“Industrial Training”: International Classic Composite Limited. Company Profile: Name of factory : International Classic Composite Limited (IC CL) Year of establishment : 2007 Investor : Mr. Milon Hossen & Mr. Khokon Ahmed Location : Naojur, Kodda, Joydebpur, Gazipur, B angladeh. Certification & awards : ISO 9001:2007 Production capacity : Knitting: 5 tons/day (Average) Dyeing: 6.5 ton/day (Average) Main Production : Knitwear& all kinds of knit garments & Knit fabrics. Website : www.icclbd.com (Processing) History Of The Project Development After successful operation in International Classic Composite Ltd., the owner had decided to start a fully information & technology based along with the social accountability and
Transcript
“Industrial Training”: International Classic Composite Limited. Company Profile:
Name of factory : International Classic Composite Limited (ICCL) Year of establishment : 2007
Main Production : Knitwear& all kinds of knit garments & Knit fabrics. Website : www.icclbd.com (Processing)
History Of The Project Development
After successful operation in International Classic Composite Ltd., the owner had decided to start a fully information & technology based along with the social accountability and quality controlled modern ready made composite knit garments industry in large scale. In this connection Mr. Milon & Mr. Khokon had decided in a resolution to start a company in Naojur, Kodda, Joydebpur, and Gazipur in the year 2007 to manufacture knitwear garments for the international market. 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, International Classic Composite 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.
Working on new concepts in styling & content of the knitwear is a continuous activity in International Classic Composite Ltd. with an objective to up the quality and the value of merchandise. In 2007, the year in which International business was started; International Classic Composite Ltd. concentrated all its strengths and resources in developing a wide range of knitwear for the international market.
Vision & Mission Of This ProjectThe mission and vision of International Classic Composite 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 International Classic Composite 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 9001:2007 quality management system within the organization.
Location Of International Classic Composite Ltd.:
CHOURA STA, GAZI PUR
INTERNATIONAL CLASSIC COMPOSITE LTD.
EastWest
North
South
ORGANIZATIONAL STRUCTURE
Managing Director
Director
Knitting division Dyeing division
Knitting In Charge General Manager
Knitting Master Asst. Production Manager
Q.C Supervisor fitter Production Executive
Operator Supervisor/ Floor In charge
Helper Sr. Operator
Operator
Helper SECTION-WISE MANPOWER
Department ManpowerKnitting section 70Dyeing 90Garments section 1000( above )Power generator boiler and utility 20Inventory / store keeper 15Administration 40Security 15Batch section 12Printing 50Finishing 30Lab 10Q.C 12Others 50
Total 1414
MANAGEMENT SYSTEM
1. Buyer sample is send to G.M or merchandising manager.2. Marching is done under lab manager. 3. Sample is prepared by asst. dyeing manager.4. Sample is send to the buyer for approval.5. Approved sample is returned and taken as STD. sample for bulk production.6. Dyeing manager gives responsibilities to asst. dyeing manager.7. Then shift in charge with the supervisors start bulk production.8. On line and off line quality check is done by lab in charge and asst. Dyeing
manager.9. After dyeing asst. manager (finishing) controls the finishing process with the
supervision of shift in charge. 10. Finally G.M checks the result with dyeing manager and decision is taken for delivery.
Shift Change For Worker
1. A shift = 8.0 am to 8.0 pm2. B shift = 8.0 pm to 8 am3. But offices time 9.0 am to 5.0 pm
Responsibilities of A Shift In Charge
1. Over all supervision of production both dyeing and finishing.2. Batch preparation and pH check.3. Dyes and chemical requisition, issue and check.4. Write fabric loading and loading time form machine.5. Programmed making, sample checking, color matching.6. Control the supervisors, operators, asst. operators and helpers of dyeing machine.7. And also other work when it is required by top level management.
Job Description
Title: asst. production managerDept/section: dyeing and finishingReport to: manager.
Job Summary
1. After having the work order, prepares production plan.2. To execute and follow up the plan along with quality conformation.3. To face various difficulties of production and overcome them.4. Inspecting the material for conformation to buyer requirements.
Job Description
Title: shift in chargeDept/section: asst. dyeing manager
Job Summary
1. To execute the plan given by asst. dyeing master.2. Organizing personnel under him.3. Control the supervisors, operators, asst. operators and helpers of dyeing machine.4. Checking of shade match.
BASIC FACTORY LAYOUT: (FOUR STORE BUILDINGS)
GROUND FLOOR FABRIC STORE ROOM CHEMICALS
FIRST FLOOR BATCH SECTION DYEING SECTION 1 DYEING SECTION 2
BOILER FINISHING SECTION
GENERATOR LAB SECOND FLOOR KNITTING UNIT PRINTING SECTION
THIRD FLOOR GARMENTS ADMINISTRATION FOUR FLOORS GARMENTS ADMINISTRATION
Raw MaterialsRaw 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. Yarn2. Fabric3. Dye stuff4. Chemical and auxiliaries
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.
Types of Knitting:There are two types1. Warp Knitting.2. Weft Knitting.
1. Warp Knitting:
In warp knitting, one or two yarn produce vertical column of loops and fabric is produced at length way. In a warp structure, each loop in the horizontal direction is made from a different thread and the no of threads used to produce such a fabric is at least equal to the number of loops in horizontal raw. In warp knitting, the threads run thoroughly in a vertical direction. e.g. – Net, Mesh fabric etc
2. Weft or Circular Knitting:
In weft knitting, one yarn produces a horizontal row of loops and fabric is produced at width way. In a weft knitted structure, a horizontal raw of loops can be made by using one thread and the thread runs in horizontal direction. e.g. – single jersey, rib, interlock etc
Single jersey:
It requires only one set of needles. The loops are intermesh in only one direction so the appearance of the face and back of the fabric are quite different.Example: Plain single jersey, Pique, lacoste etc.
Rib: It requires two sets of needles positioned at right angles to each other to form the fabric.Example: (1×1) Rib, (2×2) Rib etc.
Interlock:
Fabric is produced by using both long and short needles. It has a smooth surface on both sides.Example: Plain Interlock
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
Sequence of yarn feeding: Creel
Pipe line
Wheel
Yarn sensor
Yarn guide
Feeder
Needle
End products of Circular Knitting Machine:
Single Jersey M/C:
1. S/J Plain2. Single Lacoste3. Double Lacoste4. Single pique5. Double pique6. Mini jacquard7. Terry
Interlock M/C:
1. Interlock pique2. Mash fabric3. Face/Back rib
Rib M/C:
1. 1*1 Rib fabric2. 2*2 Rib fabric
Terms of Knitting:
Course:
Horizontal row of loops produced by adjacent needles in knitting cycle is called the course of the fabric. A course is a predominantly horizontal raw of needle loops produced by adjacent needles during the same knitting cycle called course. (Loop length * No of loop).
Wales:
Vertical column of loops produced by same needle in knitting cycle is called the Wales of the fabric.
A wale is a predominantly vertical column of intermeshed needle loops generally produced by the same needle knitting cycles. i.e. The number of vertical columns of loop of knitted fabrics is called wale.
Face loop: If the legs of new loop is passes over the old loop is called face loop.
Back loop:If the legs of new loop is passes under the old loop is called face loop
Stitch density: The term stitch density is frequently used in knitting instead of a linear measurement of courses or Wales; it is the total number of needles loops in a square area measurement such as a square inch or three square centimeters.It is expressed as,
Course per inch × Wales per inch.
Stitch length: Length of one loop in the course direction express in mm.
Number of needle: Machine diameter × Machine gauge × 3.1416.
GSM: The weight of one square meter of fabric express in gram is known as GSM.
Needle gauge:
The needle gauge of a knitting machine is a measure expressed the no. of needle per unit of the needle bed or needle bar. As for example:1. In case of circular weft knitting machine & Tricot warp knitting machine. [Gauge, N= Number of needle per inch.]2. In case of Raschel warp knitting machine. [Gauge, N= Number of needle per two inch.]
Needle:There are three types of needle-1. Bearded needle2. Compound needle3. Latch needle-
One butt needle. Two butt needle. Three butt needle. Four butt needle.
The most widely used needle is latch needle.
Cam:Cam is called the specific path of the needles to produce a specific type of fabric.There are three types of cam used in circular knitting machine:
1. Knit Cam.2. Tuck Cam.3. Miss Cam.
Knit Cam:It moves the needle upward enough to clear the old loop and receive the new yarn.Tuck Cam:It moves the needle upward not enough to clear. The old loop but receive the new yarn.
Miss cam:It does not move the needle upward. The needles neither clear the old loop nor receive the new yarn
Sinker:It is a thin metal plate with an individual or collective operation approximately at right angles at the hook side between adjacent needles.
Working Sequence of Knitting Section for International Classic Composite Ltd.
Order sheet receiving From Merchandiser Selecting of production parameter
Arranging of yarn Testing of yarn
Arranging of selected m/c Making a pre-production sample
Starting of bulk production after approval Checking of grey fabric
Delivery of grey fabrics according to batch wise
Speciation of circular knitting m\c:
No. of m/c
M/C Dia
M/CGauge
No. Of Feeder
No. OfNeedle
M/CSpec
Brand Origin
1 15” 24 45 1130 S/J Jiunn Long Taiwan
2 17” 24 51 1272 S/J Jiunn Long Taiwan
3 38” 24 114 1440 S/J Jiunn Long
Taiwan
4 19” 24 57 1440 S/J Jiunn Long
Taiwan
5 20” 24 48 1520 S/J Jiunn Long
Taiwan
6 26” 24 78 1632 S/J Jiunn Long
Taiwan
8 22” 24 52 1680 S/J Jiunn Taiwan
Long 9 20” 18 56 1120 S/J Jiunn
LongTaiwan
10 26” 20 84 1620 S/J Jiunn Long
Taiwan
11 21” 24 63 1584 S/J Jiunn Long
Taiwan
12 26” 24 78 1920 S/J Jiunn Long
Taiwan
13 26” 24 84 1944 RIB Jiunn Long
Taiwan
14 24” 24 90 2232 RIB Jiunn Long
Taiwan
15 25” 18 62 1116 RIB Jiunn Long
Taiwan
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
Relation between G.S.M. & Yarn Count:
For cotton / Blend / CVC fabric:-S/J without Lycra – Fabric G.S.M Yarn Count 110 - 120 40 S – 36 S
120 - 130 36 S - 32 S
130 - 140 32 S – 28 S
140 - 150 28 S
150 - 160 26 S
170 - 210 24 S
Rib without Lycra - Fabric G.S.M Yarn Count 180 - 190 36 S - 32 S
190 - 200 30 S
200 - 215 28 S
215 - 230 26 S
230 - 250 24 S
250 - 300 24 S
Interlock without Lycra –
Lacost (S/L, D/L) without Lycra-
Fabric G.S.M Yarn Count 180 - 190 30 S
190 - 210 28 S
210 - 230 26 S
230 – 250 26 S
40D Lycra Rib –
40D Lycra S/J –
Analysis of Fabric Design:
Fabric G.S.M Yarn Count 200 - 220 34 S
220 - 230 32 S
230 - 250 30 S
250 - 300 26 S
Fabric G.S.M Yarn Count 230 - 240 32 S
240 - 250 30 S
250 - 280 26 S
280 - 300 24 S
Fabric G.S.M Yarn Count 180 - 190 34 S
190 - 210 32 S
210 - 220 30 S
220 – 240 28 S
240 - 250 26 S
Sample analysis: After receiving an order first step is analysis the fabric. A sample is analysis as per following system.
N.B: 1 = One butt needle ´ = Knit stitch 2 = Two butt needle ∆ = Knit cam
=Tuck cam = Tuck stitch
Fabric: Terry
NOTATION DIAGRAM
´ ´ ´
― ―
´ ´ ´
― ―
CAM SETTING ARRANGEMENT
11 2 3 4
∆ ∆
∆∆ ∆∆
∆∆ ∆∆
NEEDLE ARRANGMENT
1 2 3
NB: ´ = Knit stitch 1 = One butt needle = Tuck stitch 2 = Two butt needle
= Tuck cam 3 = Three butt needle ∆ = Knit cam ― = Miss stitch
= Miss cam
Fabric: 1 ´ 1 Rib
CAM SETTING ARRANGEMENT
∆ ∆ ∆ ∆ ∆ ∆
D∆ ∆ ∆ ∆ ∆ ∆
∆
∆ ∆ ∆ ∆ ∆
C∆ ∆ ∆ ∆ ∆ ∆
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
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
Methods of increasing production:
By the following methods the production of knitted fabric can be increased. 1. 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.
2. 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.
3. By using m/c of higher gauge:The more the m/c gauge, the more the production is. So by using m/c of higher gauge production can be increased.
4. 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.
Production calculation:
Production/shift in kg at 100% efficiency:
countYarnmmSLNeedleofNoFeederofNoRPM
´´´´
80.3527
)(..
Production/shift in meter:
Fabric width in meter:
100/ .
100/.
´
´
cmWalesknittinginusedNeedlesofnoTotal
cmWaleswalesofnoTotal
Faults &Remedies of knitting fabrics:
Knitting faults: Faults in circular knitting production can be caused in various ways and quite a few of them cannot be related to just one cause. The following explanations are expected to be helpful in trying to locate the causes of these faults easier.
Sources of fabric faults: The sources of faults could be (in circular knitting m/c, 80% faults comes from yarn)
- Faults in yarn and the yarn package. - Yarn feeding and yarn feed regulator.- M/c setting and pattern defects- M/c maintenance - Climatic conditions in the knitting plant.
Fabric faults: Knitted fabric faults are very different in nature and appearance and are often superimposed. The most common faults are:
- broken ends , holes or cracks - drop stitch - cloth fall out or pressed off stitches- snagging or snags- tuck or double loop or stitches- Bunching up - Vertical stripes - Horizontal stripes - Color fly or colored tinges - Distorted stitches tinges - Distorted stitches or deformed or titled loops
1. Holes: Holes are the result of cracks or yarn breakages. During stitch formation the yarn had already broken in the region of the needle hook. Depending on the knitted structure, yarn count, m/c gauge and course density, the holes has different sizes. This size can therefore only be estimated if the comparable final appearance of a comparable fabric is known.
Possible causes: yarn parameters high yarn irregularity Incorrect yarn input tension setting; yarn running-in tension is too high. poorly lubricated yarns weak places in yarn, which break during stitch formation knots, slubs etc yarn is too high if the yarn is trapped between the cheek taper and closing latch
- Yarn damage tool small stitches
- Difficulty in casting off of the stitches Relation between cylinder and dial loop not correct yarn feeder badly set; defective
knitting elements.
2. Drop stitches: These are the result of a defective needle. They also occur when a yarn is not properly fed during stitch formation, i.e. not properly laid –in the needle hooks. These are the unlinked knitted loops.
Possible causes: inaccurate insertion of the yarn into the needle hooks; Broken needle hook. Due to high yarn twist and low fabric take down tension the knitted loop could fall
out of the hook; Improper setting of the yarn feed angle i.e. badly set yarn feeder The yarn is not caught by the needle hook, example – lower yarn feeder and high yarn
vibrations. Yarn feeder wrongly threaded in.
a. Dial loop length nit properly related to cylinder loop length; the loop jumps out of the needle hook.
b. Bad take –up.c. Very dry material.d. Insufficient yarn tension.
3. Cloth fall-out or pressed-off stitches:It is an area consisting of drop stitches lying side by side. They can occur either when a yarn is laid-out or when it breaks without any immediate connection. Cloth fall-out can occur after a drop stitch especially when an empty needle with closed latch runs into the yarn feeder and removes the yarn out of the hooks of the following needles.
Possible causes: Yarn breaks before the yarn feeder. Yarn package winding faults, poor package build up. Fiber fly block the yarn guides, feeders etc.
4. Needle marks or vertical stripes:Vertical stripes can be observed as longitudinal gaps in the fabric. The space between adjacent Wales is irregular and the closed appearance of the fabric is broken up in an unsightly manner. Vertical stripes and gaps in the fabric are often the result of a meager setting, i.e. the yarn count selected. Needles are bent, damaged, do not move uniformly smooth, come from different suppliers or are differently constructed.
Possible causes: Twisted or bent needle hooks. Stiff latches and needles. Incorrect closing of the hook by the latch. Heavily running needles. Damaged needle latch and needle hooks. Damaged dial and cylinder. Damages on other knitting elements.
5. Sinker Mark
Causes: When sinker corrode due to abrasion then some times can not hold a new
loop as a result sinker mark comes. If sinker head bend then sinker mark comes.
Remedies:Sinker should be changed.
6. Star MarkCauses:
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
7. Oil stainCauses:
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.
8. Pin hole Causes:
Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:
Change the needle
9. Bairre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) stripe(s).
Causes: This fault comes from yarn fault. If different micro near value of fiber content in yarn. Different lusture, dye affinity of fiber content in yarn. During spinning different similar classes of fiber is mixed specially in carded
yarn & these fibers have similar characteristics. In draw fame different similar classes sliver is mixed and make one sliver.
Remedies: We can use this fabric in white color.
10. 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.
11. 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
Batch Section
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: 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 dyeingPurpose of Batch Section:
To receive the grey fabrics roll from knitting section or other source.1. 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.2. 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
3. To send the grey fabric to the dyeing floor with batch card.4. To keep records for every previous dyeing.
Criteria of proper batching:1. To use maximum capacity of existing dyeing m/c.2. To minimize the washing time or preparation time & m/c stoppage time.3. To keep the no. of batch as less as possible for same shade.4. To use a particular m/c for dyeing same shade.
Functions of spectrophotometer:1. Color difference 2. Metamerism 3. Pass/fail operation 4. Fastness rating5. Shade library6. Cost comparison7. Color match production8. Reflectance curve.
Working Procedure:All ingredients had been taken according to the recipe into the pot of sample dyeing machine. At a room temp the material had run then after 10 minutes started to rise the temperature at 1°C/ min. to get 60°C temperature. For performing the required dyeing temperature it took 30 minutes. The material had dyed at 60°C for 45 minutes. Then the temperature was reduced at room temperature within in 10 minutes. The fabric washed in cold water & then the material was washed in 1 gm/l soap solution (liquor ratio 1:20) at 90°C temperature for 15 minutes. Then after rapidly cold washing the material was dried & preserved.And then check the shade match with the required sample by the lighting box.
Machine Description of Dyeing Lab:1. Name : Sample Dyeing m/c
Brand : Data color Origin : USA.
2. Name : Sample Dyeing m/cBrand : Fong’sOrigin : Hong Kong
3. Name : Sample Dyeing m/cBrand : Pyrotec-200Origin : England
4. Name : Rubbing Fastness TressBrand : Crock meter
5. Name : Spectrophotometer Brand : Data color
Model : 600 FX
6. Name : Light Source Brand : VerivideRaw material of Dyeing
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.
Calculation:0.5%for deep shade.0.1%for light shade. ICC Ltd. produces 0.5% to 5% shade for the goods. Amount of salt soda for Remazol
Usually following calculations are followed –
Recipe % ×Sample Weight For (%)/ dye % = (cc).
Stock solution %
Recipe (G/L) × 100 × Total Volume of Liquor(G/L) /Liquid / Auxiliaries = (cc)
(1000×Stock solution %)
Sample calculation for 0.5% shade:
Sample wt. = 5 mg, Let, Salt =25g, Soda Ash=10gMaterial liquor ratio = 1: 10Total liquor (5 ́10) = 50 cc 5 ́0.5%Dye solution required = = 2.5 cc 1 %
Take water in the bath at required level Load fabric Circulate the fabric & raise the temperature at 600c. Add acetic acid, nutrox MKL
Continue circulate the fabric for 60 min Drain Hot fill for 10’ at 800c Rinse & Drain
Hot wash process:
The steps for hot washing process are as follows Take water in the bath at required level Load fabric in the m/c. Add detergent sequestering agent &anti creasing agent Circulating the fabric and raise the temp at 900C Continue circulating the fabric for 30 mins at constant temp 900C Rinse and drain
Product quality check:
Check pH of the bath Absorbance of the fabric Hardness of water Iron /impurities contamination of the water Heating and cooling of the m/c
Role of auxiliaries in the stage of dyeing: Wetting agent : To wet the fabric that means of penetrate the detergent easily. Sequestering : To remove the hardness of water.Ant creasing : To prevent the crease mark Antifoaming : To reduce the foam formation Stabilizing Agent : To stable the Hydrogen per oxideAlkali : To clean the fabricHydrogen per oxide : Used as bleaching agent for permanent white Enzyme : To remove the hairy or floating fiberLeveling : To level the dye properly into fabric
Dyeing process of Cotton:After scouring & Bleaching
Acetic condition (a/acid, PH 4.5-5)
Enzymes add (temp. 550c, R.T. 45-60 min.)
Enzyme hot (800c*10´)
Rinsing wash (15´, 2 times)
Leveling agent (400c*10´)
Salt dosing (400c*10´)
PH check (5.5-6.5)
Color dosing (400c*25´)(Run time: 10/15´)
Soda dosing (400c*15´), [PH: 9-12](R.T-10/15´)
Color steam, 600c (20/min), 10/12´minR.t:20´
Sample check
OkIf not ok then it will take more time about 40´ or 60´
Rinsing wash (15´/20´)B.D
Acetic acid (400c)R.t:20´
Rinsing wash 10/15´ B.D
Hot wash for deep shade, 950c*15/20´For normal shade 900/800c*10/15´
Sample ok
Fixing (for deep shade, Run time:15´*400C)
Rinsing wash 10/15´
Softening at 40/450 c* 10/15´
Sample check (if ok)
Unload
A series of wash (hot & cold) with neutralization.
Dyeing procedure for CVC/ PC:Scouring & Bleaching:
Ant creasing agent (1.0 gm/l) [only for S/J, Lycra S/J]Stabilizer (0.20 gm /l)
Caustic Soda (2.0 gm/l)Soda (1.0 gm/l)
H2O2 (2.0 gm/l) [dosing at 700C, 6 min]Run at 950C, 40 min
Hot wash (without chemical) ↓Run at 800C, 10 min
Neutralization (bleaching)Acetic acid (1.20 gm/l)
↓Run at 700C, 10 min
Hot wash (with chemical)Per-oxide killer (0.20 gm/l) [PH Check 5.6 to 7]
↓Run at 500C, 20 minDyeing
Topping:
In addition, color matching not control, topping or redyeing or reprocessing –
Bath drain↓
Washing (400C)Leveling (1 gm/l)
↓Salt transfer (less)
↓Run at 600C, 20 minColor dosing (as required shade)
↓Run at 600C, 30 minSoda dosing
Addition:
Soda dosing↓
Sample check ↓If not OK
Cool to 400C↓
Color dosing ↓Run at 400C, 15 min
Temperature rise to 600C↓
Sample check
Color or salt which should be dosed first:1. In case of 0-1.0% (light) shade color is dosed first then salt dissolving is performed.2. In case of 1-2.5% (medium) shade salt is dissolved at first then color is dosing.3. In case of 3 & above% (dark) shade salt is dissolved at first then color is dosing.
Common dyeing faults with their remedies1. 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/cRemedies:- 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 2. Batch to Batch Shade variation:
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.3. 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, etcRemedies:- Use standard dyes and chemicals.- Proper m/c speed.- Use of soft water 4. 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 runningRemedies:- maintaining proper reel sped & pumps speed.- Lower rate rising and cooling the temperature- Reducing the m/c load- Higher liquor ratio 5. Dye spot: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 removed6. Wrinkle mark:
Causes:- Poor opening of the fabric rope- Shock cooling of synthetic material- High temperature entanglement of the fabricRemedies:- Maintaining proper reel sped & pump speed.- Lower rate rising and cooling the temperature- Higher liquor ratio 7. 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 softenerRemedies:- Maintaining proper reel sped & pump speed.- Proper Mixing of the softener before addition.- Prevent the entanglement of the fabric during application of softener
Finishing SectionFinishing:
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 in tended end use.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-B. The machines that are used for tube line are given bellow –.
- Dewatering machine- Dryer- Compactor machine
Process flow Chart for Finishing Section: Finishing
Open Finish Tube Finish
Slitting and Dewatering Dewatering
Stentering Drying
Inspection Compacting
Delivery Inspection
Delivery Utility Services
Utility Facilities Available: in ICC Ltd.
Utility Source Electricity Gas/Diesel Generator
Gas TITAS
Compressed air Air Compressor
Steam Boiler
Water Pump
Temperature Control A/C Chiller
Electricity /Power
Source:1. Generator
No of generator: 02Equipment used:
1. Gas generator 2. Diesel generator
Gas generatorManufacturer : Waukesha Power SystemsMaximum Capacity : 1030 KWRequirement Capacity : 750-800 KW
GasGas is mainly used for steam productionGas is bought from TITAS Generally 36cubic meter gas is required to produce one ton steam.WaterSource: ground waterHot water: 430 cubic meters come from pump per hour and central for water reservoir which contains hot water of 800c.Cold water: 300 cubic meters come from pump per hour and underground reservoir tank to store cold water.
A/C Chiller
The machine by which water is cooled down below its normal temperature is called chiller. It is used to control the temperature and humidity. Medium used here water.OthersElectrical wirings: here the electrical wiring system is bus bar tanking system where copper plate is used for electricity transmission instead of copper wire.
Pipeline Here there are different pipeline in the floor.
For high pressure steam1. For return steam 2. For pressure balance3. For hot water and cold water 4. For compressed air
Boiler Steam generator or boiler is usually a closed vessel made of steel. There is one boiler in ICC 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.
In wet steam is used for the relevant processes.
Boiler m/c Specification
Brand Name : COCHRANOrigin : Scotland Type : Fire tube boilerCapacity : 8 ton per hourPressure : 5 barTemperature : 188º C Fuel : Natural Gas
Water supply for the boilerWater required for steam production is supplied by deep tube well.
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 ICC Ltd. there are water softeners that act before the water enters the boiler.
Compressed AirThe compressed air is supplied from air condition from air compressor. There are one air compressors in ICC Ltd.Cost of different Utilities:
Gas Cost: 4.94 TK/m3 for boiler 3.66 TK/m3 for generator 4.6 TK/m3 for domestic Purpose
Steam Cost:4.20 TK/ m3 Kg fabric
Remarks:
For smooth running of factory main utilities like gas, electricity or steam is very essential. Sometimes gas pressure is low than required pressure. When the gas pressure is low, then diesel generators run (But ICC Ltd. Stop some m/c). Government should have to ensure proper gas supply for Industry.
WATER TREATMENT PLANT
Natural water quality:
Water for a textile plant may come from various sources. These include surface water from rivers and lakes, and subterranean water from wells. In International Classic Composite Limited they collect water from Under ground. The various salts present in water depend on the geological formations through which the water has flowed. These salts are mainly the carbonates (CO3
2- ), hydrogen carbonates or bi-carbonates ( HCO3
- ), Sulphates ( SO42-) and chlorides ( Cl-) of calcium ( Ca2+), magnesium
(Mg2+) . Although calcium and magnesium carbonates in limestone are relatively insoluble in water. So in this reasons, water hardness can be divided into two ways-
This water hardness causes some serious consequences in a textile dyeing and finishingIndustries and these are –
Precipitation of soaps. Redeposit ion of dirt and insoluble soaps on the fabric being washed , This can cause yellowing and lead to uneven dyeing and poor handle. Precipitation of some dyes as calcium and magnesium salts. Scale formation on equipment and in boilers and pipelines. Reduction of the activity of the enzymes used in washing. Incompatibility with chemicals in finishing recipes and so on.
Hardness expressed by parts per million (ppm) of CaCO3 which is standardHardness scale and it is also called American hardness. The hardness of raw water is 100 ppm or more. To use it in dyeing and in boiler this water must need to soft & foreign materials needs to remove.
Hardness range:
Industrial Soft-water std. range is 5 ppm but it is very difficult to control. So in this industry, water hardness scale maintains 7 to 8 ppm of CaCO3.
COMPLIANCES
Factory are obeying and maintaining international and local law’s, Human rights, social compliance, Labor law and other rules and instruction by related department of Government.
Welfare Facilities:
1. Induction of workers committee aimed at improving workers morale, job satisfaction & attendance.
2. Canteen facilities.3. Subsidized lunch for staff.4. Free snacks for workers.5. Full time free of medical service provide by a professional Doctor.
6. Provision for day care center for workers children, annual picnic.7. Cultural function.8. Each floor has sufficient number of washroom.9. Each floor has sufficient lighting to facilitate production.10. A large dining hall is in our factory including pure drinking water and well sitting
arrangement.11. Maternity leave and benefit for female workers are provided as per labor law.
Recruitment Policy
1. No child labor in factory.2. No gender discrimination in recruitment procedure.3. There is no force for labor
SOME SUGGESTIONS
1. Knitting production needs to increase as well as technical persons need to be employed there.
2. More skilled labor should be used in a project and the overall efficiency will increase.
3. Should increase understanding between the top level personnel and floor level personnel.
4. Finishing section need to be enlarged well as more technical persons need to be employed there.
5. 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.
6. Workers are not interested to wear their gown & hand gloves.
7. In the Laboratory there is no technical person, a textile engineer may be employed there.
LIMITATIONS OF THIS REPORT
1. Because of secrecy act, the data on costing and marketing activities have not been supplied.
2. We had a very limited time. In spite of our willing to study more it was not possible to do so.
3. Some points in different chapters are not included as these were not available.
4. 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
CONCLUSION
There is large difference between the theoretical knowledge and practical experiences. This is truer in case of the study of Textile Technology. Industrial attachment or, Industrial training is an essential part for textile education because it minimizes the gap between theoretical and practical knowledge. This Industrial training increases our thought a lot about textile technology. It also helps us to know a lot about industrial production process, machineries, and industrial management and made us suitable for industrial life. Besides it gives to the first opportunity to work in industry. So I can say industrial attachment prepare us for the expected destiny of practical life.
I have completed my industrial attachment from International Classic Composite Ltd. During my two-month short time industrial training at International Classic Composite Ltd, I got the impression that this factory is one of the new & modern export oriented composite knit garments industry of our country. This factory does not compromise in case of quality. So, they have established on-line and off-line quality control of each product. Besides, they also use the good quality yarn, dyes and chemicals in their production process. Due to this, it has earned a “very good reputation” in foreign market for its quality product over many other export oriented textile mills. It has very well educated and technically experienced manpower to get rid of any defect in production process. It has also a good organizational hierarchy.
We wish the better future of International Classic Composite Ltd.
