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Industrial attachment of APS group ltd

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF APS GROUP LTD. 1 Industrial Attachment-2014

  2. Introduction Industrial Attachment is the first step to professional life of a 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. Six weeks industrial attachment program in a dying mill was arranged for us this type of attachment program enabled us to avoid the gap between theory & its applicability the mill practice the incumbent was deeded to APS Group (Dyeing Unit). In the field of ever changing moderns fashion work. APS Group (Dyeing Unit). considers its prime mission to every new test. Which & demand of customers from around the World & all strains human culture DGL acts on the basis premise that fashion is an exploration in to the images people seek to convey about themselves & the way they live. 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. 2 Industrial Attachment-2014

  3. Table of Content Description Chapter Page no Chapter-1 Over View of the Factory 5-17 Chapter-2 Raw Materials 18-24 Chapter-3 Knitting section 25-41 Chapter-4 Laboratory section 42-46 Chapter-5 Batch section 47-53 Chapter-6 Dyeing Section 54-76 Chapter-7 Water Treatment Plant “WTP” 77-79 Chapter-8 Finishing Section 80-95 Chapter-9 Quality Control 96-105 Chapter-10 Description of ETP 106-108 Chapter-11 Garments 109-115 Chapter-12 Maintenance 116-118 Chapter-13 Store & Inventory control 119-121 Chapter-14 Social & Environmental information 122-127 3 Industrial Attachment-2014

  4. CHAPTER: 1 “Over View of the Factory” 4 Industrial Attachment-2014

  5. Address: Pubail, Gazipur, Sadar, Gazipur 5 Industrial Attachment-2014

  6. AT A GLANCE APS Group (Dyeing Unit) 100% Export Oriented Composite Knitwear Factory Address: Pubail, Gazipur, Sadar, Gazipur Tel: +88-02-9815028, www.aps-group.org Head Office - Pubail, Gazipur, Sadar, Gazipur Tel: +88-02-9815028 - Pubail, Gazipur, Sadar, Gazipur Factory Nature of project Bank Management - 1. Md. Alfaz Contact Person - 1. Engr. Md. Rashedul Islam (Babu), General Manager (Fac.) Mobile: 01713454160 -2. Md. Rezaul Karim (Babu) Manager (Dyeing & Finishing) Mobile: 01718218497 3. Md. Bellal Uddin Manager (Knitting) 4. Md. Musa Kalim (Manager Finishing) - 100% Export Oriented Composite Knitwear Factory - Bangladesh Shilpa Bank, Head Office, Dhaka. Managing Director/Chairman 6 Industrial Attachment-2014

  7. Composition of Factory The Enterprise have been organized in the following manner: APS Group (Dyeing Unit) Unit APS Group (Dyeing Unit) Unit Year of Establishment Location: Our Head office is located at a posh area called Uttara while the factory is located in an industrial area at Pubail, Gazipur which is only 2.2 Km. : Fabrics Knitting : Fabrics Dyeing : January, 2000 Production Capacity and Facilities : 1) Knitting Division : Area : 10,000 sft. Man Power : 46 Production Capacity 6000 Kgs/day : List of machinery : As below 7 Industrial Attachment-2014

  8. Type Machine of a) Circular Knitting Machineries Qty of feeder No Machine of Sl.No. Dia Gauge Brand/Origin Fabrics Jiunn long/Taiwan 1 21" 63 Single Jersey 2 2 23" 69 3 3 25" 75 3 20+24 4 28" 84 2 Single Jersey/Pique 5 30" 90 2 6 36" 108 1 7 34" 18+24 68 1 Rib/Interlock 8 40" 18+24 80 1 Equipped With Lycra Attachment Total 15 Type Machine of Flat Knitting Machineries (Specially Collar & Cuffs) b) No Machine of Sl.No. Length Gauge Colour Brand/Origin 1 52" 2 14 6 Jy-Leh/Taiwan 2 68" 1 8 Industrial Attachment-2014

  9. Type Machine : of c) Fabrics Inspection Machineries Sl.No. Model Origin Brand No of Machine 1 HCTIM Taiwan Hsing Cheng 1 2) Dyeing Division : Area : 25,200 sft. Man Power : 195 Production Capacity : 10890 Kgs/day List of Machinery : As below a) Type Machine : Dyeing Machineries of Sl.No. Origin / Brand Description of Machine Capacity KG in No. Machine Of 1 AK / Taiwan AK temperature pressure machine ( Model 2007) brand high high 500 2 & Dyeing 2 250 1 3 100 1 9 Industrial Attachment-2014

  10. 4 50 1 5 600 2 6 800 2 7 Atmoispheric Machine Dyeing 30 1 8 25 1 9 15 1 10 FONGS/China Atmoispheric Machine Dyeing 1200 1 Total 5470 13 b) Type of Machine : Finishing Machineries Sl.No. Brand Origin Description of Machine No. Machine Of 1 Corino Italy Squeezer for Tubler Knitted Fabric 2 2 LK Taiwan 4- Tensionless Dryer Chamber 1 3 FAB-CON USA Computerized Compactor 1 4 Tube-Tex USA Computerized Compactor 1 5 Hsing Cheng Taiwan Over Turning Machine 1 c) Type of Machine : Laboratory Machineries The Factory is equipped with a most modern set up of brand new & latest Model Laboratory 10 Industrial Attachment-2014

  11. and quality control machine. Sl.No. Description Machine of Brand Origin No.Of Machine 1 Infra-Red Laboratory Dyeing Machine-12pot Labtec Taiwan 1 2 Spectrophotometer Loepfe Switzerland 1 3 European Washers James.H Heal UK Switzerland & 1 4 Sartorious Portable Digital Balances 1 5 Verivide Assessment Cabinet Colour 1 6 Crockmeters 1 7 Prespiration Machine 1 FABRICS BRUSHING UNIT 01 Fabrics brushing Machines: Per Machine 24 Roller; Made in Taiwan Ar Tex For S/J Light Brush, Fleece One side Brush & polar fleece-bith sides brushed. 2 Sets 1. We Have 2 set brushing Machines We are able to raise/brushing for one side or both side brush. Capacity: 6000 Kg per day with standard quality. 11 Industrial Attachment-2014

  12. Factory Information Factory Type : 100% Export Oriented Knit Composite Industry. Year of establishment : 2000 Investor : Mr. Shihab Uddin Location : Pubail, Gazipur. Annual turnover : Tk. 10, 00, 00,000 to 12, 00, 00,000 Certification & awards : ISO 9001:2000 & WRAP Production capacity : Knitting : 15.5 tons/day (Average) Dyeing : 15.5 ton/day (Average) Sewing : 100000 pcs/day (Average) Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt, Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear& all kinds of knit garments & Knit fabrics. 12 Industrial Attachment-2014

  13. BASIC LAY-OUT OF THE FACTORY 3 2 4 1 Entry 5 9 6 10 11 7 12 13 8 1 13 Industrial Attachment-2014

  14. 1.Security office 2.Mosque 3.Store 4.Knitting section 5.Finishing (Gr. Floor)+ Knitting (2nd Floor)+ Garment section (3rd -7th Floor) 6.Fabric dyeing & finishing section 7.Yarn dyeing section 8.Garments section 9.Garments section 10.Maintenance Building 11.Water Treatment Plant (WPT) 12.Human Resources Department (HRD) 13.Generator House 14 Industrial Attachment-2014

  15. Man Power Management in APS Group (Dyeing Unit) Textile Ltd. Knitting section AGM PM Store In charge Supervisor Knitting Master Fitter man Fitter man Operator Operator Dyeing & Finishing Section GM DGM PM SPO Batch Finishing Lab PO Sewing man Lab Sewing man APO Squeeze Turning m/c Q.C. Supervisor Operator Operator Technician Dryer Helper Helper Sr. Operator Operator Astt. Operator Compactor Operator Operator 15 Industrial Attachment-2014 Helper

  16. Section-wise manpower Department Manpower Knitting 300 Dyeing & Finishing, Lab & QC Yarn Fabric 309 405 Garments 3325 Power, Boiler, Utility & Maintenance 173 Inventory 15 Administration 54 Security 135 Others 590 Total 5306 16 Industrial Attachment-2014

  17. Chapter- 2 “Raw Materials” 17 Industrial Attachment-2014

  18. 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: 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 Comd 2.95 172 850.00 Square Textile Mills 12s/1 Kard 2.05 120 500.00 Square Textile Mills 10s/1 Kard 1.65 96 1850.00 Prime Composite Mills 32s/1 Comd 2.95 172 2550.00 Pacific Textile Mills ltd. 20s/1 Kard 2.58 151 2000.00 Luksme Textile Mills ltd. 26s/1 Kard 2.62 153 2000.00 Mosharaf Textile Mills ltd. 30s/1 Kard 2.62 153 3250.00 Prime Composite Mills 32S/1 Comd 2.95 172 22500.00 PHP Textile Mills ltd. 24S/1 Comd 3.02 176 10000.00 Badsha Textile Mills ltd. 34S/1 Comd 3.25 190 20000.00 Shamsuddin Spinning 24S/1 Comd 3.00 175 6700.00 Shamsuddin Spinning 26S/1 Comd 3.00 175 4350.00 18 Industrial Attachment-2014

  19. Tara Textile Mills ltd. 20S/1 Comd 3.00 175 1500.00 Israq Textile Mills ltd. 30s/1 Kard 2.55 149 661.84 Shamsuddin Spinning 30s/1 Comd 3.05 178 1150.00 Shamsuddin Spinning 26s/1 Comd 3.00 175 1800.00 Prime Composite mills 20s/1 Kard 2.40 140 1400.00 Prime Composite mills 24s/1 Comd 2.85 166 1900.00 Prime Composite mills 26s/1 Kard 2.82 165 650.00 Prime Composite mills 30s/1 Kard 2.82 165 350.00 Hanif Spinning Mills 28s/1 Comd 3.05 178 3800.00 Square Textile Mills 26s/1 Comd 2.95 172 500.00 Square Textile Mills 24s/1 Kard 2.50 146 500.00 Square Textile Mills 10s/1 Kard 1.65 96 600.00 Shameem Spinning 30s/1 CVC 2.80 163 1600.00 Square Textile Mills 30s/1 Comd 3.00 175 1000.00 2. Grey Fabrics: Following types of grey fabrics are dyed- 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 Fillece Filleece 19 Industrial Attachment-2014

  20. Sources: The required grey fabric is produce in the industry 3. 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 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. Invadine Lun 136 19. Feloson NOF 174 20. Invadine DA 180 21. Invatex CS 74 22. Cibacel DBC 107 20 Industrial Attachment-2014

  21. 23. Sarbid LDR 150 24. Mcropan DPE 126 25. Cibapon R 150 26. Ctobalance NSR 189 27. Rucozen RES 118 28. Tinofix FRd 150 29. Lily XXL powder 40 30. Rewan Acp 145 31. Cibatex ECO 150 32. Invatex CRA 200 33. Heptole EMG 114 34. Cibafluide C 89 35. Biovin 109 181 36. Tinozym 44L 569 37. Beizym ULBD 347 38. Invatex PC 97 39. Invatex AC 117 40. Catalar BF 324 4. 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 21 Industrial Attachment-2014

  22. 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 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 22 Industrial Attachment-2014

  23. 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 Remarks: The APS Group (Dyeing Unit). 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. 23 Industrial Attachment-2014

  24. CHAPTER: 3 “KNITTING SECTION” 24 Industrial Attachment-2014

  25. Machine Description of Knitting Section: M/C M/C M/C M/C No. Of No. Of M/C Brand Origin S/L Dia Gauge Model Feeder Needle Spec Rib/Inte rlock 1 30” Rib-18 XR2B/CE 60 1692 PAI LUNG TAIWAN Int-24 KS3B- W/A/CE 2 28” 24 84 2112 S/J PAI LUNG TAIWAN KS3B- W/A/CE 3 28” 24 84 2112 S/J PAI LUNG TAIWAN KS3B- W/A/CE 4 32” 24 96 2400 S/J PAI LUNG TAIWAN 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 25 Industrial Attachment-2014

  26. Rib M/C: 1*1 Rib fabric 2*2 Rib fabric Separation fabric Honeycomb End products of Flat Bed Knitting Machine: Tripping Plain Emboss Considerable points to produce knitted fabrics: When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows- - Type of Fabric or design of Fabric. - Finished G.S.M. - Yarn count - Types of yarn (combed or carded) - Diameter of the fabric. - Stitch length - Color depth. 26 Industrial Attachment-2014

  27. Name & Picture of Knitting Machine in APS knitwear Textile Ltd. Number of machine Production per Machine Name shift(kg) S/J Machine (Mayer & Cie) 10 3 Ton. S/J Machine (Pai-lung) 08 2.3 Ton. Rib Machine (Mayer & Cie) 03 1.2 Ton. Rib Machine (Pai-lung) 05 1.6 Ton. Interlock Machine(Mayer & Cie) 04 1.6 Ton. Interlock Machine (Pai- lung) 05 1.5 Ton. 27 Industrial Attachment-2014

  28. Fig: PAI LUNG Knitting Machine 28 Industrial Attachment-2014

  29. Fig: FUKAHARA Knitting Machine 29 Industrial Attachment-2014

  30. Fig: Mayer & Cieknitting machine 30 Industrial Attachment-2014

  31. Knitting Production and Raw Materials: 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: 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. 31 Industrial Attachment-2014

  32. Production calculation: A. Production/shift in kg at 100% efficiency:    . . ( ) RPM No of Feeder . 3527 No of Needle SL mm   80 Yarn count B. Production/shift in meter: / min cm . Course  / Course   cm   . 60  12 RPM No of Feeder Efficiency  / 100 Course C. Fabric width in meter: . cm Total no of wales   / 100 Needles Wales . Total no of used in knitting   / 100 Wales cm 32 Industrial Attachment-2014

  33. Process flow chart of knitting: Yarn in cone form ↓ Feeding the yarn cone in the creel ↓ Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension device ↓ Knitting ↓ Withdraw the rolled fabric and weighting ↓ Inspection ↓ Numbering Raw materials for knitting: Type of yarn Count 24S, 26S, 28S, 30S, 32S, 34S, 40S Cotton Polyester 75D, 72D,100D Spandex yarn 20D,40D, 70D 24S, 26S Grey Mélange (C-90% V-10%) 24S, 26S, 28S, 30S PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S CVC 33 Industrial Attachment-2014

  34. 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: Major control by QAP pulley 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 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. Production Parameter: Machine Diameter; Machine rpm (revolution per minute); No. of feeds or feeders in use; Machine Gauge; Count of yarn; 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. 3. If machine gauge increase then fabric width decrease. 4. If yarn count increase (courser) then fabric width increase. 34 Industrial Attachment-2014

  35. 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 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. 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 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 35 Industrial Attachment-2014

  36. 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. 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. 36 Industrial Attachment-2014

  37. 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. 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. 37 Industrial Attachment-2014

  38. 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: 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 38 Industrial Attachment-2014

  39. Remedies: Proper greasing as well as proper maintenance Cloth fall- out: Causes: Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Remedies: Make sure all the latches of needle are closed with feeding yarn after a drop stitch. Barre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) stripe(s). Causes: This fault comes from yarn fault. If different micro near value of fiber content in yarn. Different lusture, dye affinity of fiber content in yarn. During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics. In draw fame different similar classes sliver is mixed and make one sliver. Fly: Causes: In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. 39 Industrial Attachment-2014

  40. Remedies: Blowing air for cleaning and different parts after a certain period of time. By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor. Over all ensure that lint does not attach to the fabric. Yarn contamination: Causes: If yarn contains foreign fiber then it remains in the fabric even after finishing, If lot, count mixing occurs. Remedies: By avoiding lot, count mixing. Fault less spinning. Yarn Faults: Neps. Slubs. Yarn count. Thick/Thin place in yarn. Hairiness. 40 Industrial Attachment-2014

  41. CHAPTER:4 “LABORATORY SECTION” 41 Industrial Attachment-2014

  42. Machine Description of Dyeing Lab: 1. Name : Auto Dispenser Brand : Robolab 240 Mfg. : Sclavos International Origin : England. 2. Name : Sample Dyeing m/c Brand : Datacolor (AHIBA IR) Origin : India 3. Name : Sample Dyeing m/c Brand : Datacolor (AHIBA Nunance) Origin : India 4. Name : Sample Dyeing m/c Brand : Datacolor (AHIBA Nunance) Origin : India 5. Name : Sample Dyeing m/c (High Temp.) Brand : Dexter Mfg. : Yuan Shen Enterprise Co., Ltd. Origin : Taiwan 6. Name : Washfast Test m/c Brand : Washfast uni Mfg. : Mag Engineers Ltd Origin : India 42 Industrial Attachment-2014

  43. Name and source: Fabric: 1. 100 % Cotton fabric 2. CVC fabric 3. PC fabric 4. Lycra twill fabric 5. Canvas fabric Poplin fabric 6. Dye stuff: Generic Name Source Black-S-MAX Blue-S-FR-150% Blue-SLF Blue-S-MAX Blue-S-GLD-150% Cosmos-S-MAX Navy-SLF Orange-S-MAX Bezective Bezema Red-S-2B Red-S-2B-150% Red-SGT Red-SLF Red-S-MAX Rubine-S-MAX Scarlet-S-2GF Yellow-S-3R-150% 43 Industrial Attachment-2014

  44. Yellow-SLF Yellow-S-MAX Yellow-V-5GL Bluton CHT BVBI Skaywhite BVB Blue-HGN Brill blue-NF-G Cibacron Ciba Red-NF-R Scarlet-NF-6G Yelloe-F-4G Yellow-FN-2R Black-CC-R Blue-CC Blue-S-BB Blue-SE-2R Dianix blue-ER-150 Navy-CC Dianix Dychufix Red-EFB Rubine-CC Turquise-CC Yellow-E-3GE Yellow-S-EG 44 Industrial Attachment-2014

  45. Chemicals: Generic Name Ablu Ablusoft-AC-720 Ablutex-AP-750HC Ablutex-BBV Boiler Nalco-450 CHT Felosan-NOF Meropan-CIT Meropan-Red Polyavin-3000 Saravid-VP-174 Antioxidant-M Destofil-LC Clariant Diresul-Antioxidant-M-Liq Ladiquest-1097 Sandozin-EH Adalin-11 Cognis Adasil-SME Cottoclarin-114 Dyapol Dyapol-ECO Ferrous-Sulphate-(Feso4-7H2o) Hydrochloric-Acid(HCL) Lime Effluent Polymer Sodium-Hypo-Chloride(NaOCl) Urea-Fertilizer 45 Industrial Attachment-2014

  46. Chapter- 5 “Batch section” 46 Industrial Attachment-2014

  47. Batching: Batching is the process to get ready the fabrics that should be dyed and processed for a Particular lot of a Particular order. Types: Batching Solid Batch Ratio Batch Solid Batch: It is a process to get ready the same dia fabrics that should be dyed. Ratio Batch: It is a process to get ready the different dia fabrics that shoud be dyed. Batch process follow-up: Grey Fabric Inspection Batch m/c (From back side to face side) Batch Fabric Turning Stitch the fabric Storing for dyeing 47 Industrial Attachment-2014

  48. Grey fabric inspection: Grey Fabric Check to Inspection Table. Tow person are checking continuously. Do have any problem find out any Fabric Then mark as defect zone. To inform the upper position and also to take this problem solves. Proper inspection report is not available. To attach numbering in defect fabric. Fabric faults identification & their causes and remedies: 1. Hole Mark: Causes: 1.Bad needle 2.Take down mechanism too tight 3.High tension on yarn 4.Badly tied knots. Remedies: 1.Yarn strength must be sufficient to withstand the stretch as well as uniform. 2. Correctly set of yarn feeder. 3. Knot should be given properly. 2. Needle trace: Causes: A new needle which is tight in its trick, a worn trick a bout needle, tight latch. Remedies: Needle should be straight as well as from broken latch. 3. Drop Stitches: Causes: 1. Defective needle. 2. Take-down mechanism too loose. 3. Insufficient yarn tension. 4. Badly set yarn feeder. Remedies: 48 Industrial Attachment-2014

  49. 1. Needle should be straight & well. 2. Proper feeding of yarn during loop formation. 3. Correct take up of the fabric & correct fabric tension. 4. Yarn tension should be properly. 4. Star Mark: Causes: 1. Yarn tension variation during production. 2. Buckling of the needle latch. 3. Low G.S.M fabric production. Remedies: 1. Maintain same Yarn tension during production. 2. Use good conditioned needles. 5. Oil stain: Causes: When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies: 1. Ensure that oil does not pass on the fabrics. 2. Well maintenance as well as proper oiling. 6. Pin hole: Causes: Due to break down or bend of the latch, pin hole may come in the fabric. Remedies: Change the needle. 49 Industrial Attachment-2014

  50. 10. Yarn contamination: Causes: 1. If yarn contains foreign fiber then it remains in the fabric even after finishing. 2. If lot, count mixing occurs. Remedies: By avoiding lot, count mixing. .Purpose of Batch Section: To receive the grey fabrics roll from knitting section or other source. To turn out the tubular fabric in its grey stage and to safe the face side of the fabric from any type of friction during the time of dyeing. To prepare the batch of fabric for dyeing according to the following criteria- -Order sheet (Receive from buyer) -Dyeing shade (Color or white, light or Dark) M/c available -Type of fabrics (100% cotton, PC, CVC) -Emergency To send the grey fabric to the dyeing floor with batch card. To keep records for every previous dyeing. According to Rope Length Uses This Nozzle: Rope Length(m) Nozzle 5-150 1 151-230 2 301-500 3 50 Industrial Attachment-2014