Industrial attachment of MM KNITWEAR Ltd

SOUTHEAST UNIVERSITY Department of Textile Engineering

Report on 2 months Industrial AttachmentAs a curriculum in Wet Processing Technology

(From 05th February to 06th April, 2011)At

M M Knitwear Ltd. Konabari,Nilnagar, Gazipur.

Supervising Teacher: Prof. Syed Fakhrul Hassan Murad

ChairmanDepartment of Textile Engineering

Southeast University

Submitted By :Kazi Mamun HossainID No: 2007100400024

Md.Azijul HaqueID No: 2007100400045

Dhaka, 16.05.2011

ACKNOWLEDGEMENT

At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the industrial training and this report. You have made my life more bountiful. May you name be exalted, honored and glorified.

Now I wish to take this excellent opportunity to thank a lot of people who have assisted and inspired me in the completion of my training period:

I express my gratitude to Prof. Syed Fakhrul Hassan Murad, Head, Department of Textile Engineering, and my supervisor, to whom I am extremely indebted for his tremendous support and guidance throughout my training period. Being working with him I have not only earned valuable knowledge but was also inspired by his innovativeness which helped enrich my experience to a greater extent. His ideas and way of working was truly remarkable.

I would like to thank the management of the M M Knitwear Ltd. for giving me the opportunity to do the industrial training successfully and also their valuable suggestions. My deepest appreciation goes to Mr. Nurul Islam, General Manager, M M Knitwear Ltd. for his permission to conduct my industrial training without which it would be uncompleted. The generous support is greatly appreciated.

I would also like to thank executives, senior executives and other officials of M M Knitwear Ltd. for helping me to complete industrial training successfully. My gratitude also goes to all the employees of M M Knitwear Ltd. for their sincere co-operation, support and valuable advices.

Last but not least, thanks go to my precious family for their never ending love and inspire at every stages of my life. Without their continuous support I realize that I would not be a person I am right now.

TABLE OF CONTENTS

CHAPTER – 1.......................................................................................................3

1 Project Description.......................................................................................5

1.1 COMPANY PROFILE..............................................................................................6

1.2 location:...............................................................................................................7

1.3 Basic lay-out of the factory..................................................................................8

1.4 Vision and Mission.............................................................................................10

1.5 Different Departments......................................................................................11

1.6 Remarks.............................................................................................................11

CHAPTER – II.....................................................................................................12

2 Man power management............................................................................13

2.1 Dyeing & Finishing Section................................................................................14

2.2 Knitting section..................................................................................................15

2.3 Management System.........................................................................................16

2.4 Duties & Responsibilities of Production Officer.................................................16

2.5 Duties & Responsibilities of Senior Production Officer......................................17

2.6 Duties & Responsibilities of GM (Production)...................................................17

2.7 Remarks.............................................................................................................17

CHAPTER – III....................................................................................................18

3 Machine Description...................................................................................19

3.1 Lay-out Of Dyeing & Finishing Section...............................................................19

3.2 Dyeing Machinery..............................................................................................21

3.3 Finishing Machinery...........................................................................................26

3.4 Description of Machinery..................................................................................27

3.4.1 Working principle of dyeing machinery......................................................27

3.4.2 Working principle of finishing machinery...................................................28

3.5 Remarks.............................................................................................................40

CHAPTER – IV....................................................................................................41

4 Raw material................................................................................................42

4.1 Grey Fabrics.......................................................................................................42

4.2 Dyes...................................................................................................................42

4.3 Chemicals..........................................................................................................44

4.4 Remarks.............................................................................................................44

CHAPTER-V.......................................................................................................45

5 PRODUCTION PLANNING,SEQUENCES & OPERATION.........................46

5.1 Process flow chart of knit dyeing.......................................................................46

5.2 Dyeing work flow chart......................................................................................47

5.3 Dyeing Parameters............................................................................................48

5.4 Description of production process.....................................................................49

5.5 Dyeing Recipe....................................................................................................52

5.6 Finishing............................................................................................................ 55

5.7 Finishing machine setting..................................................................................56

5.8 Daily Production Report....................................................................................57

5.9 Monthly Average Production.............................................................................57

5.10 Remarks.............................................................................................................57

CHAPTER – VI....................................................................................................58

6 QUALITY ASSURANCE SYSTEM...............................................................59

6.1 Quality Policy.....................................................................................................59

6.2 Quality Assurance Procedure............................................................................59

6.3 Inspection area..................................................................................................60

6.4 PROBLEMs ENCOUNTERED IN DYEING..............................................................61

6.5 Process of Shade Matching................................................................................63

6.6 List of Equipments.............................................................................................63

6.7 Quality Standard................................................................................................64

6.8 Remarks.............................................................................................................64

CHAPTER- VII....................................................................................................65

7 Maintenance................................................................................................66

7.1 Maintenance of Machinery...............................................................................66

7.2 Routine..............................................................................................................66

7.3 Manpower Setup for Maintenance...................................................................67

7.4 Maintenance Procedure....................................................................................67

7.5 Maintenance Tools and Equipments.................................................................70

7.6 Remarks.............................................................................................................71

CHAPTER- VIII...................................................................................................72

8 UTILITY SERVICES.....................................................................................73

8.1 Utility Facilities Available...................................................................................73

8.2 Source of Utility.................................................................................................73

8.3 Capacity and Other Technical Details................................................................73

8.4 Cost of different Utilities...................................................................................76

8.5 Remarks.............................................................................................................76

CHAPTER – IX....................................................................................................77

9 STORES & INVENTORY CONTROL...........................................................78

9.1 Scope of Inventory Control................................................................................78

9.2 Frequency of Inventory Update.........................................................................78

9.3 Inventory Control System for Raw Materials.....................................................78

9.4 Inventory Control System for Finished fabric....................................................79

9.5 Inventory Control System for Spare Parts.........................................................79

9.6 Remarks.............................................................................................................79

CHAPTER-X.......................................................................................................80

10 COST ANALYSIS.....................................................................................81

10.1 INTRODUCTION.................................................................................................81

10.2 Costing elements...............................................................................................81

10.3 Knitting Charge of Different Fabrics...................................................................81

10.4 Dyeing Charge of Different Fabrics....................................................................82

10.5 Finishing Charge of Different Fabrics.................................................................83

10.6 COSTING OF THE PRODUCT...............................................................................83

10.7 Remarks.............................................................................................................83

CHAPTER – XI....................................................................................................84

11 MARKETING ACTIVITIES........................................................................85

11.1 Consumer of Products.......................................................................................85

11.2 Country of Export..............................................................................................85

11.3 Local Market......................................................................................................85

11.4 Marketing Strategy............................................................................................85

11.5 Duties & Responsibilities of Marketing Officer..................................................86

11.6 Remarks.............................................................................................................86

CHAPTER –XII....................................................................................................87

12 Effluent Treatment Plant (ETP)...............................................................88

12.1 Process Flow chart of Biological Effluent Treatment Plant................................88

12.2 Function of different Unit of Biological Effluent Treatment Plant (E T P)..........89

12.3 Product Quality Checked...................................................................................90

12.4 Remarks.............................................................................................................90

CHAPTER –XIII...................................................................................................91

13 Conclusion...............................................................................................92

13.1 SOME SUGGESTIONS.........................................................................................92

13.2 Limitations of the report...................................................................................93

Industrial Attachment Introduction

Introduction :

Industrial attachment is the first step to professional life of student, especially of technical Side. It’s an indispensable part of study a practically running processing technology of an industrial unit for a student .In our university , processing machines are not in continuous running condition, so it would only provide demonstration of mechanical features & processing technology of the material in accomplishment of the theory there of but not of the situational variables to achieve practical knowledge. So two months industrial attachment program in a dyeing mill was arranged for us.

Textile education can’t be completed without industrial training. Because this industrial attachment program minimizes the gap between theoretical and practical knowledge and make me accustomed to industrial environment. I got an opportunity to complete two month long industrial training in M M Knitwear Ltd , which is a 100% export, oriented composite Knit Dyeing Industry. It has well planned & equipped fabric and Knit dyeing-finishing units in addition to facilitate Knitting and Knit wear manufacturing.

The rationale behind the existing structure and future expansion of M M Knitwear Ltd is to capture value-added at each stage of the textile manufacturing process.

Despite Bangladesh’s lack of indigenous cotton production capacity, M M Knitwear Ltd has leveraged Bangladesh’s labor cost advantage and export competitiveness to the Maximum.

Southeast University Page | 1

Industrial Attachment Objectives

Objectives :

To familiarize with the factory and production.

To set the sequential work and factory layout

To keep a motel on the deviation between theory and industrial bulk production

To correlate between institutional and industrial working techniques and procedures

To observe the management system

To have a concept on production planning, costing, marketing techniques etc

To know about waste reduction and utilization

To know about how a technical person developed quality of products at various steps (knitting, dyeing, finishing and garments making)

To have a proper knowledge on the product development to customer handling


CHAPTER – 1

PROJECT DESCRIPTION


Industrial Attachment Project Description

M M Knitwear LTD



1 PROJECT DESCRIPTION

M M Knitwear Ltd has started manufacture and export of garments since 2001. The beginning M M Knitwear Ltd has a very good reputation as a financially sound and ethical business house. It has a long term association with selected factories, some of them are certified in terms of social and quality compliance by world’s highest rating bodies, and outstanding sourcing capabilities. Thus M M Knitwear Ltd has been able to prove itself to be a reliable supplier for knit item in any style and design

Specializing in all kinds of knitted items. It is housed in its own building surrounding an area of 310,000 sq. ft. And 4,300 workers and stuff.

The determination to achieve superior customer service and on time delivery has earned M M Knitwear Ltd recognition as an invaluable player and the desire to succeed in customer satisfaction with every order makes the M M Knitwear Ltd team even stronger it’s these fundamental that keep this unit in the game and wining every time.

Buyers:

Sl. buyers

1 NEW YOURKE

2 MERCURY

3 ROWA

4 VISAGE

5 WHITE STONE

6 LI & FUNG

7 SPRING FIEL


GENEREL INFORMATION ABOUT THE FACTORY


1.1 COMPANY PROFILE

Name of the project : M M knitwear LTD.

Type of the project : 100% Export oriented Knitwear industries

Year of establishment : It was established in the July2001.

Address : Factory, Ambag road, Konabari , Nilnagar Gazipur, Bangladesh.

Head office : House #16, Road #10, Sector # 1,Uttara Model Town Dhaka-1230, Bangladesh

Investors : Md. Mofizul Islam, Managing Director

History of the project : M M Knitwear has started manufacture and export of garments since 2001.

Project Cost : The project cost of M M Knitwear Ltd is nearly 100.croretaka.

Annual production Capacity: The annual production capacity in MMKL ltd are given Below-

Dyeing & Finishing Capacity : 7250 Tons. (Around)

Knitting Capacity: 3250Tons. (Around)

Sewing: 50000 pcs/day (Average)

Area : 310,000 sq. ft.



1.2 location:


Department of Textile

Engineering

SEU

TANGAIL ROAD

DHAKA

H

IGHWAY

GA

ZIP

UR

R

OA

D

GAZIPUR CHOWRASTA

MYMENS

ING

HIGHWAY

M M Knitwear

Ltd.

A

M

B

A

G

R

O

A

D

KONABARI


LOCATION OF M M KNITWEAR LTD

1.3 Basic lay-out of the factory W S N

E


2

4

3

5

6

E

NTRY

E

X

I

T

7

1


Vision & mission of the project:

1 : Security office.

2 : Administration office

3 : Fabrics Store (Gr.Floor)+Knitting (2ndFloor+3rd floor), . .

Human Resources Department (HRD)(4thFloor), .

Marchanding section (5thFloor), garments(6th Floor – 9th floor)

4 : Yarn store (Gr. Floor)+ +Garment section(1st Floor – 7th floor)

5 : Fabric dyeing & finishing section.

6 : Effluent Treatment Plant (ETP).

7 : Generator house, Water Treatment Plant(WPT), Maintenance building.



1.4 Vision and Mission

The mission and vision of M M Knitwear Ltd. is to manufacture and deliver high quality readymade garments (RMG) to its customers. The core objective is to attain and enhance customer satisfaction by providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce.

To attain these objectives, the management of M M Knitwear Ltd. has decided to adopt the following-

1. To increase awareness regarding customers requirements throughout the organization.

2. By providing training to develop efficiency of the employee.3. To collect customer’s feedback regularly to know about their conception about

their company and to take timely appropriate action.4. To reduce the percentage of wastage / rejection minimum by 2% per annum’s

implement and monitor ISO 9001:2000 quality management system within the organization

Main Production : Basic T-Shirt, Tank top, Long Sleeve- Shirt, Polo Shirt, Shorts, Ladies & Kids Knitwear & all kinds of knit garments & Knit fabrics.

Fax Number : + 880 – 2 – 8922483

E–mail Address : [email protected]

URL : http://www.mmknitwearbd.com

Certification & awards : Oeko Tex Standard 100 Certified by the concern authority.

Last year Export Turnover : 18.50 Million U.S Dollars

Workers and Stuff : 4,300

The annual Production capacity of M M knitwear Ltd is an approximate idea, it may vary.


http://www.texeuropbangladesh.com/

mailto:[email protected]


1.5 Different Departments

To ensure smooth running of various activities, some departments are available they are given bellow:

KNITTING SECTION: 1.Knitting 2.Inspection

KNIT DYEING SECTION: 1.Batch section 2.Store house for dyes & chemicals 3.Dye house 4.Dyeing & QC lab 5.Finishing

GARMENTS SECTION: 1.Merchandising 2.Sample

3.Production MAINTENANCE:

1.Electrical 2.Mechanical

ACCOUNTS & COMMERCIAL SECTION ADMIN SECTION

Physical Infrastructure : Buildings- one ten storied building, one six storied building, and 1 dyeing shade.

Buildings are made by brick.

Total Area of Industry : 3,00,000 Sq.Ft

1.6 Remarks

The company owns 300000 Sq. Ft. of high land property at Ambag,Konabari,Gazipur,Dhaka; which is 10 km from the Gazipur Chourasta. Charming sights along with natural beauty of rural areas with no hazards or air pollution attracts the foreign buyers during their visits. The company has the desire to achieve recognition of the project as the ‘M M Industrial Park’ and to set up within the park area industries and health care center in near future. Plans include for Acrylic Yarn manufacturing unit, Packaging unit, Designing unit and Hospital.


CHAPTER – II

MANPOWER MANAGEMENT


Industrial Attachment Man power Management

2 MAN POWER MANAGEMENTThe company has skilled administration, management and marketing team guided by proficient, dexterous & experienced leaders of offer right solution for the consumers with the right eminence & with the shortest lead-time for the export market in Bangladesh. The best use of continuous development of human resources by providing them standard equal opportunity is the keys for achieving comprehensive competence in all level of the organizational hierarchy.M.M. knitwear ltd the Managing Director/ Chairman who controls the entire factory. And the others respective department chief controls their department in this factory.In this below the organ grams of administration and the others department is showing:


Medical Officer

Nurse

Deputy

Chief Egg.Deputy Account Officer

Accounts Officer

Assistant

Accounts Officer

Senior Clark

Junior Clark

Peon

Electrical

Eng.

Mechanical

Egg.

Sub assistant

Eng.

Foreman

Sub assistant

Eng.

Foreman

Director, H R Dept.

Managing director

Assistant General Manager

(ADMIN)Security

Officer

Assistant

Security

Officer

Marketing Officer

.Security

Guard

Security

Havilder

Asst. Chief store Manager

Asst. Officer

Store officer

Foreman

Store

Manager

Assistant Manager (ADMIN)

Administration

Officer

Assistant Administration

Officer

Peon

Administration

Assistant


2.1 Dyeing & Finishing Section


Squeeze

Operator

Dryer

Operator

Lab

Technician

GM

PM

APM

SPO Batch

In charge

Finishing

In charge

PO

APO

Supervisor

Sr. Operator

Operator

Asst. Operator

Sewing man

Helper

Turning m/c

Operator

Helper

Sewing man

Compactor

Operator

Helper

Lab

In charge

Q.C.

Technician


2.2 Knitting section

Section-wise manpower

Department ManpowerKnitting 150Dyeing & Finishing, Lab & QC 320

ETPs 10Garments 3590Power, Boiler, Utility & Maintenance 50Inventory 10

Administration 77Security 55Others 44Total 4306


Store Incharge SupervisorKnitting Master

Fitter man

Operator

Fitter man

Operator

AGM

PO


Management Medium:

Intercom telephone Fax E-mail Written letters & Papers Oral

2.3 Management System

Buyer sample is send to G.M. Matching is done by lab in charge. Sample is prepared by dyeing master. Sample is send to the buyer for approval. Approved sample is returned and taken as STD. Sample for bulk production. Asst. dyeing master gives responsibilities to production officer. Then production officer, with the supervisors start bulk production. On line and off line quality check is done by lab in charge and asst. dyeing master. After dyeing finishing in charge controls the finishing process with the supervision of

production officer. After finishing, the material is checked by dyeing master. Finally G.M. checks the result with dyeing master and decision is taken for delivery.

2.4 Duties & Responsibilities of Production Officer

1. To collect the necessary information and instruction from the previous shift for the smooth running of the section.

2. To make the junior officer understand how to operate the whole production process.3. To match production sample with target shade.4. To collect the production sample lot sample matching next production.5. To observe dyed fabric during finishing running and also after finishing process.6. To identify disputed fabrics and report to PM/GM for necessary action.7. To discuss with PM about overall production if necessary.8. To sign the store requisition and delivery challan in the absence of PM9. To execute the overall floor work.10. To maintain loading/ unloading paper.



2.5 Duties & Responsibilities of Senior Production Officer

1. Overall supervision of dyeing and finishing section.2. Batch preparation and pH check.3. Dyes and chemicals requisition issue and check.4. Write loading / unloading time from machine.5. Program making, sample checking, color measurement.6. Control the supervisor, operator, asst. operator and helper of dyeing machine.7. Any other work as and when required

2.6 Duties & Responsibilities of GM (Production)

1. Overall supervision of dyeing and finishing section.2. Check the sensitive parameters of different machines for smooth dyeing.3. Check the different log books and report to management. 4. Check the plan to control the best output.5. To trained and motive the subordinates how to improve the quality

production.6. Control the supervisor, operator, asst. operator and helper of dyeing m/c.7. Maintenance the machinery and equipments.8. Any other work as and when required

2.7 Remarks

The manpower management system of M M Knitwear Ltd. is well arranged. Every officers & stuffs are responsible for their duty. But there are only three textile engineers in the industry (General manager, Production manager and Production officer). It is not sufficient for smooth production. More technical people is required.


CHAPTER – III

MACHINE DESCRIPTION


Industrial Attachment Machine Description

3 MACHINE DESCRIPTION

3.1 Lay-out Of Dyeing & Finishing Section

N W E

S


ENTRY

ENTRY

73

4

6

5

9

8

18

10 10

2

11

13

13

13

13

13

13

13

13

13

13

1317

17

17

16

16 17

17

15

15

16

12

14


1. Office of PM

2. Offline QC

3. Inspection table

4. Compactor

5. Tube-tex

6. Equalizer Dryer

7. Steenter

8. Calender

9. Slitting m/c

10. Squzzer m/c

11. Office of GM

12. Chemical store

13. Dilmelner high pressure Dyeing m/c

14. Office & Online QC

15. Bangla dyeing m/c

16. Korean dyeing m/c

17. Sample dyeing m/c

18. Turning m/c



3.2 Dyeing Machinery In dyeing section of M M Knitwear Ltd, there are 22 Dyeing Machines, among of them 7 m/c’s are for sample dyeing and 15 m/c’s are for bulk production.

Machine no.- 01:

Name : Semi-Automatic Vertical Winch-1 chamber Brand : SungmooOrigin : KoreaCapacity : 120 kg/BatchEfficiency : 80-90 %Temperature : (maximum)Pressure : AtmosphericMaterial : Liquor : 1:8

Machine no.- 02:

Name : Semi-Automatic Vertical Winch-2 chamber Brand : SungmooOrigin : KoreaCapacity : 240 kg/BatchEfficiency : 80-90 %Temperature : (maximum)Pressure : AtmosphericMaterial : Liquor : 1:8

Machine no.- 03 :

Name : Semi-Automatic Vertical Winch-3 chamber Brand : SungmooOrigin : KoreaCapacity :350 kg/BatchEfficiency : 80-90 %Temperature : (maximum)Pressure : AtmosphericMaterial : Liquor : 1:8

Machine no.- 04 :

Name : Semi-Automatic Vertical Winch-4 chamber Brand : SungmooOrigin : KoreaCapacity :450 kg/BatchEfficiency : 80-90 %Temperature : (maximum)Pressure : AtmosphericMaterial : Liquor : 1:8



Machine no.- 05 :

Name : Semi-Automatic Vertical Winch-1 chamber Brand : TongjengOrigin : TaiwanCapacity :150 kg/BatchEfficiency : 80-90 %Temperature : (maximum)Pressure : AtmosphericMaterial : Liquor : 1:8

Machine no.-06:


Machine no.-07:


Machine no.-08:

Name : Dms Ht Jumbo Jet Flow (HP Winch) Brand : DilmenlerOrigin : TurkeyCapacity :50 kg/BatchEfficiency : 80-90 %Temperature : 135o C(maximum)Pressure : Water 4 bar and Steam 6 BarMaterial : Liquor : 1:9



Machine no.-09:


Machine no.-10 :


Machine no.-11:


Machine no.-12:




Machine no.-13:


Machine no.-14:


Machine no.-15:


Machine no.-16&17:

Name : Sample Winch Brand : SuntexOrigin : ChainaCapacity :15 kg/BatchEfficiency : 80-90 %Temperature : 95o C(maximum)Pressure : AtmosphericMaterial : Liquor : 1:8



Machine no.-18&19:

Name : Sample Winch Brand : SuntexOrigin : ChainaCapacity :30 kg/BatchEfficiency : 80-90 %Temperature : 95o C(maximum)Pressure : AtmosphericMaterial : Liquor : 1:8

Machine no.-20:

Name : Sample Winch Origin : BangladeshCapacity :10 kg/BatchEfficiency : 80-90 %Temperature : 95o C(maximum)Pressure : AtmosphericMaterial : Liquor : 1:8

Machine no.-21:


Machine no.-22:




3.3 Finishing Machinery

In finishing section of M M Knitwear Ltd, the machines which are available are listed below:

1. Slitter m/c(1 set)2. Stenter m/c(1 set)3. Detwisting m/c(2 set)4. Natural Gas Dryer m/c(1 set)5. Compacting m/c(4 set)6. Air Turning m/c(1 set)7. Calendering m/c(1 set)

Slitting machine:

Brand : Bianco Origin : ItalyCapacity :12000 kgs/Day

Sun-Supper ‘S’ Tenter(98″ Roller&8Chember) machine:

Brand : IIsungOrigin : KoreaCapacity :10000 kgs/Day

Pin chain compactor machine:

Brand : LafferOrigin : ItalyCapacity :6000-8000 kgs/Day

Open width compactor machine:

Brand : LafferOrigin : ItalyCapacity :1200-1800 M/H

Tube compactor calendar machine:

Origin : KoreaCapacity :7000 kgs/Day

Tubular compactor machine:Brand : TubetexOrigin : USACapacity :16000 kgs/Day



Soft Setting calendar machine :

Origin : KoreaCapacity :7000 kgs/Day

Natural Gas Dryer Machine 3 Chamber machine:

Brand : DilmenlarOrigin : TurkeyCapacity :14000 kgs/Day

Ait Turning machine:

Brand : DongnamOrigin : KoreaCapacity :12000 kgs/Day

Auto-detwisting Ballooning Squeezer machine :

Brand : DongnamOrigin : KoreaCapacity :7000 kgs/Day

Auto-detwisting Ballooning Squeezer machine :

Brand : MersonOrigin : TurkeyCapacity :7000 kgs/Day

3.4 Description of Machinery

3.4.1 Working principle of dyeing machinery

The dyeing m/c’s has a large tank where the fabric is loaded through out the nozzle. It has a good arrangement of water line (in let & out let), steam line, heat exchanger, liquor circulating motor and a chemical dosing tank. The loaded fabrics are circulating through out the nozzle continuously and the dyeing take place by the supplying of dye liquor by the liquor circulating motor when the fabric is passed over the drawing reel. It has also a control panel, which automatically control the production parameter. But it should firstly set manually. In case of low temperature machine it can raise up the temperature only

(maximum) where as a low temperature machine can raise up the temperature up to . During unloading of fabric drawing out reel is used.



Fig: HTHP winch dyeing machine

3.4.2 Working principle of finishing machinery

3.4.2.1 Slitting machine

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


Chemical dosing tank

Fabric


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.

Slitting machine contains the following Parts Basket Slitter Photo sensor Twist opener Padder squeezer Squeezing unit

Operational parameter

Set the padder pressure as required (3-7bar)

Set the speed as much as possible (30-80m/min).

Function of the Machine:

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



Problem causes by the Machine Photo sensor may failure For that fabric may be cut to the other line It may cause folding problem Bowing Spirality

3.4.2.2 Squeezing/Dewatering machine

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 widths 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. In feed & 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.

Different parts of dewatering m/cTube tex dewatering machine contains two unit & two bath. One is for extraction and another for processing where softener or other chemical are applied for giving extra finish.

Maintenance during operation Proper balloon form by compressor air other wise crease mark appears. Padder contract point a just perfectly according to the fabric construction otherwise

accurate water will not remove. Albatros must be clean every one or two hours later.

Function

Reduce water from fabric Fabric open from rope form Dia/width control Twisting and spirality control by twisting wheel Apply chemical Softening agent Brightening agent

Application of brightening agent / softening agent

Cationic Non / anionic Spamin Kl (white) Ultra sot QM (dull) Paranous Ic (PET)



Controlling parameter

Maximum pressure : 45 PSI For deep shade : 30-35 psi For medium shade : 20-25 psi For light shade : 10-12 psi Squeezer pressure : 4kg (maximum) Maximum speed : 80m/min

If pressure is increase, shade will be light.

Problem causes by the Machine

Crease mark Bowing Twisting Uneven padder setting causes uneven squeezing

3.4.2.3 Dryer After de-watering the fabric is passed through the dryer. 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 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 temperature 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.



Special feature of Tube Tex steam dryer

Steam dryer (two chambers). Vibration occurs in heating zone. Process air pressure switch present. Maximum temperature increase up to 2000C. Steam control switch present. Two burners present. Two conveyor belts are present.

Maintenance during operation

Temperature: Set the temperature between 1200C -1300C for white and 1500C -1700C for color fabric. If GSM is high then temperature will be high or, moisture content is high temperature will be high.

Set the over feed up to 10~20% or as required to get finish G.S.M.

Set the speed as much as possible (6~20m/min). if GSM is high then speed will be high.

Function

Dry the fabric GSM control Shrinkage control up to 3-3.5% 75% dries at 150oC




Maximum temperature : 2000C Minimum temperature : 1100C For colored fabric : 1500C-1850C White fabric : 1200C-1300C

The temperature of different chambers according to the shade of the fabric

Drying temperature depends on GSM of the fabric

GSM White Colored130 1200C 1300C140 1350C 1400C150 1400C 1450C160 145-1500C 1500C170 1550C 1550C

190-200 1600C 1650C200-250 1750C 165-1750C250-350 1850C 1850C


Shade variation due to uncontrolled temperature More roller speed caused the Wales distortion For Lycra heat setting is more necessary If heat is more Lycra fabric can be extended and create low GSM fabric Light shade due to high temperature

3.4.2.4 Stenter machine

Stenter Machine is generally used to finish the open fabric. This stenter machine consists of eight chambers; each contains one burner, two blowers, two ducting line, nozzles and suction fan attach with the suction line. The burner produces hot flue gases which guided though the ducting line by the help of blower. There are nozzles placed above and bellow the rail. When the fabric passed through the rail, then hot air is sprayed to the above and bellows the fabric with the help of nozzle. The hot air is circulating in the chamber and the moisture in the fabric is evaporated, which leave the chamber with the help of suction fan through the ducting line. Temperature of each chamber can control automatically by


Shade Chamber-1 Chamber-2Light 1200c 1300c

Medium 1350c 1400cDeep 1500c 1700c


controlling the intensity of burner. Generally lower temperature is maintained the first and last chamber then other chambers.

The speed of the fabric is maintained according to the moisture content of the fabric. After passing the fabrics to all the chambers, the fabric is collected for compaction.

Fig: Passes diagram of senter machine

The performance of the stentering range depends on proper introduction of the cloth into the machine. The finer the fabric is being processed, the greater the significance of the correct, crease free and fault free fabric introduction. In stenter m/c the fabric first passed through different rollers including weft straightening device, uncurling device for proper feeding of the fabric into the machine. Then it passed through the selvedge detector which detect the selvedge and adjust the rail for proper gripping the fabric in the pin arrangement. This stenter m/c consists of both pin and clip arrangement. The fabric first grip by pin and gust before entering the chamber, pin are locked by clip arrangement. To maintain proper dimension of the fabric, length wise overfeed and width wise tension is given to the fabric.

Important parts

- Burner (12) - Suction Fan (12)


Weft

Straighter

Walkway

Feed Roller

Delivery Roller

Feed

FabricChemical Tank Softener Tank

Six Chambers Cooling Chamber

Delivered

fabric

Padding

Rollers

Padding

Rollers


- Exhaust air fan (6) - Nozzle

- Over feed roller. - Chain arrangement

Different sections & their function of stenter machine

Padder Section: In the padder section the fabric is treated with chemicals specially with softener and acid in two tanks.

Weft straightner: The main function of Weft Straightner is to control the bowing & Skewnesss of the fabric.

Width Setting Chamber: This Chamber control the width of the fabric by clip of 10 pin.Heatting Chamber: This chamber controls the shrinkage and the G.S.M of fabric.Temperature Range: Cotton- 1500C~1700CPolyester-1650C~1850CWith Lycra -1750C~1900CCooling Chamber: This chamber cooled the hot fabric before reach to delivery zone.

Exhaust Motor: This specific part used to exit the steam produced in the chambers and also exit the extra temperature from the machine.

Delivery Zone: This zone delivered the fabric in a folded form. In this zone the fabric has toPass through several rollers in order to prevent the formation of crease mark in the finished fabric.


No. of chamber : 8 (without cooling chamber) No. of burner : 8 No. of blower : 16 Padding mangle : 2 Exhaust fan : 8 Type : pin stenter Maximum production : 5ton/day Chamber to chamber distance : 3m Padder pressure : 3-4kg

Temperature setting



Maximum temperature : 200˚c Minimum temperature : 130˚c Heat setting range : 175-185˚c Lycra heat setting range : 175˚c -180˚c for finishing

: For Dyed fabric is done at 170˚c-175˚c

Temperature setting for different shade

For light shade : Normal temp For deep shade : High temp Pigment dyeing : 150˚c -160˚c

Function of stenter machine

1. Apply chemicals 2. Apply softener 3. Drying of fabrics 4. Width control 5. Curing of fabric 6. GSM control 7. Shrinkage control 8. Spirality control 9. Heat setting on cotton/ Lycra 10. Pigment dyeing 11. Bowing effect control 12. Surface coating 13. Heat setting


Lycra may be decompose due to unbalanced heat Elasticity may be loose due to dia extension caused GSM low Color spot may be occurred due to lack of proper chemical mixing Softener spot Foaming spot Iron spot Running shade may be seen due to difference between speed and heat Crease mark may be appeared if expanding of the fabric is not accurate.

3.4.2.5 Compactor machine



The main object of compactor is to make the fabric surface smooth, to control the residual shrinkage, G.S.M and if required fabric width also. To control the residual shrinkage the fabric is previously shrinkage artificially by gathering of loops of knitted fabric and it is set by heat and pressure. In tube & open compactor, the dried knitted fabric is face to steam when it passed through the Teflon coated conveyor belt. When a cotton fabric absorbs water, it swells and shrinks (particularly in length direction) because the absorbed water allows the cellulose chains to move relative stain free position. Then the fabric is passed through the expander. This m/c contains two compaction units to compact both side of the tubular fabric. Each unit contains a hot rotating cylinder, blanket which rotate in contact with the cylinder and Teflon cover .while passing the expander roller, the fabric is over feeded. The fabric is compacted with the pressure of blanket and Teflon cover while passing through the hot cylinder .Due to compaction stitch length is reduced. Then the fabric is passed through the counting device .Before packing, the fabric is inspected carefully.

Important parts:

Over feed roller

Steam sprayers

Expander

Cylinder (2)

Blanket (2)

Teflon covers

Operational parameter

Set the temperature at 110-1390C (as required)



Set the overfeed % as required; to increase GSM, overfeed need to increase to a certain limit.

Width control

Length compaction

We know that Compaction Percentage can be calculating as following formula


Cheats mark Compaction mark Fabric folding Side loose and tight

Remedies Properly compact the fabric Properly compact the over feeding



Perfect pressures apply.

3.5 RemarksM M Knitwear Ltd is a well-equipped industry. It contains machinery of well known brands like Thies, Tubetex, Laffer, Bianco etc. The availability of these m/c’s are helpful to increase the productivity of the industry. The arrangement of machinesis very beautiful and there is enough space for movement of the workers.


CHAPTER – IV

RAW MATERIAL


Industrial Attachment Raw Materials

4 RAW MATERIAL

M M Knitwear Ltd is a knit composite textile industry. In the industry the raw materials used for production are: 1.Grey Fabrics 2.Dyes 3.Chemicals

4.1 Grey Fabrics Following types of grey fabrics are processed

Single jersey Terry & French terrySingle jersey/lycra polar

Interlock Eyelet & mini-eyeletRib Mesh (warp knitted fabric)1X1rib/lycra waffelCombined rib Collar & cuffLacoste Pique

Source 40% comes from the Knitting Department of Landmark Fabrics Ltd and other 60% comes from outward as sub-contract.

Daily Fabric Production Capacity

Item Quantity

Single jersey, Pique 3800kg/dayLacoste, Interlock 1500 kg/day

Rib 1000 kg/dayCollar & cuff 6000 pcs

4.2 Dyes

In M M Knitwear Ltd. the following types of dyes are used: Reactive dyes (cold brand & hot brand) Disperse dyes

The commercial name of the dyes with their prices are collected from the dye stock report Sl. No. Name of the Dyes Price in Tk/kg01 Remazol yellow RR 19502 Remazol blue RR 52003 Remazol red RR 42004 Remazol blue BB New 38005 Remazol G.yellow RGB 320



06 Remazol blue RGB 35007 Remazol Ultra red RGB 46008 Remazol T/blue RGB 60009 Remazol red-RGB 46610 Rifa blue RSPL-N 112011 Solazol black-B 37012 Solazol red-SP3B 65013 Solazol blue R/SPL 124214 Solazol black-GRE 21015 Solacion navy blue-HEXL 80016 Solacion yellow-HE4RN 115017 Solacion red HE3B 80018 Evercion red-HE7B 95019 Evercion orange-HER 105020 Evercion navy-HER 90021 Dri. Turqouise 52022 L/P black-KAP/KNA 31523 L/P navy-NNA 45024 Syno white-4BK25 Sun white BVB 26 San white 4BK27 Reactobond black-XL28 Reactobond blue BB29 Reactobond red BRF 55030 Reactobond blue H2R31 Reactobond red CRB32 Reactobond red F3B33 Kirazol yellow w 2BRL 48034 Kirazol blue EMRX35 Kirazol red EMX36 Taicron Billian blue SGLT37 Taicron yellow E3GT 90038 Taicron orange E3RT 85039 Taicron black SE-EXNT 62040 Taicron navy blue SE-EXNT 75041 Taicron red EF-BNT 95042 Taicron red WW2RT 88043 Taicron scarlet



4.3 Chemicals

In M M Knitwear Ltd., the following chemicals are used. The names of the chemicals with their prices are collected from the dye stock report:

Sl. No. Name of the Chemicals Price in Tk/kg01 Imarol-PCLF(Detergent) 18002 Finoscour-OSP(Multi scouring agent) 25003 Kappasoft BD New(softener) 19004 Marla ADZ(Sequester) 22505 Cros colour CHBS(Stabilizer) 6506 Cros colour FBP07 Marla KT(Anticreze) 1808 Kappaquest-A41(leveling) 10509 Kappasoft SM 20510 Enzyme VGS 600 130/L11 Jintex-ALATE SQ 117CA 9512 Cros colour BFE13 Antifoam-MX 11514 Silicon THS-18015 Optovon-SV16 Marla HAS17 Jincosofter-CBA 22418 Sandofix-EC19 Jintex-TFA20 Lyocel powder21 Egonol-DFT 11022 Cros colour-ADM23 Radiclean-AL-8024 Cros colour PCP25 Acetic acid 8526 Caustic soda 3527 Hydrozen Peroxide 2528 Soda Ash 2029 Gluber salt 1530 Common solt 1031 Kepatrx R-98

4.4 Remarks

M M Knitwear Ltd is so careful about its raw materials. The raw materials are always collected from those suppliers who supply the dyes & chemicals of higher quality.


CHAPTER-V

PRODUCTION PLANNING,SEQUENCES & OPERATION


Industrial Attachment Production Planning

5 PRODUCTION PLANNING,SEQUENCES & OPERATION

5.1 Process flow chart of knit dyeing


Grey fabric Inspection

Batching

Stitching

Bleaching

Scouring

Loading

Finishing

Dyeing


5.2 Dyeing work flow chart Scouring & bleaching(Wetting agent, sequestering agent, anti creasing agent, anti foaming agent, alkali, stabilizing agent, hydrogen per oxide) or multi functional scouring agent. ▼

Per oxide hot with a/acid ▼

Enzymes wash with a/acid ▼

Leveling with sequestering ▼

Salt dosing ▼

Dye dosing ▼ Soda dosing ▼

Sample ▼ Drain

▼ Washing off ▼ A/acid ▼ Softener

▼ Unload



5.3 Dyeing Parameters

a. pH:

- During H2O2 bleaching pH 9.2 – 12- During reactive dyeing pH 10.5 – 12.5- During disperse dyeing pH 4.5 – 6.0

b. Temperature:

- For cotton scouring 1050C- For cotton cold wash 300 – 400C- For cotton hot wash 700-800C- For cotton acid wash 450C- For cotton dyeing 980C (For hot brand)

600C (For cold brand)- Polyester dyeing: 1350C- OBA application 980C

c. Time: Set

- For scouring & bleaching 40 mins - For reactive dyeing 60-90 mins - For disperse dyeing 60-90 mins -

d. M:L ratio:

- For reactive dyeing M:L ration maintained between 1 : 6 to 1 : 8



5.4 Description of production processProcess Flow Chart of Scouring and Bleaching:

Machine filling with water

Chemical Dozing at 50 0C

Run time 10 min.

H2O2 Dozing

Heating at 60 0C

NaOH dozing

Heating at 110 0C

Run time 20 min.

Cooling at 95 0C

Rinse at 80 0C

H2O2 - Killer Dozing

Run time 10 min

Run time 10min.


Sample Check

Check H2O2


Cooling for 55 0C

Acid wash 3 min DrainProcess Flow Chart of ENZYME:


Run for 4 min. at 48 0C

Heating at 55 0C

Dozing enzyme

Run time 45 min.

Drain

Process Flow Chart of WHITE DYEING:


Heating at 55 0C

Chemicals dozing

Run time 60 min.

Dyes dozing

Heating at 80 0C

Run time 15 min.

Cooling at 55 0C

Rinse for 5 min.


PH Check

PH Check


Drain

Process Flow Chart of Color Dyeing:


Heating at 60 0C

:Chemical dozing

Run time 5 min.

Dyes dozing

Run time 1 min.

Salt dozing

Run time 20 min.

Soda dozing

Run time 4 min.

Rinse

Drain

Process Flow Chart of SOFTENING:


Heating at 50 0C


PH Check

PH Check

Sample Check

PH Check


Chemicals dozing

Run time 30 min. Drain

5.5 Dyeing Recipe

Recipe No : 01

Fabric Type: Lacoste Order No: 21172Fabric GSM: 160 Buyer Name: TEXCO BDColor: Red Fabrics wt.:604.0kg M:L: 1:8ITEM RATE QUANTITY(gm)Imarol PCLF (Detergent) 1% 4800Jintex 2ud(Sequestering Agent) 0.25% 1200Marla KT(Anti-creasing Agent) 1% 4800Cross colour CHBS (Stabilizer) 0.2% 960Caustic Soda 2% 9600H2O2 2% 9600Acetic Acid 1% 4800Fibsilase HDL-350 (Enzyme) 0.3% 1450Kappaquest A-41 (Leveling Agent) 0.25% 1200Kappaquest A-41 0.7% 3300Jintex-ALATE SQ 117CA(Leveling Agent)

1% 4800

Acetic Acid 0.1% 400Ev/red-HE-7B 4.5% 24462Ev/orange-HE-R 4.12% 22396S/ N Blue-HE-XL 0.00318% 17Solt 80% 386000soda 20% 96000RS 0.7% 3300Acetic Acid 1% 4800DRF 1% 4800Kappasoft-SM(Softener) 0.2% 1000Acetic Acid 0.1% 900



Recipe No : 02

Fabric Type: Interlock Order No: PGTD0039

Fabric GSM: 240 Buyer Name: EUROPA

Color: Navy Fabrics wt.: 720.0kg M:L: 1:8

ITEM RATE QUANTITY(gm)

Imarol PCLF 1% 5760

Marla ADZ 0.25% 1440

LSP 1% 5760

Cross colour CHBS 0.2% 1152

Caustic Soda 2% 11520

H2O2 2% 11520

Acetic Acid 1% 5760

Kappaquest A-41 0.25% 1440

Acetic Acid 0.1% 576

So/ Black-B 3% 17280

So/ Red-SP3B 0.8% 4608

So/ Yellow-SP3R 0.9% 5184

Solt 60% 345600

soda 20% 115200

AW 0.7% 4000

Acetic Acid 1% 5760

Kappasoft-SM 0.2% 1152




Recipe No : 03

Fabric Type: 1 X 1 Rib Order No: 1012315

Fabric GSM: 180 Buyer Name: LIZ FSSHION

Color: White Fabrics wt.: 380.0kg M:L: 1:9

ITEM RATE QUANTITY(gm)

Imarol PCLF 0.2% 700

Marla ADZ 0.2% 700

Cross colour CHBS 1% 3400

Caustic Soda 2.5% 8500

H2O2 6% 20000

Syno White- 4BK 0.9% 3400

Imarol PCLF 0.05% 170

Acetic Acid 1% 340

Fibsilase HDL-350 0.2% 700

Kappasoft-SM 0.5% 1700




5.6 Finishing


Tube Fabric

Hydro-extraction

Dewatering

Tube compacting

Drying

Stentering

Slitting

Drying

Dewatering

Hydro-extraction

Open fabric

Open compacting

Finishing


5.7 Finishing machine setting

Dewatering M/C Setting

Fabric type Fabric speed(m/min)

Over feed%

Single jersey(Viscose) 80 30

Single jersey(cotton/lycra) 80 22

Single jersey(cotton) 80 10-11

1X1 Rib 80 11

Interlock 80 14-15

Terry 80 5-9

Gas Burnt Dryer M/C Setting

Fabric type Fabric speed (m/min)

Temperature Over feed%

Single jersey(cotton) 6.5 140 15

Single jersey(cotton/lycra) 6.5 140 15

1x1 Rib 6 140 15

Interlock 5 140 15

Terry 5 140 15

Compactor Setting

Fabric Type Fabric speed

(m/min)

Steam pressure

(psi)

Compacting pressure

(psi)

Tempc

Overfeed%

Single jersey (cotton) 25 60 70 120-150 5-7

Single jersey(cotton/lycra)

20 50 60 120-150 6-7

Single jersey (viscose)

25 60 70 120-150 8



1x1 Rib 25 60 70 120-150 3-4

Interlock 25 60 70 120-150 3-4

Terry 25 60 65 120-150 8

Stenter Setting

FABRIC TYPE FABRIC SPEED(m/min)

TEMPERATURE(0C)

OVER FEED%

Single jersey (Cotton) 30-40 160 Upto 30

Rib/Interlock (cotton) 25-30 160 Upto 30

Single jersey (Viscose) 26 170 Upto 60

Mini-eyelet(Polyester) 20-25 185 Upto 4

Mesh (Polyester) 20-25 185 Upto 4

5.8 Daily Production ReportThe daily production report is recorded in the logbook and it contains following

informationMachine No. QuantityDate Loading Time

Batch No. Unloading TimeOrder No. RuntimeFabric Type ShiftColor Remark

5.9 Monthly Average Production

The monthly average production of dyeing unit of M M Knitwear Ltd. is 360 tons

5.10RemarksThe production process, followed by the Dye-house of M M Knitwear Ltd. is

impressive. The processes are being carried out very quickly and accurately. Due to the excellence of process, machineries and lab trials very few cases of re-dyeing is performed.


CHAPTER – VI

QUALITY ASSURANCE SYSTEM


Industrial Attachment Quality Assurance System

6 QUALITY ASSURANCE SYSTEM

6.1 Quality Policy

It is the policy of M M Knitwear Ltd. to produce quality dyed knit fabrics that meet the customer’s expectations & needs. To implement this policy the top management of Landmark Textile Mills Ltd. is committed to provide adequate resources in terms of good raw materials and trained personnel & continually improve / upgrade its processes and systems. The quality control policy of Landmark Textile Mills Ltd. is stated below-

Leadership program from the top. In-process quality control during manufacturing operation. Evaluation programs in all areas of knitting, dyeing, cutting, sewing and finishing. Maintain chain of responsibility. Follow strict stuffing, auditing and reporting. Use inspection machines in required points. Maintain standard AQL. Sufficient lighting and sanitation. Final inspection prior to packaging. Meeting the appropriate expectations of clients.

6.2 Quality Assurance Procedure

M M Knitwear Ltd. assures the quality of their products in the following three steps:1. In laboratory.2. In dyeing section3. In finishing section

The qual i ty assurance procedures are descr ibed below:

In laboratory:

Swatch card from buyer according to their requirement is received. Recipe prediction for sample dyeing using CCMS. Sample dyeing until matching with the swatch card. Acceptable color difference

is less than 1. If matching is OK, then it is sent to the buyer for approval.

In dyeing section: After approval form the buyer, sample dyeing is done in dyeing m/c, in dyeing

shed & again matched with the approved sample. If result is OK, then balk production is commenced. During dyeing process, before the final acid wash, samples are taken and checked

for accurate shade matching.



After dyeing sample is collected & matching is done. Rubbing and wash fastness tests are carried out.

In finishing section:

Correctly dyed, after treated & matched fabrics are allowed for finishing. By using a series of finishing machines correct width, softness & appearance are

maintained according to requirements. Then sampling is done several times to test GSM, Shrinkage & fastness properties. Finally fabric is inspected & prepared for delivery.

6.3 Inspection area

Shade match of fabric G.S.M. Fabric diameter Spirality Shrinkage (%) Length wise Width wise Wash fastness Rubbing fastness Faults Dyeing faults Knitting faults Finishing faults

Knitting Faults Hole Slub Needle mark Stripe Missing yarn Contamination

Dyeing Faults Uneven shade Running shade Fastness property Dye spots and marks

Finishing Faults GSM variation Spirality Shrinkage control Marks



6.4 PROBLEMs ENCOUNTERED IN DYEING

Uneven Dyeing

1. It can be caused due to rapid addition of dyes and chemicals. For this purpose the dosing of soda ash should be maintained properly.

2. Pressure difference.3. Over loading in the m/c.

4. Yarn lot mixing.5. Improper control of temperature.6. Less amount of leveling agent.7. Improper pretreatment.

Uneven Shade in Rope to Rope

1. Improper rope length in each chamber.2. Improper fabric flow speed in each nozzle.

Off Shade

1. Improper M: L ratio.2. Lower amount of auxiliaries.3. Improper mixing of dyestuffs.

Dye Spots

This is most common fault caused by operator not correctly mixing and thoroughly dissolving dyestuffs in the right amount of water.

Batch to Batch Shade Variation

If any of parameters of dyeing are changed then it will produce problems in batch to batch consistency. In order to avoid this defect the following steps should be followed-

1. Maintain the same liquor ratio.2.Check that the fabric has the same dye affinity.3. Use the same standard program procedures for each batch.4. Making sure that the operators add the right bach of chemicals at the same time

& temperature in the process.5. Check the water supply daily especially ph, hardness & Na2CO3 content.



Crease Mark

Crease marks are produced due to the lower concentration of anti creasing agent and improper cooling rate (defective cooling gradient). This is encountered by increasing the concentration of anti creasing agent and proper adjustment of cooling rate.

Running Marks

Running marks are frequently related to the material construction and are caused by poor opening of the fabric rope.

1. Reducing the machine load and running at a slightly higher nozzle pressure, or using the next largest available nozzle size, may also help.

2. Either pre setting or pre relaxation of the fabric before dyeing can avoid this problem.

3. Running and crack marks can also be a result of incorrect process procedures. A higher fabric speed, combined with slower rates of rinse and cooling will often correct the problem.

4. Care should be taken to check that bath draining temperatures are not very high especially viscose blends are involved.

5. Shock cooling of static material will also cause crack marks.

Intensive Foaming

In case of intensive foaming, which is caused when, the pumps try to pump a mixture of air and water. This resets in the loss of nozzle pressure & floating of flake. If the foaming is severe it is better to drop the bath & restart the process, after adding an anti foaming agent to the new bath.

Patchy Dyeing

It is caused, if dye solution is not correct and also scouring is improper.

Miscellaneous Problems

Batch to batch processing may vary due to the improper calculation of dyes and chemicals and improper strength of salt soda and H2O2 etc. Beside hardness of water and caustic may lead to an improper shade.



6.5 Process of Shade Matching

The required shade provided by the buyer is reproduced in the lab in lab dyeing machine after the recipe prediction. The lab in-charge first uses the Computer Color Matching System, to obtain the closest shade match recipe. Then he consults the shade card and Pentone book to verify the obtained recipe. If he thinks that certain changes in the recipe is necessary, he then alters the recipe according to his experience. This recipe is used to dye a sample of 5 gm fabric in the lab dyeing machine with following parameters.

a) Temperature and time Cold Brand Reactive Dye - 65 c temp; 60 min Hot Brand Reactive Dye - 98 c temp; 60 min

Turquoise Color (Cotton) - 85 c temp; 60 min Polyester - 130 c temp; 30 min

b) M:L ratio The samples are usually dyed using 1:10 ratio.

Pentone Book:

Pentone Textile Color SelectorTotal shade – 1701Color numbering system – 6 digit + suffix

First two digits 11 to 19 ( range of lightness)Middle two digits 01 to 64 ( range of hue)Last two digits 01 to 64 ( range of chroma)

6.6 List of Equipments1. I.C.I. Pilling Box Tester

Brand Roaches Operation Time 6 hours R.P.M. 60Total Revolution 21600Scale Range for Pilling 1 to 5Accepted Level 4 to 5

2. Rubbing Fastness Tester Brand SDLInstrument Name Crock meterMeasured Elements Wet and Dry Rubbing FastnessNumber of Rubbing 10 Scale Range 1 to 5Accepted Scale Range For Wet 3 to 4 and For Dry 4

3. Light Box



Brand: VerivideOrigin EnglandLamp option TL-84 (tube light), D65 (normal daylight), UV

(optical brightener), F (fluorescent).

4.Washing Machine Origin : U S A

5 Lab Dyeing MachineBrand: Pyretic-2000Origin : U. K

6. Tumble Dryer Origin ItalyLowest Material Loading 1 kgTime 40 to 45 minutesTemp 120 c

7 Spectra Photo meter Brand: Data Color

Origin : U. S. A

8.Electric BalanceOrigin U.S.A

6.7 Quality Standard

Shrinkage: Should not exceed 4. Wash Fastness:

Fastness to washing DIN EN ISO 20105 C 03: 60c : at least 4 -5.Staining on Cotton, Polyester, Polyamide, Wool : at least 4.

Rubbing Fastness: Fastness to rubbing DIN EN ISO 105 X 12: Dry at least 4 & Wet at least 3.

Color Difference, E: Should not exceed 1.

6.8 RemarksM M Knitwear Ltd. is always aware about the quality of their product. The

quality of the product is maintained as per requirement of the buyer. M M Knitwaer Ltd. is well equipped for checking the quality of the product. They send the quality report to the buyer from time to time/ batch to batch.


CHAPTER- VII

MAINTENANCE


Industrial Attachment Maintenance

7 MAINTENANCE

7.1 Maintenance of Machinery

Maintenance of machinery is very essential mechanical effort for achieving smooth running of different machines. Maintenance is a process by which equipment is looked after in such a way that trouble free services and increased machine life can be ensured and specific product quality required by the customers is sustained. On time maintenance increase m/c lifetime & ensures trouble free services.

In M M Knitwwar Ltd. 2 types of maintenance are done: 1. Break down maintenance

2. Routine maintenance

1. Break down maintenance: Break down maintenance is done instantly when problem arises in machine. In this case, repairs are made after the equipment is out of order and it cannot perform its normal functions.

2. Routine maintenance: After a particular period of operation, the machines are cleaned & reordered, that is routine or schedule maintenance. The maintenance department does it once in a month. Schedule maintenance varies, time in time & also depends on situation according to types of machines, because maintenance is directly related to production.Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also done. Workers inform about the problem areas of the machines. Depending on their information maintenance is done. Maintenance engineer analyze the records and take steps according to requirement.

7.2 Routine Maintenance is a necessary task in any industry. But the degree and interval of

maintenance is dependent upon the age of the machineries. Some time routine maintenance can hamper the production.So, some important machines such as Stenter,Old Dyeing machine are routinely maintained.


Break Down Maintenance

Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance

Routine Maintenance

Maintenance


7.3 Manpower Setup for MaintenanceFor electrical Maintenance:Per shift:

♦ B Sc. Engineer - 1♦ Diploma Engineer - 1♦ Senior Technician – 2♦ Junior Technician – 4

For mechanical Maintenance: Per Shift:

♦ B Sc. Engineering - 2♦ Diploma Engineering - 3♦ Senior Technician – 1♦ Junior Technician – 4

7.4 Maintenance Procedure

Maintenance: Mechanical

Machine: Dyeing Machines

Sl. No. Item needed to be checked & Serviced

1. Greasing of the winch bearing

2. Complete cleaning of machine

3. Cleaning of drain valves, replace seals if required

4. Checking of air supply filter, regulators, and auto drain seals

5. Cleaning of filter elements

6. Greasing of unloading roller bearings

7. Checking and cleaning (if required) of addition tank level indicator

8. Checking the oil level of pump bearing and refill if required

9. Checking the function of heat and cool modulating valves

10. Checking of all belts and belt tension

11. Check circulation, reel and other pumps

12. Checking of all door seals




Machine: Stenter Machine


1. Removal of gas burnt deposits from chains

2. Checking of gas burners

3. Cleaning of softener application unit

5. Checking and cleaning of steam pipe lines

4. Checking and cleaning of gas pipe lines

5. Grinding of fabric gripping pins

6. Cleaning of ventilation duct

7. Cleaning of m/c cabinet

8. Checking of motors


Machine: Dewatering Machine


1. Cleaning of softener application unit

2. Checking of rotating device of rotating trolley unit

3. Checking of pneumatic pressure valves

4. Checking and replacement (if necessary) of rubber pads of stretching unit

5. Checking of plaiting device

6. Checking of speed regulating unit




Machine: Dryer


1. Checking of gas pipe lines

2. Checking of gas burners

3. Checking of belt conveyor system



6. Cleaning of ventilation duct

7. Cleaning of m/c cabinet


Machine: Compactor Machine


1. Checking of Steam pipe lines

2. Checking of pneumatic pressure valves

3. Checking of belt conveyor system



6. Checking and replacement (if necessary) of compacting shoe

7. Cleaning of compacting shoe




Machine: Boiler


1. Checking of gas pressure and gas supply line

2. Dosing of softening chemicals to supply water

3. Checking of all steam lines

4. Cleaning of burner tank (after six month interval)

5. Checking and replacement of valves

6. Cleaning of feed water tank

7. Checking and replacement of filters

8. Cleaning of sight glass

7.5 Maintenance Tools and Equipments

Sl. No. Maintenance tools/equipments Functions

1. Adjustable wrench Used for setting nut & bolts

2. Pipe Spanner For pipe fitting

3.Spanner

Fixed Spanner for nut & bolts

fitting

4.Socket spanner

Handle system for nut & bolt

fitting

5. Hammer To apply load where required

6. Screw driver To release any screw

7. Punch Used to fit any worn out shaft

8. Lock opener To open the clip of bearing

9. Hack saw To cut any metallic thing



10. Outside calipers To measure outside dia

11. Inside calipers To measure inside dia

12. Slide calipers To measure very small dia

13. Vernier scale To measure very small dia

14. Chain ton To lift heavy load

15. Welding machine To join metallic parts

16. Grinding machine To make the smooth fabrics

17. Tester To test electric circuit

18. Pliers To grip anything & cut anything

19. Avometer/Voltmeter To measure voltage

20.Steel tape

To measure length, width &

height

21. Chisel To cut any metal

22. File To smooth the rough surface

7.6 RemarksThe maintenance department of M M Knitwear Ltd. is well equipped. It

has sufficient maintenance manpower including mechanical and electrical engineers. They perform maintenance tasks of the machines during the holidays and vacations. Otherwise, they perform breakdown maintenance, which as stated earlier is very rare in M M Knitwear Ltd. To increase the lifetime of the machineries and ensure the proper running of the machines, the task of this department is very important .


CHAPTER- VIII

UTILITY SERVICES


Industrial Attachment Utility Services

8 UTILITY SERVICES

8.1 Utility Facilities Available Electricity Gas Water Compressed air Steam etc.

Government Supply (PDB)

▪Electricity or Power

Factory's Own Generator ▪ Air Compressor ▪ Natural Gas ▪ Steam Supply ▪ Water

8.2 Source of Utility The main Utility, which is used by M M Knitwear Ltd., is Natural gas. From Natural gas generator produce electricity. From natural gas and electricity in associate with mechanical and electrical apparatus, M M Knitwear Ltd Produce other Utilities like water, steam, Compressed air etc.

8.3 Capacity and Other Technical DetailsPower (Electricity): Generator house is the main Power Producing Plant of M M Knitwear Ltd. there are two Generators in Generators house. Specifications of two Generators are given below:

Generator : 01Type : Gas GeneratorBrand Name : CAT BANGLAOrigin : U S AModel No : G- 3014Rated Power : 438KVAMaximum Current : 350 KVFrequency : 50 HzEngine R P M : 1500Voltage : 400Power factor : 0.8Water Temp. : 94º CMobil Pressure : 58 P S IGas Pressure : 10 P S IGenerator : 02



Type : Diesel GeneratorBrand Name : PerkinsOrigin : IndiaModel No : 350 – ERated Power : 350 KVMaximum Current : 274 KVFrequency : 50 HzEngine R P M : 1500Volt : 400Power factor : 0.8

Boiler: Steam generator or boiler is usually a closed vessel made of steel. There is Twq boiler in M M Knitwear.

Function: Boiler function is to the heat produced by the combustion of fuel (Gas) to water and ultimately to generator steam. The steam produced may be supplied in wet processing department for –

►Heating cylinder dryer►Steaming during dyeing

Objects: For supplying steam.

Types of steam: 1. Wet steam2. Dry saturated steam, and3. Superheated steam.

In Divine Knit dyeing Ltd. wet steam is used for the relevant processes.

Boiler Specification: Brand Name : CochernOrigin : Scotland Type : Fire tube boilerCapacity : 6 ton per hourPressure : 5 barTemperature : 180º C Fuel : Natural GasYear of Manufacturer: 1997Water supply for the boiler: Water required for steam production is supplied by deep tube well.

Pretreatment of the boiler water:



Boiler feed water needs special standard. Any deviation from the required standard may result in scale formation, which eventually reduces the efficiency of the boiler. This ultimately affects the cost of steam generation and makes the production cost high. To maintain the required standard of the water, there should be some means to pretreat that the boiler feed water. To protect scale formation of boiler, NELCO is used as chemical in water feed tank. 200 gm NELCO is injected per 12 hrs. In M M Knitwear Ltd. there are water softeners that act before the water enters the boiler.

Manufacture of the softener: The manufacturer of the softener is cleaver brocks, U S A.

No of the Softener: There are two water softener to pretreated the boiler feed water

Softener Specification:

Brand Name: Cleaver brooksModel No: ACC- SMR – 150 – 1- 1/2TSerial No: CH – 0000 236Capacity: 1500000000GRS / TANKUnit NO: HS 008892Pipe Size: 1.5 inchSalt Capacity brine marker: 576 lbs

Compressed Air: The compressed air is supplied from air condition from air compressor. There are two air compressors in M M Knitwear Ltd.

Compressor No: 01Brand Name: Atlas CopcoOrigin: BelgiumModel No: GA 34 FFSerial No: TT 254070Maximum working pressure: 10 barAverage working pressure: 6-7.5 barFree air delivery: 54 liter / secondNormal shaft power: 34 KwRotational Shaft speed: 3000 r pmGross weight: 480 kgYear of Construction: 2000

Compressor No: 02



Brand Name: BOGOOrigin: JapanModel No: S361694Serial No: 546206Maximum working pressure: 10 barAverage working pressure: 6-7.5 barYear of Construction: 2001Volt: 400Frequency: 50 Hz

8.4 Cost of different Utilities

Electricity Cost:

Gas generator = 2.70 TK/KW- HRDiesel generator = 6.50 TK/ KW-HR

Gas Cost: 4.94 TK/m3 for boiler 3.66 TK/m3 for generator 4.6 TK/m3 for domestic Purpose

Steam Cost:4.20 TK/ m3 Kg fabric

8.5 RemarksFor smooth running of factory main utilities like gas, electricity or steam is very essential. Sometimes gas pressure is low than required pressure. When the gas pressure is low, then diesel generators run. Government should have to ensure proper gas supply for Industry.


CHAPTER – IX

STORES & INVENTORY CONTROL


Industrial Attachment Store and Inventory Control

9 STORES & INVENTORY CONTROL

9.1 Scope of Inventory Control1. Raw materials

Dye store Other chemicals Gray fabric

2. Finished fabric3. Spare parts

9.2 Frequency of Inventory Update

1. Monthly inventory control2. Annual inventory control

9.3 Inventory Control System for Raw Materials

Dye store & other chemicals store

Both of these are received by the store in charge. First he sends these to quality in-charge for inspection. If they are found to be of

required quality then they are taken to store by the storekeeper. Store in-charge supplies these when required and records the date, type of material,

quantity and section in which supplied, in his register book.

Grey fabric store

Grey fabric is usually stored in another storeroom, which is separate from dyeing shade.

Grey fabric is first sent to the QC department for quality assurance and then taken to the storeroom.

Grey fabric is received by fabric store in-charge. He supplies the fabric as per requirement and records the date, type of material,



Industrial Attachment Store and Inventory Control

9.4 Inventory Control System for Finished fabric

Finished fabric from the compactor or stenter goes to inspection team. Here inspection is done by a four points system.

Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness etc are tested from the lab before packaging.

After finishing the fabric is kept in package before their transfer to the garments department.

It is controlled by the finishing in-charge who keeps a list of total finished product. He also keeps a list of delivery products.

He supplies the fabric as per requirement and records the date, type of material, quantity and section in which supplied, in his register book.

9.5 Inventory Control System for Spare Parts

Spare store officer keeps the spare parts in store and makes a list of spare parts. If the spare parts are little in stock he gives requisition to maintenance manager. Maintenance manager gives requisition to head office. Head office imports spare

parts or buys from local market as per requirement. As new spare parts arrive to store officer, he receives and catalogues them. He supplies the spare parts as per requirement and records the date, type of material,


9.6 Remarks

Landmark Textile Mills Ltd. has individual stores for raw materials, finished goods and spare parts. The store of dyestuff and chemicals are not so clean. There is not enough space to store the finished goods. It requires increasing the store area.


CHAPTER-X

COST ANALYSIS


Industrial Attachment Cost Analysis

10 COST ANALYSIS

10.1INTRODUCTION The process by which the setting price of a product is calculated is called Costing. It is a very important task for a factory which runs for business purposes. And it is also strictly followed in the M M knitwear Ltd. Costing of the products considering the raw materials expenditure, salary and wages of officers and workers, distributions and advertisement expenses etc. all direct and indirect expenses is done in this factory. It is determined by a top of accountants with advice and consultancy of executive director

Setting Price = Sum. Of the cost + Profit margin.

10.2Costing elements1. Production Cost

Direct costRaw material costDirect labor

Indirect cost Indirect labor Factory overhead Processing cost Administrative cost

2. Marketing & Selling cost Transportation cost Advertising cost Commission of sales executives

Cost of product = (Sum of all Direct & Indirect expenses + Administrative cost

+ Factory Overhead)

10.3Knitting Charge of Different Fabrics

Fabric name Charge per kg(Tk)

1. Single Jersey 10

2. Single Jersey with Lycra 30



3. Single lacost 16

4. Double lacost 16

5. Single PK 16

6. Double PK 16

7. Rib 17

8. Rib with Lycra 30

9. Interlock 25

10. Auto strip 80

11. Auto striper with Lycra 100

12. Fleece 22-25

10.4Dyeing Charge of Different Fabrics

Name of fabric process Charge per kg(Tk)

1. White with Enzyme 35

2. White without Enzyme 30

3. Avg. color with Enzyme 85

4. Avg.color without Enzyme (Light& med.) 75

5. Deep shed with Enzyme (Black) 110

6. Deep shed without Enzyme (Black) 95

7. Only wash (Tubular) 25

8. Only wash (Open) 45

9. Double dyeing (Face & Back) 115



10.5Finishing Charge of Different Fabrics

Name of fabric process Charge per kg(Tk)

1. Slitting only 5

2. Stenter only 25

3. Compacting only 15

4. Stenter + Compacting 35

5. Stenter + Compacting+ wash 50

6. Tube Compacting 10

10.6COSTING OF THE PRODUCT

Let, Count of yarn = 30/1 Ne

Price of yarn per kg. = 2.80 $

Particulars Cost (Tk.) Total Cost (Tk.)Cost of raw material / kg. 184.80Knit charge / kg. 10.00Process loss (5%) 9.25Price of Gray Knitted Fabric (S/J) per kg. 204.05Dyeing cost (Avg. color) 120.00Process loss (10%) 32.40Dyed fabric cost 356.45Packing cost 3.30Total cost of dyed fabric 359.75Fabric price (with 25% margin) 449.69

10.7RemarksThe costing of product is a secret matter of the industry. They are not interested to flash the cost related data. Therefore, we could not gather the actual price of product and costing of the product.


CHAPTER – XI

MARKETING ACTIVITIES


Industrial Attachment Marketing Activities

11 MARKETING ACTIVITIES

11.1Consumer of Products

1. Textile Pressing Germany (TPG) 2. Ananda fashion (Indian buying house) – U.K.3. Euro centra 4. Kauf hoff5. Gulden Pfenning 6. Metro Sandra

11.2Country of Export

UK Germany Italy Turkey USA Others

11.3Local Market

M M Knitwear Ltd. is a 100% export oriented industry. But the dye-house of M M Knitwear Ltd. do take orders from several local companies on sub-contract basis when they are free. These local companies are following.

Texco BD. Liz Fashion Europa Probir BD Others

11.4Marketing Strategy

Marketing strategy is a very important factor to sale the products to the buyer. If the marketing strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing the dealings with the buyer is a very important factor.

In Landmark Textile Mills Ltd. mainly senior marketing officers, merchandiser & higher officials deal with the buyer. There are some fixed buyers of the industry. These buyers give their orders continuously all over the year. The marketing officers & the merchandisers communicate with the buying houses to collect the orders.

By both side understanding the rate & the order quantity are fixed.


Industrial Attachment Marketing Activities

11.5Duties & Responsibilities of Marketing Officer

Dealing with the buyer & convincing the buyer is the main duty of marketing officer. A marketing officer also has some other duties. The main duties & responsibilities of a marketing officer are given bellow-

To prepare cost sheet by dealing with the buyer. To take different steps by discussing with the high officials & merchandisers. To maintain a regular & good relationship between commercial officers &

merchandisers. To maintain communication with the buyers and buying houses. Communicate with better knowledge of the products.

Actually the responsibilities & duties of marketing officer begin from getting order of buyer & ends after receiving payment by the buyer. So, he should be always smart, energetic & sincere.

11.6Remarks

Landmark Textile Mills Ltd. has an energetic and motivated marketing & merchandising team. They are always in communication with the buyers. The marketing section also looks after the quality & quantity requirement of the buyers.


CHAPTER –XII

EFFLUENT TREATMENT PLANT


Industrial Attachment ETP

12 EFFLUENT TREATMENT PLANT (ETP)

The effluent generated from different sections of a textile industry must be treated before they are discharged to the environment. Various chemicals and physical means are introduced for this purpose.

Capacity : 80m3/ hrCost : Tk. 2.5 / m3

12.1Process Flow chart of Biological Effluent Treatment Plant


Fabric Dyeing

Homogenizing Tank

Distribution Tank

Sedimentation Tank

Sludge Return Tank

Sludge Thickener

Filter Press

Pumping and Screening

Antifoaming

Dosing Biological Oxidation Tank

Acid Dosing

De-colorant

Dosing

Dry Sludge

Dispose to Land Filling

Polyelectrolyte Dosing


12.2Function of different Unit of Biological Effluent Treatment Plant (E T P)

♦Screening unit: It works like a filter. By filtering waste water, it removes threads, pieces of fabrics, small metal pieces etc. In this unit a rotating brush is used for clean the pores if screen. The brush rotates periodically.

♦ Storage and Homogenization tank:Different waste water from varies process is stored and makes a homogeneous mixture by mixing different concentration of waste water.

♦ Neutralization tank: Neutralization of waste water is performed by dosing 98% H2SO4 as required to control the PHOf waste water PH range 6.5 to 7.5.

♦ Distribution tank:It distributes the water to the biological oxidation tank. Continuous aeration is supplied here. Antifoam is dosed here to control the foaming in the oxidation tank.

♦ Biological oxidation tank: It is the heat of E T P. The entire harmful chemicals are damaged here by breaking their bonds. This is done by bacteria. To ensure the proper function work and growth of bacteria, few conditions must be maintained.

○Temperature : 35º to 37º C○ PH (Maximum) : 6.5○ Dissolved oxygen : 4 PPM

♦ Sedimentation Tank / Biological feeding tank:Treated water is overflowed here from oxidation tank. Decolourent is used here to destroy the color of waste water.

♦ Settling tank / Sedimentation Basin: A tank or basin in which waste water is held for a period of time, during which the heavier solids settle to the bottom and the lighter material will floats to the water surface. In this tank sludge is immersed and the harmless water is discharge to ponds, Land, river etc.

♦ Sludge Thickener: Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge. After one hour of Polyelectrolyte dosing aeration is stopped and fresh water discharge to drain when sludge is taken. The thickened sludge is transferred to the sludge thickener bed.



♦ Sludge Thickener bed:Here sludge is dried which is used as good fertilizer as well as fuel of brick field. Sludge is dried under the sunlight.Required Chemical of Biological E T P:

Sulphuric Acid:Function: Neutralize the waste water controlling the PH. It is auto dispensed in the neutralization tank.

Polyelectrolyte:Function: Used for sedimentation / sludge coagulation and also killing bacteria.

Antifoaming Agent: Function: Used for reduction / controlling foam. It is used auto / manually in the distribution tank.

De-colorant: Function: Used for removing color. It is used auto / manually in the sedimentation feeding tank.

Sodium Hypochlorite:

Function: It is used to kill the harmful bacteria. It is used in the biological oxidation tank.

12.3Product Quality Checked

o Biological Oxygen Demand (BOD) o Chemical Oxygen Demand (COD) o Total suspended solidso Total dissolved solidso Coloro pH etc.

12.4RemarksWaste water from processing industries e g. Dyeing , Printing , Finishing and washing causes great harmful effect on our environmental, As a result agricultural land loses its fertility, natural water becomes polluted aquatic life is destructive and crops are damages.So, it is important to control ETP plan.


CHAPTER –XIII

CONCLUSION


Industrial Attachment Conclution

13 CONCLUSION

There is large difference between the theoretical knowledge and practical experiences. This is truer in case of the study of Textile Technology. Industrial attachment or, Industrial training is an essential part for textile education because it minimizes the gap between theoretical and practical knowledge. This Industrial training increase our thought a lot about textile technology. It also helps us to know a lot about industrial production process, machineries, and industrial management and made us suitable for industrial life. Besides it gives us the first opportunity to work in industry. So we can say industrial attachment prepare us for the expected destiny of practical life.

I have completed my industrial attachment from M M Knitwear Limited. During my two-month long industrial training at M M Knitwear Limited. I got the impression that this factory is one of the modern export oriented composite knit garments industry of our country. This factory does not compromise in case of quality. So, they have established on-line and off-line quality control of each product. Besides, they also use the good quality yarn, dyes and chemicals in their production process. Due to this, it has earned a “very good reputation” in foreign market for its quality product over many other export oriented textile mills. It has very well educated and technically experienced manpower to get rid of any defect in production process. It has also a good organizational hierarchy.

There are some suggestions from us within our limited knowledge

13.1SOME SUGGESTIONS

Knitting production needs to increase as well as technical persons need to be employed there.

More skilled labor should be used in a project and the overall efficiency will increase.

Dyeing floor should keep always neat and clean. It kept wet after unloading the fabric from the dyeing machine specially, for Athena. Water must be swept time to time.

During the transport of the fabric and during the loading of the m/c, fabrics get soiled due to their drawing over the floor. This makes the fabric/part of the fabric dirty. It may require more scouring/bleaching agent or may create stain.

Due to the pressure of higher production some times machine operators do not maintain accurate time according to the actual process so that less quality product is



produced and may reject. So our suggestion is to increase machine and reduce the pressure on the operator.

Should increase understanding between the top level personal and floor level personal.

Finishing section need to be enlarged well as more technical persons need to be employed there.

The m/c stoppage time should be analyzed and minimized. The maintenance should be carried out when the m/c is out of action (Wherever possible) and routine maintenance should be carried out regularly.

In knitting and finishing section every workers should use mask to make protect them from fly. Otherwise the exhaust air system should be more effective.

Workers are not interested to wear their gown & hand gloves.

In the Laboratory there is no technical person, a textile engineer may be employed here.

There is shortage of proper light in the dyeing and finishing floor, specially, when smoke is produced from dryer and stenter. Proper lighting should be provided in the floor.

In Laboratory, only one sample dyeing machine is used. The rest two are out of order. So, if this activate one is in problem then the lab dip process may be hampered. So, another lab dip dyeing machine may be purchase to reduce the load of current one.

The spectrophotometer is virus affected. This must be quarantine immediately.

The person at the top level of a department must take good care of the trainees & he should provide all kinds of support to them.

13.2Limitations of the report

Because of secrecy act, the data on costing and marketing activities have not been

supplied. We had a very limited time. In spite of our willing to study more it was not

possible to do so Some points in different chapters are not included as these were not available.



It is not possible to hold the whole thing of a textile industry in such a small frame as this report. So, try our hard to summarize all the information that we are provided.


Industrial attachment of MM KNITWEAR Ltd

Engineering

Transcript of Industrial attachment of MM KNITWEAR Ltd