Industrial attachment of knit concern limited (kcl)

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTKnit Concern Limited (KCL)

Name ID

Md. Rasel Rabby 2008000400067

Md. Farid-ul-Islam 2008000400066

Md. Masud Rana 2008000400054

Md. Subuj Mia 2008000400005

Brief Presentation

Industrial Attachment

Industry Name: Knit Concern Limited (KCL)

School: Science and Engineering

Course of Studies: B.Sc. in Textile Engineering

Supervising Teacher:

Prof. Syed Fakhrul Hassan

Chairman

Department of Textile engineering.

Southeast University

Submitted By,

Batch

7th

January, 2012

iii

Abstract

Textile technology education is based on industrial ground. Theoretical background is

not sufficient so, industrial training is an essential part of study to make a technologist

techn i- cally sound in this field. Industrial training provides us that opportunity to gather

practical knowledge.

Knit Concern Limited (KCL) is a truly integrated undertaking. The textile

division has the capability to offer a complete product range for the export & domestic

textile ma r- kets. The goal of this textile factory is to become the preferred partner for

sourcing high quality fabrics & clothing from Bangladesh. With high advanced

technology & an empha- sis on developing local human resources, the textile division

has the potential to make an important contribution to the nation’s growing readymade

garments export sector.

The rationale behind the existing structure & future expansion of the textile division is to

capture value added at each stage of the textile manufacturing process. Despite Bangla-

desh’s lack of indigenous cotton production capability Knit Concern Limited

(KCL) has leveraged Bangladesh’s labor cost advantage & export competitiveness

to

maximumlevel.

iv

Acknowledgement

All the praises are for the almighty, Allah who bestowed us with the ability and

potential to complete this Internship. We also pay my gratitude to the Al-mighty for

enabling us to complete this Internship Report within due course of time.

Project paper is an academic function of the Southeast University. We are highly

delighted to express our regards & gratitude to honorable Professor supervising

teacher Prof. Syed Fakhrul Hassan for providing us the chance to complete our

internship and completion our project work in KCL.

Cordial thanks goes to Md. Touhidul Islam Kakon,Sr. Manager of KCL for their

excellent co-operation during the period of our training. We also take the opportunity

to express our sincerest gratitude to the management, administration & personnel of

KCL for their kind assistance.

Above all, we would like to acknowledge our deep debt to all teachers of our

university & particularly of Wet Processing Department for their kind inspiration &

help, which remain as the backdrop of all our efforts.

Finally, we would like to acknowledge that we remain responsible for the in-

adequacies & errors, which doubtless remain in the following report.

v

Table of contents

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

CHAPTER – 2 ............................................................................................... .................. 8

CHAPTER – 3 ............................................................................................... ................ 18

CHAPTER – 4 ............................................................................................... .............. 145

CHAPTER – 5 ............................................................................................... .............. 159

CHAPTER – 6 ............................................................................................... .............. 174

CHAPTER – 7 ............................................................................................... .............. 191

CHAPTER – 8 ............................................................................................... .............. 208

CHAPTER – 9 ............................................................................................... .............. 212

CHAPTER – 10.................................................................................................... ........ 216

CHAPTER – 11........................................................................................................... . 218

CHAPTER – 12...................................................................................................... ...... 221

Industrial Attachment Page 1 of 229

CHAPTER – 1

PROJECT DESCRIPTION


NAME : Knit Concern Limited (KCL)

TYPE : 100 % Export Oriented Knit Composite Industry

SISTER CONCERN : KC Apparels Ltd.

KC Sports Ltd.

KC Lingerie Ltd.

KC Printing Ltd.

KC Yarn Dyeing Ltd.

YEAR OF ESTABLISHMENT : 1990

ADDRESS : 62, Water Works Road, Godnail

Narayangonj-1400, Bangladesh


LOCATION

62, Water Works Road, Godnail, Narayangonj-1400, Bangladesh

Phone : 88-02-7641086: 88-02-7641088

: 88-02-7646869

Fax : 88-02-7641087

E-mail : [email protected]

Web : www.knitconcern.com


Washi

nguni

t

Resid

ential

area

OVERALL LAYOUT PLAN OF THE PROJECT

Knitting Unit

Medical center Storage(Grey fabric)

Storage(Grey fabric)

WTP

KCL + KCALGenerator

Sp. Finishing

Generator

KC Yarn dyeing Ltd KC Lingerie Ltd.

WTP

Main Storage Unit ETP

Residential area


ACHIEVEMENTS

ISO 9001:2008(Certified)

Oeko-Tex Standard 100 (Certified)

May Day Award 2010

Premium Quality Supplier by JULES

CSR awards

PRODUCT MIX

- 100 % cotton

- CVC

- Grey mellange

- Ecro mellange

- PC

PROJECT COST

450 core Taka

HISTORY OF PROJECT DEVELOPMENT

KCL launched its very humble journey in 1990 from a rented building at Nayamati.

That potential embryo by virtue of futuristic enterprising, dedication to quality, co m-

mitment to excellence, adoption of state of the art technology and keen focus on cus-

tomer’s satisfaction, it could very rapidly metamorphose into a large corporate entity,

in its most modern sense, just by 1998. Since its inception, Knit Concern has never

stopped growing - in quality, quantity, and everything in between. Over the last

couple of years, conceding to its growth requirement, using most contemporary ma-

chines and equipment of German, Swiss, USA, Japan, Italy, China and UK origin, it

has nearly doubled its capacity. At present, on a single ca mpus at Godnail, Narajan-

ganj, with all necessary integrations in all dimensions, Knit Concern is producing

1,20,000 pieces of very high quality garments per day. There are many indicators that

may sketch the profile of Knit Concern ltd. business success but, perhaps, the in-

crease of its export alone, from merely US$1.03 million in 1992 to about US$ 60 mi l-

lion in 2010, would show the degree of its exponential growth as a one-stop apparel


supplier from Bangladesh. Now it becomes Knit Concern Group with several sister

concerns.

DIFFERENT DEPARTMENTS

Production Oriented Departments:

• Yarn store

• Raw fabric store & Raw fabric inspection section

• Knitting

• Planning & Control

• Batching Section

• Chemical Store

• Knit Dyeing Unit

• Yarn Dyeing Unit

• Tubular Finishing

• Open Width Finishing

• Special Finishing

• Washing Unit

• Garments Unit

• Central Lab (Knit, Yarn, Wet & Physical)

• Quality Control

• Maintenance

• Utility

• Water Treatment Plant

• Effluent Treatment Plant

Supporting department:

- Procurement

- Merchandising

- Research & Development

- Marketing

- IT

- HRD

- Finance & Accounting


- Medical

- Administration

- Security

REMARK

Knit Concern Ltd. (KCL), the parent company of Knit Concern Group, started ma n-

ufacturing and exporting knit garments back in the 1990s. Today, KCL and its subsid-

iary, KC Apparels Ltd. (KCAL), both being fully composite units on a single campus,

produce 1,20,000 pieces of knit apparels of latest quality and design everyday for the

international markets. Knit Concern is one of the top corporate taxpayers in the in-

dustry. It employs more than 8,500 people, and exports apparels worth over 60 mi l-

lion US dollars a year now. Besides, conforming to fair and eco- friendly standards, it

contributes in terms of both wealth and welfare to the nation.


CHAPTER – 2

MANPOWER MANAGEMENT


MANAGEMENT S YSTEM:

Intercom telephone

Fax Written letters &

Oral

SHIFT CHANGE:

There are two shifts in this industry. So the shifts are changed at every12 hours.

SHIFTING FOR WORKERS:

Shift From ToA 6 2B 2 10C 10 6

RESPONSIBILITIES OF PRODUCTION OFFICER:

1. Give dyeing program slip.2. Match production sample with target shade.

3. Collect production sample lot sample matching next production,

4. Observe dyed fabric during finishing running & also after finish-ing.

5. Identity disputed fabrics & report to P.M/G.M. for necessary ac-

tions.

6. Discuss with P.M about overall production if necessary.

7. Sign the store requisit ion & delivery challan in the absence of

P.M.8. Also to execute overall floor works.

9. Maintain loading'/unloading khata.

10. Any other assignment given by higher authority.


JOB D ESCR IPTION OF PR ODUCTION OFFICER:

REPORT TO : Sr. Production officer.

JOB SUMMARY:

To plan, execute & follows up the production activities & control the quality produc-

tion with related activities.

DUTIES & RESPONSIBILITIES:

Overall supervision of dyeing, finishing production. Batch preparation & pH I chock. Dyes & chemical requisition issue & check. Write Fabrics loading & unloading time from m/c Program making, sample checking, color measurement Control the supervisors, operator, assistant operator and helper of Dyeing m/c. Andalso anyother over work as & when required by the management.

JOB DESCRIPTION OF S ENIOR PRODUCTION OFFICER:

REPORT TO : D.G.M. (production)

JOB SUMMARY :

To plan, execute & follows up the production activities & control the quality produc-

tion with related activities.

DUTIES & RESPONSIBILITIES:

Overall supervision of dyeing, finishing production. Checks the sensitive parameters of different machine for smooth dyeing Checks the different log books of different areas & report to management Checks out the plan to control the best output from supervisors & workers. Trained up & motive the subordinates how to improve the quality produc-

tion. Control the supervisor, operator, Asstt. Operator & helper of dyeing. Maintenance of machine & equipment Any other works & when required by

the management

Organogram of KCL(yarn dyeing unit)Managing Director

Director

AGM(Production)

Sr. Manager(Maintenance)

DPMAss. Manager

APMEngineer

Sr. POAss. Engineer

Incharge(QC)

Incharge(Delivery)

PO Incharge(Yarn Storage)

Incharge(Chemical Store) Sub Ass. Engineer

APOForeman

Sr. Supervisor Sr. Fitter man

Supervisor Fitter man

Ass. Supervisor Helper

Sr. Operator

Operator

Ass. Operator

Jr. Operator

Helper



MAN POWER DISTRIBUTION

KCL has a sufficient number of skilled manpower working in different sections. A view

of manpower distribution with total manpower is given below:

DEPARTMENT MANPOWER

Knitting 656

Knit Dyeing 790

Yarn Dyeing 250

Washing 38

Finishing 315

Garments & printing 6133

Merchandising 42

Maintenance 105

Administration 45

Utility 40

Security 88

Total 8502


REMARK

The man power management system of Beximco Textiles Ltd. is well arranged. Every of-

ficers & stuffs are responsible for their duty. The workers arc bounded to work for minimum

8 hours per day.


CHAPTER – 3

MACHINE DESCRIPTION


KNITTING

Knitting Capacity: 35 Tons per day

Total Machine: 128 Nos.

Knit Concern's knitting facility is equipped with the world's latest and most dependable

brand machinery like Fukuhara, Orizio and Stoll. Excellence in knitting, however, is an

inborn characteristic of the group, inherited from the family of its chief, Joynal Abedin

Mollah. This family has been in yarn trading and knitting since 1960s. In-Line inspec-

tions, invariably followed by an intensive post-production inspection, are maintained

throughout the entire knitting process. It produces numerous varieties of fabrics including

Single Jersey, S/J Cotton Elastane, Rib, 1X1 Rib Cotton Elastane, Interlock, all kinds of

Drop Rib, all kinds of PK, single Jersey and Double Jersey, Engineering Stripe, Thermal,

Jersey Twill, Terry and many more.

Figure: Single Jersey Knitting Machine (Fukuhara)


MACHINE DETAILS

TYPE BRAND MACHINE QUANTITYSingle Jersey Orizio 03 nos.Single Jersey Fukuhara 32 nos.Single Jersey Lisky 04 nos.Single Jersey Open/Slitting Fukuhara 16 nos.Single Jersey Open/Slitting Mayer & Cie 10 nos.Rib / Interlock Fukuhara 20 nos.Interlock Fukuhara 08 nos.Interlock Lisky 01 nos.Rib Well Knitting 01 nos.Rib eyelet Jinhar 01 nos.Auto Striper (Four Color) S/J Fukuhara 04 nos.Auto Striper (Six Color) S/J Fukuhara 01 nos.Auto Striper (Four Color)Rib/Interlock Fukuhara 02 nos.

Fleece 3 Thread Fukuhara 04 nos.Fleece 3 Thread Lisky 06 nos.Flat Knit Semi Jacquard Stoll 02 nos.Flat Knit Computerized Shima Seiki 05 nos.Flat Knit Computerized Matsuya 04 nos.Flat Knit Computerized Protti 04 nos

Total 128 nos.


KNIT DYEING

KCL has dyeing and finishing facilities. It has the largest machinery for fabric dyeing and

finishing. The state – of – the – art equipment reinforced with its intensive experience and

expertise result in a clone – like uniformity of the dye house material. In dyeing section

KCL uses Fong’s brand machines for high temperature and atmospheric dyeing. In fi-

nishing section KCL is using the world’s latest technology of well – known brand Tube –

Tex machine from USA and Santex brand from Switzerland. It has the bot h facilities the

open width and tubular finishing. The shade of every lot of the finished fabric is verified

with data color brand color matching system.

Dyeing Capacity: 35 Tons dyed fabric per day


TYPE BRAND MACHINEQUANTITY

Dyeing machine Fong’s 47 nos.Dewatering & detwisting MC. Santex 02 nos.Dewatering & detwisting MC. Bianco 01 nos.Efficient shrinkage dryer Fong’s 01 nos.Santa shrink jumbo dryer Santex 01 nos.Compactor (tubler) Tube-tex 03 nos.Open width compactor Tube-tex 01 nos.Open width compactor Bruckner 01 nos.Slitting machine Bianco 03 nos.Stenter Tube-tex 01 nos.Stenter Bruckner 02 nos.Sueding machine Lafer 02 nos.Raising machine Gematex 01 nos.Shearing machine Gematex 01 nos.Singeing machine Osthoff 01 nos.

Turning machine Puji/HsingCheng/Daroitex 05 nos.

Back Sewing machine GMT 03 nos.Steam Setting machine Dong Nang 02 nos.Grey Fabric Check machine UZU 09 nos.Finish Fabric Check machine Daroitex/Hsing Cheng 05 nos.

Total 92 nos.


BACK SEWING MACHINE

Machine No.: KDBS - 1

Model: CCM220

Serial no.: C05-012

No. of motor: 4

Year built : 2005


Model: MTG

Serial no.: C07-067

Country of origin : Italy

No. of motor: 4

Year built : 2007


Model: CCM-260

Serial no.: C08-035

No. of motor: 4

Year built : 2008


Model: PTD - 100

Serial no.: 20105022

Power: 400 V @ 50 Hz


TURNING MACHINE

Machine No.: KDT - 2

Brand name: HSING CHENG

Model: HC-TFM

Country of origin : Thailand



Brand name: HSING CHENG

Model: HC-TFM

Country of origin : Thailand



Brand name: PUNGI

Model: P-RP/F

Serial no.: 451050001




DYEING MACHINES

LAYOUT OF DYEING FLOOR ( KCL + KCAL):

Tubular finishing area

Office

Storage

Batching area

KCL(Dyeing floor)

KCL(Dyeing floor)

Office+ Chemical

store

Open width finishing area

KCAL(Dyeing floor)


Dry

er

LAYOUT OF DYEING FLOOR (KCL):

Dyeing m/cs

Compacting m/cs

Squeezer m/cs

Dyeing m/cs Office

KCAL floor


Dye

ing

m/c

s

LAYOUT OF DYEING FLOOR (KCAL):

Dyeing m/cs

Compacting m/cs

Sliting m/cs

Stenter

Stenter


MACHINE DETAILS

Machine No.: 01

Brand name: FONG’S

Model: GN 6-SR -6T

Serial no.:26012102

Country of origin : China

Machine type: HTHP Machine

Machine capacity: 1200 Kg

No. of nozzle: 6

No. of motor: 9


Year built : 2002

Heat exchanger:

Parameters Shell Tube

Design pressure 700 KPa 400 KPa

Design temperature 170 °C 140 °C

Hydrolic test pressure 1200 KPa 585 KPa

Safety valve set 700 KPa 380 KPa

Heating/ cooling medium Steam Dye liquor


Machine No.: 2A


Model: GN 6-SR -4T

Serial no.:26012101




No. of nozzle: 4

No. of motor: 7


Year built : 2002

Heat exchanger:








Machine No.: 01A


Model: MSR

Serial no.: 34025441H Country

of origin : China Machine

Type: HTHP machine Machine

capacity: 2000 Kg

No. of nozzle: 8

No. of motor: 18


Year built : 2009

Heat exchanger:








Machine No.: 3A


Model: GN-6 SR-3T



Machine type: HTHP machine


No. of nozzle: 3

No. of motor: 7


Year built : 2002

Heat exchanger:








Machine No.: 4B


Model: HSJ-2T




Machine capacity : 500 Kg

No. of nozzle : 2

No. of motor: 10


Year built : 2010

Heat exchanger:








Machine No.: 5A


Model: HSJ-1T

Serial no.:33024653




No. of nozzle : 1

No. of motor: 7


Year built : 2010

Heat exchanger:








Machine No.: 4D


Model: GN-6-2T





No. of nozzle : 2

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 4C


Model: HSJ-2T





No. of nozzle : 2

No. of motor: 9


Year built : 2010

Heat exchanger:








Machine No.: 9B


Model: ALLFIT-100

Serial no.: 31020952T




No. of nozzle : 2

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 9C


Model: ALLFIT-60





No. of nozzle : 1

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 4E


Model: HSJ-2T





No. of nozzle : 2

No. of motor: 9


Year built : 2008

Heat exchanger:








Machine No.: 8B


Model: ECO-38-3T



Machine type: Environmental


No. of nozzle : 3

No. of motor: 9


Year built : 2006

Heat exchanger:


Design pressure 700 KPa ATM


Hydrolic test pressure 1200 KPa -

Safety valve set 700 KPa -



Machine No.: 7C


Model: HSJ-4T





No. of nozzle : 4

No. of motor: 12


Year built : 2008

Heat exchanger:








Machine No.: 6A


Model: ECO-38-6T





No. of nozzle : 6

No. of motor: 11


Year built : 2003

Heat exchanger:








Machine No.: 6B


Model: ECO-38-6T





No. of nozzle : 6

No. of motor: 10


Year built : 2003

Heat exchanger:








Machine No.: 7A


Model: ECO-38-4T





No. of nozzle : 4

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 7B


Model: ECO-38-4T





No. of nozzle : 4

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 8A


Model: ECO-38-3T





No. of nozzle : 3

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 4PA


Model: GN-8-500





No. of nozzle : 2

No. of motor: 5


Year built : 2006

Heat exchanger:








Machine No.: 5PA


Model: GN-8-250





No. of nozzle : 1

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 10


Model: ALLFIT-60-2T





No. of nozzle : 2

No. of motor: 5


Year built : 2001

Heat exchanger:








Machine No.: 12


Model: GN-18-ST-10





No. of nozzle : 1

No. of motor: 6


Year built : 2000

Heat exchanger:








Machine No.: 14A


Model: ECO-38-1T

Serial no.: 2801420




No. of nozzle : 1

No. of motor: 7


Year built : 2003

Heat exchanger:








Machine No.: 14B


Model: ECO-38-1T

Serial no.: 2801421




No. of nozzle : 1

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 14C


Model: ECO-38-1T





No. of nozzle : 1

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 14D


Model: ECO-38-1T





No. of nozzle : 1

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 14E


Model: ECO-38-1T





No. of nozzle : 1

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 11A


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 8


Year built : 2003

Heat exchanger:








Machine No.: 11B


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 8


Year built : 2004

Heat exchanger:








Machine No.: 11C


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 8


Year built : 2004

Heat exchanger:








Machine No.: 11D


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 8


Year built : 2004

Heat exchanger:








Machine No.: 11E


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 8


Year built : 2004

Heat exchanger:








Machine No.: 13G


Model: ALLFIT-10





No. of nozzle : 1

No. of motor: 3


Year built : 2007

Heat exchanger:








Machine No.: 11G


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 11F


Model: ALLFIT-30





No. of nozzle : 1

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 13F


Model: ALLFIT-10





No. of nozzle : 1

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 13E


Model: ALLFIT-10





No. of nozzle : 1

No. of motor: 4


Year built : 2006

Heat exchanger:








Machine No.: 7D


Model: HSJ-4T





No. of nozzle : 4

No. of motor: 12


Year built : 2008

Heat exchanger:








Machine No.: 4F


Model: HSJ-2T





No. of nozzle : 2

No. of motor: 9


Year built : 2008

Heat exchanger:








Machine No.: 5B


Model: HSJ-1T

Serial no.:33024653




No. of nozzle : 1

No. of motor: 7


Year built : 2010

Heat exchanger:








Machine No.: 13B

Brand name: UGOLONI


Machine No.: 8C


Model: ECO-38-3T





No. of nozzle : 3

No. of motor: 9


Year built : 2006

Heat exchanger:








Machine No.: 4A


Model: ECO-38-2T





No. of nozzle : 2

No. of motor: 9


Year built : 2006

Heat exchanger:








FINISHING

OPEN WIDTH FINISHING

SLITING MACHINE

Machine No.: KDSL - 1

Brand name: BIANCO

Serial no.: M05305-023517


No. of motor: 13

Maximum speed: 90 m/min.

Year built : 2006


Brand name: BIANCO

Serial no.: M05305-023517


No. of motor: 13


Year built : 2006


Brand name: BIANCO

Serial no.: M05304-023517



No. of motor: 13


Year built : 2006

STANTER MACHINE

Machine No.: KDST - 2

Brand name: BRUCKNER

Country of origin : Germany

Machine type: VN-SFP-26/8-999

Heating type: Thermosol oil

Maximum temperature: 210 °C

Year built : 2006

POWER-PAD padder:

Type: FS-2

Year built : 2006

Maximum steam pressure: 2 bar

Maximum air pressure: 10 bar

Machine No.: KDST - 3



Machine type: VN-SFP-26/8-999

Heating type: Gas



Year built : 2008

POWER-PAD padder:

Type: power pad

Year built : 2008

Maximum steam pressure: 0.7 bar

Maximum air pressure: 10 bar

Compacting machine

Machine No.: KDCM - 3

Brand name: TUBE TEX

Country of origin : USA

Machine type: C 2000

Heating type: Steam




Machine type: OC-28+SV-28

Heating type: Steam

Year built : 2007


Figure: Stenter machine

TUBULAR WIDTH FINISHING

Flow chart:

Squeezer

Dryer

Turning

Steam setting machine

Compacting

QC


SQUEEZER

Machine No.: KDS - 1

Brand name: SANTEX AG

Sirial no.: 5926

Country of origin : Switzerland

Model: Santastretch Plus

Year built : 2003



Sirial no.: 5927



Year built : 2003


Brand name: BIANCO

Sirial no.: M05794-025719




Year built : 2007


DRYER

Machine No.: KDD - 1


Sirial no.: 23009238

Model: ESD28D2

Country of origin : Hong-kong


Heating type: Steam


No. of blower: 3

Year: 2003

Machine No.: KDD - 2


Sirial no.: 5927

Type: Santashrink 3KJ/300GF1 IR Dampf



Heating type: Steam


No. of blower: 3

Year: 2003


TURNING


Brand name: DAROITEX

Model: DSR-3000



Year: 2006



Model: DSR-3000



Year: 2006

STEAM SETTING MACHINE

Machine No.: KDHS - 1

Brand name: DONGNAM

Sirial no.: DN-0509

Model: DNS-1400

Country of origin : Korea


Heating type: Steam


Year: 2005

Machine No.: KDHS - 2

Brand name: DONGNAM

Sirial no.: DN-0613

Model: DNS-1400

Country of origin : Korea


Heating type: Steam

Year: 2006

COMPACTING MACHINE


Brand name: Navis Tube-tex

Sirial no.: 10421

Model: Pak-nit II SP

Country of origin : U.S.A.


Heating type: Steam & oil


Brand name: Tube-tex

Sirial no.: 10631

Model: Pak-nit II Delta Plus - SP






Brand name: Tube-tex

Sirial no.: BM-9847

Model: Pak-nit II Delta Plus




QC

INSPECTION MACHINE

Machine No.: KDQCM - 1


Machine type: Inspecting machine

Sirial no.: 301

Model: QCM-F


Year: 2002


Brand name: Hsing Cheng



Model: HC-GIM-2400mm

Country of origin : Tailand




Model: QCM/R PLATTER



Year: 2006


Brand name: Hsing Cheng Machine

type: Inspecting machine Model:

HC-TIW-3000mm-A19179

Country of origin : Taiwan

Year: 2010


Brand name: Hsing Cheng Machine

type: Inspecting machine Model:

HC-TIW-3000mm-A19179



16'-0

"58

'-0"

19'-2

3/8"

Sup

ervi

sor’s

desk

19'-2

3/8"

19'-2

3/8"

19'-2

3/8"

19'-2

3/8"

60'-0

"

Year: 2010

SPECIAL FINISHING

Layout plan

144'-0"

22'-0"

SuedingMachineULTRASOFT-L

22'-0"

RaisingMachine

GEMATEX

22'-0"

SuedingMachineULTRASOFT-Y

22'-0"

ShearingMachine

GEMATEX

22'-0"

SingeingMachine

OSTHOFF

8'-0"

Temporary open storage

144'-0"

SUEDING MACHINE

Machine No.: KDLS - 01

Brand name: Lafer

Machine type: Sueding machine

Sirial no.: 10GSX1952

Model: ULTRA SOFT-L


Connected load: 25 kW

No. of roller: 6


Year: 2005


Filter:

Code: SW12L

Serial no.: 726L03

Connected load: 25 kW

Year: 2005

Machine No.: KDLS - 02

Brand name: Lafer

Machine type: Sueding machine

Sirial no.: 10GSY2393

Model: ULTRA SOFT-Y


No. of roller: 4


Year: 2005

RAISING MACHINE

Machine No.: KDR - 1

Brand name: GEMATEX

Machine type: Raising machine


No. of pile roller: 12

No. of counter pile roller: 12



SHEARING MACHINE

Machine No.: KDR - 02

Brand name: GEMATEX

Serial no.: 300.103

Machine type: Shearing machine


No. of brushing roller: 1

No. of shearing roller: 1

Connected load: 15kW


Year: 2007

SINGEING MACHINE

Machine No.: KDSG - 01

Brand name: Osthoff

Serial no.: 7000

Machine type: Singeing machine


Model: WW2006

Temperature range: (40 - 200) °C

Speed range: (15 - 100) m/min.


Working width: 2400 mm

No. of gas burner: 2


Year: 2008

Figure: Osthoff singeing machine


WASHING UNIT

Daily Washing Capacity :

Pigment Dyeing : 3000 Pcs.

Acid Dyeing : 3000 Pcs.

Garment Wash : 50000 Pcs.

Ready Dye : 3000 Pcs.

MACHINE DETAILS

01. Industrial Washing 10 nos.

02. Tumble Dryer 08 nos.

03. Hydro Extractor 03 nos.

04. Pigment Dyeing 01 no.

05. Garments Dyeing 01 no.

06. Deep Dyeing 01 no.


YARN DYEING

Yarn Dyeing Capacity: 25 Tons per day


TYPE BRAND MACHINEQUANTITY

Yarn Dyeing M/C Fongs, China 48 Nos.Soft Winding M/C SSM, Switzerland 05Soft Winding M/C Fadis, Italy 02Hard Winding M/C SSM, Switzerland 03Hard Winding M/C Fadis, Italy 02Aquasplicer Mesdan, Italy 08Soft Thread Winding SSM, Switzerland 01Hydro Dettin, Italy 02Dryer Stryfield, England 02Dryer Stalam, Italy 01Auto DosingSilos-Dos Lawer, Italy 02Dos-Chem Lawer, Italy 04Rotary Dyes Store Lawer, Italy 01Total 81


Figure: Yarn dyeing floor


Figure: Silos-Dos (Lawer)

General flow chart:

Soft winding

Dyeing Hydro

extraction

Drying

Hard winding


Toi

let

Tem

pora

ry o

pen

stor

age

stai

r

stai

rS

uper

viso

r’sde

sk

SOFT WINDING

Layout plan of soft winding floor

12 8 1

13 9 5 2

14 10 6 3

15 11 7 4

Temporary open storage

Lift Lift

1-15 : Soft winding machines

Machine No.: 1

Brand name: SSM


Machine type: TW2-W

Serial no.: 856.0130/06

No. of spindle: 78

Imax: 38 A

U: 400 V @ 50 Hz


Machine No.: 2

Brand name: SSM


Machine type: TW2-W

Serial no.: 856.0130/06

No. of spindle: 60

Imax: 38 A

U: 400 V @ 50 Hz

Machine No.: 3

Brand name: SSM


Machine type: TW2-W

Serial no.: 856.0130/06

No. of spindle: 60

Imax: 38 A

U: 400 V @ 50 Hz

Machine No.: 4

Brand name: SSM-P26


Machine type: PS6 Plus-W

Serial no.: 883.1066/10


No. of spindle: 60

Imax: 25 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 5

Brand name: SSM


Machine type: PS6 -W

Serial no.: 883.0427/06

No. of spindle: 60

Imax: 32 A

U: 400 V @ 50 Hz

Year: 2007

Machine No.: 6

Brand name: SSM



Serial no.: 883.0429/06

No. of spindle: 60

Imax: 32 A

U: 400 V @ 50 Hz


Year: 2007

Machine No.: 7

Brand name: SSM



Serial no.: 883.0427/06

No. of spindle: 60

Imax: 32 A

U: 400 V @ 50 Hz

Year: 2007

Machine No.: 8

Brand name: Fadis-Sincro


Machine type: FT P300

Serial no.: G0023DX

No. of spindle: 96

U: 400 V @ 50 Hz

Machine No.: 9

Brand name: SSM-P26




Serial no.: 883.1060/10

No. of spindle: 60

Imax: 25 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 10

Brand name: SSM-P26



Serial no.: 883.1062/10

No. of spindle: 60

Imax: 25 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 11

Brand name: SSM-P26



Serial no.: 883.1063/10

No. of spindle: 60

Imax: 25 A


U: 400 V @ 50 Hz

Year: 2011

Machine No.: 12



Machine type: FT P300

Serial no.: G0023DX

No. of spindle: 96

U: 400 V @ 50 Hz

Machine No.: 13

Brand name: SSM-P26



Serial no.: 883.1059/10

No. of spindle: 60

Imax: 25 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 14

Brand name: SSM-P26




Serial no.: 883.1061/10

No. of spindle: 60

Imax: 25 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 15

Brand name: SSM-P26



Serial no.: 883.1064/10

No. of spindle: 60

Imax: 25 A

U: 400 V @ 50 Hz

Year: 2011

Hydro

Extractor

BID

machine

Micro

Win

LabW

in

65

78

RotaryD

yesStore

stai

r

34

12

31

2

stai

r

DYEING

Layout plan of dyeing floorRF Dryer

Yarn storage

Chemicalstorage Office

Lift Lift

4 5

Silos-Dos 6

8 7

All Win

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Dos-Chem

Lift

Lab Win

6 2 3 4 5

All WinYarn Conditioner



MICROWIN

Machine No.: 1


Model: Microwin




Machine capacity: 350 gm


Year built : 2011

Machine No.: 2


Model: Microwin






Year built : 2011

Machine No.: 3



Model: Microwin






Year built : 2011

Machine No.: 4


Model: Microwin






Year built : 2011

Machine No.: 5


Model: Microwin







Year built : 2011

Machine No.: 6


Model: Microwin






Year built : 2011

Machine No.: 7


Model: Microwin







Year built : 2011

Machine No.: 8


Model: Microwin






Year built : 2011


LABWIN

Machine No.: 2


Model: LABWIN 12-K1




Machine capacity : 14Kg


Year built : 2007

Heat exchanger:

Parameters Jacket Shell






Machine No.: 3


Model: LABWIN 12-K1







Year built : 2007

Heat exchanger:







Machine No.: 4


Model: LABWIN 6-KO






Year built : 2007


Heat exchanger:







Machine No.: 5


Model: LABWIN 6-KO






Year built : 2006

Heat exchanger:








Machine No.: 6


Model: LABWIN 6-KO






Year built : 2008

Heat exchanger:








ALLWIN

Machine No.: 1


Model: ALLWIN-43-6A






Year built : 2007

Heat exchanger:







Machine No.: 2


Model: ALLWIN-53







Year built : 2007

Heat exchanger:







Machine No.: 3


Model: ALLWIN-53-8A






Year built : 2007


Heat exchanger:







Machine No.: 4


Model: ALLWIN-70-9A






Year built : 2007

Heat exchanger:








Machine No.: 5


Model: ALLWIN-85-9A






Year built : 2007

Heat exchanger:







Machine No.: 6


Model: ALLWIN-85-9A







Year built : 2007

Heat exchanger:







Machine No.: 7


Model: ALLWIN-120-9A






Year built : 2007


Heat exchanger:







Machine No.: 8








Year built : 2007

Heat exchanger:








Machine No.: 9








Year built : 2007

Heat exchanger:







Machine No.: 10









Year built : 2007

Heat exchanger:







Machine No.: 11








Year built : 2007


Heat exchanger:







Machine No.: 12








Year built : 2007

Heat exchanger:








Machine No.: 13








Year built : 2007

Heat exchanger:







Machine No.: 14









Year built : 2007

Heat exchanger:








HDRO-EXTRACTOR

Machine No.: 1

Brand name: Dettin Benta

Model: 1205568

Serial no.: 0155




Year built : 2007

Machine No.: 2


Model: 1205568

Serial no.: 0154




Year built : 2007

Machine No.: 3


Model: 1205568

Serial no.: B11053





Year built : 2011

Machine No.: 4


Model: 1205568

Serial no.: B11052




Year built : 2011

LAIP DYEING MACHINE

Bobbin Injection Dyeing Machine

Machine type: Type R

Code: C1055

No. of motor: 6

No. of color tank: 4

Year built: 2011


YARN CONDITIONING MACHINE

Model: Steamer VS/HT

Machine type: D 1450

Code: C0924

Pressure: 0.27 MPa

Year built: 2011

DRYING

Machine No.: 1

Brand name: RF

Model: S0100/TE

Serial no.: 89350T

Country of origin : UK

Machine type: Radio frequancy dryer

Frequancy used: 27 mHz

Power: (380- 420) V @ 50 Hz

Year built: 2007

Machine No.: 2

Brand name: RF

Model: S0100/TE

Serial no.: 89349T





Power factor: 0.9

Power: (380- 420) V @ 50 Hz

Year built: 2007

Machine No.: 3

Brand name: STALAM

Model: RF-150 KW

Serial no.: 89349T




Power factor: 0.9


Year built: 2009

Machine No.: 4

Brand name: STALAM

Model: RF-150 KW

Serial no.: 89349T




Toile

tO

ffice

stai

r

Sup

ervi

sor’s

desk

stai

r


Power factor: 0.9


Year built: 2011

HARD WINDING

Layout plan of hard winding floor

9 5 1

Office

765 sq. ft.

10 6 2

11 7 3

12 8 4

HACOBA

Lift Lift

1-12 : Hard winding machines

Machine No.: 1

Brand name: SSM


Machine type: CW2-W

Serial no.: 863.0029/07

No. of spindle: 96


Imax: 28 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 2

Brand name: SSM


Machine type: CW2-W

Serial no.: 863.0028/07

No. of spindle: 96

Imax: 28 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 3

Brand name: SSM


Machine type: CW2-W

Serial no.: 863.0027/07

No. of spindle: 96

Imax: 28 A

U: 400 V @ 50 Hz

Year: 2011


Machine No.: 4

Brand name: SSM


Machine type: CW2-W

Serial no.: 863.0080/09

No. of spindle: 96

Imax: 28 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 5



Machine type: FT/RT P300

Serial no.: G0025DS

No. of spindle: 96

Imax: 16 A

U: 440 V @ 50 Hz

Year: 2008

Machine No.: 6

Brand name: SSM



Machine type: CW8-W

Serial no.: 863.1029/11

No. of spindle: 128

Imax: 7 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 7

Brand name: SSM


Machine type: CW8-W

Serial no.: 863.1032/11

No. of spindle: 128

Imax: 7 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 8

Brand name: SSM


Machine type: CW8-W

Serial no.: 863.1030/11

No. of spindle: 128


Imax: 7 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 9



Machine type: FT/RT P300

Serial no.: G0024DX

No. of spindle: 96

Imax: 16 A

U: 440 V @ 50 Hz

Year: 2008

Machine No.: 10

Brand name: SSM


Machine type: CW8-W

Serial no.: 863.1028/11

No. of spindle: 128

Imax: 7 A

U: 400 V @ 50 Hz

Year: 2011


Machine No.: 11

Brand name: SSM


Machine type: CW8-W

Serial no.: 863.1033/11

No. of spindle: 128

Imax: 7 A

U: 400 V @ 50 Hz

Year: 2011

Machine No.: 12

Brand name: SSM


Machine type: CW8-W

Serial no.: 863.1031/11

No. of spindle: 128

Imax: 7 A

U: 400 V @ 50 Hz

Year: 2011

SEWING THREAD WINDING MACHINE

Machine No.: 1

Brand name: HACOBA


Model: Thread Prince 850C


Serial no.: 881.1101/06

No. of spindle: 12

Imax: 6.8 A

U: 400 V @ 50 Hz

Year: 2007

PRINTING

Knit Concern is capable of printing all specifications in the range from film to screen

developments. It has ability of pigment, silicon, puff, flock, glitter, metal stone and rub-

ber printing with equal proficiency. It can print 100000 pieces of garments a day in a sin-

gle design; it is capable of printing in 12 colors.

MACHINE DETAILS

PRINTING MACHINE

NAME MACHINE QUANTITY

Auto printing machine 4 Nos.

Conveyor curing machine 8 Nos.

Hit press machine 14 Nos.

Stone machine 5 Nos.

Flock machine 12 Nos.

Spray printing unit 1 Nos.

Printing table 4000 meters

Flock suckering machine 2 Nos.

Generator 3 Nos.

Mex newton 2 set

Auto exposing unit 1 set


Manual exposing unit 3 set

CENTRAL LAB

Laboratory is an independent department. It plays a critical role in every production

phase especially in knitting, fabric dyeing and yarn dyeing section manufacturing the

quality standard.

Type Brand MC. Qty.

Wet Lab Wascator Electrolux 05 Nos.

T. Dryer SDL 03 Nos.

Rote – wash SDL 01 Nos.

Perspirometer & Ovenincubator SDL+J.H.Heals 01 Nos.

Light fastness tester J.H.Heals 01 Nos.

Conditioned Lab Elec - Crockmeter SDL 01 Nos.

ICI Pill box SDL+J.H.Heals 02 Nos.

TPI Tester SDL 02 Nos.

Yarn appearance Tester SDL 01 Nos.

Yarn count system Brustio 01 Nos.

Tru – Brust J.H.Heals 01 Nos.

Conditioning system OEDA 01 Nos.

Analytical Lab Formaldehyde Tester Parkins Elamar 01 Nos.

Knit machine Lab Auto – Lab Dispense (40cmb) Datacolor 01 Nos.


Ahiba Infrared Dryer Datacolor 02 Nos.

Spectrophotometer – SF600CT Datacolor 01 Nos.

Data color Conditioner Datacolor 01 Nos.

Yarn Machine Lab Auto – lab Dispense (120CMB) Datacolor 01 Nos.

Ahiba Infrared Dryer Datacolor 03 Nos.

Spectrophotometer – 650x Datacolor 01 Nos.

Total 31 Nos.

KNIT DYEING LAB

Auto lab dispansing machine

Machine No.: KDSM - 01

Brand name: LAWER

Serial no.: 2629

Model: TD-LAB V34M


Machine type: Auto lab dispanse

No. of container: 181

Maximum capacity per container: 900 ml

Year: 2010


Sample dyeing machine

Machine No.: KDSD - 01

Brand name: COPOWER

Serial no.: R1728-1SCN124

Model: Supermat


Machine type: Sample dyeing machine

No. of cylinder: 24

RPM: 50

U: 220 V @ 50 Hz


Brand name: COPOWER


Model: Supermat



No. of cylinder: 24

RPM: 50

U: 220 V @ 50 Hz



Brand name: COPOWER


Model: Supermat



No. of cylinder: 24

RPM: 50

U: 220 V @ 50 Hz


Brand name: COPOWER


Model: Supermat



No. of cylinder: 24

RPM: 50

U: 220 V @ 50 Hz


Brand name: COPOWER



Model: Supermat



No. of cylinder: 24

RPM: 50

U: 220 V @ 50 Hz


Brand name: COPOWER


Model: Supermat



No. of cylinder: 24

RPM: 50

U: 220 V @ 50 Hz


Brand name: Data Color



No. of cylinder: 14

RPM: 50


U: 220 V @ 50 Hz

Programe used

Programe #1: ISO

Programe #2: Migration

Programe #3: 80 °C x 60 min. (HOT)

Programe #4: 98 °C x 45 min. (WHITE)

Programe #5: 135 °C x 45 min. (DISPERSE)

Programe #6: (60-130) °C x 45 min. (DISPERSE LYCRA)

Programe #7: 80 °C x 40 min. (REDUCTION CLEARING)

Lab hydroextractor

Machine No.: KLE - 02

Brand name: SDL Country

of origin : UK Machine

type: Lab extractor U: 250

V @ 50 Hz

Oven and incubator

Machine No.: KOI - 02

Brand name: J. H. Heal


Machine type: Oven and incubator


Recipe for reduction clearing

Dark shade: >2%

Na2S2O4 – 6 g/l

NaOH – 2 g/l

OS – 2 g/l

Time x Temperature - 80 °C x 40 min.

Medium/Light shade:

Na2S2O4 – 4 g/l

NaOH – 2 g/l

OS – 2 g/l

Time x Temperature - 80 °C x 40 min.

Sampling

Actual Calculate

d

4.5 g 5 g

9 g 10 g


Salt and soda recommendation

Drimarin

% of

dyestuff

0.01-0.5 0.5-1 1-2 2-3 3-5 5 & above

Gluber

salt (g/l)

20 40 50 60 70 80

Soda (g/l) 1 1.5 2 2.5 3 4

Synozol

% of

dyestuff

0.01-0.1 0.1-0.5 0.5-1 1-3 3 & above

Gluber

salt (g/l)

20 30 40 50 60

Soda (g/l) 10 15 15 20 20

Amtex

% of

dyestuff

0.01-0.5 0.5-1 1-2 2-4 Red/Navy

4 &

above

Black

5 & above

Gluber

salt (g/l)

30 50 60 70 80 80

Soda (g/l) 10 15 20 20 15 15

Custic

(g/l)

1 1


Remazol

% of

dyestuff

≤ 0.1 0.1-0.5 0.5-1 1-2 2-3 3-5 5 &

above

Gluber

salt (g/l)

20 25 30 40 50 60 80

Soda (g/l) 5 8 10 12 15 20 20

Novacron

% of

dyestuff

0.01-

0.1

0.1-

0.25

0.25-

0.5

0.5-1 1-2 2-3 3-4 4-5 5 &

above

Gluber

salt (g/l)

10 15 20 30 40 50 60 70 80

Soda

(g/l)

8 10 12 14 16 18 20 20 5

Custic

(g/l)

1

WET LAB

Washing machine

Machine No.: KDWS - 01

Brand name: Electrolux

Model: W455H

Machine type: Washing machine

Country of origin : Sweden




Model: W455H




Brand name: Electrolux Washcator









Model: F0M71 CLS





Brand name: Meiling Ston

Model: XQG50-998




Brand name: Meiling Ston

Model: XQG50-998



Rota washing machine

Machine No.: KDRW - 01

Brand name: SDL

Machine type: Rota washing machine


Machine No.: KDRW - 02


Serial no.: 97-11-288

Machine type: Rota washing machine


U: 415 volt @ 50 Hz


Tumble dryer

Machine No.: KDTD - 01


Serial no.: 60130/0002728

Model: T4130

Machine type: Tumble dryer


U: 220 volt @ 50 Hz


Brand name: Ariston

Model: Electrolux/3




Brand name: SDL




Brand name: SDL




Sample cutter

Machine No.: KDQP - 01

Brand name: Roches Model:

Ouick Punch Machine type:

Sample cutter Country of

origin : UK Quick wash

Machine No.: KDQP - 01

Brand name: Raitech

Model: Ouick Wash Plus

Machine type: Quick washing machine


PHYSICAL TESTING LAB

Oven and incubator










Pilling tester

Machine No.: KIPT - 01


Model: Orbitor


Machine type: Pilling tester

Machine No.: KIPT - 02

Brand name: SDL


Machine type: Pilling tester

Pilling assesment viewer

Brand name: Veri Vide

Twist tester

Machine No.: KTT - 02

Brand name: SDL


Machine type: Electronic twist tester

Principle used: untwist- twist method


Wrap reel

Machine No.: KYCM - 01

Brand name: SDL


Machine type: Wrap reel

Sublimation tester

Machine No.: KLST - 01

Brand name: SDL


Machine type: Sublimation tester

Bursting tester

Machine No.: KBT - 01


Model: TruBurst2


Machine type: Bursting tester

Rubbing tester

Machine No.: KCM - 01


Model: Crock Master



Machine type: Rubbing tester

Yarn examiner

Machine No.: KYE - 01

Brand name: SDL Country of

origin : UK Machine type:

Yarn examiner

Light and weather fastness tester

Machine No.: KYE - 01


Model: Apollo


Machine type: Light and weather fastness tester


Permisible testing limit of varfious tests demanded by buyers

Test H & M Jules Okaidi We K & L Philder

Shrinkage L-5% L-5% L-5% L-5% L-5% L-6%

W-5% W-5% W-5% W-5% W-5% W-4%

Twisting 5% 3% 2%(Solid) 3% 5% 2%

1%(Y/D)

CF(wash) S- (3-4) S- 4 S- 4 S- (3-4) S- (3-4) S- >4

C- 4 C- 4 C- (4-5) C- (4-5) C- 4 C- >4

Rubbing Dry- (3-4) Dry- 4 Dry- 4 Dry- 4 Dry- 4 Dry- >(3-

4)

Wet- (3-4) Wet- 4 Wet- (2-3) Wet- (2-3) Wet->(3-4)

Perspiration S- (3-4) N/A S- 4 S- (3-4) S- (3-4) S- >4

C- 4 C- 4 C- (3-4) C- (3-4) C- >4

Saliva C- 4 N/A C- 5 N/A N/A C- >4

S- 4 S- N/A N/A

Light C- 4 C- 4 C- 4 C- 4 Dk- (4-5);

Lt- 4

C- >4

Pilling 3(14400) 3(14400) 3-4(14400) 3(10800) 4(10800) >3(10800)

Formalodehyde

ISO-14184-1 JIS-1041.1983, Option-A


ISO-14184-1

1 gm sample + 100 ml distilled water

40° x 60' in water bath

Cooling 1 hr. at room temperature

Filtering by filter paper

5 ml liquid + 5ml Nash reagent


Cooling 30 min. at room temperature

Measurement


JIS-L-1041.1983, Option-A

2.5 gm sample + 100 ml distilled water


Cooling 1 hr. at room temperature

Filtering by filter paper

5 ml liquid + 5ml Nash reagent


Cooling 30 min. at room temperature

Measurement


Nash Reagent Acetic

acid – 1.5 ml Acetyl

acetone – 1 ml

Ammonium acetate – 75 gm

Distilled water – 500 ml


CHAPTER – 4

RAW MATERIALS


Raw material is a unique substance in any production oriented textile industry. It plays a

vital role in continuous production & for high quality fabric.

Types of Raw Materials

The basic raw materials used are

Yarns

Dyes

Chemicals & auxiliaries

Fabric

Name & Sources of raw materials

Yarn

C.V.C

P.C

100% cotton

Gery méllange

Viscose

Lyocell

Modal

100% polyester etc.

Yarn source

Padma Textiles

Badsha Textiles

Thermax Group & others

Grey Fabric

Single jersey Lycra Single jersey Single lacoaste Double lacoaste


Polo pique Slub jersey Heavy jersey 1x1 rib 2x2 rib 2x1 rib 1x1 lycra rib 2x2 laycra rib Pointal rib V-rib Flat bed rib French terry One side fleece Both side fleece 1x1 interlock 2x2 interlock

Fabric Sources :

Knit Concern Ltd. Knitexcel Noor Textile Mother Knitting Microfibre Ibrahim Knitex


CHEMICALS LIST

Name of agent No. Name of item Name of company

Antifoam 1. Kappasol AF-2000 Kapp Chemi GMBH

2. Albaflow FFC Huntsman Singapore

Anticreasing 3. Albafluid C

4. Kappavon AC 65

Kapp Chemie GMBH5. Kappavon CL

6. Kappavon FCB

7. Hexapon NEH Hancle

8. Fincrease K5 Marlateks Teknoloji

Detergent 9. Kappawet BOSS Kapp Chemie GMBH

10. Kappawet SOB

11. Fistol ET-OLS Marlatex Teknoloji

12. Fabrevol KNN Conc Denimist

13. Ultravon EL Hantsman Singapore

Oil remover 14. Muscour OSRn Matex International

Sequestering 15. Denquest HYN Denge KimyaTesktil

Stabilizer 16. Denstab ESG

Enzyme 17. Unizyme 1000L Shangha i Youtell

Peroxide killer 18. Antiper R

Levelling 19. Albatex-DBC Huntsman Singapore

20. Denwet TYDY Denge KimyaTesktil

Soaping agent 21. Kappacom E 12 Kapp Chemie GMBH

22. Exaclean BLC Denimist


Fixing 23. Albafix ECO Huntsman Singapore

24. Albafix FRD

Cat- ionic softner 25. Softner SA 1000 Taiwan surfactant

26. Kappasoft BD Kapp Chemie GMBH

27. Softner GWS Mollah Enterprise

28. Mesoft CCS Matex International

Non-ionic softner 29. Softner E 31 Taiwan surfactant

30. Kappasoft N 69 Kapp Chemie GMBH

31. Sapamine FPG Huntsman Singapore

32. Densoft-N (liq.) Denge KimyaTesktil

Silicon softner 33. Kappasoft SM Kapp Chemie GMBH

34. Wisifect MIC H Denimist

Core Nutralizer 35. Invatex AC

Huntsman SingaporeFixing remover 36. Invalon DAM

Special chemical 37. Lyoprint RG GRAN

38. Denkom SYT Denge KimyaTesktil

39. Alpclean (Viscose)

40. Albatex co Huntsman Singapore

41. Defaten FX(Hit set) Denge KimyaTesktil

42. Cyclanon XC W NEW BASF

43. Hayclean(M/c wash) Denge KimyaTesktil

Basic Chemicals 44. Glaber salt Tradeasia Internationa l

45. Castic soda Gojrat


46. Soda ash Human Chembird Indust.

47. Hydrose BASF

48. Oxalic Acid Mollah Enterprise

49. Formic Acid BASF

50. Kappatex R98 Kapp Chemie GMBH

51. Acetic Acid OCI Corporation

Disperse Chemical 52. Albatex AB45

Huntsman Singapore

53. Albatex AR

54. Eriopon OLS

55. ErioponOS

56. Ultraphil HSD

57. Univadine DIF

58. Univadine DP

Extra Chemical 59. Orgasoft CP Organic Kimya

60. Prepart VA NEW BASF

61. Vivatex HKN Huntsman Singapore

62. Decoloring Agent

63. Pragama FLOC-C Panta Rai

64. Jintex WD Conc Jintex Corporation

65. Jintex WRN

66. Dymacle DMB 101

Polyester Chemical 67. Stabilon CT Huntsman Singapore

68. Stabilon NY


69. Ultraphil PA

70. Univadin PA

71. Eripon LT

DYES LIST

NO. Name of item Name of company Remarks1. Avitera Deep Blue SE

2. Avitera Red SE

3. Avitera Yellow SE

4. Novacron Deep Cherry S-D

5. Novacron Blue FNR

6. Novacron Brili Yellow H4GN

7. Novacron Briliant Blue FNG

8. Novacron Dark Blue- WR

9. Novacron Red FN-2BL

10. Novacron Brown NC

11. Novacron Red FNR

12. Novacron Yellow-S3R

13. Novacron Yellow F4G

14. Novacron Brilliant Red FN3GL

15. Novacron Deep Neight SR

16. Novacron Yellow-FN2R

17. Novacron Brilliant Blue-HGR


18. Novacron Super Black G

HUNTSMAN Reactive dyes19. Novacron Turquish GN

20. Novacron Navy FNB

21. Novacron Ocean SR

22. Terasil Black WNS

Disperse dyes

23. Terasil Red WWFS

24. Terasil Blue WBLS

25. Terasil G yellow 3R

26. Terasil Navy WSR

27. Terasil Red WSR

28. Terasil yellow W6GS

29. Uvitex BAM

OBA30. Uvitex BHT

31. Uvitex CIDN

32. Bezactive Red-S3B-300%

Bezama AG33. Bezactive Blue-SMAX

34. Bezactive Red-SLF

35. Dychufix Yellow-3R-XF 150%

Dysin Chem36. Dychufix Yellow-4GL

37. Dychufix Yellow-EC

38. Synozol Navy blue HB

39. Synozol Red HB

40. Synozol Deep Red HB


41. Synozol Yellow HB

Kyung-ln Synthetic

Corporation

Reactive dyes

42. Synozol Blue K-BR

43. Synozol Turquish Blue HF-G 266%

44. Synozol Brilliant Blue RSPL 150%

45. Synozol Ultra Black G

46. Synozol Red K-3BS

47. Synozol Red HF-3B

48. Synozol Yellow KHL

49. Synozol Red KHL

50. Synozol Blue KHL

51. Synozol Yellow HF-4GL

52. Synozol Yellow HF-3GN

53. Synozol Yellow K-3RS

54. Amron Navy HR-2D

55. Amron Yellow HR-2D

56. Amron Yellow HF2GL

57. Amron Brilliant Red HF2R

58. Amron Red HF2F

59. Amron Red HR2D

60. Amron Blue RSPL

61. Amron Orange HFGR

62. Amron Yellow HFGR


63. Amron Blue HFBR

Amtex Dyechem

Reactive dyes

64. Amron Red HF4BL

65. Amron Blue RC

66. Amron Blue HR2D

67. Amron Ultra Red HR4D

68. Amtex Yellow 3R-XF

69. Amtex Red 3B-XF

70. Drimarine Violet K-2RL Clariant

71. Drimarine Yellow K-2R

72. Reactive Yellow 3R

OH Young Industrial

Co.

73. Sunfix Blue HBR

74. Sunfix Red MF-3BD

75. Reactive Black VG Virag Int.

76. Remazol Blue RR

Dystar

77. Remazol Red RR

78. Remazol Yellow RR

79. Remazol Navy RGB

80. Remazol Ultra Carmine RGB

81. Remazol Brilliant Yellow 3GL

82. Remazol Ultra Red RGB

83. Remazol Ultra Yellow RGB

Hangzhou Jihua84. Reactive Starfix Black B 150%

85. Reactive Starfix Navy RGN


86. Reactive Starfix Red 3BFN

87. Reactive Starfix Yellow 3RFN

88. Reactive Starfix Red ED

89. Reactive Starfix Black ED-HG

90. Polar White 4BK (HQ4BK) OBA

WASHING PLANT DYES & CHEMICALS LIST

NO. Name of Items Name of Company Remark1. Asuprint Black E-B

Asutex

Pigment dyes

2. Asuprint Brilliant Pink EB

3. Green Brilliant Asuprint EG

4. Asuprint Blue E-BR 90

5. Asuprint Navy Blue E-BH

6. Violet Asuprint EB

7. Asuprint Orange E-R

8. Yellow Asuprint E-GC

9. Asuprint Goldren Yellow E-AO

10. Asuprint Red E-BA

11. Asuprint Red E-BBK

12. Asuprint Blue E-GC 150

13. Compund Blue Jeans/Print

14. Asuprint Brown E-X

15. SW 117 Pink


16. SW 115 Lemon Yellow

Dysin chem17. SW 114 Orange

18. SW 113 Red

19. SW 116 Orange Yellow

20. Lenaset Blue 2R

Huntsman21. Lenaset Red 2B

22. Lenaset Yellow 2R

23. Albagel SET Huntsman

Pigment Chemicals

24. Zipper Protector RPY

25. Mordiente PIM

Asutex

26. Asufix FPI

27. Asuprend WS

28. Proder PIM

29. Antifoam R/P

30. Proder SCPC/LF

31. Producto EAPS/P (Enzyme)

32. Asumin AB Micro (Silicon)

33. Asumin C ESCAMAS

34. Compound Neutro Jel

35. Bleaching

36. Protefix DPE Dysin chem


REMARK

The list is for the time of our industrial attachment. It varies according to the

availability of the material & their price.

The price has not been supplied to us due to their secrecy act.

The annual requirement was not available & is a record of the procurement de-

partment.


CHAPTER – 5

PRODUCTION PLANNING, SEQUENCES

&

OPERATIONS


SEQUENCE OF OPERATION

Lab dip approved

▼

Grey fabric inspection

▼

Batching

▼

Scouring & Bleaching

▼

Enzyme ( If required )

▼

Dyeing

▼

Bath Drain

▼

Cold Wash

▼

Neutral With Acetic Acid

▼

Soaping

▼

Fixing (If required )

▼

Softening


GREY FABRIC INSPECTION

In grey fabric inspection the available faults are

-Hole

-Loop

-Set up

-Needle breaking

-Needle mark

-Chain stair

-Sinker mark

-Yarn contamination

-Patta

-Wheel mark

-Oil mark

-Oil spot

-Patty

-Group needle mark

-Lycra out

BATCHING

Batching preparation is the process where inspected grey fabrics are divided into different

batches with reasonable quantity according to machine capacity, nozzle number in order

to make them suitable for the further operation In batching. It must be carefully observed

that each Nozzle of a machine contains equal length of fabric.

SEQUENCE OF BATCHING

Grey fabric divided into batches

▼

Batches divided nozzle wise according to lengh & Dia


INSTRUMENT USED

-Turning m/c

-Plaiting m/c

-Weighting m/c

-Back sewing m/c

-Overlock m/c

INFORMATION CHECKED

-Order No

-Color

-Yarn Count

-Yarn lot

-Yarn brand

-Knitting factory

-Machine No

-Roll No

PRE-TREATMENT

-For scouring & bleaching at first the fabric is loaded on to the bath .

-Required amount of water is taken to the bath .

-Wetting Agent & Anti creasing Agent is added.

-Scouring Agents (Caustic/Soda) & Stabilizer are added by the aid of dosing when the

temperature reaches at 50° C.

-H202 is added by the aid of dosing system for 5' .

-Temperature is raised to 98° C & the process is carried for 1 hr.

-The liquor are drained at 80° C.

-After that chemical wash & enzyme wash are done.

Curves for Pre-treatment:

Scouring & Bleaching:

60▫C × 5' 2▫C /min

98▫C × 60'80▫

Room Temperature

1 2 3 4 5 6 7

Cold Cold

H2O2 1) Anticreasing

2) Wetting Agent

3) Sequestering Agent

4) Antifoam

5) Stabilizer

6) Soda

7) Caustic

5' 5'

Chemical wash

Industrial Attachment Room

Tem

pera

Pature

60▫C × 5'

80▫C × 15' ge 163 of 229


1) Oxalic Acid

Cold Cold 2) Peroxide Killer

5' 5'

Enzyme wash

PH= 4.5-5

55▫C × 60'

70▫C × 10'

1 2

Cold Cold1) Acetic Acid

2) Enzyme

5' 5'

PROCEDURE FOR DYEING LIGHT /MEDIUM SHADE


Dyeing Bath Preparation :

- Auxiliaries are added at 50° C

-Salt added by dosing system ( time : 10-20')

- pH maintained at 6.5-7

-Color dosing at 6O° C for 20'

Exhaustion & Fixation :

-After 30' soda ash added by dosing for 30-35'

-pH checked & maintained at 10.5

-Dye bath is kept at 60° C for 40-60'

-After every 10' the sample is checked fixation occurs during this time.

-Rinse for 10' & the bath is drained.

Neutralization :

-The material should be neutralized to remove alkaline condition at room temperature by

acid wash for 15 min & rinsing will be carried on for 10 min.

Soaping :

-Then soaping agent is added & temperture raised to 90°-100°C for 10 min.

-The bath is cooled 7 rinsed for 10 min.

-Dye bath temperature then cooled to 60° C.

Softening:

Softener is applied to soften the fabric as well as it improves the hand feel. The material

is treated at 60°C for 20 mins. Then rinsing again & material unload.

Procedure of Dark shade


At first the bath is set at 50° C & take the right volume of water in the dye bath.

▼

Required amount of wetting agent is added.

▼

Caustic soda is added & second heat command 60°C & stabilizer is added also.

▼

H202 is dosed & 10' runs.

▼

Temperture raised to 100° C & run the material for 30'

▼

Cooling the bath at 75°C & bath is drained .

At 90° C the material is run for 15 mins

▼

Cooling the bath to 75°C to darin

▼

Add Acetic Acid to neutralize the whole bath of fabric & run time is 20'

▼

Rinse the fabric for 5' & bath is drained .

▼

New water from reserver is taken & pH should be 4.5-5 .

▼

Enzyme is injected to the bath . Run time is 60' at 55°C

▼

Temp. raised to 70° C & run time 10' & then drain

▼

Again new water is taken & dosing of glaubar salt for 20' & pH should be check

(pH =7)


▼

Color dosing for 30' at 50°C

▼

Soda is added by dosing for 40'at 50°C

▼

Then raise the temp. & run the fabric for 35-60'.At this time after every 10' the sample ischecked.

▼

Rinse the material for 10' & bath is drained.

▼

At room temp. acid treatment is done for 20'& rinse the material for 5'

▼

Soaping is done at 90°C for 10 min & bath is drained.

▼

Fixing agent is added at 50° C & run time is 20' & bath is drained

▼

Softening is done at 60° C for 20'& balli is drained.

▼

Finally the fabric is unloaded.

White Shade:

At first Scouring bleaching chemicals are added to the bath & they are treated at 98°C for60'

▼

Temperature is lowered at 80°C & OBA is added.Run time is 10'.

▼

Temperature israised to 98° C & Run time is 20'.


▼

Then enzyme treatment is applied & then softening occurs

Dyeing Curve

60▫C × 60'

Room temperature

1 2 3 41) Auxiliaries

2) Salt

3) Color dosing (20-30')

Cold Cold Cold4) Soda dosing (30-40')

5' 5' 5'

Normal Hot

60▫C × 10' Acetic

20'

Chemical Hot


60▫C

80▫C

90▫C

Soaping chemical80▫

Fixing & Softening (if dark shade):

50▫C× 20′ 20′

Fixing agent Softener

Softening:

40▫C × 20′

Softener & Acid

Stripping Recipe :

-First of all these two chemicals are taken & treated with fabric in cold temperature for 30min.

Soda ash =0.5 g/L

Bleaching powder =0.5 g/L

Then Direct drain is done.

-After that some other chemicals named below are treated at 98°C for 45 min.

Anticreasing Agent =0.3 g/L

Levelling Agent =0.3 g/L


Wetting Agent =0.3 g/L

Caustic soda =1-2 g/L

-After that 3-5 g/L Reducing Agent is taken and treated at 80°C for 10'.

Then Direct Drain is done.

-After that half or full scouring takes place

-Lastly fabric is treated by acetic acid.

Stripping for white :

-First of all these two chemicals are taken & treated with fabric in cold temperature for 30min.

Soda ash =0.5 g/L

Bleaching powder =0.5 g/L

Then Direct drain is done.

-After that these two chemicals are taken & treated with fabric at 98°C for 60 min.

Hydrose =1-2 g/L

Caustic Soda =1-2 g/L

-Lastly fabric is treated by acetic acid.

Machine Wash:

Add hydrose (6 g/L) & caustic Soda (6 g/L)

▼

Run 20' at 110° C

▼

Run 10' at 95° C

▼

Run 10' at 80° C

▼

Run 10' at 60° C


▼

Run 10' at 40° C

▼

Drain

FINISHING

Textile finishing, in a restricted sense, is the term used for a series of processes to which

all bleached, dyed, printed & certain grey fabrics are subjected before they are put to

market.

OBJECTIVE OF FINISHING

-Improving the appearance,luster, whiteness etc.

-Improving the feel, which depends on the handle of the material & its softness,suppleness, fullness etc.

-Wearing qualities, non- soiling, anticrease, antishrink comfort etc .

-Special properties required for particular uses -water -proofing flame proofing etc .

-Covering of the faults in the original cloth .

-Increasing the weight of the cloth .

FINISHING EFFECTS

-Easy care .

-Crease recovery.

-Dimensional stability

-Good abrasion resistance

-Improved tear strength

-Good sew ability

- Soft or stiff handle

-Shine or luster


SEQUENCE OF OPERATION :

For Open fabric:

Slitting

▼

Stenter( Softener used )

▼

Compactor

Tubular width finishing

Squeezer

Dryer

Turning

Steam setting machine

Compacting

QC

FINAL INSPECTION REPORT:

For final inspection , Inspection table & Inspection m/c is used .

The 4-point system is given below-

Size of Defect Penalty pointLess than 3 inches 1

3-6 inches 2More than 6- 9 inch 3

More than 9 inch 4


Size of holes & opennings-

1 inch or less 2

More than 1 inch 4

Some general rules of the inspection are-

1. Not 1 metre of cloth is penalized more than 4 points.2. Cloth is inspected on face side only unless specified.3. If the total defect parts per 100 yards of fabric are 40 or more the fabric will be

rejected.But it may be changed according to buyer’s requerments.

REMARK

KCL strictly follow up the production parameters like Temp, M:L ratio pH check etc. As

they do some difficult shade it takes more time for the production of the Batch.The

production officer & Sr. production Officer try their best to reduce the production time.


CHAPTER – 6

QUALITY ASSURANCE SYSTEM


Introduction and Basic Procedure of Planning and Control

A planned work brings success. Without planning nothing is completed within the re-quired time. So planning has its own importance which is intolerable. "Planning" gives ascheduled task and 'control' completes it successfully. But production planning and controlis not an easy task. So Micro Fibre Group has a high-performance department called "Pro-duction Planning & Control". Its Basic working procedure is as follows –

1. Taking orders from marketing division.

2. Analyzing the orders.3. Planning for knitting the fabric.

4. Planning for dyeing the fabric.

5. Planning for finishing the fabric.

It is only a basic procedure. It may change according to the type of order. Sometimes, or-der is places only for finishing the material or only for dyeing the white goods. Then somesteps are omitted for planning procedure.

Objects of quality control

1.Research

2.Selection of raw material

3.process control

4.Process development

5.Product testing

6.Specification test

Scope of quality control, quality assurance & testing :

-Testing lab

-Machine auditing system

-A good training system

-Excellent analytical


-Technical Expertise

PRODUCTION PLANNING

In KCL following flow diagram is followed-

Yarn Processing

▼

Yarn test

▼

Pass Fail

▼ ▼

Knitting Send to spinning mill

▼

Grey fabric inspection

Pass Fail

▼ ▼

Grey store Send to store as reject

▼

Batch making

▼

Dyeing

▼

Dewatering

▼

Drying/Stenter

▼


Compacting

▼

Fabric checking

▼

Lab Inspection Shade

▼

Pass Fail

▼ ▼

Delivery

▼ Rechargeable Reject

Send to concern ▼

Department Send to store as reject

I.aboratory :

Lab is the heart of the textile industry Higher precision lab can aid easily to achieve the

goal of the organization Before bulk production a sample for the approval from industry

is sent to the buyer As per the requirement of the buyer the shade is prepared in a lab

considering the economical aspects .


LABORATORY STANDARD DYEING CURVE

50▫C × 60'

35▫C × 10' 35▫C × 5' 1) Auxiliaries

1 2 3 4 52) Dyes

3) Gluber salt

4) Fabric

5) Soda ash

RE-DYEING PROCESS

When shade is not matched then fabric is treated again in dyeing machine for shade

matching is known as re-dyeing.

Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur

when the fabrics absorb one or two colors more or less. One re-dyeing process is de-

scribed below.

- Drain the let off solution- Hot wash at 700-800C- Acid wash at 600-700C(600 for light shade & 700 for deep shade).- Soda ash washes at 900-1000C for 60mins to reduce the depth of shade.- Acid wash at 600C.- Addition to required dyestuffs.- Salt addition.- Soda ash addition.

Other operations are same as previous described dyeing operations.


STRIPPING PROCESS

Add water Fabric load

TPA+G.ACID

Temp=90oC run=20min

Drain

Fill water SCF+NaOH

Temp=98oC run=30min

Cooling at 80OC

Hydrose

Temp=98oC run=60min

Drain

Hot wash

Half scouring

Temp=98oC run=35-50min

Dyeing

Recipe:

Antifixing agent (TPA)= 3.0g/l

A.Acid (G.Acid)= 3.0g/l

Wetting agent(SCF)= 0.2g/l

Hydrose= 4.0g/l

Caustic= 3.0g/l


AFTER TREATMENT OF ALL PROGRAMS:

For light color For Deep / Medium color

C Neutralizer=0.425g/l

Temp=60c-65c Run=20min

Hot Wash

(AW-501=0.17g/l)

Temp=80c-90c

FS(10% Solution)=3-4g/l

Temp=50Oc-For light color

Temp=60Oc –For deep color

PH=4.0-4.5

Run =20min

Hot Wash

C Neutralizer=0.425g/l-0.552g/l

Temp=60c-65c Run=20min

Hot Wash 90Oc-

run 10min

(AW-501=0.255-0.425g/)

Fixing agent =0.425g/l

Temp=50oc-60oc Run=20min

PH=5.0-5.5

FS(10%solution)=3-4g/l

Temp=60oc run=20min

PH=4.0-4.5


After dyeing for neutralization:

For

white(without

enzyme)

For white

(with enzyme)

For light color For medium color For deep color

A.Acid=1.5g/l

Temp 65oc

Run=20min

PH=4.5-4.8(By

using A.Acid)

Temp 55oc

Run=60min

C.Neutralizer=

0.425g/l

Temp 63-65oc

Run=20min

C.Neutralizer=

0.425-0.552g/l

Temp 63-65oc

Run=20min

C.Neutralizer=

0.552g/l

Temp 63-65oc

Run=20min

For fixing:

For medium color For deep color

SR=0.425-0.85g/l

Temp 50-60oc

Run=20min

PH=5.0-5.5(By using C.neu)

SR=1.275-1.7g/l

Temp 50-60oc

Run=20min



Softener solution(10% solution)

For white For light color For medium/deep color

WCS(10%Soln)=2.55-

3.4owf

Temp 60oc

Run=20min

PH=4.0-4.5(By using

A.Acid)

FS(10%Soln)=2.55-3.4owf

Temp 50oc

Run=20min


FS(10%Soln)=2.55-3.4owf

Temp 60oc

Run=20min


COMMON TEXTILE AUXILIARIES USED IN DYEING

Acid - The chemical compounds that dissolve in water and provide H+(proton). Itchanges the color of litmas paper from blue to red.

Alkalis - The chemicaL compound that dissolve in water and provide 0H- . It changes thecolor of litmas paper from red to blue.

Buffer - lt is a saturated solution of acid-salt or alkali-salt mixture. lt resists the change ofpH on addition of acid or alkali. Usually it is used to control the any bath solution. Buffersolutions are solutions containing mixtures of a weak acid or base and a salt of that acidor base.

Oxidizing agent - The chemical compound which provide oxygen during chemical reac-tion and converting to oxide, They gain electrons in a redox chemical reaction.

Reducing agent - The chemical compound which losses electron during chemical reac-tion. lt reduces other substances chemically, especially by donating an electron or elec-trons, 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 be-tween solid- liquid interface and reduce the surface tension of liquid. lt has a versatile ap-plication in textile industries especially in textile coloration, for example, Wetting agent,Detergent, Lubricant, Foaming agent, Anti- foaming agent, Leveling agent, Dispersingagent.

Wetting agent - lt accelerates the wetability of material in solution; thus helps to easypenetration of chemicals into substrate. Usually it is used in scouring, bleaching and dye-ing 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 alwaystrue. The surfactants which have detergency power and the number of carbon in aliphaticchain are not less than 9. Usually it is used in textile to clean the materials by removingundesirable substances. These products are either soaps or synthetic detergents.

Lubricant - The chemical compounds use to prevent contact between solid surfaces inrelative motion in order to reduce friction, wear, overheating, and rusting. They are verygood coolants, provide the appropriate range of viscosities, and are thermally stable.

Anti-foaming agent - Anti- foaming agents are another type of surfactants which are ableto prevent or reduce foam. Usually, anti- foaming agents are used in dyeing bath and inprinting paste to hinder foam generation. Excess foam generation can create adverse e f-fect in processing and product.

Anti-creasing agent - Usually used in dyebath or in finishing stage to prevent creasing offabric or garments.

Anti-pilling agent - Some man-made and blended fibre fabrics can easily form pills intheir surface. Thus it reduces the aesthetic value of the fabric or garment. Anti-pillingagents 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 uniformdyeing 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 availablein market in liquid form.

Dispersing agent - usually it is used in disperse and vat dyeing process helps to distri-bute the dye molecules in dye bath. it is also help to penetrate the dye molecules into thesubstrate. lt is available in market in powder form.

Retarding agent - The chemical compound that are able to retard or control the dye up-take inside of the fibre .Using retarders is very common in acrylic dyeing with cationicdyes.

Carrier - Carriers are relatively small organic substances that usually have affinity forpolyester. lt acts as a catalyst to accelerate the dye penetration into the fibe in dispersedyeing process.


PROBLEMS IN DYEING

Uneven Dyeing

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

2. Pressure difference.3. Over loading in the m/c.4. Yarn lot mixing.5. Improper control of temperature.6. Less amount of leveling agent.7. Improper pretreatment.

Uneven Shade in Rope to Rope

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

Off Shade

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

Dye Spots

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

Batch to Batch Shade Variation

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

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

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


Crease Mark

1. Crease marks are produced due to the lower concentration of anti creas-ing agent and improper cooling rate (defective cooling gradient). Thisis encountered by increasing the concentration of anti creasing agentand proper adjustment of cooling rate.

Running Marks

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

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

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

3. Running and crack marks can also be a result of incorrect process proce-dures. A higher fabric speed, combined with slower rates of rinse and coo l-ing will often correct the problem.

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

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

Intensive Foaming

1. In case of intensive foaming, which is caused when, the pumps try to pumpa mixture of air and water. This resets in the loss of nozzle pressure & floa t-ing of flake. If the foaming is severe it is better to drop the bath & restartthe process, after adding an anti foaming agent to the new bath.

Patchy Dyeing

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

Miscellaneous Problems

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


Daily Production Report:

The daily production report is recorded in the logbook and it contains followinginformation

Machine No. Quantity

Date Loading Time

Batch No. Unloading Time

Order No. Runtime

Fabric Type Shift

Color Remark

FINISHING

Textile finishing , in a restricted sense , is the term used for a series of

processes to which all bleached , dyed , printed and certain grey fabrics are

subjected before they are put on the market . In fact , finishing includes the fi-

nal treatment of every kind of fabric made from every kind of fiber .

OBJECTIVE OF FINISHING

- Improving the appearance – Lustre , whiteness , etc .- Improving the feel , which depends on the handle of the material and its

softness , suppleness , fullness , etc .- Wearing qualities , non – soiling , anticrease , antishrink , comfort , etc .- Special properties required for particular uses – water – proofing , flame –

proofing , etc. .- Covering of the faults in the original cloth.- Increasing the weight of the cloth.


Types of finishing:

1) Chemical finishing:i) Chemical reaction of auxiliaries with fibers.ii) Application of the handle modifying products / additives.

2) Mechanical finishing: Mechanical treatment with machines. Finishing effects Easy – care Crease recovery. Dimensional stability. Good abrasion resistance. Improved tear strength. Good sewability Soft or stiff handle. Shine or luster

After dyeing knit fabric is required to finish. During eyeing all knit fabric are dyed in t u-

bular form. According to buyer’s requirement knit fabric are finished in open form or tu-

bular form.


Flow chart of final process (knit fabric)

Dyed Fabric from Dyeing Department

Shade check

Open with Tubular form

Dewatering Dewatering

Slitting Drying

Stentering/Dryer Calendering & compactor

Open compactor Final Inspaction

Final Inspection Packing

Packing Delivery

Delivery


Finishing section is divided into two section, they are:

-Open line

-Tube line

The machines that are used in open line that are given bellow:

1. Slitting m/c

2. De-watering m/c

3. Stenter

4. Compactor

The machines that are used in tube line that are given bellow:

5. De-watering m/c

6. Dryer

7. Compactor

8. Calendering


SPECIAL FINISHING

It is given according to the buyers demand. Sueding, raising, singeing, shearing machines

are available here.

FINAL INSPECTION REPORT

For final inspection , Inspection table & Inspection m/c is used .

The 4-point system is given below-

Size of Defect Penalty pointLess than 3 inches 1

3-6 inches 2More than 6- 9 inch 3

More than 9 inch 4

Size of holes & opennings-

1 inch or less 2

More than 1 inch 4

Some general rules of the inspection are-

1. Not 1 metre of cloth is penalized more than 4 points.2. Cloth is inspected on face side only unless specified.3. If the total defect parts per 100 yards of fabric are 40 or more the fabric will be

rejected.But it may be changed according to buyer’s requerments.

REMARKS

The production process, followed by the Dye-house of KC group is impressive. Theprocesses are being carried out very quickly and accurately. Due to the excellence ofprocess, machineries and lab trials very few cases of re-dyeing is performed.


CHAPTER – 7

MAINTENANCE


MAINTENANCE

Maintenance is the actions taken to prevent a device or component from failing or to re-

pair normal equipment degradation experienced with the operation of the device to keep

it in proper working order.

British Standard Glossary of terms (3811:1993) defined maintenance as:

The combination of all technical and administrative actions, including supervision ac-

tions, intended to retain an item in, or restore it to, a state in which it can perform a re-

quired function.

Maintenance is a set of organised activities that are carried out in order to keep an item inits best operational condition with minimum cost acquired.

OBJECTIVES OF MAINTENANCE

Maintenance objectives should be consistent with and subordinate to production goals.

The relation between maintenance objectives and production goals is reflected in the ac-

tion of keeping production machines and facilities in the best possible condition.

Maximising production or increasing facilities availability at the lowest cost andat the highest quality and safety standards.

Reducing breakdowns and emergency shutdowns. Optimising resources utilisation. Reducing downtime. Improving spares stock control. Improving equipment efficiency and reducing scrap rate. Minimising energy usage. Optimising the useful life of equipment. Providing reliable cost and budgetary control. Identifying and implementing cost reductions.


TYPES OF MAINTENANCE

Maintenance can be classified as following way:

Maintenance

Preventivemaintenance

Breakdownmaintenance

Mechanicalmaintenance

Electricalmaintenance

Mechanicalmaintenance

Electricalmaintenance

Reactive / Break down maintenance

Reactive maintenance is basically the “run it till breaks” maintenance mode.

No action or efforts are taken to maintain the equipment as the designer originally in-

tended to ensure design life is reached.

Advantage

Low cost Less staff

Disadvantage

Increased cost due to unplanned downtime of equipment. We are spending more dollars associated with capital cost because, while waiting

for the equipment to break, we are shortening the life time of the equipment re-sulting in more frequent replacement or repair.

If is a critical piece of equipment that needs to be break on line quickly, we willhave to pay maintenance overtime cost.

Possible secondary equipment or process damage from equipment failure


Preventive / Schedule Maintenance

Preventive maintenance can be define as action performed on a time or machine – run –

based schedule that detect, preclude or mitigate degradation of a component or system

with the aim of sustaining or extending is useful life time to an acceptable level.

Advantage

Increase component life cycle. Flexibility allows for the adjustment of maintenance periodicity. Reduce equipment or process failure & estimated 12% to 18% cost savings over

reactive maintenance program.

Disadvantage

Labor intensive Includes performance of unneeded maintenance. Potential for incidental damage to components in conducting unneeded mainten-

ance.

CHECK POINTS OF DIFFERENT MACHINES DURING MAINTENANCE

During maintenance procedure following points should be checked.

Machine : Dyeing Machines (Mechanical)

Sl.

No.Items need to be checked & Serviced

1 Crease the winch bearing.

2 Complete cleaning of machine

3 Cleaning of drain valves, replace seals if required

4 Check air supply filter, regulators, and auto drain seals

5 Clean filters element and blow out


6 Greasing of Unloading Roller Bearings.

7 Checking of oil level and bolts of Unloading Roller Gearbox.

8 Checking of unloading roller coupling and packing.

9 Checking and cleaning (if required) of Min Vessel Level Indicator

10 Check the oil level of pump bearing and refill if requird.

11 Check the function of heat and cool modulating valves

12 Check all belts and belt tension

13 Check all door seals

Machine : Dyeing machine (Electrical)

Sl.No. Items need to be checked & Serviced

1 Check & clean fluff and dirt at dirt at all motor fan covers.

2 Check all motor’s terminals

3 Check main panels (by using compressed air)

4 Check panel cooling fan & clean its filter

5 Clean main pump inverter and its cooling fan.

6 Check all circuit breaker, magnetic conductors and relays.

7 Check current setting of all circuit breacker & motor over load.

8 Visual checking of all power & control cables.

9 Check DC drive of neel motors


10 Check all pressure switches

11 Check calibration of main vessel & all addition tank

12 Check all pneumatic solenoids

13 Check calibration of heating/cooling modulating value

14 Check setting of tangle sensor.

15 Check setting & operation of lid safely switches.

16 Check all emergency switches

17 Check all indicating lamps

18 Check all on/off switches

19 Check all signal isolators.

Machine : Lab dye ing m/c.

Sl. No. Ite ms need to be checked & Serviced

1 Check rotating main sha ft bearing.

2 Check cooling water inlet and out let nose and nose clips.

3 Check cooling fans

4 Check driving belts and pulle ys.


Machine : Lab dye ing m/c.

Sl. No. Ite ms need to be checked & Serviced

1 Check & clean fluff and d irt at a ll mo tor fan cove rs

2 Check all motors termina ls

3 Check min pane ls (by us ing compressed a ir)

4 Check panel coo ling fan & clean it filter

5 Clean main pump inve rter and its coo ling fan

6 Check all c ircuit breaker, magnet ic contractors and re lays

7 Check current sett ing of a ll c ircuit breaker & motor over loads.

8 Visua l check ing of a ll power & contro l cab les

9 Check DC drive o f ree l motors

10 Check all pressure switches

11 Check calibrat ion o f main vesse l & a ll add it iona l tank

12 Check all p neumat ic so leno ids

13 Check calibrat ion o f heat ing/coo ling. Modula t ing va lue

14 Check setting o f tangle sensor.

15 Check setting & operat ion of lid sa fety switches

16 Check all emergency Switches

17 Check all ind icat ing la mps

18 Check all o n/o ff switches


19 Check all s igna l iso lators

20 Check key pad & disp lay o f contro ller

Dyeing machine maintenance Schedule

Daily

Check belt tension Check steam or water system & air supply Check chemical pump Machine clean

Weekly

Bearing & belt check Check leakage of air, steam & Water line Greasing bearing points Add gland packing at pump

Monthly

Greasing bearing points Replace bearing points (if required) Gasket check Clean steam trap Lubricating all chemical pump

Quarterly

Replace belts Repairing of pulley, shaft & bearing housing Painting m/c & pipe line Clean steam trap Replace seals (if leakage) Change gasket of steam of water lines

Half yearly

Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing

Yearly


Machine overhauling

Machine: Dewatering Machine (Mechanical)

Sl. No. Items need to be checked & Serviced

1. Cleaning of softener application unit

2. Checking of rotating device of rotating trolley unit

3. Checking of pneumatic pressure valves

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

5. Checking of plaiting device

6. Checking of speed regulating unit

Slitting machine

1. Check and tightening all motor terminals2. Check and clean Pressure sensor and tightening terminals3. Clean the ventilation fans of Panel board. (Every 15 days)4. Clean the fan and the heat sink of the inverters in the panel board. (15 days)5. Check activity of wide band sensor and pneumatic regulator6. Check and tightening the proximity switch terminals7. Inspection, cleaning and tightening all the terminals in the panel8. Check and tightening limit switch and the Emergency switch9. Checking the Fabric Tension controller (Dancing Roller)10. Check and clean rope de-twisting and turn able system and tightening the termin-

als.11. Check and clean Fabric needle mark sensor and the regarding arrangement.


Machine: Stenter Machine


1. Removal of gas burnt deposits from chains

2. Checking of gas burners

3. Cleaning of softener application unit

5. Checking and cleaning of steam pipe lines

4. Checking and cleaning of gas pipe lines

5. Grinding of fabric gripping pins

6. Cleaning of ventilation duct

7. Cleaning of m/c cabinet

8. Checking of motors

Machine: Compactor Machine


1. Checking of Steam pipe lines

2. Checking of pneumatic pressure valves

3. Checking of belt conveyor system

4. Checking of plaiting device

5. Checking of speed regulating unit


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

7. Cleaning of compacting shoe

Machine: Rais ing Machine


1. Checking of Gearing system and replacement of faulty gears

2. Cleaning of fiber deposits from the pile and counter pile rollers

3. Grinding of pins of pile and counter pile rollers

4. Lubrication of gearing system

Maintenance : Electrical

SL NO. Items need to be checked & serviced1 Check main panels2 Check panel cooling fan & clean its filter3 Clean main pump inverter & its cooling fan4 Check all circuit breaker ,magnetic ccnductors & relays5 Check current setting of all circuit breaker & motor over load6 Visual checking of all power & control cables7 Check all motor’s terminals8 Check & clean fluff & dirt at all motor fan covers9 Check DC drive of neel motors

10 Check all pressure switches11 Check calibration of main vessel & all addition tank12 Check all signal isolators13 Check setting & operation of lid safely switches14 Check setting of tangle sensors15 Check all pneumatic solenoids16 Check all indicating lamps17 Check calibration of heating/ cooling modulating valve18 Check all on/off switches


The following tasks are generally done during maintenance:

Inspect ions & check up Lubrica t ions Planning & scheduling Record ana lys is Tra ining of the maintenance crew Collect ion or purchase of spares

Boiler maintenance schedule

Daily

Check gas pressure Maintain log sheet Chemical dosing

Weekly

Check all steam line Fire quality of boiler

Monthly

Check all steam line Fire quality of boiler Gas consumption report Burner clean

Quarterly

Burner clean Economizer clean Feed tank clean Chemical tank clean Sight glass clean

Half yearly

Burner clean Feed tank clean Chemical tank clean Economizer clean Replace gasket Replace valve Check gas line & filter & pressure


Yearly

Overhauling of boiler Chemical cleaning of boiler Safety valve test Economizer clean Feed tank clean Chemical tank clean Burner clean Check safety valve setting Replace valve & gasket Boiler inspection by authority

Hydro extractor maintenance

Daily

Machine clean Belt checking

Weekly

Machine clean Belt clean Greasing & lubricating of all points

Monthly

Machine clean Check gear oil quality

Quarterly

Change of gear oil Belt change

Half yearly

Change of gear oil Belt change (if required)

Yearly

Machine overhauling


Dryer maintenance

Daily

Check belt tension Check steam supply & air system Machine clean

Weekly

Check fabric drying quality Greasing bearing points Clean air-filter & regulator

Monthly

Clean radiator & machine cabinet Greasing bearing points Clean air filter and regulator

Quarterly

Replace belt Replace gear oil Duct clean

Half yearly

Check roller condition Greasing & lubricating all points

Yearly

Machine overhauling

Tumble dryer maintenance

Daily

Check belt Steam leakage area Machine clean

Weekly

Heat exchange clean Greasing & lubricating of all points Belt check Machine clean


Monthly

Filter clean Steam trap clean

Quarterly

Replace belt Replace gear oil Duct clean Gasket & valve change

Half yearly

Gasket & valve change

Yearly

Machine overhauling

MAINTENANCE TOOLS/EQUIPMENT & THEIR FUNCTIONS

Maintenance tools /equipment Functio ns

1. Adjustab le wrench Used for sett ing nut & bolts

2. Pipe Spanner For pipe fitt ing

3.Spanner Fixed Spanner for nut & bo lts fit t ing

4.Socket spanner Hand le s ystem for nut & bolt fitt ing

5. hammer To apply load where req uired

6. Screw driver To release any screw

7. Punch Used to fit any worn out sha ft

8. Lock opener To open the c lip o f bear ing

9. Hack saw To cut any meta llic thing


10. Outside calipers To measure outs ide d ia

11. Inside ca lipers To measure ins ide d ia

12. Slide ca lipers To measure very small d ia

13. Vernier sca le To measure very small d ia

14. Chain ton To lift heavy load

16. Grind ing machine To make the smooth fabric s

17. Tester To test e lectr ic c ircuit

18. Pliers To gr ip anything & cut anything

19. Avometer/Vo ltmeter To measure vo ltage

20. Steel tape To measure length, width & he ight

21. Chise l To cut any meta l

22. Gasket cutter For gasket cutt ing

23. File To smooth the rough surface

Maintenance machine

Equipment name Function

Grinding machine Grinding

Cutting machine Cutting

Drill machine Drilling

Shaping machine Shaping


Lathe machine To make something

Bending machine Bending

REMARK

Maintenance is very important for prolonging the machine’s useful life-time. Mainten-

ance system is must for keeping the factory plants, equipment, machine tool etc in opti-

mum working condition and ensuring accuracy of product & time schedule to delivery

customers and to modify or improve productivity of existing machine to meet the need

for production & thus avoid sinking of additional capital.


CHAPTER – 8

UTILITY SERVICES


AVAILABLE FACILITIES OF UTILITY

Electricity Gas Water Compressed air Steam ETP

ELECTRICITY

It is impossible to continue the production without electricity. A frequent supply of

electricity is necessary for soundless production. In KCL all machines in dyeing &

finishing sections are provided electricity by the own generator of the industry . The main

utility electricity is supplied form PDB and also by Generator.

Knit dyeing: Four (4) Gas Generators

Yarn deying: Two (2) Gas Generators

Reserve: Two (2) Diesel Generators

GAS

Gas is mainly used for steam production

The gas is used from TITAS

Generally 36 m3 gas is required to produce 1 ton steam

Water

Knit dyeing: Four (4) Water Teratment Plant

Yarn deying: Two (2) Water Teratment Plant

Drinking water: One (1) Drinking Water Teratment Plant

Compressed Air

Natural gas is drawn by pipe through the filter above the compressor & the air is

compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to

reduce the temperature of compressed air. Thus the cold water becomes slightly hot &

goes through outlet pipe to the overhead reservoir. Then the water falls slowly through a


compressed air along with some vapors are transferred to the reservoir where the vapours

are condensed & outlets drop by drop. The moist compressed air is transferred to the

dryer& a slight warm compressed air is delivered to require sections of KCL.

Compressor: Five (5) nos.

Company: BOGE (Germany), Atlascapco (Belgium)

Steam

Steam is an important utility for dyeing section. Steam produced by the boiler Supply

water is simply treated in the boiler section by the two softener tank Then water reserves

to the feed water tank & this feed water tank warms the water Then water passes to the

boiler which produces steam & that steam supplies to the factory .

Knit dyeing: Two (2) Boilers; capacity 10 tons, Loos , Germany

Yarn deying: One (1) Boiler; capacity 10 tons, Loos , Germany

ETP

Parameters Unit Concentration DOE H&M

In- let water Out- let

water

BOD5 mg/L 198 28 50 30

COD mg/L 430 56 200 200

TDS mg/L 2493 1949 2100 -

TSS mg/L 178 30 150 30

PH - 9.27 7.3 6-9 6-9

Temperature ° C 40 36 40 S/45 W 37

EC μδ/cm 4986 3898 1200 -

Phosphate mg/L 2.1 2 8 -

Sulphate mg/L 10 9 - -

Ammonia mg/L 3.35 0.29 5 -

Nitrate mg/L 4.9 3.6 10 -


Nitrite mg/L 3.2 0.07 50

Color Pt-co

Hozen

211 59 - -

DO mg/L 0.0 4.7 4.5-8 -

Equipment used:

Spectrophotometer Thermometer BOD Sensor System PH meter TDS meter Electric balance Microscope

Capacity: 3000 m3/day

Cost: 30000 tk/day

Total space: 22000 sq. feet

REMARKS

For smooth running of a factory utilities are unavoidable. It has no direct use but help in

the production So, utility should have the proper characteristics to met up the production

parameter.


CHAPTER – 9

STORES & INVENTORY CONTROL


INVENTORY CONTROL

Store is the place where every type of raw materials, spares, finished goods arekept in proper system. Inventory control means the accurate calculation and data ofevery type of raw materials spares and finished goods in time to time store 4 inventorycontrol are necessary, because –

1. To know about the required amount of raw material2. To know about the job no – which would be processed3. To be continued the production process4. To find out the profit or loss of a company5. Stock and stock value for consumption measuring

FREQUENCY OF INVENTORY UPDATE

- Monthly inventory control.- Annual inventory control.

SCOPE OF INVENTORY CONTROL

- Raw materials

Dyes store. Other chemicals. Grey fabrics.

- Finished fabric.

- Spare parts.

- General store:

Capital equipments. Accessories. Stationary. Maintenance parts.


INVENTORY CONTROL SYSTEM FOR RAW MATERIALS

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

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

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

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

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

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

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

INVENTORY CONTROL SYSTEM FOR FINISHED FABRIC

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

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

After finishing the fabric is kept in package before their transfer to the garments de-partment.

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

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

INVENTORY CONTROL SYSTEM FOR SPARE PARTS

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

parts or buys from local market as per requirement. As new spare parts arrive to store officer, he receives and catalogues them.


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

REMARK

- The inventory system of KCL covers both knitting & dyeing inventories.

- The space is noticed to be insufficient considerably.


CHAPTER – 10

COST ANALYSIS


Costing system mainly describes how the cost of the final product is fixed by the compa-

ny. According to buyer/customers requirement at first the fabric is collected from local

and foreign suppliers. Then it id calculated how much dyestuff and chemical is required

to the end of the processing of that specific fabric .After that, the final cost is fixed in-

cluding some profit. Then the unit price is offered to the buyer for approves it.

POINTS FOR COSTING

The following points are considered for costing any dyed product in KCL:

1. Total dyes & chemical cost2. Total utility cost3. Salary4. Payment5. Transport cost6. Lunch7. Entertainment cost8. Miscellaneous cost9. Government cash incentive

PRICE OF THE PRODUCT

Generally price of product is determined by the required profit adding to the total e x-penses. So,

Price of products

= (Direct expenses + Indirect expenses + Factory Overhead) + Required profit

REMARK

Every company has its own coasting policy, which they keep it secret and do not want to

give any information regarding it. So don’t get any idea about their costing policy.


CHAPTER – 11

MARKETING ACTIVITIES


CONSUMER OF THE PRODUCTS:

KCL is a 100% export oriented industry. All the goods produced in this industry are

exported into various foreign country . Name of the buyers of the products of the

industry are-

H & M K & L Okaidi Philder Obaibi Bizbee Camaieu Jacadi Joules

There are some countries which are importing goods from KCL which are given below-

United State of America England Germany Denmark Europe Europe Union

Manpower of Marketing:

Marketing plays a vital role in the field of displaying / showing the goods criteria of theproducts to the buyer & to communicate with the buyer.

Marketing Strategy:

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

KCL mainly senior marketing officers, merchandiser & higher officials deal with thebuyer. There are some fixed buyers of the industry. The buyers give their orders cont i-nuously all over the year. The marketing officers & the merchandisers communicate withthe buying houses to collect the orders.


By both side understanding the rate & the order quantity are fixed. A well defined mar-keting strategy has the following characteristics:

Good quality Low price or competitive price Prompt service Good commitment Good business communication

DUTIES & RESPONSIB ILITIES OF MARKETING OFFICER

Job summery

i) Market searchii) Market developmentiii) Customer’s motivationiv) Production follow upv) Technical assistance of customer

Dealing with the buyer & convince the buyer is the main duty of marketing officer. Amarketing officer also has some other duties. The main duties & responsibilities of amarketing officer are given bellow-

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

chandisers To maintain a communication with the buyers and buying houses Communicate with better criteria of the products

Actually the responsibilities & duties of marketing officer begins from gett ing order ofbuyer & ends after receiving foods by the buyer. So, he should be always smart, energetic& sincere.

REMARKS

KCL has a well learned marketing & merchandising team. They always communicatewith the buyers. KCL has some fixed buyers. The marketing section also looks the quali-ty & quantity buyers.


CHAPTER – 12

CONCLUSION


We have completed our industrial attachment success fully by the grace of Almighty.

Industrial attachment sends us to the expected destiny of practical life The completion of

the two months Industrial Attachment at KNIT CONCERN LIMITED, we have got the

impression that the factory is one of the most modern export oriented knit composite in

Bangladesh Though it was established only a few year's ago ,it has earned " very good

reputations " For its best performance over many other export oriented textile mills .

Mill is settled with utility to give all convenient supports to the productions for twenty-

four hours . KCL has its own water pre-treatment plant & 26,300 cubic feet water

reservoirs in its Godnail campus The Godnail premises has its own power generation

plant where 1,900 kw power generators guarantee smooth & uninterrupted power supply

to its every operation .

However there are some points to be mentioned :

During the transport of the fabric in the dyeing floor & also during the loading of

the machine, fabrics are soiled for the contact with floor. This makes the

fabric/part of the fabric dirty. It may require more scouring/bleaching agent or

may create stain making it faulty.

The dyeing floor is watery most of the time. It should be cleaned all the time.

Many time the dosing pipelines are clogged due to the careless dosing of the

chemicals. The supervisors should supervise the floor more sincerely.

The machine stoppage time should be analyzed & minimized. The maintenance

should be carried out when the machine is out of action (wherever possible).

OUR APOLOGY :

The management of KCL are very helpful Our respective seniors gave us time

when ever they got .

Due to secrecy act, all the data on costing & marketing activities has not been

supplied & hence this report excludes these chapters.

Some of the points in different chapter are not described as these were not

available.


The whole process is not possible to bind in such a small frame as this report,

hence our effort spent on summarizing them.

But it must be said that KCL is a best place to get the practical knowledge about

the dyeing as they have lot of production of all quality .

LIMITATIONS OF THE REPORT

We can not able to collect the necessary information about garments section prop-

erly.

Because of secrecy act, the collected data on costing and marketing activities are

not sufficient.

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

possible to do so.

It is not possible to bind the whole process in such a small frame as this report;

hence our effort was to summarize them.

AT THE END

We are enough fortunate that we have got an opportunity of having a training in this mill

During the training period we are received co-operation & association from the authority

full & found all man , machines & materials on appreciable working condition All stuffs

& officers are very sincere & devoted there duties to achieve their goal .

Industrial attachment of knit concern limited (kcl)

Engineering

Transcript of Industrial attachment of knit concern limited (kcl)