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Industrial attachment of micro fibre ltd

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Industrial attachment of micro fibre ltd

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT MICRO FIBRE LTD

  2. ACKNOWLEDGEMENT At first my gratefulness goes to Almighty Allah for giving me strength and ability to complete the industrial training and this report. You have made my life more bountiful. May your 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, Prof. Syed Fakhrul Hassan my supervisor, to whom I am extremely indebted for his tremendous support and guidance throughout my training period. Working with him I have not only earned valuable knowledge but also was inspired by him innovativeness which helped enriches my experience to a greater extent. His ideas and way of working was truly remarkable. I would like to thank the management of the MICRO FIBRE LTD. for giving me the opportunity to complete the industrial training successfully and also for their valuable suggestion. My deepest gratitude goes to Executive Director Mr. Amirul Haque, General Manager Mr. Mizanur Rahaman Patwoary, Assistant general manager Mr. Solaiman Hossain, MICRO FIBRE LTD. for their permission to conduct my industrial training without which it would be impossible. Their generous support is greatly appreciated. I would also like to thank specially our senior brothers and sisters working there efficiently as textile engineer. I am greatly indebted to them. I also want to thank executives, senior executives and other official’s employee of MICRO FIBRE LTD. for helping me to complete industrial training successfully. My gratitude also goes to all the employees of MICRO FIBRE LTD. for their sincere co-operation, support and valuable advices. Finally my heartfelt thanks goes to my training mates for their indescribable co-operation & sincerity.

  3. Introduction: Final course industrial training is one of the most essential parts of engineering & technical education. This industrial training is included in our syllabus to acquaint us with the practical implementation of the technology studied within the industrial environment. Though it is very helpful & lays the milestone for starting the carrier for fresh Textile graduates. Fabric manufacturing and Wet processing technology which occupies a vast field in modern Textile technology is undergoing many stages of processing. Many problems are generally being encountered during each operation stage starting from yarn to fabric and fabric desizing to finishing stage. Finally from mill training, we learn practical Knowledge about on fabric manufacturing and wet processing under industrial environment. We think it will be helpful in our future carrier. Vision: To establish as a one stop source for the Global knit Apparel market and to satisfy and meet customers expectation by developing and providing products and services on time, which offer value in terms of Quality, Price, Safety and Environmental impact. Assuring complete compliance with the international quality standards and also providing the employees internationally acceptable working condition and standards. To promote the development and to use human talent and equal opportunityof employment. Mission: Micro fibre realizes the need to take out a competitive segment in the changing global market of todaythrough technological excellence and human expertise. Micro fibre is committed to transpose its local success to the world scene.

  4. Industrial Attachment Report 2011 S Chashara E W Narayanganj Location Of The MICRO FIBRE GROUP N Fatullah Shibo Market Ramarvag Micro Fibre Fatullah Fatullah Rail Stadium Tikatol Sign Board Chittagong ZatraBari Kamolapur Gulistan railstation

  5. Industrial Attachment Report 2011 Contents CHAPTER-01..............................................................................................................1 PROJECT DESCRIPTION.......................................................................................1 Name of the project........................................................................................................................................................... 1 Sister organizations........................................................................................................................................................... 1 Type of the mill ................................................................................................................................................................. 1 Year of establishment........................................................................................................................................................ 1 Registered Office............................................................................................................................................................... 1 Factory Address................................................................................................................................................................ 1 Communication................................................................................................................................................................. 1 Sponsors............................................................................................................................................................................ 1 Capacity............................................................................................................................................................................. 2 Project cost........................................................................................................................................................................ 2 Project area....................................................................................................................................................................... 2 History of project development:....................................................................................................................................... 2

  6. Industrial Attachment Report 2011 Different departments:...................................................................................................................................................... 3 Product mix:...................................................................................................................................................................... 3 LAYOUT DESIGN ........................................................................................................................................................... 4 Layout plan of printing section:....................................................................................................................................... 5 Remark:............................................................................................................................................................................. 6 Physical Infrastructure: ................................................................................................................................................... 7 CHAPTER -2...............................................................................................................8 MANPOWER MANAGEMENT...............................................................................8 Organ gram of man-power administration...................................................................................................................... 8 Management system:........................................................................................................................................................ 8 Shift change:..................................................................................................................................................................... 9 Total Section Wise Man power Management system:.................................................................................................... 9 Responsibilities of S.P.O/P.O:........................................................................................................................................ 10 Job description of S.P.O/P.O................................................................................................................................10 Remarks........................................................................................................................................................................... 10 CHAPTER-3..............................................................................................................11 MACHINE DESCRIPTION....................................................................................11

  7. Industrial Attachment Report 2011 List of Single Jersey Circular knitting Machineries :................................................................................................... 11 List of Single Jersey Circular knitting Machineries :................................................................................................... 12 List of Double Jersey Circular knitting Machineries :................................................................................................. 13 List of Auto Stripe Circular knitting Machineries :...................................................................................................... 14 List of Flat Bed knitting Machineries :......................................................................................................................... 14 List of Cloth Inspection Machineries :.......................................................................................................................... 15 Machine Picture.............................................................................................................................................................. 16 Lay-out Plan of knitting Machineries :......................................................................................................................... 18 Remarks : ........................................................................................................................................................................ 20 CHAPTER -04...........................................................................................................22 RAW MATERIALS..................................................................................................22 Types of Raw Materials:................................................................................................................................................. 22 Yarn:............................................................................................................................................................................22 Grey Fabrics:.............................................................................................................................................................23 Chemicals: ..................................................................................................................................................................24 Commonly used dyes in fabric dyeing section in Micro fibre Ltd................................................................24

  8. Industrial Attachment Report 2011 Chemicals & their function:........................................................................................................................................... 26 Chemicals used in Dyeing and their function:...................................................................................................26 Printing chemicals function:..................................................................................................................................28 Urea..............................................................................................................................................................................28 Resist salt......................................................................................................................................................................28 Na .................................................................................................................................................................................28 Thickener......................................................................................................................................................................28 Price: ...........................................................................................................................................................................29 Annual requirement: ................................................................................................................................................29 Remarks: ......................................................................................................................................................................... 29 Chapter-05.................................................................................................................30 Production planning, sequence & operation..........................................................30 Introduction and Basic Procedure of Planning and Control:................................................................................. 30 Recommendable points of a buyer:................................................................................................................................ 30 Production Planning:..................................................................................................................................................... 31 Knitting section............................................................................................................................................................... 32

  9. Industrial Attachment Report 2011 Production parameters:..........................................................................................................................................32 Points that shouldconsider in case of G.S.M. changing:................................................................................32 Production flow chart:.................................................................................................................................................... 33 Description of production process:................................................................................................................................ 33 GSM:............................................................................................................................................................................34 Fabric width:.............................................................................................................................................................34 RPM:.............................................................................................................................................................................34 Loop length:...............................................................................................................................................................34 No. of feeder or no. of cone: ................................................................................................................................34 Gauge:..........................................................................................................................................................................35 Production calculation:............................................................................................................................................35 Following Counts are used to achieve the mentioned G.S.M:..................................................................................... 38 Relation between yarn count, fabric type, stitch length and finished GSM:............................................................... 39 Fabric Dyeing Section:................................................................................................................................................... 44 Production flow chart for fabric:........................................................................................................................44

  10. Industrial Attachment Report 2011 Process sequence: ....................................................................................................................................................45 Pretreatment:...........................................................................................................................................................45 Scouring-Bleaching:....................................................................................................................................................... 46 Pretreatment program: (scouring ,bleaching and enzyme) ............................................................................46 Bio-Scouring:.................................................................................................................................................................. 48 Enzyme Treatment:.................................................................................................................................................48 Dyeing:............................................................................................................................................................................ 50 Dying program for ME dyes: .................................................................................................................................50 Dyeing program for HE Dyes: ...............................................................................................................................51 Dying program for W Dyes:...................................................................................................................................52 Dying program for Turquise Dyes:.......................................................................................................................53 Dying program for KHW Dyes: .............................................................................................................................54 Dyeing program for HF dyes:................................................................................................................................55 Dyeing program for WHITE color (Without enzyme):...................................................................................56 Dyeing program for WHITE color (With enzyme):.........................................................................................57

  11. Industrial Attachment Report 2011 Dyeing program for Disperse Dyes: ....................................................................................................................58 Re-dyeing Process:...................................................................................................................................................59 Stripping process:....................................................................................................................................................60 After Treatment Of All Program:.......................................................................................................................61 After dyeing for neutralization:..........................................................................................................................62 For fixing:..................................................................................................................................................................62 Softener solution(10% solution):..........................................................................................................................62 Necessary calculations used in textile dyeing processes:.............................................................................................. 63 Molarity......................................................................................................................................................................63 Normality ...................................................................................................................................................................63 Stock solution preparation ....................................................................................................................................63 Dyeing calculation.....................................................................................................................................................63 Common textile auxlliaries used in dyeing:.................................................................................................................. 64 Acid..............................................................................................................................................................................64 Alkalis..........................................................................................................................................................................64

  12. Industrial Attachment Report 2011 Buffer.........................................................................................................................................................................64 Oxidizing agent.........................................................................................................................................................64 Reducing agent..........................................................................................................................................................64 Surfactants...............................................................................................................................................................65 Wetting agent...........................................................................................................................................................65 Detergent...................................................................................................................................................................65 Lubricant....................................................................................................................................................................65 Anti-foaming agent..................................................................................................................................................65 Anti-creasing agent.................................................................................................................................................65 Anti-pilling agent......................................................................................................................................................65 Leveling agent ...........................................................................................................................................................65 Dispersing agent.......................................................................................................................................................65 Retarding agent........................................................................................................................................................65 Carrier ........................................................................................................................................................................66 Chemical formula of common chemicals used in textile dyeing:...................................................................66

  13. Industrial Attachment Report 2011 Problems Encountered In Dyeing: ............................................................................................................................... 66 Uneven Dyeing...........................................................................................................................................................66 Uneven Shade in Rope to Rope..............................................................................................................................67 Off Shade..................................................................................................................................................................67 Dye Spots...................................................................................................................................................................67 Batch to Batch Shade Variation...........................................................................................................................67 Crease Mark ..............................................................................................................................................................67 Running Marks...........................................................................................................................................................67 Intensive Foaming ....................................................................................................................................................68 Patchy Dyeing............................................................................................................................................................68 Miscellaneous Problems..........................................................................................................................................68 Remarks: ......................................................................................................................................................................... 68 Printing............................................................................................................................................................................ 68 Sample Preparation........................................................................................................................................................ 69 Bulk Production:............................................................................................................................................................. 70

  14. Industrial Attachment Report 2011 Available Printing Style in Micro Fibre LTD................................................................................................................ 70 Types of Printing in Micro Fibre Group:...................................................................................................................... 70 Reactive printing:.....................................................................................................................................................70 Discharge printing: ..................................................................................................................................................71 Pigment printing: ......................................................................................................................................................71 Recipe of Pigment paste:........................................................................................................................................71 Recipe of Discharge paste:....................................................................................................................................71 Recipe of reactive Paste:.......................................................................................................................................71 Pollutants during printing process: ......................................................................................................................72 Finishing section............................................................................................................................................................. 72 Objective of finishing:............................................................................................................................................72 Types of finishing:...................................................................................................................................................73 Flow chart of final process (knit fabric)...........................................................................................................74 The machines that are used in open line that are given bellow: ..................................................................74 The machines that are used in tube line that are given bellow: ..................................................................75

  15. Industrial Attachment Report 2011 Machine Specification:...........................................................................................................................................75 Squeezer Machine:...................................................................................................................................................78 Hydro-extractor m/c..............................................................................................................................................78 Dryer m/c :..............................................................................................................................................................78 High Production Dryer:...........................................................................................................................................78 Utility:.............................................................................................................................................................................. 79 Calendar M/C: ...........................................................................................................................................................80 Width Compactor.....................................................................................................................................................80 Stentering Machine......................................................................................................................................................... 84 Purpose of the m/c:.................................................................................................................................................84 Main parts of the machine:....................................................................................................................................85 Procedure for Heat set for Lycra s/j fabric:..................................................................................................87 Factor Consideration:..............................................................................................................................................88 CHAPTER-6..............................................................................................................90 Quality Assurance System........................................................................................90

  16. Industrial Attachment Report 2011 Quality assurance:.......................................................................................................................................................... 90 Object of quality control:................................................................................................................................................ 90 Scope of quality control:................................................................................................................................................. 91 Quality Control Flow Chart:.......................................................................................................................................... 91 Quality Management system:......................................................................................................................................... 92 Online QC ...................................................................................................................................................................92 Off Line Test:...........................................................................................................................................................93 WORKING PROCEDURE FOR LAB........................................................................................................................... 94 List of Dyeing and Qc Laboratory Machinaries............................................................................................................ 95 Quality Standard:.......................................................................................................................................................... 100 Fabric Inspection:..................................................................................................................................................100 Grey Fabric Inspection.........................................................................................................................................100 FinishedFabric Inspection:................................................................................................................................. 101 Procedure of the Different Laboratory Tests:............................................................................................................. 103 Color Fastness to Wash Test: ............................................................................................................................103 Required instrument:.............................................................................................................................................104

  17. Industrial Attachment Report 2011 Procedure :...............................................................................................................................................................104 Evaluation:................................................................................................................................................................104 Washing fastness for solid dyeing is checked normally 3 times e.g. ........................................................104 Color the Fastness to Rubbing (Dry &Wet) Test:........................................................................................104 Procedure:................................................................................................................................................................105 Evaluation:................................................................................................................................................................105 Color Fastness to cool Water:............................................................................................................................105 Testing Solution:....................................................................................................................................................105 Color Fastness to hot Water:.............................................................................................................................106 Testing Solution:....................................................................................................................................................106 Color Fastness to Perspiration Test:................................................................................................................107 Color fastness to light:.........................................................................................................................................108 Accepted Quality standard: .......................................................................................................................................... 108 Measuring the Dimensional Stability (Shrinkage &Spirality):...................................................................108 Spirality test calculation: ....................................................................................................................................110

  18. Industrial Attachment Report 2011 pH of a Dyed Fabric Test.....................................................................................................................................111 Quality Standard:.......................................................................................................................................................... 112 SHORTLY DESCRIBED ABOUT OEKO-TEX STD100:................................................................................. 112 Remarks: ....................................................................................................................................................................... 113 CHAPTER-07..........................................................................................................114 MAINTENANCE....................................................................................................114 Maintenance of machinery:......................................................................................................................................... 114 Break down Maintenance:..................................................................................................................................... 114 Routine Maintenance:............................................................................................................................................ 114 Manpower Set-Up For Maintenance:.......................................................................................................................... 115 Maintenance procedure:............................................................................................................................................... 115 Maintenance work to the different machines:............................................................................................................. 116 Boiler Maintenance Schedule:............................................................................................................................. 116 Dyeing m/c maintenance Schedule ....................................................................................................................117 Compacting m/c maintenance:.............................................................................................................................118 Maintenance tools/equipments & their functions:...................................................................................................... 119

  19. Industrial Attachment Report 2011 Remarks: ....................................................................................................................................................................... 120 CHAPTER-08..........................................................................................................121 UTILITY SERVICE...............................................................................................121 Available Utility Facilities:........................................................................................................................................... 121 Electricity:............................................................................................................................................................... 121 Gas:................................................................................................................................................................................ 122 Water:............................................................................................................................................................................ 122 Boiler:............................................................................................................................................................................ 122 Compressor:.................................................................................................................................................................. 123 Source of Utility:........................................................................................................................................................... 124 Utility cost: .............................................................................................................................................................124 Remark:......................................................................................................................................................................... 125 Water treatment plant................................................................................................................................................... 125 Process Flow chart.................................................................................................................................................125 Effluent Treatment Plant (ETP).................................................................................................................................. 126 Flow chart for ETP: ...............................................................................................................................................127

  20. Industrial Attachment Report 2011 Effluent analyzing report:...................................................................................................................................128 Ref:............................................................................................................................................................................128 USPEA(United States Environment Protection Agency) .............................................................................128 Product Quality Checked:....................................................................................................................................128 Chemicals Used in ETP:.........................................................................................................................................129 CHAPTER-09..........................................................................................................130 STORE & INVENTORY CONTROL..................................................................130 Inventory system for raw material:.............................................................................................................................. 130 Grey fabrics store:................................................................................................................................................130 Dyes &chemicals store:.......................................................................................................................................130 Spares:......................................................................................................................................................................130 Finished goods: ....................................................................................................................................................... 131 Remarks: ....................................................................................................................................................................... 131 CHAPTER-10..........................................................................................................132 COST ANALYSIS...................................................................................................132 Price of the product:..................................................................................................................................................... 132

  21. Industrial Attachment Report 2011 Remarks: ....................................................................................................................................................................... 132 CHAPTER-11..........................................................................................................133 MARKETING ACTIVITIES.................................................................................133 Consumers of Product:................................................................................................................................................. 133 Name of buyer:.............................................................................................................................................................. 133 Product Label:............................................................................................................................................................... 133 Package Size & Label:.................................................................................................................................................. 134 Local Market:................................................................................................................................................................ 134 Importing countries:..................................................................................................................................................... 134 Manpower of marketing:.............................................................................................................................................. 134 Marketing strategy:....................................................................................................................................................... 135 Duties and responsibilities of marketing officer:........................................................................................................ 135 Remarks: ....................................................................................................................................................................... 135 CHAPTER -12.........................................................................................................136 CONCLUSION........................................................................................................136

  22. Industrial Attachment Report 2011 CHAPTER-01 PROJECT DESCRIPTION Name of the project MICRO FIBRE GROUP Sister organizations A-One polar Ltd, Liberty Knitwear Ltd, Midland Knitwear Ltd, Orient Chem.-Tex Ltd. Type of the mill 100% export oriented knit composite textile mill. Year of establishment 1998 Registered Office 331, Tongi Dioversion Road, Moghbazar, Dhaka – 1217, Bangladesh Factory Address Ramarbagh, Bangladesh 0189-214648, 0173-034617 (E.D) 0171-3001607(D.G.M-Production), 0173- 011112 (Merchandising Manager) Kutubpur, Fatullah, Narayangonj, Communication The project is easily accessible by road. The route has been clarified in the location map presented in the previous page. Sponsors The mill is sponsored by M.S. Zaman. 1 | P a g e

  23. Industrial Attachment Report 2011 Capacity Gray (approximately) knit fabric production 8000 Kg/day Dyed knitted fabric 22-24 ton/day (approximately) Project cost Cost 250,00,00,000 of the project is approximately in Taka Project area 7.00 acres History of project development: It is a moment of rejoice to introduce Micro Fiber Group (MFG) to its clients and patrons. MFG believes whatever it has achieved; its credits should be directed toward its clients. Micro fibre group started their Textile business in 1998 by starting construction of the building for project setup. At 1stthey set up Garments project. In 1999 they went to production of fabric and dyeing with a dryer of 400 kg & 6 ton capacity boiler. As an ambition to expand the business they setup knitting section in 2000 & to fill the demand of knitting they setup as well as stenter, calendar, dewatering m/c, dryer for finishing. With the passage of time different type of m/c were brought to the mill to improve the quality & production. The mill is well oriented for knit composite project. Therefore, when manystruggle to survive in post-MFA world; its business in fact enjoying a healthy growth. Moreover, having endless efforts to ensure internationallyaccepted employment practice, its clients recognize us as a partner to protect their value system and images among final consumers. 2 | P a g e

  24. Industrial Attachment Report 2011 Different departments: i. Knitting section Circular Flat ii. Dyeing section: Knit dyeing iii. iv. v. vi. vii. viii. Garments section Costing & Finance Logistics Maintenance Planning section QC section Product mix: Types of raw materials processed here are- i. cotton- 100% combed or carded polyester-cotton blend (p/c or t/c), (65%pet+35% cotton) CVC (60% cotton+40% polyester) grey melange (85% cotton+15% viscose) Ecru melange (98% cotton+2% viscose or 99% cotton+1% viscose) ii. iii. iv. v. 3 | P a g e

  25. Industrial Attachment Report 2011 S E ETP W LAYOUT DESIGN N Midland Knitting Maintenanc e Laborator y Liberty Office M idl a n & Garments Department Garments Midland Finishing Midland finishing Midland Micro Micro Dyeing Dyeing Finishing Office Cantee n Entrance Office Store Utilities Room Security Car parking Prayer Room Health Utilities Midland facilities Dyes & Room Dyeing Midland Office Room Chemicals Office Printing 4 | P a

  26. Industrial Attachment Report 2011 Layout plan of printing section: In the printing section of Micro fibre ltd there are 2 floors. In ground floor there are 3 Allover printing m/c and E Store W Store MKT Keeper N S Office C E AGM C Office 1. Computer 2. Expose m/c 3. Retouching table C. Computer E. Entrance Ink Jet m/c 2 Sample Table T. Toilet 1 3 T Fig: 2ndFloor of printing section 55 | P a g e

  27. Industrial Attachment Report 2011 E Screen washing zone W S N Allover Printin g Allover Printin g Allover Printin g E m/c # 1 m/c # 3 m/c # 2 E Fig: Production Floor Printing Section Remark: Micro Fiber Group is a well established knit composite industry. The industry stands on industrial area of Ramarbagh, Narayangonj. It is a Group of Companies, . It is going to prove its own standard of product quality in world market as they know that their reputation depends on quality. It is a profitable project and contributes the economy of our country. 66 | P a g e

  28. Industrial Attachment Report 2011 Physical Infrastructure: MICRO FIBRE GROUP Knittin g Dyeing Garment Admin Maintena nce Knit (admin) Knit (prod) Cost & finance Accounts Knit dyeing Prod QC Gmt(Ad min) Gmt (Prod) Clea ning Mechanica l Dept Utility Electric Dept 77 | P a g e

  29. Industrial Attachment Report 2011 CHAPTER -2 MANPOWER MANAGEMENT Organ gram of man-power administration MANAGING DIRECTOR EXECUTIVE DIRECTOR GENERAL MANAGER ASST. GENERAL MANAGER ASSISTANT PRODUCTION MANAGER MANAGER (LAB & QC) SENIOR PRODUCTION OFFICER OFFICER PRODUCTION OFFICER SENIOR OFFICER ASSISTANT PRODUCTION OFFICER ASSISTANT SENIOR LAB SENIOR SUPERVISOR LAB ASSISTANT SUPERVISOR LAB BOY ASSISTANT SUPERVISOR SENIOR OPERATOR OPERATOR ASSISTANT OPERATOR HELPER Management system: 88 | P a g e

  30. Industrial Attachment Report 2011 In Micro Fiber Group the management system is regular. employees are well skilled and are graduate in their respective profession. Shift change: The industry has two shift .Duration of every shift is 12 hours. Workers get one hour break time. Shift change depends on the work order and production. There is a supervisor in every shift who takes the working activities & understands his responsibilities from previous supervisor during shift change. Total Section Wise Man power Management system: Micro Fibre Group has sufficient number of skilled manpower working in different sections. A picture of manpower distribution with total manpower is given below: DEPARTMENT MANPOWER Knitting 445 Dyeing 560 Printing 138 Finishing 315 Garments 3587 Maintenance 40 Administration 23 Utility 20 Security 28 Total 5136 99 | P a g e

  31. Industrial Attachment Report 2011 Responsibilities of S.P.O/P.O: The main job as well as main responsibility of a s.p.o is to control process. The responsibility of a s.p.o/p.o is to complete a batch in required time. Any fault or disturbance happens in a batch, the blame goes to s.p.o/p.o. The p.o should try to minimize overhead expenditures and also try to make a batch more profitable. In a word he is in charge of the floor & his responsibility is to keep moving the production smoothly. Job description of S.P.O/P.O 1. To give program slip according to daily production plan. 2. To follow up production process from raw materials to finished goods. 3. To match shade in connection with fabric quality according to buyer requirements. 4. To find out fabric faults as early as possible (before finishing), & take stes to recover it. 5. To rectify the finished fabric rejected from quality control department. 6. To coordinate with unit technical manager for achieving the target production. 7. To motivate supervisors and workers for achieving maximum production with minimum faults. 8. To check the daily production report. 9. To study dye & chemicals nature delivery by the manufacturer & apply them Correctly to the production to get best product. Remarks The manpower management system in Micro Fiber Group is well arranged. There are good number of textile engineers in the industry. but they are not adequate enough to undertake the huge production of the industry. Some more are expected to be enrolled there in the shortest possible time to meet up the growing need. The efficiency of the worker should be increased for more quality production. 1010 | P a

  32. Industrial Attachment Report 2011 CHAPTER-3 MACHINE DESCRIPTION List of Single Jersey Circular knitting Machineries : Serial No 01 Machine Brand Name Jiunn Long M/C Type S/J M/C Dia 22 M/C Gauge 24 M/C Feeder 66 F Origin Taiwan 02 Jiunn Long S/J 22 24 66 F Taiwan 03 Jiunn Long S/J 23 24 69 F Taiwan 04 Jiunn Long S/J 23 24 69 F Taiwan 05 Jiunn Long S/J 24 24 72 F Taiwan 06 Jiunn Long S/J 24 24 72 F Taiwan 07 Jiunn Long S/J 25 24 75 F Taiwan 08 Jiunn Long S/J 25 24 75 F Taiwan 09 Jiunn Long S/J 25 24 75 F Taiwan 10 Jiunn Long S/J 25 24 75 F Taiwan 11 Jiunn Long S/J 26 24 78 F Taiwan 12 Jiunn Long S/J 26 24 78 F Taiwan 13 Jiunn Long S/J 26 24 78 F Taiwan 14 Jiunn Long S/J 26 24 78 F Taiwan 15 Jiunn Long S/J 28 24 84 F Taiwan 16 Jiunn Long S/J 28 24 84 F Taiwan 17 Jiunn Long S/J 32 24 96 F Taiwan 18 Jiunn Long S/J 34 24 102 F Taiwan 19 Jiunn Long S/J 36 24 108 F Taiwan 1111 | P a

  33. Industrial Attachment Report 2011 20 Jiunn Long S/J 34 24 102 F Taiwan 21 Jiunn Long S/J 40 24 120 F Taiwan 22 Jiunn Long S/J 38 24 114 F Taiwan List of Single Jersey Circular knitting Machineries : Serial No 23 Machine Brand Name Jiunn Long M/C Type S/J M/C Dia 36 M/C Gauge 24 M/C Feeder 108 F Origin Taiwan 24 Jiunn Long S/J 23 24 69 F Taiwan 25 Jiunn Long S/J 24 24 72 F Taiwan 26 Jiunn Long S/J 21 24 63 F Taiwan 27 Jiunn Long S/J 20 24 60 F Taiwan 28 Jiunn Long S/J 32 24 96 F Taiwan 29 Jiunn Long S/J 30 24 90 F Taiwan 30 Jiunn Long S/J 28 24 84 F Taiwan 31 Jiunn Long S/J 30 24 90 F Taiwan 32 Jiunn Long S/J 36 24 108 F Taiwan 33 Jiunn Long S/J 30 20 90 F Taiwan 34 Jiunn Long S/J 30 20 90 F Taiwan 35 Jiunn Long S/J 30 20 90 F Taiwan 36 Jiunn Long S/J 30 20 90 F Taiwan 37 Jiunn Long S/J 30 24 90 F Taiwan 38 Jiunn Long S/J 40 24 120 F Taiwan 39 Jiunn Long S/J 30 20 90 F Taiwan 40 Jiunn Long S/J 30 20 90 F Taiwan 41 Jiunn Long S/J 36 24 108 F Taiwan 1212 | P a

  34. Industrial Attachment Report 2011 42 Jiunn Long S/J 30 20 90 F Taiwan 43 Jiunn Long S/J 30 20 90 F Taiwan 44 Jiunn Long S/J 30 20 90 F Taiwan 45 Jiunn Long S/J 36 24 108 F Taiwan 46 Fukuhama S/J 30 24 90 F Taiwan 47 Fukuhama S/J 31 22 72 F Taiwan List of Double Jersey Circular knitting Machineries : Seri al No 01 Machine Brand Name Fabric type M/C Type M/C Dia M/C Gaug e 16 M/C Feeder Origin Falmac Interloc k Rib D/J 24 38 F Singap ore Singap ore Singap ore Singap ore Taiwan 02 Falmac D/J 34 16 54 F 03 Falmac Rib D/J 30 16 48 F 04 Falmac Rib D/J 30 16 48 F 05 Hubter Rib D/J 38 18 80 F 06 Hubter Rib D/J 40 18 84 F Taiwan 07 Hubter Rib D/J 20 16 32 F Taiwan 08 Hubter Rib D/J 30 16 48 F Taiwan 09 Fukahama Interloc k Interloc k Rib D/J 36 18 72 F Taiwan 10 Fukahama D/J 36 18 72 F Taiwan 11 Fukahama D/J 36 18 72 F Taiwan 12 Fukahama Rib D/J 34 18 72 F Taiwan 13 Fukahama Rib D/J 34 18 102 F Taiwan 14 Fukahama Interloc k D/J 28 20 84 F Taiwan 1313 | P a

  35. Industrial Attachment Report 2011 List of Auto Stripe Circular knitting Machineries : M/C Type S/J M/C Dia 30 M/C Gauge 24 M/C Feeder 48 Serial No 01 Machine Brand Name Fukuhara Origin Japan 02 Fukuhara S/J 30 24 48 Japan 03 Fukuhara S/J 34 24 48 Japan 04 Fukuhara S/J 34 24 48 Japan 05 Fukuhara Rib/ 36 18 48 Japan Interlock List of Flat Bed knitting Machineries : Seri al No 01 Machine Name M/C Type M/C Bed Length 40 M/C Gauge M/C Cares Origi n Around Star Around Star Around Star Around Star Around Star Around Star Around Star Around Star Around Star Around Star Around Star Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C 14 Single Cares Single Cares Single Cares Single Cares Single Cares Single Cares Single Cares Double Cares Double Cares Double Cares Double Cares Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n 02 40 14 03 40 14 04 40 14 05 40 14 06 40 14 07 86 14 08 68 14 09 68 14 10 68 14 11 68 14 1414 | P a

  36. Industrial Attachment Report 2011 12 Around Star Around Star Around Star Around Star Around Star Around Star Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C Computerized Flat Bed M/C 68 14 Double Cares Double Cares Double Cares Double Cares Double Cares Double Cares Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n Taiwa n 13 68 14 14 68 14 15 68 14 16 68 14 17 68 14 List of Cloth Inspection Machineries : Serial No 01 Machine Name Nos Brand Origin Grey Fabric Inspection Machine 02 Sets UZU® Thailand 1515 | P a

  37. Industrial Attachment Report 2011 Machine Picture SINGLE JERSEY CIRCULER KNITTING MACHINE JIUNN LONG MACHINE CO. LTD. TAIWAN. Specification: Model: JLS Cyl. Dia: 30" Feeders: 90 F Gauge: 24 G Needles: 2256 T SINGLE JERSEY CIRCULER KNITTING MACHINE JIUNN LONG MACHINE CO. LTD. TAIWAN. Specification: Model: JLS Cyl. Dia: 30" Feeders: 90 F Gauge: 24 G Needles: 2256 T SINGLE JERSEY CIRCULER KNITTING MACHINE FUKAHAMA MACHINERY CO. LTD. YUANHSIEN, TAIWAN. Specification: Model: SH-JFA3 Cyl. Dia: 34" Feeders: 102 F Gauge: 24 G Mfg. Date: Sep. 2010 1616 | P a

  38. Industrial Attachment Report 2011 FUKUHARA STRIPER MACHING PRECISION FUKUHARA WORKS,LTD. JAPAN. Specification: Gauge: 20/24 Feeders: 192 F Size: 34" Mfg. Date: March.2007 COMPUTERIZED FLAT KNITTING MACHINE AROUND STAR INTERNATIONAL CO. LTD. TAIWAN. Specification: Bed Length: 40" Gauge: 14 G UZU® FABRIC INSPECTION MACHINE AATPR INDUSTRY CO. LTD. THAILAND. Mfg. Date: April-2007 1717 | P a

  39. Industrial Attachment Report 2011 Lay-out Plan of knitting Machineries : K S W E D N H I M A C B J E F G L 1818 | P a

  40. Industrial Attachment Report 2011 A = Office of A.G.M (Knitting) B = Office of Production Officer C = Cloth inspection machine D = Re-conning machine E = Supervisor office & Knit Admin F = Flat bed knitting section G = Spare Cylinder room H = Stair I = Lift J = Store of Spare parts & equipments K = Fitter / Staff office L = Toilet M = Auto stripe Machine Section = Circular Knitting Machine (Single & Double Jersey) = Eyes marking or Floor marking Total Floor space of the knitting floor = 20,338.93 Sq.ft (approximately) Space of A.G.M. Office Sq.ft Space of P.O Office Sq.ft Space of Knit admin office Sq.ft Staff office space Sq.ft Stair space Sq.ft Lift space Sq.ft Space of Re-conning M/c Sq.ft Cloth inspection M/c Sq.ft = 172.85 = 175 = 96.15 = 175 = 472.5 = 157.5 = 52.5 = 78.72 Sq.ft ×2 = 157.44 1919 | P a

  41. Industrial Attachment Report 2011 Space of equipments office Sq.ft Space of Spare Cylinder room Sq.ft Space of Toilet Sq.ft Space of Flat Bed Knitting Section Sq.ft Space of Auto Stripe Knitting M/c Section Sq.ft Total space used for different section Sq.ft = 228 = 383.8 = 547.1 = 1372.61 = 1478.73 = 5512.74 Now ,Rest of the free space for circular knitting machine according with floor marking, = Total Floor space of the knitting floor - Total space used for different section = (20,338.93 - 5512.74) Sq.ft =14862.19 Sq.ft In Micro Fibre Group the total number of knitting machine is 83 ( where Single jersey circular knitting machine is 47, Double jersey circular knitting machine is 14, Auto Stripe circular knitting machine is 5, And Flat Bed knitting machine is 17, total 83). But there has another knitting floor where other knitting machines are positioned. The space of 14862.19 Sq.ft for Circular knitting machines which are assembles in previous page.And in this lay out plan 40 No’s of Circular knitting machine are situated. One circular knitting machine with creel stand which required 262.44 sq.ft So, the number of 40 knitting machines required space is, = 262.44 sq.ft × 40 = 10497.6 Sq.ft The totally free space is = 14862.19 Sq.ft - 10497.6 Sq.ft = 4364.59 Sq. ft Remarks : The Lay out plan of the machineries is well Micro Fiber Ltd. arranged. There are good number of textile machineries in the industry. They are adequate 2020 | P a

  42. Industrial Attachment Report 2011 enough to take the huge production of the industry. The efficiency of the worker should be increased for more quality production. 2121 | P a

  43. Industrial Attachment Report 2011 CHAPTER -04 RAW MATERIALS Micro Fiber Ltd. is a knit composite industry. In the industry raw materials for different section is different. As for example knitting uses yarn as raw material, Fabric processing department uses the knit fabrics, dyes and chemicals. Types of Raw Materials: Different type of raw materials are found like 1. Yarn 2. Grey Fabric 3. Dyes 4. Chemicals Order is usually obtain in the form of making complete garments grey fabric or yarn dyeing that is main raw material is fabric & yarn. Fabric is made in its own knitting section from different types of yarn according to requirement, but sometimes buyer may supplies this. Yarn: Following types of yarns are used to knit fabrics: 1. Cotton — 30 s/1, 80/2, 20/1, 60/2,34s/l, 26/1, 20/1, 18/1, 24/1 (Carded or combed.) 2. Filament —20/D, 24/D, 30/D, 40/D,75/D, 100/D, 150/D. 3. Polyester spun — 50/2 Ne, 20/2 Ne. 4. T/C —+30/1, T/C. 5. Viscose —26/1. 6. CVC (varying proportion) The count mentioned above was found during mill training. Sources: Yarn is collected from the fo1lowing sources: 2222 | P a

  44. Industrial Attachment Report 2011 1. 2. Delta spinning 3. Israk spinning mills 4. Delsy spinning mills 5. Techno spinning mills 6. Jamuna spinning mills 7. Malek spinning mills 8. Kader spinning mills Shohagpur spinning mills Price: Not provided. Grey Fabrics: Following types of grey fabrics are dyed: 1.Single jersey: - Single and double lacoste - Polo pique - Terry fleece - Engineering stripe 2. Single jersey with Lycra 3. Double jersey: - Rib - Interlock 4. Double jersey with Lycra 5. Flat bed : -Single Collar and Cuff -Design Collar and cuff Sources: The required grey fabric is produce in the industry. The required fabrics are supplied from Micro Fiber Ltd. Price: Price of grey fabrics depends upon the price of yarn and the making charge of the fabric. For example, in case of 30’s spun cotton yarn, the price of yarn is $3/kg and for single jersey fabric the knitting charge is $0.18. So the price of single jersey fabric is $3.18/kg. 2323 | P a

  45. Industrial Attachment Report 2011 Chemicals: CHEMICAL NAME CHEMICAL NAME TRADE NAME TRADE NAME Bluton –BVB ACN Optical brightening Anticreasing agent SCF CL-225 Wetting agent Leveling agent SR FS Fixing agent Softener OEM SF Peroxide killer Antifoaming agent RLF-349 CBA Leveling agent Anticreasing agent SQ-117 TPA Sequestering agent Antifixing agent WCS EAS Softener Softener 2UD AW-501 Sequestering agent Soap RH SQ-114 Alkali Sequestering agent G.acid SQS Acetic acid Brightening agent PE-40 MC Silicon Wetting agent ER330 MKL Optical brightening Enzyme WRN BBU Optical brightening Flame retardant Flock BM InSA Dust remover Sequestering agent SR BUBZAM Optical brightening Fixing agent Commonly used dyes in fabric dyeing section in Micro fibre Ltd For light color: RR dyes 2424 | P a

  46. Industrial Attachment Report 2011 i. Yellow RR ii. Red RR iii. Blue RR If color shade% not matching under three different light source (D-65, TL-83,A), then below dyestuffs are used: DRI dyes: i. DRI yellow HFR ii. DRI Red HF3B iii. DRI Blue HFRL For medium shade: ME dyes (Navy blue, olive etc G.yellow SP-3R i. ii. RED SP3B iii. N.BLUE ME2G iv. BLUE RSPL v. BLACK B vi. BLUE BBNEW and so on. RED: W-dyes i. ii. Orange W-3R iii. Red KHW iv. DK Blue WR v. Yellow KHW Black: Super black G i. ii. Black WNN 2525 | P a

  47. Industrial Attachment Report 2011 Turqious : Yellow 4GL i. ii. Blue BBNEW /N.Blue 2GL iii. Blue G Chemicals & their function: Chemicals used in Dyeing and their function: ♦ Acid - The chemical compounds that dissolve in water and provide H+(proton). It changes the color of litmas paper from blue to red. Strong acids - completely ionized in water; For example: HClO4, Hl, HBr, HCl, HNOs, H2SO4, H3PO4.Weak acids - partial ionized in water; For example: HF, H2S, HCN, HC2H3O2and most organic acids. ♦ Alkalis - The chemicaL compound that dissolve in water and provide 0H-. It changes the color of litmas paper from red to blue. Strong alkalis - completely ionized in water; For example: NaOH, KOH, LiOH, Mg(OH)2most metallic hydroxides Weak alkalis - partial ionized in water; For example: NH4OH and most organic alkalis ♦ Buffer - lt is a saturated solution of acid-salt or alkali-salt mixture. lt resists the change of pH on addition of acid or alkali. Usually it is used to control the any bath solution. Buffer solutions are solutions containing mixtures of a weak acid or base and a salt of that acid or base. For exampre, the mixture of acetic acid and sodium acetate, which dissociates as: CH3COOH CH3COO-+ H+ CH3COONa CHs COO-+ Na+ ♦ Oxidizing agent - The chemical compound which provide oxygen during chemical reaction and converting to oxide, They gain electrons in a redox chemical reaction, for example, O3, H2O2, Ca0Cl2. ♦ Reducing agent - The chemical compound which losses electron during chemical reaction. lt reduces other substances chemically, especially by donating an electron or electrons, for example, Hydrose (Na2S2O4), Rongalite C. ♦ Surfactants - Surfactants or surface-active agents act in solid-liquid, solid-gas, or liquid-gas interfaces and reduces the interfacial tension. ln textile wet processing it works in between solid-liquid interface and reduce the surface tension of liquid. lt has a versatile application in textile industries especially in textile coloration, for example, Wetting agent, Detergent, Lubricant, Foaming agent, Anti-foaming agent, Leveling agent, Dispersing agent. 2626 | P a

  48. Industrial Attachment Report 2011 ♦ Wetting agent - lt accelerates the wetability of material in solution; thus helps to easy penetration of chemicals into substrate. Usually it is used in scouring, bleaching and dyeing processes. lt is available in market in form of clear or yellowish liquid. ♦ Detergent - Detergents are one kind of surface active agents but the reverse is not always true. The surfactants which have detergency power and the number of carbon in aliphatic chain are not less than 9. Usually it is used in textile to clean the materials by removing undesirable substances. These products are either soaps or synthetic detergents. ♦ ♦ Lubricant - The chemical compounds use to prevent contact between solid surfaces in relative motion in order to reduce friction, wear, overheating, and rusting. They are very good coolants, provide the appropriate range of viscosities, and are thermally stable. ♦ Anti-foaming agent - Anti-foaming agents are another type of surfactants which are able to prevent or reduce foam. Usually, anti-foaming agents are used in dyeing bath and in printing paste to hinder foam generation. Excess foam generation can create adverse effect in processing and product. ♦ Anti-creasing agent - Usually used in dyebath or in finishing stage to prevent creasing of fabric or garments. ♦ Anti-pilling agent - Some man-made and blended fibre fabrics can easily form pills in their surface. Thus it reduces the aesthetic value of the fabric or garment. Anti-pilling agents are used to prevent such kind of pills formation during wearing of cloth. ♦ Leveling agent - Leveling agent is used in textile coloration process to achieve uniform dyeing over the whole substrate by controlling the rate of dyeing. Generally it is a non-ionic surfactants type compound either fibre substantive or dye substantive. lt is available in market in liquid form. ♦ Dispersing agent - usually it is used in disperse and vat dyeing process helps to distribute the dye molecules in dye bath. it is also help to penetrate the dye molecules into the substrate. lt is available in market in powder form. ♦ Retarding agent - The chemical compound that are able to retard or control the dye uptake inside of the fibre .Using retarders is very common in acrylic dyeing ♦ with cationic dyes. ♦ Carrier - Carriers are relatively small organic substances that usually have affinity for polyester. lt acts as a catalyst to accelerate the dye penetration into the fibe in disperse dyeing process. 2727 | P a

  49. Industrial Attachment Report 2011 ♦ Chemical formula of common chemicals used in textile dyeing: Water – H2O Hydrochloric acid - HCI Sulfuric acid –H2SO4 Phosphoric acid – H3PO4 Sodium chloride (common salt) - NaCl Sodium carbonate – Na2CO3 Sodium sulfate (glauber salt) – Na2SO4 Sodium bicarbonate – NaHCO3 Sodium hydroxide - NaOH Potassium hydroxide - KOH Sulfur dioxide – SO2 Tri sodium Phosphate – Na3PO4 Benzene – C6H6 Acetic acid - CH3COOH Oxalic acid - (COOH)2 Cellulose – C6H10O5 Starch - C6H10O5 Hydros (sodium hydrosulfite) – Na2S2O4 Bleaching powder- Ca(OCl)Cl Printing chemicals function: The functions of chemical used in printing process are given below Urea: Hydroscoping agent, by using urea the steaming is finished within 5 to 10hours. Resist salt: NaCl is penetrated by heating but resist salt is penetrated into fabric without heating. Na2CO3: Fixing the dyes molecules properly. Thickener: Thickener helps the past or chemical to be not sprayed on the fabric or not to be bleeding. Increased paste viscosity. Reduce screen pore radius. 2828 | P a

  50. Industrial Attachment Report 2011 Price: Price of dyes & chemicals depend on the quality, type availability & requirement. For high quality product, better dye & chemical should be used though cost is high. Annual requirement: Annual requirement of dyes & chemical depend on the order of production but for various reasons such as improper weighting, carelessness of operators, hydrolysis of dyes, uneven process control, wrong recipe formulation, incorrect batching, improper storage facilities & for different unwanted expenditure increases dyes & chemicals requirement. Remarks: For smooth running of a factory uninterrupted supply of raw materials is very essential. As far as we saw the raw material control of MFG is good. 2929 | P a

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