WELCOME TO THE

PRESENTATION

Bangladesh University of Textiles

Report on Industrial AttachmentAt

METRO KNITTING & DYEING MILLS LTD.(From 01 July to 31 August, 2012)

Supervising TeacherRASHEDA BEGUM DINA

(Lecturer)Dept. of Wet Processing Engineering

Bangladesh University of TextilesSubmitted by

SERIAL NO. NAME IDENTIFICATION NO.

01 UDAY RAY 2008-1-046

02 ELIAS KHALIL 2008-1-048

03 QMD. IMRAN HASSAN 2008-1-073

04 MD. SAMSUL ALAM 2008-1-104

Export Growth Turnover

Project Descriptionsister Concerns

• Metro Knitting &

Dyeing Mills Ltd

(Factory-2)

• Bea-Con Knitwear

Ltd

• Mercer Design Tex

Ltd

• KB Traders ltd

• AAA Textile Mills

Ltd

• Panam Agrovet Ltd

Company Name: METRO KNITTING & DYEING MILLS LTD.

Type: 100%Export oriented composite knit Dyeing Industry.Product Mix:

100% cotton100% polyesterNylonPolyester Cotton blendGray mélange (15% Viscose 85% cotton, 10% Viscose 90% cotton,30% Viscose 70% cotton) Ash mélange (1% Viscose 99% cotton)

Address: : Ramarbag, Kutubpur, Fatullah, Narayanganj-1400,Year of Establishment: 1st Sept. 2000 Website : http://www.metrokd.comDepartments : Knitting, Dyeing, Garments, Maintenance & Store

Man power Management(Dyeing Section)GENERAL MANAGER

SENIOR PRODUCTION MANAGER

PRODUCTION MANAGER

LAB (QAD)

IN-CHARGE

ASST. IN CHARGE

SR. SUPER VISOR

SUPER VISOR

ASST. SUPER VISOR

LAB (COLOR MATCH

ASST. MANAGER

TECHNICIAN

ASST. OFFICER

OFFICER

SENIOR OFFICER

DYEING

PRODUCTION

OFFICER

ASST. SUPERVIS

OR

SUPERVISOR

SHIFT IN-CHARGE

FLOOR IN-CHARGE

OPERATOR

HELPER

FINISHING

PRODUCTION

OFFICER

ASST. SUPERVIS

OR

SUPERVISOR

SHIFT IN-CHARGE

FLOOR IN-CHARGE

OPERATOR

HELPER

Machine Description

SCLAVOS DYEING MACHINEORIGIN : GREECEQUANTITY: 10MAXIMUM CAPACITY: 1500 KGMAX TEMPARATURE:142oCMAX NOZZLE: 6WORKING PRESSURE: 2.8 BAR

THIES Dyeing MachineOrigin: GermanyMaxm Temperature: 130-135oCLoading per nozzle: 250kgCapacity: 250-750kg

FONG DYEING MACHINEORIGIN:CHINA MAXTEMPERATURE: 140oCNO OF NOZZLE: 1~8

CIRCULAR KNITTING MACHINEBRAND: MAYER& CIEPAILUNG, JUINN LUNG, LISKYQUANTITY: 106

STENTER MACHINEBRAND: BRUCKNER ORIGIN: GERMANYSPEED: 4-100 M/MINPADDER PRESSURE: 0.7-10 BARMAX. PRODUCTION: UPTO 10 TON / MACHINE

COMPACTING MACHINE

BRAND: TUBETEX ORIGIN: USASPEED: 5-35M/MINMACHINE PRESSURE: 20-35 BARTEMPERATURE:90-120oC

GARMENTS MECHINERIESBRAND:JUKI, PEGASUS, YAMATOBROTHER, UZU, OSHIMA, TOYOLOCK, HASHIMALEEWAI, NISSINTOTAL :1229

Raw Materials

Types of raw material used:1. Yarn2. Fabric3. Dye stuff4. Chemical and auxiliaries

FABRICS USED COMMONLY•Single Jersey•Lycra Single Jersey •1x1 Rib•2x1 Rib•2x2 Rib•Fleece•Terry

Sources of yarn:

1. Cotton (Both Carded & Combed)- Loyal, Malek, N.ZJabber, KeyaS.Q Gill, Mix, Israq, Negreeka, Multizim 2. Polyester

- India 3. Mélange

- Shamim spinning mill- Prime spinning mills - Thermex spinning mill

4. Lycra- Korea, Vietnam, china

MOSTLY USED

CHEMICALS• Caustic Soda• Soda Ash • Hydrogen

Peroxide• Glauber Salt• Hydrose

COMMONLY

USED DYES

•Begacron (China)

•Novacron (China)

•Remazol

(Germany)

•Levafix

(Germany)

•Supra (India)

•Sumifix(China)

•Dianix (Germany)

•Terasil (China)

Production Planning, Sequence & Operations

Production per day: • Maximum Loading capacity 100% (11.36 tons)• Possible maximum loading 80% (9.088 tons)• Total production per days (3 shifts) = 9.088 x 2.5

(considering 2.5 batch in 3 shifts)= 22.72 tons

.

PH

• Scouring PH – 10.5-11

• During H2O2 bleaching PH 10.5-11

• Enzyme PH – 4.5• Before dyeing (Leveling) PH – 6.5• Salt PH – 7-8• During reactive dyeing PH 10.5-11.5• During disperse dyeing PH 4.5-6.0• Softener PH – 6.5

2) TemperatureFor cotton fabric scouring: 105ºC During NaOH addition 65oC During H2O2addition 70oC Peroxide killing at 80oC Sequestering at 90oC Bio-polishing at 55oCFor cotton dyeing: Low brand – 45oC Medium brand - 600C Hot brand – 80oCo Migration for turquoise color at – 90oCo Optical brightening agent (OBA) atb 80oCo Polyester dying: 1000-1300Co Softener at – 45oC

3) Time:-For white shade 4-5hrs-For 100% cotton 8-10hrs-For 100% polyester 5hrs-CVC 2 parts 13-14 hrs.

4) M: L ratio:-For reactive dyeing M: L ratio maintained within 1:6

Cycle Time 2-3 mins

Reel Speed 250-300 m/min

Dyeing Parameter

32%

30%

30%

3% 2% 1% 1% 1% 1 Uneven dyeing

2 Running shade

3 Dye spots

4 Batch to batch shade variation

5 Crease mark

6 Roll to Roll

7 Soda spot

8 Others

Dyeing Faults

Uneven Dyeing Crease Mark Dye Spot

Soda spot Hole Resist spot

Machine used in finishing section:•Dewatering machine •Slitting machine•Dryer•Compactor (Open/Tube)•Stenter•Raising machine•Sueding machine•Padder

Knit fabrics are finished in 2 forms 1.Tubular form2.Open form

Effects of Finishing-Easy care. -Crease recovery. -Dimensional stability. -Good abrasion resistance. -Improved tear strength. -Good sew ability.- Soft or stiff handle. -Shine or luster.

FinishingTypes of Finishing:1. Mechanical Finishing (Used to control dimension to improve appearance & handle)2. Chemical Finishing (Used to make glossy protection. To improve performance or serviceability)

Flow diagram of open & tube fabric finishing

Quality Assurance System

Quality Control system mainly two types: 1. Online QC

Raw material ControlProcess ControlLaboratory test

2. Offline QC A. Physical tests

GSM test Shrinkage test Spirality test Tensile strength Abrasion resistance Pilling resistance Button Strength Testing Crease resistance Dimensional stability Bursting strength test

B. Chemical TestColor Fastness to washing. Color Fastness to light. Color Fastness to Chlorinated water. Color Fastness to water spotting. Color Fastness to perspiration. Color Fastness to Sea-water. Fiber analysis. PH test. Spray test (water repellency

Fabric Inspection

Grey Fabric Inspection

Grey Fabric Inspection is performed

according to 4-point system.

Maintenance of MachinaryRoutine/Schedule

Preventive Breakdown

Maintenance Tools and their Functions

Name of the Tools

Functions

L-Key Loosen and tighten the screw

Air suctioner Clean machines by suctioning

Screw driver Loosen and tighten the screw

Spanner Loosen and tighten nut & bolts

Star driver Screw unlocking

Pliers Cutting, Holding, Joining of wire, Gripping

Pulley Key To loosen pulleys

Maintenance

Utilities

Types of Generator:A.Gas Generator (Running) 1.Brand: Perkins, England Capacity: 400 KW 2.Brand: Waukesh, USA Capacity: 900 KWB. Diesel Generator (Backup) Brand: Perkins, England Capacity: 200 KW

Fig:Gas generator 1

Source of utilities:Electricity : PDB & GeneratorSteam : BoilerWater : PumpGas : Titas gas Ltd

Utilities services available in Metro Industries Ltd

ElectricityWaterGasSteam

Gas generator 2

Diesel generator

Boiler Brand: COCHRAN , Scotland Maximum Temperature: 188 Maximum Steam Output: 10 ton/hr Steam pressure: 7.5 bar

Boiler

Store & Inventory Control

Objectives Financial activities Property protection Operating

Scope of Inventory Control

Grey Fabric Store

Dyes & Chemical

Stores

Spare Parts

Finished Goods Others

Effluent Treatment Plant

Metro has Combined Bio-chemical ETP in the factory premises. The output of the ETP is about -200CBM/Hr)

Chemical Name Chemical Used

H2SO4 & HCl 25 Kg/Day

Lime 250Kg/shift

Alum 250Kg/Day

Polyelectrolyte 1 Kg/day

H3PO4 1 Kg/shift

Urea 1 Kg/shift

Consumption of the chemical used

Types of ETP

Physio-Chemical Chemical-Biological Biological

Discharge water quality of Metro Industries:pH = 6-9BOD = 50 mg/ LCOD = 220 mg / LSuspended solid = 145 mg/LColor = color less.

Functions of different chemicals used in ETP:

H2SO4 & HCl:Neutralize the water from alkaline state.

Ferrous Sulphate & Lime: To remove the color of the effluent.

Alum & Polyelectrolyte: To agglomerate the smaller particles. For sedimentation of the smaller particle.

H3PO4/Urea: For increasing the production of the bacteria.

Dyeing Cost Along with Dyes and Chemical

Sl. No. Types Of Shade Type Of Finishing Price/Kg

1 Light Color Tube Finish 65 Tk2 Light Color Open Finish 75 Tk3 Medium Color Tube Finish 75 Tk4 Medium Color Open Finish 85 Tk5 Dark Color Tube Finish 85 Tk6 Dark Color Open Finish 95 Tk7 Black Color Or Extra Dark Tube Finish 110 Tk

8 Black Color Or Extra Dark Open Finish 125 Tk

9 Deep Black Or Deep Royal Tube Finish 115 Tk

10 Deep Black Or Deep Royal Open Finish 125 Tk

11 Only Wash Tube Finish 25 Tk12 Only Wash Open Finish 35 Tk13 White Tube Finish 40 Tk14 White Open Finish 50 Tk

Finishing Cost

Serial No.

Price quotation of finishing Price

1 ONLY STENTER 20 TK/KG2 ONLY OPEN COMPACTING 15 TK/KG3 STENTER + OPEN COMPACTING 30 TK/ KG4 ONLY TUBE DRY 8 TK/KG5 TUBE COMPACTING 8 TK/KG6 ONLY SUEDING 25 TK/KG7 SUEDING+ STENTER+ OPEN

COMPACTING55 TK/KG

8 ONLY BRUSH 15-20 TK/KG

Serial

No.Fabrication

Knitting Price(Tk./Kg)

1. Single Jersey 8-10

2. Lacoste/PK 14

3. Terry 14

4. Fleece 18-20

5. 1x1 Rib 14

6. Interlock 18

7.Single Jersey E.

Stripe100

8. Lacoste/PK E. Stripe 120

Cost Analysis

Knitting Cost

Exporting countries:GermanyNetherlandJapanUKSingaporeCanadaUSA

Marketing Activities

So, that was the very brief of our Industrial attachment program. It excludes so many subjects and facts. In this short presentation its very hard to include everything we did and learned in that program.

Thanks for giving us the opportunity to do this presentation.

Conclusion