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Industrial attachment of mitali fasions ltd

Industrial attachment of mitali fasions ltd

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Industrial attachment of mitali fasions ltd

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  1. SOUTHEAST UNIVERSITY INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF INDUSTRIAL TRAINING IN MITALI FASIONS LTD. (MITALI GROUP) P a g e | 1

  2. SOUTHEAST UNIVERSITY TABLE OF CONTENT CHAPTER NO. CHAPTER NAME PAGE NUMBER 01 Introduction 07 02 Over View of the Company 08-20 03 Raw Materials 21-56 04 Laboratory 57-69 05 Batch Section 70-74 06 Dyeing Section 75-98 07 Printing Section 99-105 08 Finishing Section 106-117 09 Garments Section 118-142 10 Quality Control Services 143-149 11 Maintenance 150-152 12 Utilities Services 153-156 12 Social & Environmental Information 157-160 13 Discussion &Conclusion 161 P a g e | 2

  3. SOUTHEAST UNIVERSITY INTRODUCTION The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skillness about various processing stages. It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. The above mentioned can not be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility. Textile education can‘t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. We got an opportunity to complete two-months long industrial training at Mitali Fashions Ltd. In the field of ever changing moderns fashion work Mitali Fashions Ltd. considers it prime mission to every new test. Which & demand of customers from around the World & all strains human culture Mitali Fashions Ltd acts on the basis premise that fashion is an exploration in to the images people seek to convey about themselves & the way they live. It has well planned & equipped Knit fabric dyeing-finishing and Garment units in addition to facilitate knitting and knitwear manufacturing. We have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for our future carrier. P a g e | 3

  4. SOUTHEAST UNIVERSITY P a g e | 4

  5. SOUTHEAST UNIVERSITY AT A GLANCE Name of Company : Mitali Fashions Ltd. Address Gazipur - 1346, Bangladesh. Tel: 880-2- 9297771-2, 9297351, 9298570-1 Fax: 880-2-9297352 Web: www.mitalifashions.net : Hatimara Road, Barenda, Kashimpur, Head Office Dhaka - 1213, Bangladesh. Tel: 880-2- 8820200, 9892999, 9861197 : Road # 22, House # 19 , Block – K, Banani, P a g e | 5

  6. SOUTHEAST UNIVERSITY FACTORY INFORMATION Factory Type : 100% Export Oriented Knit Composite Industry. Year of Establishment : 2000 Investor Location Annual Turnover : Mr. Syed Abu Yousuf Abdullah : Kashimpur, Gazipur. : Tk. 10, 00, 00,000 to 12, 00, 00,000 Certification &Awards : ISO 9001:2000 & WRAP Production Capacity Embroidery 2,000 SFT 5,000 Unit/Day Dyeing 12,500 SFT 8 Tons/Day Sewing 58,000 SFT 40,000 Pcs/Day Cutting 15,000 SFT 45,000 Pcs/Day Finishing 24,000 SFT 40,000 Pcs/Day Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt, Polo : Knitting 16,000 SFT 12 Tons/Day Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear& all kinds of knit garments & Knit fabrics. P a g e | 6

  7. SOUTHEAST UNIVERSITY MITALI FASHIONS LTD. A BSCI, WRAP, OEKO-TEX, ISO & SEDEX STANDARD COMPANY P a g e | 7

  8. SOUTHEAST UNIVERSITY MITALI has been established since 2000 and has rapidly become a major supplier of ready-made garments from Bangladesh. When it comes to ready-wear manufacturing, Mitali Fashion is a cut above the rest. Mitali Fashion is a 'tells a tale of' a company that has everything right about it -its people, its technology, its systems, its customers and its location. At Mitali Fashions Ltd we endeavor to provide our customers with an exceptional service of the highest standard and quality to guarantee client satisfaction. Today, Mitali‘s success is a result of state of the art equipment and experienced personnel from the management team to the factory force. With a team of such quality Mitali is able to run a highly efficient and competitive production unit, enabling us to meet the industries continuous increasing standards and demands. As Mitali‘s reputation grows, so does interest from other countries. Our high quality product ranges include Knitwear, Woven and Sweaters for Ladies, Mens and Children. P a g e | 8

  9. SOUTHEAST UNIVERSITY Mr. Syed Abu Yousuf Abdullah, Managing Director of the Group. Mitali Fashions Ltd. was established in 2000s under the leadership of Mr. Syed Abu Yousuf Abdullah, Managing Director of the Group. From humble beginnings, Mitali Fashions Ltd. became a Group of companies. With their leadership, Mitali has expanded rapidly over the years & become one of the largest and 100% export oriented composite knit garments industry in Bangladesh. Mr. Syed Ehsan Abdullah, Mrs. Mafruza Chowdhury, Mrs. Maisha Abdullah Ahammad and Mrs. Tania Ahmed are the Directors of the Group. Mitali Fashions Ltd is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh. As time is essential to space so is taste to its products. The secret is love-which, paired with meticulous efficiency and a keen sensitivity to style, makes Mitali Fashions Ltd an emerging brand destined to light up horizon of fashion. Mitali Fashions Ltd has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipments to match international standard of all kinds of knitwear products. The mission and vision of Mitali Fashions 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 P a g e | 9

  10. SOUTHEAST UNIVERSITY providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce. To attain these objectives, the management of Esquire Knit Composite 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. North West East South P a g e | 1 0

  11. SOUTHEAST UNIVERSITY Gate 6 13 13 10 12 14 7 11 9 8 6 5 4 3 2 1 Mitali Fashions 1.Security office 2.Gas Pump 3.Knitting sectionUnit – I & Air Compressor Room (1st Floor) + Garment section (2rd -4th Floor) 4.Color Store (1st Floor) + Medical Care (2nd Floor) + Quarter (3rd Floor) 5.Chemical Store 6.Fabric dyeing (Unit – I ) &Tube finishing section + Boiler Room 7.Dyeing Lab + Open Finishing Section 8.Fabric Dyeing Unit – II +Boiler Room Main Gate of the Mitali Fashions P a g e | 1 1

  12. SOUTHEAST UNIVERSITY 9.Generator 10.Yarn & Hanger Store 11.WTP Plant 12.Dyes & Chemical Store (Under Ground) + Kniting& Fabric Inspection Section& Air Compressor Room (1st Floor) + Garment Section (2nd– 6th Floor) + Garment Printing Section (&th Floor) + Office Room, Mercendiser Section, HR Department (8th Floor) 13.ETP Plant 14.Under Constructed Building P a g e | 1 2

  13. SOUTHEAST UNIVERSITY Mitali Fashions Ltd. was established in 2000s under the leadership of Mr. Syed Abu Yousuf Abdullah, Managing Director of the Group. From humble beginnings, Mitali Fashions Ltd. became a Group of companies. With their leadership, Mitali has expanded rapidly over the years & become one of the largest and 100% export oriented composite knit garments industry in Bangladesh. Mr. Syed Ehsan Abdullah, Mrs. Mafruza Chowdhury, Mrs. Maisha Abdullah Ahammad and Mrs. Tania Ahmed are the Directors of the Group. Dyeing & Finishing Section GM AGM Manager Batch Incharge Finishing Incharge Lab Incharge Sewing man Lab Sewing man Technician Incharge Squeeze Operator Turning m/c Operator P a g e | 1 3 Q.C. Supervisor Technician Dryer Operator Helper Helper Sr. Operator

  14. SOUTHEAST UNIVERSITY Knitting section AGM PM Store In charge Supervisor Knitting Master Fitter man Fitter man Operator Operator Garments Department Managing director Merchandiser Manager General manager Director Senior Factory Manager Finance HRD Merchandiser P a g e | 1 4 Junior Sewing Cutting Finishing Quality Merchandiser

  15. SOUTHEAST UNIVERSITY Department Manpower Knitting 300 Dyeing & Finishing, Lab & QC Yarn Fabric 309 405 Garments 3325 Power, Boiler, Utility & Maintenance 173 Inventory 15 P a g e | 1 5

  16. SOUTHEAST UNIVERSITY Administration 54 Security 135 Others 590 Total 5306 Mit ali Group can produce wide range of products and they deals with some renowned buyers from Europe and USA market some of those are with whom they worked and those whom they are still working. Main buyers name of the company are given below-  Stylex  C & A  Lindex  Forever  Mango  Lidl  Nazzal Tex P a g e | 1 6

  17. SOUTHEAST UNIVERSITY Raw Material 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. Types of Raw Materials: 1. Yarn 2. Grey Fabric 3. Dyes 4. Chemical Raw Materials Sources and Costs: 1. Yarn: P a g e | 1 7

  18. SOUTHEAST UNIVERSITY RATE (Tk. / KG) PARTY NAME YARN CATEGORY RATE $ (KG) QUANTITY (KGS) Shameem Spinning 20s/1 CVC 2.70 158 400.00 Shameem Spinning 30s/1 CVC 2.80 163 500.00 Padma Textile Mills 30s/1 CVC 3.00 175 3628.80 Square Textile Mills 24s/1 Comb 2.95 172 850.00 Square Textile Mills 12s/1 Card 2.05 120 500.00 Square Textile Mills 10s/1 Card 1.65 96 1850.00 Prime Composite Mills 32s/1 Comb 2.95 172 2550.00 Pacific Textile Mills ltd. 20s/1 Card 2.58 151 2000.00 Luksme Textile Mills ltd. 26s/1 Card 2.62 153 2000.00 Mosharaf Textile Mills ltd. 30s/1 Card 2.62 153 3250.00 Prime Composite Mills 32S/1 Comb 2.95 172 22500.00 PHP Textile Mills ltd. 24S/1 Comb 3.02 176 10000.00 Badsha Textile Mills ltd. 34S/1 Comb 3.25 190 20000.00 Shamsuddin Spinning 24S/1 Comb 3.00 175 6700.00 Shamsuddin Spinning 26S/1 Comb 3.00 175 4350.00 Tara Textile Mills ltd. 20S/1 Comb 3.00 175 1500.00 Israq Textile Mills ltd. 30s/1 Card 2.55 149 661.84 Shamsuddin Spinning 30s/1 Comb 3.05 178 1150.00 Shamsuddin Spinning 26s/1 Comb 3.00 175 1800.00 Prime Composite mills 20s/1 Card 2.40 140 1400.00 Prime Composite mills 24s/1 Comb 2.85 166 1900.00 Prime Composite mills 26s/1 Card 2.82 165 650.00 Prime Composite mills 30s/1 Card 2.82 165 350.00 P a g e | 1 8

  19. SOUTHEAST UNIVERSITY Hanif Spinning Mills 28s/1 Comb 3.05 178 3800.00 Square Textile Mills 26s/1 Comb 2.95 172 500.00 Square Textile Mills 24s/1 Card 2.50 146 500.00 Square Textile Mills 10s/1 Card 1.65 96 600.00 Shameem Spinning 30s/1 CVC 2.80 163 1600.00 Square Textile Mills 30s/1 Comb 3.00 175 1000.00 2. DIFFERENT YARN AND COUNT FOR KNITTING: SL/No Yarn Type Composition Yarn Count Remark 10s, 12s, 16s, 20s, 20/2, 22s, 24s, 26s,28s, 30, 32s, 34s, 01 Carded Yarn 100% Cotton 20s, 22s, 24s, 26s, 28s, 30s, 32s, 34s, 36s, 40s, 50s, 60s. 02 Combed Yarn 100% Cotton 03 G/M (Viscose %) 1%, 2%, 5%, 10%, 15%, 20%, 30%, 40% 04 Spun Yarn 100% Polyester 36D, 70D, 72D, 75D, Polyster + Cotton 05 PC 24s, 26s, 28s,30s, 32s, 34s, Cotton + Polyester 06 CVC 24s, 26s, 28s, 30s, 34s, 36s, 40s Cotton 50% + Polyester 50% 07 C/M 26s, 28s, 30s, 08 Lycra Synthetic 20D, 40D, 70D, 3. Grey Fabrics: Following types of grey fabrics are dyed- P a g e | 1 9

  20. SOUTHEAST UNIVERSITY Single jersey Double jersey Single jersey with lycra Interlock Single Lacoste Double Lacoste Rib Lycra rib 1 x 1 rib & others Collar & cuff Polyester fabrics Single Pique Double Pique Terry Fleece Fleece Sources: The required grey fabric is produce in the industry. 4. Chemicals: Chemicals Rate per kg 01. Soda ash light 13 02. Caustic Soda 30 03. Common salt 7 04. Glauber Salt 9 05. H2O2 28 06. Acetic Acid 12 07. Oxalic Acid 44 08. Bleaching Powder 22 09. Hydrose 48 10. Leuphore BMB 520 P a g e | 2 0

  21. SOUTHEAST UNIVERSITY 11. Uvtex BHT 309 12. Uvtex BHV 289 13. Uvtex BAM 310 14. Syno White 4BK 340 15. Uvtex BFE 919 16. Albatex FFC 344 17. CHTE nt. K50 249 18. InvadineLun 136 19. Feloson NOF 174 20. Invadine DA 180 21. Invatex CS 74 22. Cibacel DBC 107 23. Sarbid LDR 150 24. Mcropan DPE 126 25. Cibapon R 150 26. Ctobalance NSR 189 27. Rucozen RES 118 28. TinofixFRd 150 29. Lily XXL powder 40 30. RewanAcp 145 31. Cibatex ECO 150 32. Invatex CRA 200 33. Heptole EMG 114 34. Cibafluide C 89 35. Biovin 109 181 P a g e | 2 1

  22. SOUTHEAST UNIVERSITY 36. Tinozym 44L 569 37. Beizym ULBD 347 38. Invatex PC 97 39. Invatex AC 117 40. Catalar BF 324 5. Dyes: Dyes Rate per kg 01. Solazol Black sp GRI 300 02. Reactofix Red ME4BL 262 03. Cottofix Red ME4BL 262 04. Reactofix Orange ME2RL 294 05. Reactofix N.ME2GL 354 06. Reactive Yellow H4GL 500 07. Reactive Deep Black N 200 08. Cottofix Black B 141 09. Reactive Blue R(SP) 950 10. Remazol Red RR 1080 11. Remazol Yellow RR 746 12. Remazol Blue RR 908 13. Remazol Blue BB NEW 2280 14. Remazol T. Blue G 344 15. Remazol B Yellow 3GL 1167 16. Remazol Red RGD 725 P a g e | 2 2

  23. SOUTHEAST UNIVERSITY 17. Cibacron Red FN2BL 1488 18. Cibacron Red FB 918 19. Cibacron Red FN3G 1018 20. Cibacron Red WB 542 21. Cibacron Blue FNR 1488 22. Cibacron Blue FGFN 1540 23. Cibacron Navy WB 323 24. Drimarin Yellow CL2RL 510 25. Drimarin Red CL5B 494 26. Drimarin Violet K2RL 1600 27. Drimarin Navy CLB 743 28. Drimarin Blue CT2R 1647 29. Bezaktrive Yellow S3R 516 30. Bezaktrive Yellow SLF 975 31. Bezaktrive Yellow V GL 1321 32. Diss Yellow F5GL 400 33. Diss Red BF 600 34. Diss Blue FRL 1100 35. Diss Navy 2GL 300 36. Diss Black EXNSF 300 37. Terasil Black WNS 300 38. Terasil Red FB 600 39. Terasil Red WFS 600 40. Terasil Red W4BS 600 P a g e | 2 3

  24. SOUTHEAST UNIVERSITY Remarks: The Mitali Fashions Ltd Composite Knitting Ind. Ltd uses best quality raw materials. It produces fabrics from best quality yarn. They uses the best quality dyes like REMAZOL, REACTRON, REACTIVE, TERACIL etc. During the time of using dyestuff they give importance upon the quality of dyes than the price of the dyes and chemicals. P a g e | 2 4

  25. SOUTHEAST UNIVERSITY PROCESS DEFINITION Knitting is the interlocking or intermeshing of one or more yarns through a series of loops. The length wise columns of stitches, corresponding to the warp in woven cloth, are called WALES; the cross wise rows of stitches, corresponding to the filling in woven cloth, are called COURSES, FILLING KNITS (WEFT KNITS) are those fabrics in which the courses are composed of a single strand of yarn, while warp knits are those in which the Wales are composed of single strand of yarn. GAUGE corresponds to the yarn in a woven fabric, and is defined as the number of needles of yarns in half inches of cloth. The higher the gauge, the more compact and finer is the cloth. Lay-Out of Knitting Section (Unit-I) Window Window Window Window Window Self Self Rib m/c Rib m/c Rib m/c Rib m/c M/c Room Table Table P a g e | 2 5

  26. SOUTHEAST UNIVERSITY box aid S/J m/c Rib m/c Table Checking Emergency Exit Entrance Stair S/J m/c S/J m/c S/J m/c S/J m/c Air Compressor m/cRoom v F.F. Stair Cylinder S/J m/c S/J m/c S/J m/c S/J m/c S/J m/c Window Window Window Window Window North North West East (Unit-II) West East South South Entrance Stair W Office Room W W S/J m/c S/J m/c S/J m/c W W Stripe Engineering Engineering S/J m/c S/J m/c W W Stripe S/J m/c S/J m/c W W Stripe Engineering S/J m/c Rib m/c W W Stripe Engineering S/J m/c Rib m/c W W P a g e | 2 6

  27. SOUTHEAST UNIVERSITY Washing m/c Dryer S/J m/c W W Table Table Air Compressor m/c Room Stair Entrance Window Window Process flow chart of knitting: Sample fabric Design analysis Machine selection Setting the machine for the specific design Yarn in cone form Feeding the yarn cone in the creel P a g e | 2 7

  28. SOUTHEAST UNIVERSITY Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension devices Knitting Withdraw the rolled fabric and weighting Inspection Numbering Image of Knitting Machine in Mitali Fashions Ltd. Fig: PAI LUNG Knitting Machine Fig: FUKAHARA Knitting Machine P a g e | 2 8

  29. SOUTHEAST UNIVERSITY Fig: Mayer &Cieknitting machine Fig: Image of Dust Removal Fan of Knitting M/c P a g e | 2 9

  30. SOUTHEAST UNIVERSITY Fig: Image of VDQ Pulley of Knitting M/c Fig: Image of Positive Feeder of Knitting M/c P a g e | 3 0

  31. SOUTHEAST UNIVERSITY Fig: Image of Yarn Feeder Guide & Needle Action With Yarn of Knitting M/c Fig: Image of Cam Box With Cam of Knitting M/c P a g e | 3 1

  32. SOUTHEAST UNIVERSITY Fig: Image of Cam setting to the Cylinder Fig: Image of Take down & Cloth Roller Fig:Image of Knitting M/c’s Meter Sequence of yarn feeding: Creel Pipe line Wheel Yarn sensor Yarn guide Feeder Needle P a g e | 3 2

  33. SOUTHEAST UNIVERSITY Parts of knitting Machines: Creel:Creel is used to place the cone of yarn. Feeder:Feeder is used to feed the yarn to make a fabric. 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. Terms of Knitting: Course: Horizontal row of loops produced by adjacent needles in knitting cycle is called the course of the fabric. A course is a predominantly horizontal raw of needle loops produced by adjacent needles during the same knitting cycle called course. (Loop length * No of loop). P a g e | 3 3

  34. SOUTHEAST UNIVERSITY Wales: Vertical column of loops produced by same needle in knitting cycle is called the Wales of the fabric. A wale is a predominantly vertical column of intermeshed needle loops generally produced by the same needle knitting cycles. i.e. The number of vertical columns of loop of knitted fabrics is called wale. Face loop: If the legs of new loop is passes over the old loop is called face loop. Back loop: If the legs of new loop is passes under the old loop is called face loop. Stitch density: The term stitch density is frequently used in knitting instead of a linear measurement of courses or Wales; it is the total number of needles loops in a square area measurement such as a square inch or three square centimeters. It is expressed as, Course per inch × Wales per inch. Stitch length: Length of one loop in the course direction express in mm. Number of needle: Machine diameter × Machine gauge × 3.1416. GSM: The weight of one square meter of fabric express in gram is known as GSM. Needle gauge: The needle gauge of a knitting machine is a measure expressed the no. of needle per unit of the needle bed or needle bar. As for example: P a g e | 3 4

  35. SOUTHEAST UNIVERSITY 1.In case of circular weft knitting machine & Tricot warp knitting machine. [Gauge, N= Number of needle per inch.] 2.In case of Raschel warp knitting machine. [Gauge, N= Number of needle per two inch.] Needle: There are three types of needle- 1.Bearded needle 2.Compound needle 3.Latch needle- One butt needle. Two butt needle. Three butt needle. Four butt needle. The most widely used needle is latch needle. Fig:Main parts of latch needle Cam: Cam is called the specific path of the needles to produce a specific type of fabric. P a g e | 3 5

  36. SOUTHEAST UNIVERSITY There are three types of cam used in circular knitting machine: 1.Knit Cam. 2.Tuck Cam. 3.Miss Cam. Knit Cam: It moves the needle upward enough to clear the old loop and receive the new yarn. Tuck Cam: It moves the needle upward not enough to clear. The old loop but receive the new yarn. Miss cam: It does not move the needle upward. The needles neither clear the old loop nor receive the new yarn. P a g e | 3 6

  37. SOUTHEAST UNIVERSITY Sinker: It is a thin metal plate with an individual or collective operation approximately at right angles at the hook side between adjacent needles. Function of sinker: In circular knitting m/c sinker helps to form the loop by holding down the yarn Loop forming sequence of latch needle: P a g e | 3 7

  38. SOUTHEAST UNIVERSITY Latch opening: The needle goes upward and the sinker comes in action to hold down the loop. Then the old loop press down the latch and it gets open. Yarn receiving: The needle iscontinuous moving upward enough to receive the new yarn. The old loop remains on the open latch that is called tucking on the latch position. Clearing: The needle goes to its ultimate height to clear the old loop and the new yarn still within the reach of the needle. Landing: According to the path of cam, the needle starts moving downward. Being pushed by the old loop the latch gets closed and the new yarn is entrapped within the closed hook. Knock off: The needle continues moving downward. When it reaches at the down position, the old loop slides off from the back of the latch over the tip of the needle.This old loop then taken by the take up roller hangs from the new loop. P a g e | 3 8

  39. SOUTHEAST UNIVERSITY End products of Circular Knitting Machine: Single Jersey M/C: S/J Plain Single Lacoste Double Lacoste Single pique Double pique Mini jacquard Terry Interlock M/C: Interlock pique Eyelet fabric Mash fabric Honeycomb fabric Face/Back rib Rib M/C: 1*1 Rib fabric 2*2 Rib fabric Separation fabric Honeycomb End products of Flat Bed Knitting Machine: Stripping Plain Emboss P a g e | 3 9

  40. SOUTHEAST UNIVERSITY 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. Analysis of the Fabric Sample analysis: After receiving an order first step is analysis the fabric. A sample is analysis as per following system. Design analysis:- Example: P a g e | 4 0

  41. SOUTHEAST UNIVERSITY P a g e | 4 1

  42. SOUTHEAST UNIVERSITY P a g e | 4 2

  43. SOUTHEAST UNIVERSITY Relationship between knitting parameter: 1. Stitch length increase with decrease of GSM. 2. If stitch length increase then fabric width increase and Wales per inch decrease. P a g e | 4 3

  44. SOUTHEAST UNIVERSITY 3. If machine gauge increase then fabric width decrease. 4. If yarn count increase (courser) then fabric width increase. 5. If shrinkage increases then fabric width decrease but GSM and Wales per inch . increase. 6. For finer gauge, finer count yarn should use. 7. Gray GSM should be less than finish GSM Production Parameter: Machine Diameter; Machine rpm (revolution per minute); No. of feeds or feeders in use; Machine Gauge; Count of yarn. Methods of increasing production: By the following methods the production of knitted fabric can be increased – By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed. By increasing the number of feeder: P a g e | 4 4

  45. SOUTHEAST UNIVERSITY If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. By using machine of higher gauge: The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased. By imposing other developments: Using creel-feeding system Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage Using yarn feed control device Using auto lint removal. Production calculation: Production/shift in kg at 100% efficiency:    . . ( ) RPM No of Feeder . 3527 No of Needle SL mm   80 Yarn count Production/shift in meter: P a g e | 4 5

  46. SOUTHEAST UNIVERSITY min / cm . Course  / No Course   cm   . 60 8 RPM of Feeder Efficiency  100  / Course Fabric width in meter: . cm Total no of wales   / 100 Needles Wales . Total no of used in knitting   / 100 Wales cm Factors that should be change in case of fabric design on quality change: a)Cam setting b)Set of needle c)Size of loop shape If shrinkage increases then fabric width decrease but GSM and Wales per inch increase. For finer gauge, finer count yarn should use. Effect of stitch length on color depth: If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted then. Similarly in case of light shade loop length should be relatively smaller Some points are needed to maintain for high quality fabric: Brought good quality yarn Machines are oiled and greased accordingly G.S.M, Stitch length, Tensions are controlled accurately Machines are cleaned every shift and servicing is done after a month Grey Fabrics are checked by 4 point grading system Changing of GSM: P a g e | 4 6

  47. SOUTHEAST UNIVERSITY   Minor control by stitch length adjustment  Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley moves towards the positive direction then the G.S.M. is decrease. And in the reverse direction G.S.M will increase Major control by QAP pulley Other m/c in Knitting Section: Gray Inspection M/c, Brand : Uzu fabric inspection machine Electric Balance for Fabric Weight. Electric Balance for GSM check. Compressor 2 pieces. Image of fabric Inspection M/c Faults & Remedies of knitting fabric: 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. P a g e | 4 7

  48. SOUTHEAST UNIVERSITY If the yarn count is not correct on regarding structure, gauge, course and density. Badly knot or splicing. Yarn feeder badly set. Remedies: 1.Yarn strength must be sufficient to withstand the stretch as well as uniform. 2.Use proper count of yarn. 3.Correctly set of yarn feeder. 4.Knot should be given properly.  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.  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. P a g e | 4 8

  49. SOUTHEAST UNIVERSITY Star Mark: 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. 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. Oil stain Causes: P a g e | 4 9

  50. SOUTHEAST UNIVERSITY 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. Rust stain: Causes: If any rust on the machine parts. Remedies: If any rust on the machine parts then clean it. Proper maintenance as well as proper oiling. Pin hole: Causes: Due to break down or bend of the latch, pin hole may come in the fabric. Remedies: Change the needle. Grease stain: Causes: Improper greasing Excess greasing Remedies: Proper greasing as well as proper maintenance Cloth fall- out: Causes: P a g e | 5 0

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