure: 50 m barCapacity: 150 KW (HS)
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Important parts of stenter
-Burner (12) - Exhaust air fan (16) -Over feed roller. - Suction fan (12) -Nozzle -Chain arrangement.
FUNCTION OF STANTER:
- Drying - Shrinkage control. - Heat setting. - Width control Finishing chemical application. - Loop control. - Moisture control. - Spirility control.
Machine no. 09:
Machine name: DryerBrand name: AMSMaximum temperature: 180 COrigin: GERMANYMinimum temperature: 120 CModel: JHK-9700No of chamber: 04Maximum speed: 30 m/minNumber of burner: 08Minimum speed:26 m/minOver feed %: 6%Capacity: 16 tons/dayHeating source: Direct Gas heating systemManufacture: AMS textile machinery co.ltd
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DRYER
Machine no. 10
Machine name: DryerBrand name: ObermairTemperature (1st chamber)Temperature (2nd chamber) Temperature (3rd chamber) Temperature (4th chamber) Heating Source :116C Origin: FRANCE:115C Type: DRY 24/1.6.2:120C No of chamber : 04 :135C No. of air blower : 04: Steam.:
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Flow path of dryer (Obermair)
Dry fabric out Wet fabric in
Fig: Flow path of dryer
Working principle of dryer:
After de-watering then the fabric through the dryer. The main function of the dryeris given below,
-To dry the fabric.-To control the overfeed system.-To control the vibration which increase the G.S.M.
This machine contains two chambers. Two mesh endless conveyors are placed lengthwise to the chamber named conveyor net and filter net, each chamber contain a burner,which supply hot air .This hot air is guided through the ducting line by suction fan .There are nozzles placed in between filter net and conveyor net .When the fabric pass on the
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conveyor net, hot air is supplied to the wet fabric to dry it. There are exhaust fan which such the wet air and deliver to the atmosphere through the ducting line. The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric. If the m/c temp. is high then m/c speed also high and the m/c temp. is low then m/c speed also low . The vibration speed of the m/c for heavy fabric is 730 m/min and normal fabric is 480 m/min.
Machine no. 11
Machine name: Tube compact Manufacture: Sperotto Rimer Heating source: Steam.Origin: ITALYMaximum Speed: 10-29 m/min.Normal speed: 16-20 m/min Maximum Temperature : 150 CNormal temperature: 150 CAir temperature : 4 bar/ 60 PSICapacity: 3 ton (S/J); or 2.2 ton (Rib) / day.Width control: 2 inchGSM control: -10 inch; +5 inch
Machine no. -12
Machine name: Compactor(TUBE)Brand name: FAB- CONOrigin: AmericanTemperature in roller: 180CHeating source: Steam.Temperature in show: 200 Cpressure: PSI (by air)Speed: 38 m/min
Manufacture: FAB - CON
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Blade setting in compactor (FAB - CON) machine
Serial no.Fabric GSMBlade no.1120902120-1501103150-1801254180-2501405250-3201706320-above200
Machine no. -13:
Machine name: Tube compactManufacture: FERRRARO Heating source: Steam.Origin: ITALYMaximum Speed: 20 m/min.Normal speed: 10-15 m/min Maximum Temperature : 140 CNormal temperature: 120 CAir temperature : 3 bar/ 60 PSI
Machine no.-14
Machine name: Singeing machineManufacture: OSTHOFF-seng GmbH and companyOrigin: GermanyHeating source: Direct gas heating system.Temperature: 120-130CSpeed: For single jersey cotton: 50-60m/min (burner position -02) For 100% viscose: 65-75 m/min (burner position -02) For lycra single jersey: 90/95 m/min (burner position -01) Flame: (10-12) bar for single jersey. (18-20) bar for single jersey. (16-18) bar for viscose lycra
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Singeing machine (Open)
Machine no. -16
Machine name: Back sewing machine:Manufacture: RIMOLDI NECHIOrigin: Italy
MACHINE NO. - 20
Machine name: shearing machine.Brand name: I KUANGNo of machine: Two (02)Model : SE1ESerial no.: SE10503703A6Power : 400 v; 50 HzOrigin: TAIWAN
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Machine no. - 15
Machine name: Peach finish.Brand name : LAFEROrigin: TURKEYSerial no.: 3 CSM 007-TOut pot tension: 3.5-8.5 %Year: 2006Number of pile roller: 05Number of counter pile: 05 Type: CSM - H 2200Taker in tension : -(5-6) % Folder tension: (8-11) % Drum speed : (20-30) rpm Speed : 10 m/min. Drum tension: S/J= (23-24) %, Rib + Interlock = (16-20) %Lycra = (30-42)%The ratio of Drum and roller speed: (1:180)Manufacturer:
Peach finishes m/cCounter pile
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Machine no. -17
Machine name: Brushing machine Brand name: I KUANGNo of machine: six (06)Model : RG 2- 2000Serial no.: RP 20503701 CPower : 400 v; 50 HzOrigin: TAIWANManufacturer: I KUANG machinery works co. ltd
Brushing machine
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Printing section
Capacity: 80,000 pcs per day.
Machineries: Manual rotary printing machine: 11 pcsAuto printing machine: 01 pcsDryer: 01 pcsExpose machine: 01 pcs
Recipe of pigment paste (standard)
Pigment gum...05 % Binder .30 % NK...10 % Oxuzel ..05 % Water 50 %
Total .100 %
CHEMICAL USED
Pigment gum (PG): Pigment gum that others name thickener. It is a main compound for making a pigment. It is a high viscosity and liquid compound. That color is off white.
Binder: To control color fastness.
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Oxuzel : To control curing (when drying at high temperature about 170 C )
NK: NK is a chemical. This is worked as like binder and fixer. When make a deep color pigment paste then it is used. And if this fabric is washing at 65 C, 5 times then NK is used. For protect from the pilling.
Major fault it pigments Fatting: If the pigment printed fabric is fatted(on printed portion) after washing. Then this fabric is rejected. So it is major fault for printing.
Recipe for rubber paste For whit color
White paste -NR - 10195 % Oxuzel .05 %
Total 100 % For black color
NK copper EL - 251 95 % Oxuzel ..05 %
Total .100 % `Then add required black color for making black shade.
For color making
NK copper EL - 594 95 % Oxuzel ..05 %
Total .100 % Then add required basic color for making a certain shade.
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Faults of rubber printing
Cracking: If the rubber printed fabric is braking (on printingportion)after elastration.
Name of chemicals used in rubber printing (Purchase from Japan)
BASIC COLOR ORIENT PASTE NR-201 HN ORIENT PASTE NR-251 HN ORIENT PASTE TSK-251 HN ORIENT PASTE SR-200
FOR WHITE COLOR
WHITE PASTE NR-101 HN WHITE PASTE NR-151 HN WHITE PASTE TSK 510 HN WHITE PASTE SR- 100 WHITE PASTE SR - 150
FOR BLACK COLOR
NK COUPER EL-594 HN NK COUPER NR-351 HN NK COUPER SR -300
FOR TABLE ADHESIVE
NK PLASTER EH-HN
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FOR LIKE BINDER NK BINDER R- 5 HN NK NEORSIN F-50
FOR GLIENT PRINTE NK RESIN ST -60 HN
FOR PUP PRINTE NK SKYRESIN SP-37 HN
TEXTILE PRINTING AGENTS, INKS & CHEMICAL
PRINTINGS INKS FROM SERICOL, UK:
PIONEER ULTRA YC / YCP (PVC & PHTHALATE FREE PLASTISOL) AQUATEX AT / ATP (WATER BASED MACHINE SUITABLE)
PIGMENT COLOR:
SEIKAFIX SEIRES FORMOTON ECO SERIES
FLOUROSENT PIGMEMT COLOR:
SINLOIHI SW SERIES
BINDER & FIXER:
NK BINDER R- 5HN (BINDER CUM FIXER) BINDER CR - 4038
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THICKENER:
TEXIPOL 63-237 FORASIN PTE - 1 DYMATHIK DM- 5239
PIGMENT PRINTING AGENT:
BR- 1000 HN SEIKA PASTE VA - 1000(CLEAR) SEIKA PASTE VA - 1200(MAT) SEIKA PASTE VA - 1600(WHITE)
RUBBERIZED PRINTING AGENT- HAND PRINTING:
## WHITE: WHITW PASTE NR -101 HN (GLOSSY TYPE) WHITW PASTE NR- 151 HN, (MATTY TYPE) SEIKAPRENE EDC - 6 MW (K- 2) WHITE
## MAT: ORIENT PASTE NR - 201 HN (GLOSSETY TYPE) ORIENT PASTE NR - 251 HN (MATTY TYPE) SEIKAPRENE EDC- 5 M (K-2) NWHITE
## CLEAR: NK COUPER EL- 594 HN (GLOSSEY TYPE) NK COUPER NR - 351 HN (MATTEY TYPE ) SEIKAPRENE EDC - 4 M (K- 2) SEMI CLEAR
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HIGH STRETCH RUBBERIZED PRINTING AGENT:
STRETCH WHITE - 701W STRETCH MAT 701M STRETCH CLEAR 701B UNDER COAT BINDER 301-1
HIGH MESH PRINTING AGENTS (PLASTISOL SUBSTITUTE) - HAND PRINYING: UNI BINDER UN - 2W (WHITE) UNI BINDER UN - 2M (MAT) UNI BINDER UN - 2C (CLEAR)
HIGH MESH PRINTING AGENTS (PLASTISOL SUBSTITUTE) - MACHINE PRINYING: DIASLUE W 10(CLEAR) DIASLUE W 15(MAT) DIASLUE W 20W (WHITE) DIASLUE W 23W (WHITE)
HIGH DENSITY PRINTING AGENT:
MAT BINDER BB 22 UNN
GLASS BEADS PRINTING AGENT:
GLOBAL RESIN 1010 OXAL GB CONC.
FOIL PRINTING AGENT:
MEI BINDER K - 40 SP TOP NK - 2
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GLITTER PRINTING AGENT:
NK RESIN ST - 60 HN
FOAM PRINTING AGENT:
NK SKY RESIN SP - 37HN
METALIC PRINTING AGENT:
MATALLIC BINDER F - 733HN
GLOW IN DURK PRINTING AGENT:
LUMI COLOR G - 31NN
DENIM DISCHARGE AGENT:
BINDER 801 PRINTG[EN 801
DENIM PRINTING AGENT:
UNIBINDER NK-20
CRACK PRINTING AGENT:
CRACK BINDER 812(VINTAGE) UNIBINDER YL - 7 (VERTICAL) UNIBINDER YL - 8G(STIFFCRACK)
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SUEDE PRINTING AGENT:
UNIBINDER SED (N)
BURN - OUT PRINTING AGENT:
PRINTGEN OP- 30PS
TABLE ADHESIVE: NK PLASTER EH- HN
FLOCK PRINTING AGENT: MECOFLOCK D - 303 MECODUR D - 6207
PRODUCT AND PRICE LIS
PIGMENT COLOR FROM JAPAN:
SL.ITEMSPACKINGRATE:NOTK. PERKGPIGMENT COLOR (APEO FREE)01SEIKAFIX BLACK FLI CONC25 KGS350.0002SEIKAFIX BLUE FLB CONC25 KGS800.0003SEIKAFIX BLUE FLGB CONC25 KGS925.0004BRILLIANT RUBINE FLR25 KGS2450.0005SEIKAFIX GOLDEN YELLOW FL3R CONC25 KGS950.0006SEIKAFIX GOLDEN YELLOW FL5G CONC25 KGS875.0007SEIKAFIX GREEN FLB CONC25 KGS1175.00
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08SEIKAFIX LIGHT YELLOW FL2G25 KGS0625.0009SEIKAFIX ORANGE FLR CONC.25 KGS920.0010SEIKAFIX NAVY BLUE FL3R CONC.25 KGS1250.0011SEIKAFIX RED FL3G CONC.25 KGS1650.0012SEIKAFIX VIOLET FL3R25 KGS1725.0013EMF RED HR25 KGS1250.00FLUORESENT PIGMENT COLOR(APEOFREE)01SW - 12N GREEN25 KGS1000.0002SW - 14N ORANGE25 KGS1000.0003SW- 15N LEMON YELLOW25 KGS1000.0004SW - 28 BLUE25 KGS1000.0005SW- 13 RED25 KGS915.0006SW- 37 RUBINE25 KGS850.0007SW- 16N YELLOW25 KGS900.0008SW- 47 VIOLET25 KGS900.0009SW- 17 PINK25 KGS850.0010SW- 27 ROSE25 KGS850.00PIGMENT COLOR (AZO FREE)01MATSUMIN GLOW ROSE MI5B25 KGS700.0002MATSUMIN GLOW ORANGE MI2G25 KGS600.0003SANDY SUPER GREEN - LXB EXP25 KGS525.0004SANDY SUPER BLUE - FBL-16025 KGS750.00
THE ABOVE PRICE IS SUBJECTED TO CHANGE AT ANY TIME.
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PICTURES OF PRINTING MACHINE
Auto screen printing m/c
Manual revolvingprinting
Manual flat bed printing
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Embroidery
Machine no. -01
Machine name : Eletronic multi head Automatic Embroidery. Manufacture: TOKAI Industrial sewing m/c co. Ltd .Type: 2-2AModel: TFKN-912Origin: JapanNo. of needle: 09 pcs / headNo. of head: 12 pcsMachine speed: 700 rpm
Machine no.-02
Machine name : Eletronic multi head Automatic Embroidery.Manufacture: TOKAI Industrial sewing m/c co. Ltd .Type: 1-1AModel : TFGN-920Origin: JapanNo. of needle: 09 pcs / headNo. of head: 20 pcsMachine speed: 750 rpm
Machine no. -03
Machine name: Electronic multi head Automatic Embroidery.Manufacture: TOKAI Industrial sewing m/c co. Ltd .Type: 2-2AModel : TCMX-60915Origin: JapanNo. of needle: 09 pcs / headNo. of head: 15+15(MOSS) pcsMachine speed: 850 rpm
Machine no.-04
Machine name : Eletronic multi head Automatic Embroidery.Manufacture: TOKAI Industrial sewing m/c co. Ltd .Type: 2-2AModel : TFKN-912Origin: JapanNo. of needle: 09 pcs / head and 06 pcs /moosNo. of head: 15+15(MOSS) pcsMachine speed: 900 rpm
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Machine no.-05
Machine name: Laser cutterBrand name: Golden LASERManufacturer: WUHAN Golden Laser Equipment manufacturing co.Ltd
PICTURES OF EMBROIDERY MACHINE
Embroidery machine
Embroidery machine ControllerLaser cutter
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UTILITIE SECTION
Boiler: The equipment used for producing steam from water is called steam generator or boiler. The boiler used for producing steam in GKL is Cochran boiler which is a fire tube type boiler. This produced steam is supplied by the steam line in different section. Simple vertical boiler of fire tube type is mainly used in small plant requiring small quantity of steam and where floor area is limited.
Uses: Steam use for -
Power generation (steam engine / turbine). Processing in industries (dyeing & finishing mill, sugar mill, paper mill etc.). Heating purposes (houses, offices, hospitals etc in cold countries). Hot water supply.
Essentials of a good boiler:
Required pressure and quality at minimum fuel. Initial installation and maintenance cost low. Parts approachable for repairs. Quick starting capacity. Conform to the safely regulations of boiler act.
Working principle:
The gas is fed through the front side to the furnace where fire created by electric spark. The blower move the fire into the flue pipe by compress air and then the flue gases enter through the combustion chamber which is lined with fire bricks on the outer wall of boiler. The hot gases passing through the horizontal smoke tubes give their heat to the water and
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convert water into steam. This steam gets accumulated in the upper portion of shell from where it can be supplied to the users .Finally , the flue gases are discharged to the atmosphere through the smoke box and chimney .
Gas flow diagram ---
Gas
Air
FurnaceCombustionFlue pipeChambe rlue
Smoke boxChimneytubes Atmosphere
Water flow diagram ---
Water
FeedPump
Feed checkShell,StopValveSurroundingValve
Steam Boiler specification
Boiler -01:
Types of boiler: Fire tube boiler.Capacity of the boiler10 ton /hour.Source of the foul: Directly Gas used.Gas consumption: 345 m3 /shift.Rattingmin 8000-max 8500 KWSupply process: min-15 - max- 500 m bar.Control voltage: 230 VMain volt: 400 VElectric ratting2389 KWType of the burner: G70/2-A
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Safety valve setManufacturer
Boiler -2:
Types of boilerCapacity of the boilerSource of the foulGas consumptionRattingSupply processControl voltageMain voltElectric rattingType of the burnerSafety valve setManufacturer
Boiler -03:
Types of boilerCapacity of the boilerSource of the foulGas consumptionRattingSupply processControl voltageMain voltElectric rattingType of the burnerSafety valve setManufacturer
: 10.5 kgLOSS INTERNATIONAL (GERMANY)
: Fire tube boiler.8 ton /hour.: Directly Gas used.: 280 m3 /shift.min 8000-max 8500 KW: min-15 - max- 500 m bar.: 230 V: 400 V2389 KW: G70/2-A: 8.5 kgLOSS INTERNATIONAL (GERMANY)
: Fire tube boiler.5 ton /hour.: Directly Gas used.: 175 m3 /shift.min 8000-max 8500 KW: min-15 - max- 500 m bar.: 230 V: 400 V2389 KW: G70/2-A: 8.5 kgLOSS INTERNATIONAL (GERMANY)
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Burner
Fire tube boiler
Magnetic valve (used for gas feed to the
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GasGas meterGasPump
Generator
The only one source of electricity of FAKIR KNITWEAR LIMITED is the gas generator. They had four gases Generator to overcome the required electricity of the FKL.
Total power production capacity Water pump 900 KW/ Gas generator.
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Power distribution diagram
Generator
LT Panel Total Power needed/Day
Distribution Board
Knitting Section
Number of Generator
Machine no.-(01 and 02)
Name of the Generator
Dyeing SectionGarments Section
: Four (04) pcs {three pcs all time running rest of the generator is kept for any problem on thers generator
: WAUKESHA POOWER SYSTEM Origin: AmericaAgent of the Bangladesh: DATA ENGENEERS INT. LTD.Capacity of the Generator: 900KW / generator.Model: ECP 506 ESerial no.: C-94945-902/1Operating System: Digital VLC system.Date: September -06AC Amps: 1565AC Volts: 415/240Speed: 1000 rpm.Rotation of the generator: Anti clock wise.No. of cylinder: 12 pcs.
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Machine no. - (03 and 04)
Name of the Generator: WAUKESHA POOWER SYSTEM.Origin: AmericaAgent of the Bangladesh: DATA ENGENEERS INT. LTD.Capacity of the Generator: 900KW / generator.Model: 3080 EsmSerial no.: C-94636-902/1AC Amp: 1565AC Volt.: 415/240Operating System: analog system.Date: September -04Speed: 1000 rpm.Rotation of the Generator: Anti clock wise.No. of Cylinder: 12 pcs.
Flow chart of electricity distribution on FKL
Generator
Main panel board
ACP (sub panel board)
Distribution
Machine number (5, 6, 7, 8, 9 and 10) Name of the machine: compressor.Manufacturer: KAESAR ASP-47(GHERMANY)Capacity: 8.0 bars /machine /hour.Temperature: 82C
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Machine number (11, 12 and 13)
Name of the machine: Dryer.Manufacturer: KAESAR TE -141 (GERMANY).Temperature: 120
Gas GeneratorGenerator controller
Different parts of Generator
Battery. Panel. Distribution board (DB). Generator control panel.
A. Battery: It is just used to support the engine starting time other wise it is not work forany.
B. Panel:To store the power (volts & amps) from the for every section in the factory.There are
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Two types of panel -
a) PFI (power factor improvement) panel. b) LT (low tension) panel.
a) PFI panel - To store the power ( volts & amps ) from the generator for the boiler House, dyeing & finishing section in the factory. Supply AC current, 4 amps, 400 volts & 50 Hz. b) LT panel - To store the power ( volts & amps ) from the generator for the boiler House, dyeing & finishing section in the factory. Supply AC current 4 amps, 400 volts & 50 Hz.
This factory only used LT panel.
C. Distribution board: To supply the power for the light, AC, fan etc in different section. Supply AC current, 4 amps, 400 volts & 50 Hz.
D. Generator control panel: To control generator for generates power.
Effluent treatment plant (ETP)
The major sources of liquid discharge are: - De - sizing and scouring. - Bleaching. - Dyeing. - Washing.
Dye wastes content:
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- Carbon, nitrogen, phosphorus.
Bleaching: - Dilute hypochlorite solution. - H2O2
Raw materials: 1. main raw material: -Cotton yarn.- mixed yarn - Dyes - Chemical 2. dye include: - Reactive. - Disperse. 3. Chemical includes: - Detergent - Soda ash - Caustic soda. - H2O2 - Stabilizer. - Acetic acid.
The characteristics of waste water of FKL assumed as follows:
- pH = 11 - BOD = 300 mg/L - COD=200 mg/L - Suspended solid (SS) = 200 mg/L - Color = dark
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Effluent treatment plant ETP
Process: chemical.
Capacity: 120 m3 / hour.
Step -1: EQUALIZER(Certain amount of BOD & COD decreases by air agitation)
Step-2: FLOCCULATION(Here mixing Ferrous sulphate, lime,& polymer by dozing).
Step-3: CLARIFIER (separation the water and flock)
Step - 4 PH CORRECTION TANK (Here ph controlled by adding required acid / alkaline)
Step - 5 SAND FILTER (Extra suspended impurities separation by passing into the sand)
Step-6 CARBON FILTER (Here removed suspende4d solution and correction the watercolor)
Final treated Quality of FKL discharge is:
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- PH = 6-9 - BOD = 30 mg/ L - COD = 160 mg / L - Suspended solid = 30 mg/L - Color = color less. BSTIS required: - Ph = 6-9 - BOD = 50 mg/L - COD= 200 mg/L - Suspended solid = 150 mg/L - Color = Light brownish. Deferments unit of ETP
Ferrous sulphate tankLime tankPolymer tank
EqualizerFloc
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PH controllerCarbon filterFresh water
Function Of Different Ingredients Used In E.T.P Plant
Lime (CaCO3): Lime is used to change the color of effluent and also to increase the transparency of the colored water. Ferrous Sulphate (FeSO4): Ferrous Sulphate is basically used for the agglomeration of the colloidal matters present in the effluent. Polymer (Poly Electrolytes): Poly electrolytes help to flocculate precipitate for easy deposition at the bottom of the clarifier tanks.
Hydrochloric acid (HCl): Hydrochloric acid is used to maintain the required pH of the water.
Compressor
Basically Compressor generate the compress air which distributed in the knitting, dyeing & finishing section and this air is used for following reasons-
-To clean the m/c parts in knitting zone.-To open different type of valves in dyeing m/c during dozing, water feeding,drainage time.
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-Squeezer needed compress air for balloon form.-Turning M/Cs needed compress air for batch preparation.
Compressed air is produced by air compressor. There are six air compressors and threedryers in FAKIR Knitwears Limited. For producing compressed air.
Name of the compressor: KAESAR.Origin: GARMANY.
Dryer: Dryer dried the moisture which present in the compress air.
Name of the compressor: KAESAROrigin: GARMANY.
Maintenance
Maintenance is a process by which equipment is looked after in such a way the equipment can give the best services of it. Machine, buildings and other facilities are subjected to deterioration due to their use and exposure to environmental condition. Process of deterioration, if unchecked, culminates in rendering these service facilities unserviceable and brings them to a standstill. In Industry, therefore has no choice but to attend them from time to time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so. Maintenance increases the life time of the machine. Now a days maintenance has become the essential for the modern time industrialization.
Objectives of maintenance: 1. To keep the factory plants, equipments, machine tools in an optimum working condition. 2. To ensure specified accuracy to product and time schedule of delivery to customer.
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3. To keep the downtime of machines to the minimum thus to have control over the production program. 4. To keep the production cycle within the stipulated range. 5. To modify the machine tools to meet the need for production
Types of maintenance:
MAINTAINANCE
PERIODIC
MECHANICAL
ELECTRICAL
Periodic Maintenance:
PREVENTIVE
MECHANICAL
ELECTRICAL
BREAKDOWN
MECHANICAL
ELECTRICAL Maintenance of different machines is prepared by expert engineer of maintenance department for a period of time. Normally in case of dyeing machine maintenance after 30 days complete checking of different important parts are done.
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.
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Break down maintenance: In this case, repairs are made after the equipment is out of order or broken and it can not perform its normal functions.
Flowchart of maintenance: Problem
Inform to maintenance department
Detect problem
Problem can be repairing or replacing Repair can be solved immediately, replacing requires time (parts needed to buy & then solved the problem)
WATER TREATMENT PLANT
Natural water quality:
Water for a textile plant may come from various sources. These include surface water from rivers and lakes, and subterranean water from wells. In Fakir Knitwears Limited they collect water from Under ground. Natural and pretreated water may contain a variety of chemical species that can influence textile wet processing in general, and dyeing in particular.
The various salts present in water depend on the geological formations through which the water has flowed. These salts are mainly the carbonates (CO32- ), hydrogen carbonates or bi-carbonates ( HCO3- ), Sulphates ( SO42- ) and chlorides ( Cl- ) of calcium ( Ca2+), magnesium (Mg2+) . Although calcium and magnesium carbonates in limestone are relatively insoluble in water. So in this reasons, water hardness can be divided into two ways-
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1) Temporary hardness : Ca(HCO3)2 , Mg(HCO3)2 , Fe(HCO3)2 .
2) Permanent hardness : CaCl2 , CaSO4 , Ca (NO3)2 , MgCl2 , MgSO4 , Mg(NO3)2 .
This water hardness causes some serious consequences in a textile dyeing and finishing industries and these are -
-Precipitation of soaps.-Redeposit ion of dirt and insoluble soaps on the fabric being washed ,this can cause yellowing and lead to uneven dyeing and poor handle.-Precipitation of some dyes as calcium and magnesium salts.-Scale formation on equipment and in boilers and pipelines.-Reduction of the activity of the enzymes used in washing.-Incompatibility with chemicals in finishing recipes and so on.
Hardness expressed by parts per million (ppm) of CaCO3 which is standard hardness scale and it is also called American hardness. The hardness of raw water is 100 ppm or more. To use it in dyeing and in boiler this water must need to soft & foreign materials needs to remove.
Methods of water softening There are mainly three methods by which hardness of water is removed in Industrial scale -
A. Lime-soda process. B. Base Exchange process (Permutit process). C. Demineralization process.
Above these three processes, Fakir Knitwears Ltd used the Base Exchange Process.
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The flow chart of water treatment plant is given below -
StoneHard Water Store TankFilter
CarbonResinDele-FilterFilterVeryPump
Soft Water Store Tank
Fig: Water treatment plan
Removal of Water hardness test:
Necessary equipments & chemicals: -Buffer soln .-Indicator.-Liquid EDTA soln .-Beaker.Procedure:
-Take 50 ml water in a beaker which treated by WTP-plant.-Take 4/5 drops buffer soln in a beaker .-Take 1 drop indicator in a beaker and form the violet color.
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-Now EDTA soln is dropped until the pink color is not form a crystal color.
Here, 1 drop EDTA soln = 3 ppm .
Result: Industrial Soft-water std. range is 5 ppm but it is very difficult to control. So in this industry, water hardness scale maintains 7 to 8 ppm of CaCO3.
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