INDUSTRIAL ATTACHMENT OF rupa fabrics ltd.

INDUSTRIAL TRAINING

Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

RUPA GROUP LTD.

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Report

On INDUSTRIAL INTERNSHIP

Course Code: Tex -4036

Duration: 6 weeks

RUPA FABRICS LTD.

Kunia, Barobari, Gazipur.

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Objective

The main object of our training is to gather the practical knowledge on various textile

processes related with the industry. During the training period we have tried to meet

the gap between theoretical and practical knowledge. As we are the students of wet

processing technology so our main concern was about knitting, knit dyeing, knit

finishing & quality control of knitted fabrics?. We have also tried to gather knowledge

about machine maintenance and various utility services.

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TABLE OF CONTENT

Chapter No. Title page no.

Chapter- 1 Introduction 6-8

Chapter- 2 Project Description

9

Chapter-3 Management System 10-12

Chapter-4 Raw materials 12-15

Chapter-5 Production Planning &

Sequence of operation:

16-112

1.Knitting 16-34

2. Batching 35-36

3. Laboratory 37-541

4. Dyeing Section

(Knit Dyeing)

42-57

5. Finishing Section

58-71

6. Garments 72-80

Chapter-6 Quality Assurance

System

81-86

Chapter-7 Maintenances 87-90

Chapter-8 Utility Services 91-93

Chapter-9 Safety Management 94

Chapter-10 Store & Inventory

Control

94

Chapter-11 Cost Analysis 95

Merchandising

&marketing

96

Chapter-12 Social & Environment

Information

96-106

.Chapter-113 Conclusion 107-109

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INTRODUCTION

By means of practical knowledge it’s not possible to apply the theoretical

knowledge in the practical field. For any technical education, practical experience is

almost equaled important in association with the theoretical knowledge. The industrial

attachment is the process, which builds understanding, skills and attitude of the

performer, which improves his knowledge in boosting productivity and services.

University education provides us vast theoretical knowledge as well as more practical

Attachment, in despite of all these industrial attachment helps us to be familiar

with technical support of modern machinery, stillness about various processing stages.

It also provides us sufficient practical knowledge about production management,

work study, efficiency, industrial management, purchasing, utility and maintenance of

machinery and their operation techniques etc. the above mentioned cannot be

achieved successfully by means of theoretical knowledge only. This is why it should

be accomplished with practical knowledge in which it is based on. Industrial

attachment makes us reliable to be accustomed with the industrial atmosphere and

improve courage and inspiration to take self responsibility. Textile education can’t be

completed without industrial training. Because this industrial training minimizes the

gap between theoretical and practical knowledge and make us accustomed to

industrial environment. I got an opportunity to complete two-months long industrial

training at RUPA FABRICS LTD , which is a 100% export-oriented composite Knit

Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments

units in addition to facilitate knitting and knitwear manufacturing.

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COMPANY PROFILE

Name : Rupa Fabrics Ltd.

Type : 100% Export Oriented Composite Knit

Industry.

Year of establishment : 2010(Dyeing Section)

Investor : Md. Shahidul Islam

Location : Kunia, Barobari, Gazipur.

Certification & awards : ISO 9001:2000.

Production capacity : Knitting: 4 tons/day

Dyeing: 13 ton/day

Sewing: 50,000 pcs/day

Main Production : Basic T-Shirt, Long Sleeve, Sweater,

T-Shirt, Polo Shirt, Pajama, Ladies, Kids

Knitwear& all kinds of knit

Garments & Knit fabrics.

E–mail Address :[email protected]

[email protected]

Website : www.rupagroup.net

Phone : 9292997, 9291704

mailto:[email protected]

http://www.rupagroup.net/

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History of the project:

After successful operation in Rupa fabrics Ltd, the owner had decided to start

a fully information & technology based along with the social accountability and

quality controlled modern readymade composite knit garments industry in large scale.

In this connection Shahidul Islam had decided in a resolution to start a company in

Kunia, Barobari, Gazipur. Right from inception the policy of the company has been to

provide total customer satisfaction by offering quality knitwear in time. To meet the

commitments of quality and prompt delivery, Rupa fabrics Ltd Decided to integrate

the manufacturing process in a planned manner. Over the years the entire process has

been integrated by importing sophisticated machinery from world-renowned

manufacturers.

Vision & mission of the project

The mission and vision of Rupa fabrics Ltd. is to manufacture and deliver high

quality readymade garments (RMG) to its customers. The core objective is to attain

and enhance customer satisfaction by providing on time delivery of desired quality

readymade garments and also to increase efficiency of workforce.

To attain these objectives, the management of Rupa fabrics Ltd. has decided to adopt

the following-

To increase awareness regarding customers requirements throughout the

organization.

By providing training to develop efficiency of the employee.

To collect customer’s feedback regularly to know about their conception

about their company and to take timely appropriate action.

To reduce the percentage of wastage / rejection minimum by 2% per

annum’s implement and monitor ISO 9001:2000 quality management

system within the organization.

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Man Power Organogram in RUPA FABRICS LTD.

Knitting section

Dyeing & Finishing Section

AGM

PM

Store In

charge Knitting Master Supervisor

Fitter

man

Operator

Fitter

man

Operator

GM

AGM

PM

SPO Batch

Incharg

e

Finishing

Incharge

Lab

Incharg

e

PO

APO

Superviso

r

Sr. Operator

Operator

Astt. Operator

Sewing man

Helper

Turningm/c

Operator

Helper

Sewing man

Squeeze

Operator

Dryer

Operator

Compactor

Operator

Helper

Lab

Technician

Q.C.

Technician

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Management System:

Buyer sample is send to G.M.

Matching is done by lab in charge.

Sample is prepared by dyeing master.

Sample is send to the buyer for approval.

Approved sample is returned and taken as STD. Sample for bulk

production.

Asst. dyeing master gives responsibilities to production officer.

Then production officer, with the supervisors start bulk production.

On line and off line quality check is done by lab in charge and asst.

dyeing master.

After dyeing finishing in charge controls the finishing process with the

supervision of production officer.

After finishing, the material is checked by dyeing master.

Finally G.M. checks the result with dyeing master and decision is taken

for delivery.

Designation & their Responsibilities:

General Manager:

Report to: Reports to the Board of Directors.

Position objective: To direct promote & coordinate the operations of the

cooperative in a manner that will optimize the cooperative market share &

savings, improve the cooperatives efficiency, help cooperative’s mission &

goals making result in outstanding customer service.

Position responsibilities: The General Manager’s responsibilities involve

supervision, public relation, marketing, profitability & sales, service,

reporting, capital requirements & other duties as assigned by the board of

directors.

Dyeing Manager:

Report to: Reports to the General Manager.

Position objective: To direct promote & coordinate the operations of the

cooperative in a manner that will optimize the cooperative market share &

savings, improve the cooperatives efficiency, help cooperative’s mission &

goals making result in outstanding customer service.

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Position responsibilities: To promote and managing the safety of their

employees and their work environment. Overall supervision of dyeing &

finishing section & quality control. The dyeing manager will maintain a

positive attitude that promotes team work within the cooperative & a favorable

image of the cooperative. Managers also must report failures to follow safety

standards by others outside of their departments and take immediate actions to

implement controls for situations that are clearly unsafe.

Production Officer:

Report to: Dyeing Manager.

Position objective: To plan execute & follow up the production activities &

control the quality production with related activities.

Position responsibilities: Overall supervision of dyeing & finishing, dyes

chemicals requisition issue & check, program making, sample checking, color

measurement.

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Raw materials

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

It plays a vital role in continuous production and for high quality fabric.

Types of Raw Materials: 1. Yarn

2. Fabric

3. Dye stuff

4. Chemical and auxiliaries

Raw Materials Sources: Cotton Yarn: 1. ARMAN Spinning Mill.

2. RISING Spinning Mill.

3. THERMAX MELANGE Spinning Mill.

4. NZ Spinning Mill.

Polyester Yarn: India

Lycra : Singapore, Indonesia, Korea, Japan

Fabric : 01. RUPA Fabrics Ltd.

02. Cotton Club (BD) Ltd.

Types of fabrics:

Single jersey

Single jersey with lycra

pique

Polo pique.

Single lacoste

Double Lacoste

Fleece

Rib

Rib with lycra

1×1 Rib

2×1 Rib

CVC.

Polyester.

PC.

Different Types of Dyes Used In RUPA FABRICS LTD with Their Brand Name:

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Reactive Dye

BRAND

NAME

COUNTRY

NAME NAME OF DYE STUFF

DY-STAR. GERMANY

Remazol Blue RR

Remazol Yellow RR

Remazol Deep Black GWF

Remazol Red RR

Remazol Turquoise Blue G

Remazol B/Yellow3GL

Remazol Blue BB new

Remazol Orange RR

Remazol Blue RSPL

Levafix Rubine CA Gran

Levafix Red CA Gran

Levafix Olive CA Gran

Levafix Fast Red CA Gran

Levafix Brillant Red E-4BA Gran

Dianix Navy CC

Dianix Turquoise S-BG

IMPOCOLOR GERMANY

Imcozin Blue E-NR

Imcozin Blue V-CR 150%

Imcozin Brilliant Red V-F3B

Imcozin Brilliant Yellow V-4GL

Imcozin Yellow E-3R 150%

BENZEMA SWITZER LAND

Bezaktive Blue S-GLD 150

Bezaktive Yellow S-3R 150

Bezaktive Red S-3B 150

CLARIANT SWITZER LAND Drimarine Yellow K-4G Cdg

HUNTSMAN SWITZER LAND

Terasil Red W-4BS

Terasil Navy W-RS

Novacron Red FN-R-01

Novacron Yellow F-4G

JIHUA CHINA Starfix Black B 150%

Starfix Red EP 150%

SUMIFIX JAPAN Sumifix Supra Blue E-XF

Sumifix Supra Yellow E-XF

UN COLOR KOREA Sunfix Navy Blue

Different Types of Chemicals Used In Rupa Fabrics Ltd With Their Brand Name:

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CHEMICAL NAME BRAND NAME COUNTRY NAME

Wetting agent FELSON NOF Germany

Levelling agent N.D.L.S. Con Switzerland

Anti-creasing agent Marla KT Germany

Per Oxide Stabilizer

Kapazon H-53

Germany CBB

Rucorit Wez

Caustic Caustic China

Soda Ash Soda Ash Chaina

H2O2 H2O2 Chaina+Korea

Optical Brightening

Agent

Uvitex-BMA

Switzerland Uvitex-BHV

Uvitex-BBT

Syno White 4Bk Korea

H2O2 Killer Catazyme 200L Germany

Acetic Acid Acetic Acid India

Sequestering Agent

MS China

SIRIX 2UD

P cone India

Enzyme BIOPOLISH,AVOCEF China

Cellzyme 335i India

Electrolyte / Salt

Sodium Sulphate

Anhydrose India

Glubar Salt

Detergent Marla OLS Germany

KRCP Switzerland

Soaping agent

Rukozen-NZA Germany

Dekol ISN China

Erapon R

Softener

Nerosoft-JS(an-ionic) China

Nerosoft-NI(non-ionic)

Kappa Soft BD Bangladesh

Stabilizer Sandofix-EC

Germany Marla PS 100

Disperse Dye

Black EX SF

Yellow K 4GB

Blue KFBL

Crimson-XFT

D-Red-XFT

Orange-HWT

Blue BBL

Orange F-3R

Red KRB

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Production Planning & Sequence of Operation

Production of the industry describe to the below sequentially given which may

expresses the working principle of every operation:

KNITTING SECTION

Knitting:

Knitting is the method of making fabric by transforming continuous

strands of yarn into a series of interloping loops, each row of such loops forms the one

immediately preceding it.

Flow chart of knitting Section:

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and

Tension device.

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

Machine Description of Knitting Section:

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No. of

m/c

M/C

Dia

M/C

Gauge

No. Of

Feeder

No. Of

Needle

M/C

Type

Brand Origin

1 30” 24 60 2256 D/J PAI

LUNG

Taiwan

2 38” 24 76 2856 D/J PAI

LUNG

Taiwan

3 34” 24 72 2544 D/J PAI

LUNG

Taiwan

4 32” 24 64 2400 D/J PAI

LUNG

Taiwan

5 42” 24 126 3168 S/J PAI

LUNG

Taiwan

6 38” 24 114 2856 S/J PAI

LUNG

Taiwan

7 38” 24 114 2856 S/J PAI

LUNG

Taiwan

8 36” 24 108 2712 S/J PAI

LUNG

Taiwan

9 36” 24 108 2712 S/J PAI

LUNG

Taiwan

10 32’’ 24 64 2400 S/J PAI

LUNG

Taiwan

11 36” 24 108 2712 S/J PAI

LUNG

Taiwan

Flat Bed machine

M/C No : 04

Flat : 54 inch

Feeders No : 06

Gauge : 14

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Image of knitting M/c

Raw materials for knitting:

Type of yarn Count

Cotton 24S, 26S, 28S, 30S, 32S, 34S, 40S

Polyester 75D, 72D,100D

Spandex yarn 20D,40D, 70D

Grey Mélange (C-90% V-10%) 24S, 26S

PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S

CVC 24S, 26S, 28S, 30S

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Image of Knitting action

RUPA FABRIC’S Ltd. produce the following product-

Single jersey-

a. Single Jersey (Plain)

b. Single lacoste

c. Double lacoste

d. Polo pique

Double jersey-

a. 1×1 rib (normal)

b. 1×1 rib (lycra)

c. 2×1 rib .

Flat Bed-

a. Plain collar

b. 3×2 rib.

c. Cuff

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Image of Dust Removal Fan of Knitting M/c

Interlock M/C:

a) Interlock pique

b) Mash fabric

c) Face/Back rib

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Image of Grey GSM setting cylinder

Rib M/C:

a) 1*1 Rib fabric b) 2*2 Rib fabric

Considerable points to produce knitted fabrics:

When a buyer orders for fabric then they mention some points related to production

and quality. Before production of knitted fabric, these factors are needed to consider.

Those are as follows-

- Type of Fabric or design of Fabric.

- Finished G.S.M.

- Yarn count

- Types of yarn (combed or carded)

- Diameter of the fabric.

- Stitch length

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Image of needle action with yarn

Operation procedure:

Sample analysis: After receiving an order first step is analysis the fabric. A sample is

analysis as per following system.

a) Design analysis:-

Example:

Here,

= Knit loop

= Tuck loop

1 2 3 4 = Miss loop

1 2 1 2

Cam set up:

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1

2

3

4

Needle arrangement: - 1 2 3 4/ 1 2 3 4//

This fabric can by produced by two tuck cam

Optimum cam set up: 1

2

Optimum needle: - 1 2 1 2/ 1 2 1 2//

In BKL most of the fabrics are produced by using three track cam.

The truck cam set up for different fabric that is usually produced in BKL single jersey

knitting machine are given below:

S.T.B – PK B – PK

In BKL for double jersey machine two Truck cam are generally used to produce Rib,

Interlock Thermal, Mini-Thermal, Waffle, Mini-Waffle etc fabric.

Inter lock

Rib

D D

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C C

Fabric: Single jersey

NOTATION DIAGRAM

CAM SETTING ARRANGEMENT

∆ ∆ ∆ ∆

∆ ∆ ∆ ∆

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Image of Cam with Cam box


∆ ∆ ∆ ∆ ∆ ∆

D

∆ ∆ ∆ ∆ ∆ ∆

∆ ∆ ∆ ∆ ∆ ∆

C ∆ ∆ ∆ ∆ ∆ ∆

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Image of Cam box

NEEDLE ARRANGMENT

HL

HL

L

LS

11

11

22

22

N.B:

∆ = Knit cam

H =High butt needle

L = Low butt needle

1 = One butt needle

2 = Two butt needle

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Image of Cam setting to the Cylinder

Fabric: 2 2 Rib


∆ ∆ ∆ ∆ ∆ ∆

D

∆ ∆ ∆ ∆ ∆ ∆

∆ ∆ ∆ ∆ ∆ ∆

C

∆ ∆ ∆ ∆ ∆ ∆

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Image of Knitting M/c

By increasing m/c speed:

Higher the m/c speed faster the movement of needle and ultimately production will be

increased but it has to make sure that excess tension is not imposed on yarn because

of this high speed.

A. By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the number

of courses will be increased in one revolution at a time.

B. By using machine of higher gauge:

The more the machine gauge, the more the production is. So by using machine of

higher gauge production can be increased.

C. By imposing other developments:

a) Using creel-feeding system.

b) Applying yarn supply through plastic tube that eliminates the possibilities

of

yarn damage.

c) Using yarn feed control device.

d) Using auto lint removal.

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Image of rolled fabric

Production calculation:

Production/shift in kg at 100% efficiency:

countYarn

mmSLNeedleofNoFeederofNoRPM

80.3527

)(..

Production/shift in meter:

100/

1260.

/

.min/

cmCourse

EfficiencyFeederofNoRPM

cmCourse

Course

Fabric width in meter:

100/

.

100/

.

cmWales

knittinginusedNeedlesofnoTotal

cmWales

walesofnoTotal

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Some points are needed to maintain for high quality fabric:

a) Brought good quality yarn.

b) Machines are oiled and greased accordingly.

c) G.S.M, Stitch length, Tensions are controlled accurately.

d) Machines are cleaned every shift and servicing is done after a month.

e) Grey Fabrics are checked by 4 point grading system

Changing of GSM:

Major control by QAP pulley.

Minor control by stitch length adjustment.

Altering the position of the tension pulley changes the G.S.M. of the fabric. If

pulley moves towards the positive direction then the G.S.M. is decrease. And

in the reverse direction G.S.M will increase.

Other m/c in Knitting Section:

01. Gray Inspection M/c, Brand : UZU fabric inspection machine

02. Electric Balance for Fabric Weight.

03. Electric Balance for GSM check.

04. Compressor 2 pieces

Image yarn insertion

Production Parameter:

Machine Diameter;

Machine rpm (revolution per minute);

No. of feeds or feeders in use;

Machine Gauge;

Count of yarn;

Required time (M/C running time);

Machine running efficiency.

Relationship between knitting parameter:

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Stitch length increase with decrease of GSM.

If stitch length increase then fabric width increase and Wales per inch

decrease.

If machine gauge increase then fabric width decrease.

If yarn count increase (courser) then fabric width increase.

If shrinkage increases then fabric width decrease but GSM and Wales

per inch increase.

for finer gauge, finer count yarn should use.

Considerable points to produce knitted fabrics:

When a buyer orders for fabric then they mention some points related to production

and quality. Before production of knitted fabric, these factors are needed to consider.

Those are as follows-

- Type of Fabric or design of Fabric.

- Finished G.S.M.

- Yarn count

- Types of yarn (combed or carded)

- Diameter of the fabric.

- Stitch length

- Color depth.

Effect of stitch length on color depth:

If the depth of color of the fabric is high loop length should be higher because in case

of fabric with higher loop length is less compact. In dark shade dye take up% is high

so GSM is adjusted then. Similarly in case of light shade loop length should be

relatively smaller

Factors that should be change in case of fabric design on quality change:

a) Cam setting

b) Set of needle

c) Size of loop shape

Methods of increasing production:

By the following methods the production of knitted fabric can be increased –

A. By increasing m/c speed:

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Higher the m/c speed faster the movement of needle and ultimately

production will be increased but it has to make sure that excess tension is not

imposed on yarn because of this high speed.

B. By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the

number of courses will be increased in one revolution at a time.

C. By using machine of higher gauge:

The more the machine gauge, the more the production is. So by using machine

of higher gauge production can be increased.

E. By imposing other developments:

a) Using creel-feeding system.

b) Applying yarn supply through plastic tube that eliminates the possibilities

of yarn damage.

c) Using yarn feed control device.

d) Using auto lint removal.

Faults &Remedies of knitting fabrics

1. Hole Mark: Causes: Holes are the results of yarn breakage or yarn cracks.

During loop formation the yarn breaks in the rejoin of the needle hook.

If the yarn count is not correct on regarding structure, gauge, course and density.

Badly knot or splicing.

Yarn feeder badly set.

Remedies: Yarn strength must be sufficient to withstand the stretch as well as

uniform.

Use proper count of yarn.

Correctly set of yarn feeder.

Knot should be given properly.

2. Needle Mark

Causes:

When a needle breaks down then needle mark comes along the fabrics.

If a needle or needle hook is slightly bends then needle mark comes on the fabrics.

Remedies:

Needle should be straight as well as from broken latch.

3. Sinker Mark

Causes:

When sinker corrode due to abrasion then some times can not hold a new

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loop as a result sinker mark comes.

If sinker head bend then sinker mark comes.

Remedies:

Sinker should be changed.

4. Star Mark

Causes:

Yarn tension variation during production.

Buckling of the needle latch.

Low G.S.M fabric production.

Remedies:

Maintain same Yarn tension during production.

Use good conditioned needles.

5. Drop Stitches

Causes:

Defective needle.

If yarn is not properly fed during loop formation i.e. not properly laid on to the needle

hook.

Take-down mechanism too loose.

Insufficient yarn tension.

Badly set yarn feeder.

Remedies:

Needle should be straight & well.

Proper feeding of yarn during loop formation.

Correct take up of the fabric & correct fabric tension.

Yarn tension should be properly.

6. Oil stain

Causes:

When oil lick through the needle trick then it pass on the fabrics and make a

Line.

Remedies:

Ensure that oil does not pass on the fabrics.

Well maintenance as well as proper oiling.

Dear Madam or Sir:

7. Pin hole

Causes:

Due to break down or bend of the latch, pin hole may come in the fabric.

Remedies:

Change the needle.

8. Bairre:

A fault in weft knitted fabric appearing as light or dark course wise (width

wise) stripe(s).

Causes:

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This fault comes from yarn fault.

If different micro near value of fiber content in yarn.

Different lusture, dye affinity of fiber content in yarn.

During spinning different similar classes of fiber is mixed specially in carded yarn &

these fibers have similar characteristics.

In draw fame different similar classes sliver is mixed and make one sliver.

Remedies:

We can use this fabric in white color.

9. Fly:

Causes:

In knitting section too much lint is flying to and fro that are created from yarn due to

low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface

tightly during knit fabric production.

Remedies:

Blowing air for cleaning and different parts after a certain period of time.

By cleaning the floor continuously.

By using ducting system for cleaning too much lint in the floor.

Over all ensure that lint does not attach to the fabric.

10. Yarn contamination

Causes:

If yarn contains foreign fiber then it remains in the fabric even after finishing,

If lot, count mixing occurs.

Remedies:

By avoiding lot, count mixing.

Fault less spinning

Yarn Faults:

Neps.

Slubs.

Yarn count.

Thick/Thin place in yarn.

Hairiness.

Batching

Batching is the process to get ready the fabrics that should be dyed and

processed for a Particular lot of a Particular order.

Batch Management:

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Primarily Batching is done by dyeing manager taking the above criteria under

consideration. Batch section in charge receives this primary batch plan from dyeing

Manager. Some time Planning is adjusted according to m/c condition.

Batch process follow-up:

Grey fabric inspection

Batching

Fabric Turning

Storing for dyeing

Purpose of Batch Section:

To receive the grey fabrics roll from knitting section or other source.

To turn out the tubular fabric in its grey stage and to safe the face side of the

fabric from any type of friction during the time of dyeing.

To prepare the batch of fabric for dyeing according to the following criteria-

Order sheet (Receive from buyer)

Dyeing shade (Color or white, light or Dark)

M/c available

Type of fabrics (100% cotton, PC, CVC)

Emergency

To send the grey fabric to the dyeing floor with batch card.

To keep records for every previous dyeing.

Criteria of proper batching:

- To use maximum capacity of existing dyeing m/c.

- To minimize the washing time or preparation time & m/c stoppage time.

- To keep the no. of batch as less as possible for same shade.

- To use a particular m/c for dyeing same shade.

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Fabrics Faults Identification:

Hole Mark: Five are acceptable.

Needle Mark: five are acceptable. Visualize on the face side of the fabric.

Sinker Mark: These problems are not acceptable. It is Visualize on the back

side of the fabric.

Patta: acceptable for only white color producing.

Star Mark: Five are acceptable.

Thick and thin place.

Lycra out.

Loop hole.

Oil spot.

Drop Stitches

LABORATORY

Lab department: Lab dip is a process by which buyers supplied swatch is

matched with the varying dyes percentage in the laboratory with or without help of

“DATA COLOR”

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Lab dip plays an important role in shade matching & and detaching the

characteristics of the dyes and chemicals are to be used in the large scale of

production so this is an important task before bulk production

Lab Working Procedure:

Lab dip receive

↓

Input id number entry

↓

By reference ←Recipe making→ from data color

↓

Recipe calculation

↓

Pipetting

↓

Fabric weighting & fabric input

↓

Fabric input into dye bath for dyeing

↓

Unloading

↓

Cold wash

↓

Hot wash→ with chemical

↓

Hot wash→ normal water

↓

Acid wash→ normal water

↓

Dryer

↓

Ironing

↓

Shade matching

↓

Shade ok

↓

Lab dip cutting

↓

Submit to buyer

↓

Buyer approval

OK Not OK

Send to floor

.

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Available Stock Solutions:

Red – 0.1%, 0.5%, 1.0%, 2.0% (very common)

Yellow – 0.1%, 0.5%, 1.0%, 2.0% (very common)

Blue - 0.1%, 0.5%, 1.0%, 2.0% (very common).

Preparation:

To prepare 0.1% Stock solution, it is necessary to mix

0.1 g dye and 100 cc water.

To prepare 0.5% Stock solution, 0.5 g dye stuff is

mixed with 100 cc water.

To prepare 1.0% & 2.0% Stock solution similar

procedure is followed.

To prepare 10% Stock solution of Soda ash, 10 g Soda

is mixed with 100 cc water.

Depth of shade:

Rupa Fabrics Ltd. Produces 0.1% to 5% shade for the goods.

2.0%for deep shade.

1.0%for medium shade.

0.5%for deep shade.

0.1%for light shade.

Usually following calculations are followed :-

Recipe % × Sample Weight

Dye Solution = (cc).

Stock solution %

Recipe % × Liquor)

Salt = (gram per liter).

1000

Recipe % × 100 × Liquor)

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Soda Solution = (cc).

(1000 × Stock solution %)

SAMPLE CALCULATION FOR 0.5% SHADE

Sample wt. = 5 mg

Material liquor ratio = 1: 10

Total liquor (5 10) = 50 cc

5 0.5%

Dye solution required = ------------------- = 2.5 cc

1 %

50 25

Salt solution required = ------------------- = 6.25 cc

20 10

50 10

Soda ash solution required = ------------------- = 2.5 cc

20 10

Water required {50 - (2.5 + 6.25 + 2.5)} = 38.75 cc

Procedure for100 % cotton fabric:

1. Calculate the recipe.

2. Weight the fabric.

3. Take the beaker keep the fabric into the beaker.

4. Then the dyes, chemicals & required amount of water take in to the beaker by

the digital pipetting.

5. Then weight the salt by the electric balance and add in to the beaker.

6. Then the beaker set in to the lab dyeing machine for dyeing.

7. Start the program for dyeing the whole dyeing time 60 min at 60 °C

temperature. (The dyeing time and temperature depends on which classes of

dyes are used for dyeing.)

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8. After 30 min add the then add the soda ash. By pipetting.

9. Again run the program next 30 min at the same temperature.

10. Finished the dyeing time then the sample taken from the beaker first

Hot wash & then cold wash.

11. Then acid wash as for neutralization.

12. Then soaping required soap solution 10 min at 90° C temperature.

13. After the fabric again cold.

14. Then dry the lab dip and compare with the standard.

LABORATORY MACHINERIES WITH ITS SPECIFICATION:

Machine Type : Color Fastness to Rubbing (Crook Meter)

Brand : ATLAS

Test Method : ISO 105-C06, ISO105-F09

Machine Type : Spectra Photo meter

Brand : Data Color

Manufacturer : U. S. A

Test Name : Color fastness to Wash (Rota Wash).

Brand : ATLAS

No.of m/c : 01

Test Method : ISO 105-C06, ISO105-D02

Test Name : Color Fastness to Perspiration

Brand : Paramount

Origin : U.K

No.of m/c : 02

Test Method : ISO 105-C06

Test Name :PH (Ph Meter)

Brand :HANNA

Origin :ROMANIA

Lab Dip m/c:

Brad name : Starlet

Origin : U.S.A

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M/C No : 02

Color Matching Cabinet (Light box):

Light Box no: 02

Brand : Verivide

Origin : U.K

Light Source:

Day Light (D-65)

UV

TL-84

* CWF

Machine Type : Washing M/C.

Brand : SIEMENS

Manufacturer : JARMAN

Machine Type : Weight Balance M/C

Brand : KERN

Dyeing

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Section

DYEING: Dyeing is the process of imparting colors to a textile material in loose fiber, yarn,cloth

or garment form by treatment with dyes.

General Classification of dye stuff (Dyers Point of view):

Coloring matters

Dyes Pigment

Water soluble Water insoluble Vat Azoic

Mineral Mineral

http://en.wikipedia.org/wiki/Yarn

http://en.wikipedia.org/wiki/Cloth

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Flow Chart For Dyeing:

Grey fabric receive from knitting section

Batching

Select m/c no

Fabric loading

Select production program

Pre treatment

Select recipe for dyeing

Recipe confirm by D.M / S.P.O

Dyeing

Post treatment

Unload

Vat Sulpher Disperse

Direct Acid Basic Reactive Optical whitener

MACHINE DESCRIPTION

DYEING FLOOR

Dyeing Machines:

The RUPA Fabrics Ltd. There are 14dyeing machines. Among them 5 are sample

dyeing machine and 9 are bulk dyeing machine.The description and specifications of

the machine are given below-

Machine Type 01

Name of the machine : Sample Dyeing Machine

Brand Name : Fongs

Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD.

Capacity : 10 Kg

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Hydraulics Test Pressure : 540 KPa

Design pr. : 350 KPa

Design temp. : 1400C

Machine Type 02


Brand Name : Fongs


Capacity : 30 Kg




Machine Type 03


Brand Name : Fongs


Capacity : 10 Kg




Machine Type 04


Brand Name : Fongs


Capacity : 30 Kg




Machine Type 05

Name of the machine : Sample Dyeing Machine (ALLFIT – 1T)

Brand Name : Fongs


Capacity : 120 Kg




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Machine Type 06

Name of the machine : Winch Dyeing Machine (Innoecology)

Brand Name : Brazzoly

Manufacturer :Italy

Capacity : 1000 Kg




Machine Type 07

Name of the machine : Winch Dyeing Machine (ECO -1T)

Brand Name : Fongs


Capacity : 250 Kg




Machine Type 08

Name of the machine : Winch Dyeing Machine (ECO – 2T)

Brand Name : Fongs


Capacity : 500 Kg

Hydraulics Test Pressure : 1100 KPa (Shell)

Design pr. : 700 KPa (Shell),ATM KPa (tube)


Machine Type 09


Brand Name : Fongs


Capacity : 750 Kg


Design pr. : 700 KPa (Shell),


Machine Type 10


Brand Name : Fongs


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Capacity : 1000 Kg




Machine Type 11


Brand Name : Fongs


Capacity : 1500 Kg




Machine Type 12

Name of the machine : Winch Dyeing Machine (HSJ -1T)

Brand Name : Fongs


Capacity : 280 Kg


Design pr. : 700 KPa (Shell)

Design temp. : 1700

Machine Type 13


Brand Name : Fongs


Capacity : 560 Kg




Machine Type 14


Brand Name : Fongs


Capacity : 840 Kg




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Image of dyeing machine

Pretreatment Process of SCOURING/ BLEACHING:

Fabric Load

↓

Chemical Dozing

(Detergent+Anticreasing+Stabilizer+Sequstering) at 50 0C (5 min)

↓

Caustic Soda 500C (10min)

↓

H2O2 700C (5min)

↓

Run time at 98 0C (60min)

↓

Cooling at 780C

↓

Scouring sample check

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↓

Hot Wash 900C (Acetic Acid + H2O2 killer + Sequestering agent) at 90

0C (10min)

↓

Normal Wash

↓.

Acetic Acid at 550C (10min)

↓

PH check (Acceptable Range 4.5-5.5)

↓

Enzyme at 550C (60min)

↓

Sample Check

Process for COTTON FABRIC DYE:

Fabric Load

↓

Chemical Dozing

(Detergent+Anticreasing+Stabilizer+Sequstering) at 50 0C (5 min)

↓

Caustic Soda 500C (10min)

↓

H2O2 700C (5min)

↓

Run time at 98 0C (60min)

↓

Cooling at 780C

↓

Scouring sample check

↓

Hot Wash 900C (Acetic Acid + H2O2 killer + Sequestering agent) at 90

0C (10min)

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↓

Normal Wash

↓.

Acetic Acid at 550C (10min)

↓

PH check (Acceptable Range 4.5-5.5)

↓

Enzyme at 550C (60min)

↓

Sample Check

(If OK)

↓

Levelling Agent at 550C (5min)

↓

Run time 5 min

↓

Salt dosing at 550C (10min)

↓

Run time 5 min

↓

Color dosing at 550C (30min)

↓

Run time 10 min

↓

Salt sample check

↓

Soda dosing at 550C (40min)

↓

Run time 10 min

↓

Temp raise to 600C

↓

Sample check

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Process for POLEYSTER FABRIC DYE:

Fabric Load

↓

Chemical Dozing

(Detergent+Soda ash) at 90 0C (10 min)

↓

Wash

↓

Acetic Acid

↓

PH check ( range 4.5)

↓

Levelling Agent

↓


↓

Run time 5 min

↓

Temp up 1300C (maintain 1.5 C/min)

↓

Run time 40 min

↓

Cooling at 780C (maintain 1.5 C/min)

↓

Color sample check

↓

Bath drain

↓

Reduction (detergent+caustic soda+hydrose) at 900C (100min)

↓

Normal hot wash at 700C (10min)

↓

Acedic acid

↓

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Wash at 600C (20min)

↓

Fabric unload

Process for VISCOSE FABRIC DYE:

Fabric Load

↓

Chemical Dozing

(Detergent+Soda ash) at 90 0C (20 min)

↓

Cooloing Wash at 70 C

↓

Normal hot wash at 70 0C (10 min)

↓

Acetic Acid

↓

PH check ( range 6)

↓

Levelling Agent at 400C (5 min)

↓

Run time 5 min

↓


↓

Run time 5 min

↓

Salt dosing at 40 0C (15 min)

↓

Run time 10 min

↓

Soda dosing at 50 0C (25 min)

↓

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Run time 30 min

↓

Color steam at 600C (10 min)…..

↓

Color sample check

↓

RSK hot wash at 700C (10 min)

↓

Acedic acid

↓

Wash at 600C (20min)

↓

Fabric unload

Flow chart of Rema Turquoise Color dyeing:

Fabric Loading

Levelling+Anticreasing+Sequestering

Dosing at 60˚c for 5 mins.

↓

Run time at 60˚c for 10 mins.

↓

Dyes stuff dosing at 60˚c for 40 mins.

↓

Run time at 60˚c for 10 min

↓

Half Salt dosing at at 60˚c for 15 mins.

↓


↓

Rest Salt dosing at 60˚c for 15 min

↓


↓.

Temp. Raise to 90˚c (Maintain at at 1.5˚c/min)

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↓

Run time at 90˚c for 20 mins

↓

Cooling to 60˚c

↓

20% soda dosing at 60˚c for 20 mins.

↓

Run time at 60˚c for 10 mins

↓

Rest Soda dosing at 60˚c for 15 mins

↓

Color steam at 60˚c for 10 mins…..,80˚c for 10 mins……

Flow chart of White fabric dyeing:

Fabric load

↓

Wet Fabric

↓

Drain

↓.

Fill water

↓

Acid

↓

Ph check-(4-4.5)

↓

Enzyme at 60˚c for 60 min

↓

Enzyme hot at 90˚c for 10 min

↓

Scouring & bleaching at 98˚c for 90 min

↓

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Syno color at 60˚c for 30 min (dosing)

↓.

Runtime time at 98˚c for 20 min

↓

Sample check-

↓

Color out

↓

Color hot wash at 80˚c for 10 min

↓

Acid at 60˚c for 20 min

↓

Softener at 45˚c for 20 min

↓

Rinsing

↓

Unload

↓

Drain

Dyeing Machine:

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Image of dyeing M/c

Common dyeing faults with their remedies:

Uneven dyeing:

Causes:

- Uneven pretreatment (uneven scouring & bleaching).

- Improper color dosing.

- Using dyes of high fixation property.

- Uneven heat-setting in case of synthetic fibers.

- Lack of control on dyeing m/c

Remedies:

- By ensuring even pretreatment.

- By ensuring even heat-setting in case of synthetic fibers.

- Proper dosing of dyes and chemicals.

- Proper controlling of dyeing m/c

Batch to Batch Shade variation:

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Causes:

- Fluctuation of Temperature.

- Improper dosing time of dyes & chemicals.

- Batch to batch weight variation of dyes and chemicals.

- Dyes lot variation.

- Improper reel speed, pump speed, liquor ratio.

- Improper pretreatment.

Remedies:

- Use standard dyes and chemicals.

- Maintain the same liquor ratio.

- Follow the standard pretreatment procedure.

- Maintain the same dyeing cycle.

- Identical dyeing procedure should be followed for the same depth of the

Shade.

- Make sure that the operators add the right bulk chemicals at the same time

and temperature in the process.

-The pH, hardness and sodium carbonate content of supply water should

check daily.

Roll to roll variation or Meter to Meter variation:

Causes:

- Poor migration property of dyes.

- Improper dyes solubility.

- Hardness of water.

- Faulty m/c speed, etc

Remedies:

- Use standard dyes and chemicals.

- Proper m/c speed.

- Use of soft water

Crease mark:

Causes:

- Poor opening of the fabric rope

- Shock cooling of synthetic material

- If pump pressure & reel speed is not equal

- Due to high speed m/c running

Remedies:

- maintaining proper reel sped & pump speed.

- Lower rate rising and cooling the temperature

- Reducing the m/c load

- Higher liquor ratio

Dye spot:

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Causes:

- Improper Dissolving of dye particle in bath.

- Improper Dissolving of caustic soda particle in bath.

Remedies:

- By proper dissolving of dyes & chemicals

- By passing the dissolved dyestuff through a fine stainless steel mesh

Strainer, so that the large un-dissolved particles are removed

Wrinkle mark:

Causes:

- Poor opening of the fabric rope

- Shock cooling of synthetic material

- High temperature entanglement of the fabric

Remedies:

- Maintaining proper reel sped & pump speed.

- Lower rate rising and cooling the temperature

- Higher liquor ratio

Softener Mark:

Causes:

- Improper mixing of the Softener.

- Improper running time of the fabric during application of softener.

- Entanglement of the fabric during application of softener

FINISHING

Finishing:

The making of a marketable and consumer usable textile is not completed after fabric

production dyeing or printing operation. Fabrics usually still need to undergo an

additional processing known as finishing, which is the final processing before the

fabric is cut into apparel or made into any articles of textiles. Finishing is what

improves attractiveness and makes fabrics suitable for their intended end use.

Machine Description for Finishing Section:

Finishing section is consisting of two lines. They are –

A. Tube line

B. Open line

A. The machine that are used for open line are given bellow –

Slitting and Dewatering machine.

Stenter machine

Compactor machine

B. The machines that are used for tube line are given bellow –.

Dewatering machine

Dryer

Compactor machine

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Process flow Chart for Finishing Section:

Finishing

Open Finish Tube Finish

Slitting and Dewatering Dewatering

Stentering Drying

Compacting Soft setting

↓

Inspection Compacting

Delivery Inspection

Delivery

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DEWATERING MACHINE: (M/C Specification)

Working principle :

After completing the dyeing process from the dyeing m/c then the fabrics are

Ready for de-watering. In de-watering m/c tubular fabrics are mainly processed.

There is a magnetic sensor which scene the twist of the fabric and its direction and

turn the fabric in opposite direction to remove twist automatically. Here dewatering is

performed De-watering is the process to remove the water from the fabric

completely by squeezing and it is done by the padder. A suitable expander is used

before the fabric is passed through the nip of the padders, which expands the fabric

flat wise and adjust the width.

The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%, Lacoste-40% wider

than the required width. There is a pair of rubber coated padder, where water is

removed from fabric when passed through the nip of it.

Normally squeezer contain single or double padders where,

One for removing water and

Other for applying finishing chemicals such as softener.

But this finishing is done only for the tubular fabric. Open widths knitted fabrics are

applied finishing treatment later in stenter.

Here present the compressor which given compress air to form ballooning before

passing through the padder. This balloon remove crease mark but not form the

maximum balloon otherwise shrinkage increase.

In feed & out feed traverses which present in albatross control the following functions

by over feeding system.

Machine name : Dewatering

Brand name : CORINO

Country : ITALY Power(max) :26kw

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Function:

Reduce water content.

Apply chemicals.

Apply over feed to give some compaction.

Open the fabric from the rope form.

Width wise stretch the fabric.

Plait the fabric.

To control the crease mark of the fabric.

To control the length of the fabric

Operational parameter:

Speed: As much as possible (40-60 m/min). Higher the GSM lower the speed.

Over feed: As required. Higher the GSM higher the over feed.

Padder pressure: 1-1.5 bar as required. Higher the GSM lower the padder

pressure.

Width: Fabric width is adjusted as per required width.

Different parts of dewatering m/c:

N.B: Helot contains two baths. One for padder bath and another for softener bath

where softener given 1 g/l. The softener bath capacity is 80 liters.

Maintenance during operation: Proper balloon form by compressor air other wise

crease mark appears.

Padder contract point adjusts perfectly according to the fabric

construction otherwise accurate water will not remove.

Albatros must be clean every one or two hours later.

N.B: This Data’s are varied depending upon the Gray G.S.M and Finished G.S.M and

also on the dia of the fabric. All this parameters are suitable for G.G.S.M range

140~160 to get Finish G.S.M 170~185 without Lycra Fabric. All This data’s are

practiced in mills which may varied factory to factory.

DRYER MACHINE: (M/C Specification)

Fuel combustion chamber:

Fuel- Natural gas

Fuel pressure-7.2m bar

Capacity-300kw

Voltage-240/400v

Frequency-50Hz

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Image of dryer

Working principle of dryer:

After de-watering then the fabric through the dryer.

The main function of the dryer is given below,

To dry the fabric.

To control the overfeed system.

To control the vibration which increase the G.S.M.

This machine contains two chambers. Two mesh endless conveyors are placed

lengthwise to the chamber named conveyor net and filter net, each chamber contain a

burner, which supply hot air .This hot air is guided through the ducting

line by suction fan .There are nozzles placed in between filter net and conveyor net.

When the fabric pass on the conveyor net, hot air is supplied to the wet fabric to dry

it. There are exhaust fan which such the wet air and deliver to the atmosphere through

the ducting line.

The speed of the dryer depends on the temperature of the m/c & the G.S.M of the

fabric. If the m/c temp.is high then m/c speed also high and the m/c temp. is low then

m/c speed also low . The vibration speed of the m/c for heavy fabric is 730 m/min and

normal fabric is 480 m/min.

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The temp.is different chambers according to the shade of the fabric –

Shade Chamber-1 Chamber-2

Light 1200c 130

0c

Medium 1350c 140

0c

Deep 1500c 170

0c

Operating parameters:-

Temperature:-Set the temperature between 1200c -130

0c for white and 150

0c

-1700c for color fabric. GSM temperature Or, moisture content

temperature

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

Set the speed as much as possible (6~20m/min). GSM speed

Special feature of Steam dryer:

Steam dryer (two chambers).

Vibration occurs in heating zone.

Process air pressure switch present.

Maximum temp. Increase up to 1700c.

Steam control switch present.

Two burners present.

Two conveyor belts are present.

N.B: For Polyamide: Temp range is 1100C~ 115

0C.Speed range16~18: Overfeed

range- 5%. This Data’s are varied depending upon the Gray G.S.M and Finished

G.S.M and also on the dia of the fabric. All this parameters are suitable for G.G.S.M

range 140~160 to get Finish G.S.M 170~185 without Lycra Fabric.

Following tings are also considered incase of Dryer machine:

If fabric is redder than the standard one, then reduce the temperature.

If fabric is more Yellowier than the standard one, then increase the temperature.

If fabric is more Bluer than the standard one, then increase the temperature.

All this data’s are practiced in mills which may vary factory to factory.

COMPACTOR MACHINE: (M/C Specification )

Tube Compactor:

Machine name – NavisTube Tex

Brand name –PAK-NIT

Country – U.S.A

Manufacturing Year – 2009

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Working principle:-

The main object of compactor is to make the fabric surface smooth, to control the

residual shrinkage, G.S.M and if required fabric width also. To control the residual

shrinkage the fabric is previously shrinkage artificially by gathering of loops of

knitted fabric and it is set by heat and pressure. In tube compactor, the dried tubular

knitted fabric is face to steam when it passed through the Teflon coated conveyor belt.

When a cotton fabric absorbs water, it swells and shrinks (particularly in length

direction) because the absorbed water allows the cellulose chains to move relative

stain free position. Then the fabric is passed through the

Expander. This m/c contains two compaction units to compact both side of the tubular

fabric. Each unit contains a hot rotating cylinder, blanket which rotate in contact with

the cylinder and Teflon cover .while passing the expander roller, the fabric is over

feeded. The fabric is compacted with the pressure of blanket and Teflon cover while

passing through the hot cylinder .Due to compaction stitch length is reduced. Then the

fabric is passed through the counting device .Before packing, the fabric is inspected

carefully.

Operational parameter:-

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

Set the overfeed % as required; to increase GSM, overfeed

need to increase to a certain limit.

Function:

Shrinkage control

GSM control

Width control

Special feature of Santex –ag Compactor:

Operating system is computerized.

Steam bar present which soften the fabric for compacting.

In compacting zone, edge & retard roller, compacting shoe and

steel plates are present.

A pair of pulley present for fabric dia control.

Fabric G.S.M, shrinkage and dia control.

Following things are also considered incase of compacting machine:

If fabric is less Reddish than the standard one, then increase the

temperature, reduce steam.

If fabric is less yellowish than the standard one, then increase the

temperature, without steam.

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If fabric is less Bluish than the standard one, then reduce the

temperature, increase steam.

N.B: Overfeed Steam G.S.M

Overfeed Steam Stretch G.S.M

Teflon speed (+) – More compaction

Teflon speed (-) – Less compaction, G.S.M because overfeed is less.

N.B:

To remove twisting the tube fabric may be heat set before compacting.

For Viscose with Lycra more overfeed required.

All this data’s are practiced in mills which may vary factory to factory.

Open Compactor:

Function:

To control shrinkage.

To control width.

To control GSM.

To smooth fabric.

Heat seating of fabric for Lycra.

Important parts

- Over feed roller.

- Expander.

- Blanket(2)

-

Operational parameter:

-Set the temperature at 120 °C (as required)

-Set the speed as much as possible (15-25 m/min).GSM m/c speed.

Machine name – Open compactor

Brand name – FERRARO

Country – Italy

Manufacturing Year – 2009

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-Set the overfeed % as required; to increase GSM, overfeed need to increase

to a certain limit

Image of open compactor

SLITTING AND DE-WATER MACHINE: (M/C Specification)

PASSAGE DIAGRAM OF CORINO SLITTING MACHINE:

Brand name-EMC

Country- Italy

Year of manufacturing-2009

Velocity maximum-90m/min

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Working principle:

The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After

dyeing completed and falling of water from fabric the fabric is fed in slitting m/c. So

it is necessary to remove some water initially for the case of further processing in this

m/c. The initial squeezer does this work. The de-twisting unit removes twists that may

present in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation

drum and 2 feeler rollers with sensors. By these rollers it detects twist in fabric and

removes by rotating rope fabric in opposite direction. Before slitting there is a blower

which blows air to open the tubular fabric & makes it easy to pass over cigger. The

cigger can be extended in circumference and opens the tubular fabric in full

circumference. Slitting is done by using open mark detecting golden eye by around

knife. Then the fabric passes through the padder where washing or chemical treatment

is done. Squeezer is used to remove 60-70% of water. After removing water width is

controlled by stretcher and fabric is delivered by folding device.

Operational parameter:-

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

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

Function of the Machine:

Used to remove excess water after pretreatment and dyeing

To slit the tube fabric by the knife for opening of the fabric and ready

for stentering

Delivered fabric in crease free state

Before squeezing balloon is formed with the help of compressed air

passing by a nozzle or air sprayer

It can control the diameter of fabric and GSM and shrinkage by over

feeding mechanism

STENTER MACHINE: (M/C Specification)

Brand name - EMC

Country of origin -TURKEY

Manufacturing date-: 2009

Maximum Speed - 100m/min

Chamber – 7

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Working Principle:

Stenter Machine is generally used to finish the open fabric. This stenter

machine consists of six chambers; each contains two burners, two blowers, two

ducting line, nozzles and suction fan attach with the suction line. The burner produces

hot flue gases which guided though the ducting line by the help of blower. There are

nozzles placed above and bellow the rail. When the fabric passed through the rail,

then hot air is sprayed to the above and bellows the fabric with the help of nozzle. The

hot air is circulating in the chamber and the moisture in the fabric is evaporated,

which leave the chamber with the help of suction fan through the ducting line.

Temperature of each chamber can control automatically by controlling the intensity of

burner. Generally lower temperature is maintained the first and last chamber then

other chambers.

The speed of the fabric is maintained according to the moisture content of the fabric.

After passing the fabrics to all the chambers, the fabric is collected for compaction.

The performance of the stentering range depends on proper introduction of the cloth

into the machine. The finer the fabric is being processed, the greater the significance

of the correct, crease free and fault free fabric introduction. In stenter m/c the fabric

first passed through different rollers including weft straightening device, uncurling

device for proper feeding of the fabric into the machine. Then it passed through the

selvedge detector which detect the selvedge and adjust the rail for proper gripping the

fabric in the pin arrangement. This stenter m/c consists of both pin and clip

arrangement. The fabric first grip by pin and gust before entering the chamber, pin are

locked by clip arrangement. To maintain proper dimension of the fabric, length wise

overfeed and width wise tension is given to the fabric.

Important parts:

- Burner - Suction Fan

- Exhaust air fan - Nozzle

- Over feed roller. - Chain arrangement

Function:

- Drying

- Shrinkage control

- Heat setting

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- Width control

- Finishing chemical application.

- Loop control

- Moisture control, etc.

Fig:Stenter Machine

Different sections of Stenter Machine:

A. Padder Section:

In the padder section the fabric is treated with chemicals specially with softener and

acid in two tanks. Each chemical tanks contains-

FOR POLYESTER: Arristan PSR (Softener) - 10kg

+ Acetic Acid (acid) – 200gm 100 liter water

or

Aqua IC (Softener) – 10 kg

+ Acetic Acid (acid) – 200gm 100 liter water

FOR COTTON: (COLOR):- Gemsol ASEM 20P - 10 kg

Reaknitt –FF - 7 kg 100 liter water

MgCl2 - 3 kg

Acetic Acid - 200gm

FOR COTTON: (WHITE):- Tubengal SMF - 10 kg

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Arristan 64 - 3 kg

MgCl2 - 3 kg 100 liter water

Acetic Acid - 200g

B. Weft Straightner:

The main function of Weft Straightner is to control the bowing & Skewnesss of the

fabric.

C. Width Setting Chamber:

This Chamber control the width of the fabric by clip of 10 pin.

D. Heating Chamber:

This chamber controls the shrinkage and the G.S.M of fabric.

Temperature Range: Cotton-- 1500C~170

0C.

Polyester- 1650C ~ 185

0C.

With Lycra - 1750C ~ 190

0C.

E. Cooling Chamber:

This chamber cooled the hot fabric before reach to delivery zone.

F. Exhaust Motor:

This specific part used to exit the steam produced in the chambers and also exit the

extra temperature from the machine.

G. Delivery Zone:

This zone delivered the fabric in a folded form. In this zone the fabric has to

Pass through several rollers in order to prevent the formation of crease mark in the

finished fabric.

Parameters Used For Different Constructed Fabric :

For Polyester Fabric:

Fabric Type

Overfeed %

Temperature0C

Speed

(m/min)

Stretch (%)

Inch

Light

Color

Deep

Color

Depend on

fabric G.S.M

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Single Jersey 5 % to 10%

1750C

1550C

14~15

Single

Lacoste

45 % to 50%

1750C

1600C

14~15

Depend on

fabric G.S.M

Polo Pique

45 % to 50%

1700C

1600C

18~20

Depend on

fabric G.S.M

Interlock

0 % to 15%

1800C

1650C

16~18

Depend on

fabric G.S.M

For Cotton Fabric:

Fabric Type

Overfeed %

Temperature0C

Speed

(m/min)

Stretch (%)

Inch

Light

Color

Deep

Color

Single Jersey

60 % to 75%

1650C

1600C

15~17

3~4

Single

Lacoste

60 % to 70%

1650C

1600C

14~15

2.5~3.5

Polo Pique

60% to 65%

1650C

1600C

14~15

2~3

Interlock

60 % to 70%

1700C

1550C

12~14

2

Rib

60 % to 70%

1650C

1500C

12~14

2

N.B: All this data’s are suitable for this machine only. All this parameters are suitable

for. Grey G.S.M range 140~160 to get Finished G.S.M 170~185 without Lycra

Fabric

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N.B: If fabric is less Redder than the standard one, then increase the temperature,

reduce steam.

If fabric is less Yellowier than the standard one, then increase the

temperature, without steam.

If fabric is less Bluer than the standard one, then reduce the temperature,

increase steam.

N.B: Polyester rib fabric is finished in tube form. All this data’s are practiced in mills

which may vary with the change of fabric type. The quality assurance department is

assigned to maintain consistently uniform quality of the material; in process and

various stages of its manufacturing.

GARMENTS

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Image of a Garments M/c

The garment production processing steps and techniques involved in the

manufacturing garments for the large scale of production in industrial basis for

business purposes is called garments manufacturing technology.

Garments Manufacturing Process: Stepwise garments manufacturing sequence on

Rupa Fabrics Ltd is given below:

Design / Sketch

Pattern Design

Sample Making

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Production Pattern

Grading

Marker Making

Spreading

Cutting

Sorting/Bundling

Sewing/Assembling

Inspection

Pressing/ Finishing

Final Inspection

Packing

This is the Basic Production Flowchart of a Garment. In advance some of the process

can be added or removed.

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Image of Piping Ribbon

Image of Neck Rib by over lock M/c

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Image of servicing ribbon

Image of servicing by over lock M/c

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Image of Piping by Over lock M/c

Image of Swing Operation

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Image of Servicing

Image Body Attaching

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Image Neck Joining

Image of attaching mobilen tap

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Image of Piping by feed of the M/c

Image piping by over lock M/c

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Image Sleeve Joining

Image of Button Attaching

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Quality Assurance System

Quality Control: Mainly this factory follows ISO Standard. But testing Standard

depends on buyer requirements.

List of Equipments:

Computer

Light box

Electric Heater

Sample Dyeing M/C

Electrical Balance

pH meter

G S M Cutter

Washing M/ C

Shrinkage & Spirality measurement instrument

Quality Assurance Procedure: Quality assurance Procedure may be divided two major

Parts:

1. Online quality Control

2. Offline System Control

Objects of quality control:

Research.

Selection of raw materials.

Process control.

Process development.

Product testing.

Specification test

Scope of Quality Control, Quality Assurance and Testing:

Testing Lab

Machine-Auditing System

A good Training System

Technical Expertise

On Line test:

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G S M of the fabric

Exact Diameter and Width

Grey Fabric Inspection

Shade Check

Bias and Bowing

Visual Appearance (Enzyme Performance)

Off Line Test:

All the off line tests for finished fabrics can be grouped as follows –

Physical Test and

Chemical Test

Physical Test:

Finished Fabric Dia

G S M of Fabric

Rubbing Fastness

Pilling Test

Diameter and Width

Light Fastness test

Course Per inch

Wales per inch

Finished Fabric dia: In Knit, dyeing finishing, finished diameter is Very important

factor. It should be kept as the buyer requirements. Simply a measuring tape measures

it. Finished diameter is controlled at compacting m/c.

G S M Test: G S M is the most important factor. There is a G S M Cutter. The Sample

cut by this weighted in the electronic balance. The reading (gm) from the balance

multiplied by 100 to get Value of G S M.

Rubbing Fastness test:

Purpose: The fastness test to rubbing is used on a Variety of fabrics to evaluate the

transfer of surface from the test fabric when it applied surface friction or rubbed

against a rough surface.

Rubbing fastness test is determined by Crock meter. The test fabric is clamped in the

plate of the crock meter. A standard fabric is used for rubbing the test sample. `0

cycles are given manually by a handle. Then the standard fabric is assessed with the

help of the grey scale. The scale is graded from 1 to 5, being the Poorest and 5 being

and 5 being the best.

Pilling Test: Generally, pilling test is applicable for fabric with synthetic fabric. This

test is carried out in pilling box. A Sample of 10 cm x 10 cm is sewn round a rubber

tube. Then the tube in the Pilling box and the door of it is closed. Then the meter is set

for 14400 cycles. After the cycle is completed, the fabric is assessed by a special grey

scale. The grey scale is provided Pilling box.

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Light fastness test:

Purpose: Light fastness is the test design to evaluate the laundering fastness test of

dyeing, Pigment which re to be made in comparison of result obtained on many test

pieces treated under light.

Method: ISO

Apparatus:

1. Light fastness tester & blue scale

2. scale

3. scissor

4. hard paper

5. 11cm X 4.5 cm

Procedure: At first, we took the blue woolen cloth & test sample. The blue woolen

clothes were dyed with acid blue, 104,109 etc. Then we cut the woolen cloth &

sample according to template. The blue woolen cloth is cut to make standard &

sample is cut to test light fastness. Then we put the holder of woolen cloth and sample

in the set of machine and set the time, which was 24 hrs. After completing the process

we get the slandered test result. Then we compared with the standard rating.

Standard Rating

8 Fast

7 Fast

6 Average

5 Average

4 Average

3 Average

2 Not fast

1 Not fast

Result: The test result of light fastness test is equivalent to the class of standard 6.So

we can say that the color fastness of dyed fabric is average.

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Chemical Test:

Shrinkage and Spirality or Twisting

Fastness to wash

Fastness to Perspiration

PH test

Wash fastness Test:

Purpose: The resistant of color of my dyed or printed material to washing is known as

Wash fastness.

The test fabric is sewn with multifibre such that two multifibre strip remain at the

both side of the test fabric. Then they are washed with the following recipe:

Liquor Ratio: 1:50

5 gm fabric + 250 cc water + 4 g/l detergent + 1 g/l sodium perborate +10Steel balls.

Washes with: 40º c x 30 min

Then the multifibre is detached from the test fabric. It is dried and wash fastness is

assessed by grey scale.

Color Fastness to Perspiration:

Purpose: To assess the degree of change of shade or cross staining due to Perspiration.

Method: ISO

Reagent: Acidic Solution:

L Histadine monohydrochloride monohydrate 0.5 g/l

NaCl 5g/l

Sodium Di– Hydrogen Orthophosphate dehydrate 2.2 g/l

Reagent: Alkaline Solution:

L Histadine monohydrochloride monohydrate 0.5 g/l

NaCl 5g/l

Di – Sodium Orthophosphate dehydrate 2.5 g/l

Temp 37º C

Time 4hr

Multifibre 4cm

Water 1000ml

Test Specimen: Fabric (4x 10) cm

Procedure: (Alkaline Perspiration)

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Keep the specimen in contact with S.D.C multifibre stripe of (4x10) cm

Allow the Specimen to soak for 4hr min

Place the specimen glass slide and lightly scrap of with a glass rod.

Place the specimen indicator for hrs at 37º C. Then remove from incubator

Open out keep sometime in open air.

Repeat the same process with another specimen using the acid solution.

Assessment: Assess the change in color of each specimen and the staining of the

multifibre strip using the grey scale.

Report: Record the change in color of each specimen and & the staining of the

individual components of the multifibre adjacent fabric separately for both the acid

alkaline test.

PH Check:

Purpose: To fulfill the buyer requirements to keep the pH of the fabric as Per

standard.

Method: ISO

Procedure:

Take many Pieces of 10 gm sample

Take 250ml of distilled water (pH – 5.5 to 7.5) in Conical Flask.

Shake them for 10 min in normal temperature.

Temp:95 º C

Standard pH range for colored fabric 6 to 8

Standard pH range for colored fabric 5 to 8.

Shrinkage and Spirality Test: Shrinkage and Spirality both are very important for

Control the quality of fabric.

Buyer’s requirements:

Template size: 50cm & 50cm

Shrinkage: length wise--- 5%

Width wise----5%

Spirality: Left -------- 5%

Right -------- 5%

Procedure:

At first take two ply of fabric & put the template (50cm) on to the fabric. The

template has 8 holes. Both length & width wise the template holes can measure 50 cm

at 3 places.

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Then we mark the 8 holes by permanent marker & also at the edges of the template.

Then sewn the fabric & it is given to the washing m/c for run at 60°C for 60minutes

with water. After that dry the sample & then measure the fabric

Spin speed --- 500rpm

Drum speed--500rpm

Calculation:

Shrinkage Test:

Lengthwise:

After wash – Before wash

= ----------------------------------×100

Before wash

Width wise:

After wash – Before wash

= ----------------------------------×100

Before wash

Spirality test:

= M)&Hfor th Length(wid

2

sideRight sideLeft

× 100 %

Quality Control: Mainly this factory follows ISO Standard. But testing Standard

depends on buyer requirements.

Remarks: Quality Control is the most important department in every Textile industry.

It is strongly recommended that the Quality should be maintained as exactly the

buyer’s requirements.

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MAINTENANCE

Maintenance:

The act which is done to Keep the factory plan equipments machine tools etc. in an

optimum working condition, minimize the break down of m/c's to improve

Productivity of existing m/c tools and avoid sinking of additional capacity and to

Prolong the useful life of the factory plant & machinery is called Maintenance.

Objectives of Maintenance:

To Keep the factory Plants, equipments, Machine tools in an optimum

working condition.

To ensure specified accuracy to product and time schedule of delivery to

customer.

To keep the downtime of Machines to the minimum thus to have control over

the production Program.

To Keep the Production cycle within the stipulated range.

Preventive Maintenance:

In Rupa Fabrics Ltd the Preventive Maintenance is a predetermined routine

activity to ensure on tome inspection or checking of facilities to uncover conditions

that may lead to Production break downs or harmful depreciation.

Break down Maintenance:

Maintenance

Preventive Maintenance

Mechanical

Maintenance

Electrical

Maintenance

Break down

Maintenance

Electrical

Maintenance

Mechanical

Maintenance

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In this case, repairs made after the equipment is out of order and it can not

perform its normal functions.

Rupa Fabrics Ltd. follow the above two types Maintenance.

Maintenance Tools & Equipments and their functions:

Combination tools (Spanner)

Function: Tightening & Loosening of Nuts & bolts.

Socket Ratchet set

Function: Tightening of Nuts & bolts.

Slide Range

Function: Tightening & Loosening of Nuts & bolts

Pliers

Function: Tightening & Loosening of Nuts & bolts

Pipe threat Cutting Tools

Function: To Cut the threat in Pipe.

Bearing Puller

Function: To assist the Opening of bearing from shaft.

Pipe Range

Function: Tightening & Loosening of Pipe Joint

Pipe Cutting Tools

Function: For Pipe Cutting.

Hole Punch

Function: Punching the hole.

Divider

Function: For circle marking on metal & wood

Easy Opener

Function: To open the broken head bolt

Heavy Scissor

Function: Cutting of gasket & steel sheet

.

Oil Can

Function: Oiling of moving Parts.

Drill M/C and Drill bit.

Function: For Drilling.

Grease Gum.

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Function: For greasing of moving Parts of M/C

Girding M/C

Function: For grinding & Cutting of mild steel.

Welding M/C

Function: For welding & Cutting.

File

Function: For Smoothing the Surface.

Hammer

Function: For Scaling & right angling.

Hacksaw blade.

Function: For metal Cutting.

Handsaw (wood)

Function: For wood Cutting.

Grinding Stone.

Function: For smooth finishing

Grinding Paste

.Function: For easy Cutting of metal

Maintenance Procedure:

Normally Preventive Maintenance is done here. During Maintenance Procedure

following Point should be checked:

Maintenance: Mechanical

Machine: Dyeing M/C

Serial Item need to be checked & Serviced

1 Creasing the winch bearing

2 Complete cleaning of Machine

3 Cleaning of drain Valves, replace scales if required

4 Check air supply filters, 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 of main vessel level indicator

10 Check the oil level of Pump bearing and refill if required

11 Check the function of heat and cool modulating valves

12 Check all belts and belt tension

Maintenance: Electrical

Machine : Dyeing

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Serial Item needed to be checked and serviced

1 Check & Clean fluff and dirt at all motor fan covers

2 Check all motors

3 Check Main Panels boards

4 Check Panels Cooling fan & clean it filter

5 Check all circuit breaker , magnetic contractors and relays

6 Check Main Pump inverter and its Cooling fan

7 Check Current setting of all circuit breaker & motor over Loads

8 Visual Checking of all Power & Control & Cables

9 Check all Pressure switches

10 Check Calibration of Main vessel

11 Check DC drive of kneel motors

12 Check Calibration of all additional tank

13 Check all Pneumatic solenoids

14 Check Calibration of Heating / Cooling

15 Check setting & operation of lid safety switches

16 Check all emergency switches

16 Check all indicating Lamps

17 Check all On / Off switches

18 Check all Signal isolators

19 Check Key Pad & display of Controller

20 Check Proximity Switches

Remarks: When I was trainee of Rupa Fabrics Ltd. then I saw that the Maintenance

staffs and overhead of Maintenance department were skilled enough and efficient.

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Utility Service

Utility Facilities Available:

Utility Source Steam Boiler

Gas TITAS

Compressed air Compressor

Electricity PDB & Generator

Temp.Control AC chiller

Capacity and Other Technical Details:

Power (Electricity):

Generator house is the main Power Producing Plant of Rupa Fabrics Ltd. there are

two Generators in Generators house. Specifications of two Generators are given

below:

Specification of Generator

Image of Gas Generator

Boiler

Equipment Name : Gas generator

Nos. : 02

Manufacturer : Waukesha Power Systems

Model : UHP 7100GSID

Volts : 415/24 hr

RPM : 1000

Generator : 02

Type : Diesel Generator

Brand Name : Perkins

Origin : India

Model No : 350 – E

Rated Power : 350 KV

Maximum Current : 274 KV

Engine R P M : 1500

Volt : 400

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

boilers in Rupa Fabrics Ltd.

Function: Boiler function is to the heat produced by the combustion of fuel (Gas) to

water and ultimately to generator steam. The steam produced may be supplied in wet

processing department for –

Heating cylinder dryer

Steaming during dyeing

Objects: For supplying steam

Types of steam:

Wet steam

Dry saturated steam, and

Superheated steam.

Specification of Boiler:

Pretreatment of the boiler water:

Boiler feed water needs special standard. Any deviation from the required standard

may result in scale formation, which eventually reduces the efficiency of the boiler.

This ultimately affects the cost of steam generation and makes the production cost

high. To maintain the required standard of the water, there should be some means to

pretreatment that the boiler feed water. To protect scale formation of boiler, NELCO

is used as chemical in water feed tank. 200 gm NELCO is injected per 12 hrs. In Rupa

Fabrics Ltd. there are water softeners that act before the water enters the boiler.

Boiler No : 01

Brand Name : COCHRAN

Origin : Scotland

Type : Fire tube boiler

Max Heat Output : 5678kw

Pressure : 11 bar

Temperature : 188º C

Fuel : Natural Gas

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Image of Boiler

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Safety Management:

Fire removal devices are attached into the wall of every floor. Working or using

principles are attached with it. There are some hoses pipe attached long building.

Image of fire distinguisher

Every floor of this factory contains first aid box where there are some direction given.

There are two well trained person are working in each floor.

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Store & Inventory Cost

Inventory is the stock of goods. It is a vital part of business. It protect against stock

outs. The type of inventory carried in this factory as follows-

Gray fabric : Own knitted or imported

Dyes and chemicals : Local or Imported

Spare parts : Local or Imported

Packing materials : Local or Imported

Finished fabrics : Good or Rejected

Policy of store keeping: Normally first come first out policy can maintain in the

company. Some case supposes according to needs of the company decide their

opinion according to buyers wants.

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Cost Analysis

Cost analysis is the important feature of our garments production. Its starts from yarn

producing period. It’s include with yarn dyeing, knitting, dyeing, garments

manufacturing cost, transportation cost, personnel cost. Then we are service a

production of a company.

There are some points are include of a garments production. These are given below:

1. Name of Buyer

2. Style no.

3. Fabrication

4. Gsm

5. Full Description of item

6. Yarn Price

7. Knitting charge per unit

8. Dyeing per unit

9. Process loss (During Dyeing)

10. Measurement consumption element

T-shirt/Polo Shirt:

Body Length

Chest/bottom width which more wide is the accept

Sleeve length

Pant:

o Total length/out seam

o Half thigh

Costing rule of a garments which are giving below:

Rules of Measurement of a T-shirt/polo shirt:

{Body length + Sleeve + 10 × (Chest + 4) × 2 × Gsm} ⁄ 10,000 ⁄ 1000 × Process loss%

Rules of Measurement of a Pan/trouser:

Total length + 10 × (Thigh + 4) × 4 × Gsm / 10,000 / 1,000 × 12 × Process %

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Merchandising & Marketing

There are two types of merchandising can be run the Rupa FabricsLtd. These are

given as below:

1. Production Merchandising

2. Cost Analysis Merchandising

Production Merchandising:

In this section merchandiser are works to take order and after completion of

ordered goods they arrived to the buyer.

At first they can get invitation notice from buyer. Buyer can sent notice by e-mail,

Fax, meeting place. After invitation merchandiser are meets with buyer. Those are

deciding their own agreement. There are some protocols held at the meeting. At this

time buyer give a sample to the company’s merchandiser. According to agreement of

buyers merchandisers are send the sample to the cost merchandiser to cost analysis.

According to sample satisfaction they can take order hugely for bulk production.

Cost Merchandising:

When garments take a sample cost analysis can be done for sampling by cost

merchandiser. Cost merchandisers are costing for a piece of garments. Then garments

decide to bulk production according to garments piece of buyer.

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Social & Environment information

Effluent Treatment Plant (ETP):

Introduction:

ETP stands for “Effluent Treatment Plant”. Textile industries, particularly the dyeing

component produce wastewater, otherwise known as effluent, as a by-product of their

production. This effluent contains several pollutants, which can be removed with the

help of an ETP.

The outputs from an ETP are normally “clean” water. Effluents from dye houses need

to be treated to produce an effluent that confirms to Bangladesh environmental

standards.

• The outputs from an ETP are normally “clean” water. Effluents from dye

houses need to be treated to produce an effluent that confirms to Bangladesh

environmental standards.

•

• Now I will try to mention some information about of an ETP which is used in

the Rupa knit composite ltd. In Esquire knit composite, conventional ETP is

used.

• The volume of ETP is 110 m3/day

Process Flow chart of Biological Effluent Treatment Plant:

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Function of different Unit of Biological Effluent Treatment

Plant (E T P):

Screening unit: It works like a filter. By filtering waste water, it removes

threads, pieces of fabrics, small metal pieces etc. In this unit a rotating brush is

used for clean the pores if screen. The brush rotates periodically.

Storage and Equalization tank:

Waste Water

Lifting Pump Shump

Storage &

Homogenizing tank

Sedimentation Tank

Return Sludge pump

sump

Sludge Thickener

Screening

Neutralization Tank

De-colorant

Dosing

Land Filter Press

Polyelectrolyte

Dosing

Biological Oxidation Tank

Distributor

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In this unit hot liquid waste to kept cool. Different waste water from varies

process is stored and makes a homogeneous mixture by mixing different

concentration of waste water.

The purpose of equalization for industrial treatment facilities are:

To help adequate pH control.

To minimize the chemical requirements necessary for neutralization 03. To

prevent high concentrations of toxic materials from entering the biological

treatment plant

Neutralization of waste water is performed by dosing 98% H2SO4 as required

to control the PH Of waste water PH range 6.5 to 7.5.

It distributes the water to the biological oxidation tank. Continuous aeration is

supplied here. Antifoam is dosed here to control the foaming in the oxidation

tank.

Biological oxidation tank: It distributes the water to the biological oxidation

tank. Continuous aeration is supplied here. Antifoam is dosed here to control

the foaming in the oxidation tank. It is the heat of E T P. The entire harmful

chemicals are damaged here by breaking their bonds. This is done by bacteria.

To ensure the proper function work and growth of bacteria, few conditions

must be maintained.

Primary clarifier: A primary treatment is intended for removal of floating and

settles able materials i.e. suspended solids and chemical organic matter.

Primary treatment consists of the following treatments;

A. Coagulation - to coagulate the suspended solid to coagulate

• FeSO4

B. Flocculation - to flocculate by coagulants

• Polyelectrolyte

C.Neutralization- to adjust the pH between 6.5 to 8.5

D.Sedimentation- to precipitate small suspended solids.

• All the above processes contribute to removal of substantial amount of all

the polluting parameters.

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• The following chemicals are used in the primary clarifier. Namely:

01. Lime

02. Ferrous sulphate

03. Ferric Sulphate

04. Alum

05. Poly-electrolyte.

Settling tank / Sedimentation Basin:

A tank or basin in which waste water is held for a period of time, during which

the heavier solids settle to the bottom and the lighter material will floats to the

water surface. In this tank sludge is immersed and the harmless water is

discharge to ponds, Land, river etc.

Secondary clarifier: Secondary treatment is carried out to removal

biodegradable organic matters which include removal of BOD and COD &

decomposition of organic matter. Biological treatment can be aerobic and

anaerobic.

Sludge Thickener:

Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge.

After one hour of

Polyelectrolyte dosing aeration is stopped and fresh water discharge to drain

when sludge is taken. The thickened sludge is transferred to the sludge

thickener bed.

Sludge Thickener bed:

Here sludge is dried which is used as good fertilizer as well as fuel of brick

field. Sludge is dried under the sunlight.

Required Chemical of Biological E T P:

H2SO4:

Function: Neutralize the waste water controlling the PH. It is auto dispensed in

the neutralization tank.

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Polyelectrolyte:

Function: Used for sedimentation / sludge coagulation and also killing

bacteria.

De-colorant:

Function: Used for removing color. It is used auto / manually in the

sedimentation feeding tank.

Sodium Hypochlorite:

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

oxidation tank.

Product Quality Checked:

o Biological Oxygen Demand (BOD)

o Chemical Oxygen Demand (COD)

o Total suspended solids

o Total dissolved solids

o Color

o pH etc.

o

Remarks: Waste water from processing industries e g. Dyeing , Printing , Finishing

and washing causes great harmful effect on our environmental, As a result agricultural

land loses its fertility, natural water becomes polluted aquatic life is destructive and

crops are damages.

So, it is important to control ETP plan.

Water Treatment Plant

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Introduction: In a textile processing plant, water is a vital raw material not only for the boilers

supplying steam for heating and drying purpose, but also for the all wet process such

as scouring, bleaching, dyeing, printing and finishing. Water with a high degree of

purity is rarely obtainable from natural source. Supplies of water may be broadly

classified into three groups-

1. Surface water

2. Subsoil water

3. Deep well water

In knit concern limited deep well water is used for wet processing units because water

from deep wells is collected from a considerable depth below the ground. Such water

is generally free from organic matters due to filtration and bacterial action. The

mineral content, however, may be very high because of prolonged contact with

several layers of rocks and soil.

Hardness of water: the presence of salts of calcium or magnesium in water is

responsible hardness of water and leads to the formation of insoluble precipitates with

soap. These may deposit on the goods, thereby assisting soiling and even impairing

handle of the cloth. Usually they are not deposited evenly and is one of the causes if

poor leveling in subsequent dyeing or from complexes resulting in dulling of shades.

Two types of hardness may be distinguished-

1. Temporary hardness

2. Permanent hardness

Temporary hardness arises from bicarbonates and can be removed simply by boiling

when the bicarbonates precipitate as carbonates.

Ca (HCO3)2 CaCO3 + H2O + CO2

It is a contributory factor in the formation of scales in boilers, which is a deposit,

amongst other things, of calcium carbonate and magnesium hydroxide, the latter is a

product of magnesium carbonate.

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MgCO3 Mg (OH) 3 + CO2

Permanent hardness is associated with sulphates and chlorides of calcium and

magnesium. These are highly soluble expulsion of dissolved gases makes no

difference in their solubility. These require chemical treatment for their removal.

Most waters contain both temporary and permanent hardness, but the proportion of

the two varies.

Measurement:

It is possible to measure the level of hard water by obtaining a free water testing kit.

These are supplied by most water softening companies. There are several different

scales used to describe the hardness of water in different contexts.

Parts per million (ppm)

Usually defined as one milligram of calcium carbonate(CaCO3) per liter of

water (the definition used below)

grains/gallon (gpg)

Defined as 1 grain (64.8 mg) of calcium carbonate per U.S gallon(3.79 liters),

or 17.118 ppm

mmol/L (millimoles per liter)

One millimole of calcium (either Ca2+

or CaCO3) per liter of water

corresponds to a hardness of 100.09 ppm or 5.608 dGH since the molar mass

of calcium carbonate is 100.09 g/mol.

Degrees of General Hardness (dGH).

One degree of General Hardness is defined as 10 milligrams of calcium oxide

per litre of water, which is the same as one German degree (17.848 ppm).

Various obsolete "degrees":

o Clark degrees (°Clark)/English degrees (°E)

One degree Clark is defined as one grain(64.8 mg) of calcium

carbonate per Imperial gallon (4.55 liters) of water, equivalent to

14.254 ppm.

o German degrees (Deutsche Härte, °dH)

One degree German is defined as 10 milligrams of Calcium oxide per

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litre of water. This is equivalent to 17.848 milligrams of calcium

carbonate per litre of water, or 17.848 ppm.

o French degrees (°F)

One degree French is defined as 10 milligrams of calcium carbonate

per litre of water, equivalent to 10 ppm.

o American degrees

one degree American is defined as one milligram of calcium carbonate

per litre of water, equivalent to 1 ppm.

Because it is the precise mixture of minerals dissolved in the water, together with the

water's pH and temperature, that determines the behaviour of the hardness, a single-

number scale does not adequately describe hardness. Descriptions of hardness

correspond roughly with ranges of mineral concentrations:

Methods of water softening: There are three ways in which hardness is removed on

industrial scale-

Lime- soda process

Base exchange process

Demineralization process

Very soft: 0-70 ppm, 0-4 dGH

Soft: 70-140 ppm, 4-8 dGH

Slightly hard: 140-210 ppm, 8-12 dGH

Moderately hard: 210-320 ppm, 12-18 dGH

Hard: 320-530 ppm, 18-30 dGH

Very hard >530 ppm, >30 dGH

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In the primitive lime-soda process, hydrated lime and sodium carbonate are added to

precipitate calcium and magnesium ions as compounds of low solubility. The method

is less effective and produces a large amount of sludge. The pH of water also changes

during treatment. The method is not useful particularly for the wet processing

industry.

Both base-exchange and demineralization process are based on exchange of ions by

natural products, zeolites,(Na2O)x(Al2O3)y(SiO2)z(H2O)n or synthetic ion exchange

complexes. In demineralization process, two subsequent exchange process is used,

one for the anions and another for the cations

In WTP of Rupa fabric’sLTD base exchange process is used. In base-exchange

reaction with hard water may be represented as follows:

Ca(HCO3)2 + Na2Z CaZ + 2NaHCO3

CaSO4 + Na2SO4 CaZ + Na2SO4

MgCl2 + Na2Z MgZ + 2NaCl

These reaction virtually go to completion and after hard water has percolated through

a bed-exchange substance, generally presenting granular from (sieved to a particle

size around 1-2 mm in diameter in case of zeolite), the water emerges with a hardness

of 0.2 degree or even less.

Regeneration: However the base-exchange capacity is limited and will eventually

become exhausted. Fortunately the process is reversible and the bed can be

regenerated by passage of a concentrated salt solution.

CaZ + 2NaCl CaCl2 + NaZ

The calcium (or magnesium) chloride and residual sodium chloride are wasted away,

and the regenerated sodium zeolite compound can be used again. The regeneration

can be repeated for a large number of times until the granules break down into

powder.

Advantages:

. It yields water zero hardness.

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. It occupies little space.

. There are no sludge to be deposited off.

. The process is very convenient.

Hardness test: Preparation of reagents-

1. Dissolve properly 1 gram Erichrome Black T indicator in 250

ml methanol.

2. 1 M Ethylene Diamine tetra acetic acid Disodium salt.

- Dissolve properly 262 gram of Ethylene Diamine tetra acetic

acid Disodium salt into 500 ml of distilled water.

TEST: (In Rupa fabric’s LTD)

- At first 10 ml of softened water taken in a beaker.

- Ammonium buffer (1-2ml) solution & Erichrome Black T indicator (1-2

drops) added into it respectively.

- Then prepared EDTA solution drops into it until the color turns from pink

to blue.

- Number of EDTA drop measures the hardness of softened water. For

example if 1 drop is required for color change hardness counted as 10 PPM

and similarly for two drops it will be 20 PPM. We have found, raw water

hardness- 340 PPM And, soft water hardness- 20 PPM.

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Conclusion

Findings At the end of our industrial training we can say that we have successfully completed

our training at KNIT CONCERN Ltd. Every textile student should do their training

attentively and regularly because it minimizes the gap between our theoretical and

practical knowledge. By this industrial training we have gathered the practical

knowledge about different production process, machinery maintenance, industrial

management and the environment of the industry, which will help us in our job life.

The KNIT CONCERN Ltd. management helped us a lot about our inquiry.

Limitations of the report:

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

supplied.

We had a very limited time. In spite of our willing to study more it was

not possible to do so.

Some points in different chapters are not included as these were not

available.

It is not possible to hold the whole thing of a textile industry in such a

small frame as this report. So, try our hard to summarize all the

information that we are provided.

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There are some suggestions from us within our limited

knowledge

SOME SUGGESTIONS:

Knitting production needs to increase as well as technical persons need to

be employed.

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

will increase.

Dyeing floor should keep always neat and clean. It kept wet after

unloading the fabric from the dyeing machine specially, for Athena. Water

must be swept time to time.

During the transport of the fabric and during the loading of the m/c, fabrics

get soiled due to their drawing over the floor. This makes the fabric/part of

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

create stain.

Due to the pressure of higher production some times machine operators do

not maintain accurate time according to the actual process so that less

quality product is produced and may reject. So our suggestion is to

increase machine and reduce the pressure on the operator.

Should increase understanding between the top level personal and floor

level personal.

Finishing section need to be enlarged well as more technical persons need

to be employed there?

The m/c stoppage time should be analyzed and minimized. The

maintenance should be carried out when the m/c is out of action (Wherever

possible) and routine maintenance should be carried out regularly.

In knitting and finishing section every workers should use mask to make

protect them from fly. Otherwise the exhaust air system should be more

effective.

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

There is shortage of proper light in the dyeing and finishing floor,

specially, when smoke is produced from dryer and stenter. Proper lighting

should be provided in the floor.

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In Laboratory, only one sample dyeing machine is used. The rest two are

out of order. So, if this activate one is in problem then the lab dip process

may be hampered. So, another lab dip dyeing machine may be purchase to

reduce the load of current one.

The person at the top level of a department must take good care of the

trainees & he should provide all kinds of support to them.

INDUSTRIAL ATTACHMENT OF rupa fabrics ltd.

Engineering

Transcript of INDUSTRIAL ATTACHMENT OF rupa fabrics ltd.