Industrial attachment of aman tex ltd.

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTAMAN TEX LIMITED

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ACKNOWLEDGEMENT

A number of People have made significant contribution to the preparation of this report. Theirinsights, advice & suggestions helped us a lot.

Firstly, I am very much thankful to our supervising teacher Rajib Saha for his encouragement &valuable suggestions for incessant improvement of the report.

I would like to express my sincere gratitude & appreciation to Mr. Khalid Hossain Khan,Director (Production),for allowing me to perform my industrial attachment in the Aman TexLmtd. I am also very grateful to all managers & assistant managers for helping to get properinformation about every section during industrial training.

Finally I want to thank our teacher Professor Syed Fakhrul Hasan for his guidance,encouragement & keen interest in delivering thoughtful advice during the period of industrialtraining.

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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 equal 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, skills 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 can not 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

Aman Tex 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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PICTURE: AMAN TEX LIMITED

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1. ABOUT AMANTEX:

Aman Tex Limited is a young & dynamic Knit Garments industry. Though incorporated

in the year 2004 as a private limited company it came came into existence in late

December 2008. The mill being established in Boiragirchala, Sreepur, Gazipur,

Bangladesh aspires to create a niche within a short period of time in highly competitive

global market of Knit Garments. Promoted by a team of young & dynamic visionaries,

Aman Tex is 100% export oriented Composite Knit Industries. It posses all the latest

machineries from the from the European Countries with few from United States of

America, Japan & Taiwan. The entire plant has been installed & erected by foreign &

local engineers jointly under the same roof. The total plant is located in a eight storied

building in an area of more than 500,000 square feet. Other than the plant area an

additional area of 20,500 square feet covered by an ETP & Supply Water plant. The main

Building accommodate all the department Knitting, Dyeing, Finishing & the Utilities

required for this with all the relevant sections of those departments to cater the needs of a

inimitable Garment manufacturing unit in totally meeting all the criteria of updated

compliance.

Certification:

ISO: 9001-2008 (Quality management systems)ISO: 14001-2004 (Environmental management systems)

WRAP (Worldwide Responsible Accredited Production )

Oeko-Tex@ Standard 100(Confidence in Textile)

URS (United Registrar of System)

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COMPLIANCE:

Strict compliance is observed in the case of female workers in terms of any harassment.

Gender equality is also mention in the factory.

Child labor never allowed or employed.

The mill strictly follows no policy of discrimination appointment of workers.

Working hours follow as ILO convention.

CONTACT DETAILS

FACTORY NAME : AMANTEX LIMITED

CORPORATE OFFICE 2, Ishakha Avenue

Sector-6 Uttara

Dhaka, 1230

TEL : 88-02-7911691-3

88-02-8962297

FAX : 88-02-8921489

FACTORY: Boiragirchala, Sreepur

Gazipur

TEL : 06825-52790

FAX : 06825-52791

[email protected]

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1.1 LAYOUT FOR GOING TO THE AMAN TEX FROM DHAKA:

WEST

SOUTH NORTH

EAST

DHAKA-MAYMANSHING HIGHWAY

Fakruddin Textile MillsDenimak Garments

CrystalSweterFactory

Chittagong Denim

AMAN TEX & AMAN COTTON & FIBROUS LTD

Mita Textile

MaunaSquare

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1.2 Different Section of Aman Tex:

Different Sections

a) knitting Section: Knitting Inspection

b) Dyeing section: Batch section Sample Section Dyeing lab. Dye Section Quality control Finishing

c) Garments section: Merchandising Sample Cutting Section Printing Section Embroidery Section Sewing Section Finishing Section

d) Maintenance section: Electrical Mechanical

e) Store Sectionf) Administration Sectiong) Security Sectionh) Marketing Sectioni) PMC, Work Study & IE Departmentj) Human Resource & Development Section

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KNITTING SECTION

2.1 Machine List of Knitting Section in Aman Tex :

Machine Name Machine QuantityCircular Knitting(Single jersey) m/c 16Circular Knitting(Rib) m/c 11Engineering Stripe m/c 08V-bed Knitting m/c 08Grey Fabric Inspection m/c 02

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2.2 Specification of Circular Knitting Machine:Machine no-01M/c type: Single JerseyBrand name: FukuharaOrigin: JapanCylinder Dia: 32Gauge: 24Capacity: 300 Kgs

Machine no-02M/c type: Single JerseyBrand name: FukuharaOrigin: JapanCylinder Dia: 32Gauge: 24/28Capacity: 280 Kgs

Machine no-03M/c type: Single JerseyBrand name: FukuharaOrigin: JapanCylinder Dia: 30Gauge: 24/28Capacity: 280 Kgs

Machine no-04M/c type: Single JerseyBrand name: FukuharaOrigin: JapanCylinder Dia: 30Gauge: 24Capacity: 280 Kgs


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Machine no-11M/c type: RibBrand name: FukuharaOrigin: JapanCylinder Dia: 36Gauge: 24Capacity: 300 Kgs

Machine no-12M/c type: RibBrand name: FukuharaOrigin: JapanCylinder Dia: 30Gauge: 18/24Capacity: 280 Kgs




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Machine no-17M/c type: Three Thread FleeceBrand name: FukuharaOrigin: JapanCylinder Dia: 30Gauge: 20Capacity: 280 Kgs




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Machine no-28M/c type: Engineering Stripe/Auto Stripe (Single Jersey)Brand name: FukuharaOrigin: JapanCylinder Dia: 30Gauge: 24Capacity: 100 Kgs



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Pictures of Knitting Machine of Aman Tex :

Single Jersey Circular Knitting m/c Flat Knitting M/C

Interlock Knitting/Rib M/C Auto Stripe Knitting M/C

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2.3 DIFFERENT PARTS OF KNITTING MACHINE

Creel: Creel is used to place the cone.

Feeder: Feeder is used to feed the yarn.

Tensioning device: Tensioning device is used to give proper tension to the yarn.

VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length.

Guide: Guide is used to guide the yarn.

Sensor: Sensor is used to seen & the machine stops when any problem occurs.

Spreader: Spreader is used to spread the knitted fabric before take up roller.

Take up roller: Take up roller is used to take up the fabric

Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to

feed the yarn at specific finger.

Rethom: These devise are used in Electrical Auto Striper Knitting machine

2.4 PROCESS FLOW CHART OF KNITTING:

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement andTension device.

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

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2.5 RAW MATERIALS USE FOR KNITTING:

Type of yarn Count

Cotton Yarn 16s ,20s, 22s, 24s, 26S, 28S, 30S, 34S, 40S

Polyester Yarn 75D, 100D,150D

Spandex yarn 20D,40D,70D

Grey Mellange (C-90% V-10%) 20S ,22S ,24S, 26S ,30S ,34S

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

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

2.6 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-

Finished G.S.M. Type of Fabric or design of Fabric. Yarn count Types of yarn (combed or carded) Diameter of the fabric. Stitch length Color depth.

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Fabric Type GSM Yarn Count Color Stitch Length M/c dia x gauge Finished WidthPlain 115 40/1 CB Black 2.54 30 x 28 33" Tube

Single 135 30/1 CD Anthracite 2.68 36 x 24 72" OpenJersey 150 28/1 CB Black 2.75 36 x 24 74" Open

160 26/1 CD Ribbon red 2.7 30 x 24 62" Open

Lycra H.F.L-190 32/1+20DL Wash 2.85 30 x 28 64" OpenSingle F.F.L-250 30/1CB+40DL Black 2.98 30 x 28 64" OpenJersey 190 32/1+20DL Wash 2.85 30 x 28 64" Open

160/65 32/1CD Blue 2.7 30 x 24 43" Tube210/20 22/1CD White 2.72 28 x 24 76" Open

Single 210/20 22/1CD White 2.75 25 x 24 35.5" TubeLacost 220 22/1CD White 2.75 24 x 24 66" Open

220 22/1CD White 2.75 25 x 24 66" Open215/20 24/1CB Light 2.64 32 x 24 46" Tube

Lycra S/Lacost 210 28/1+40DL Average 2.85 26 x 24 66" Open

160/65 30/1CD White 2.65 30 x 24 43" TubeDouble 160/65 30/1CD White 2.65 28 x 24 41" TubeLacost 160/65 32/1CD Blue 2.58 30 x 24 43" Tube

160/65 32/1CD White 2.52 30 x 24 43" Tube

175 34/1 CB Light 2.54 40 x 18 37" Tube200 30/1 CB Light Violet 2.52 38 x 18 74" Open200 30/1 CB Medium 2.64 38 x 18 37" Tube

1x1 Rib 200 30/1 CB Light 2.54 38 x 18 68" Open200 32/1 CB Black 2.54 38 x 20 41" Tube200 28/1 CB White 2.58 38 x 18 74" Open220 28/1 CB Red/Green 2.52 36 x 18 68" Open

1x1 Lycra 280 28/1CB+70DL Average 2.85 34 x 18 32" TubeRib 380 34/2CB+70DL Average 3.1 36 x 16 34" Tube

2x2 Rib 300 24/1 CB Average 3.3 40 x 18 24" Tube380 20/1 CB Average 3.42 40 x 18 24" Tube

2x2 Lycra Rib 340 24/1CB+70DL Average 3.45 36 x 18 22" Tube

Pique 220 20/1CD Average 2.78 26 x 24 37" Tube

Fleece 260 30/1CD+75DP+26/2CB Medium P-4,B-3,L-1.5 30 x 20 68" Open280 34/1GM+75DP+20/2CB Anthalatic Grey P-3.5,B-3.25,L-1.6 30 x 20 68" Open

B/B 270 32/1CD+12/1CD Dark P-4.3,B-3.3,L-1.6 30 x 20 74" OpenB/B 300 32/1CD+12/1CD Dark P-4.1,B-3.3,L-1.6 30 x 20 74" Open

Lycra Fleece 260 30/1CD+70DP+26/1CB+20DL Medium P-4,B-3.1,L-1.5 30 x 20 68" Open260 30/1CD+75DP+26/1CB+20DL Dark P-4,B-3,L-1.5 30 x 20 64" Open

Engineering 165 26/1Dyed Wash 2.75 30 x 24 64" Open

Stripe(S/j) 190 Wash 3 36 x 24 76" Open

200 Wash 2.85 30 x 24 64" Open

2.7 Yarn Count, Stitch length for different types fabric knitting:

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2.8 END PRODUCTS OF CIRCULAR KNITTING MACHINE:

Single Jersey M/C:a) S/J Plainb) Single lacostec) Double lacosted) Single piquee) Double piquef) Terry

Rib M/C:a) 1*1 Rib fabricb) 2*2 Rib fabricc) Honeycomb

V-BED KNITTING M/C:a) Collarb) Cuffc) Emboss

2.9 PRODUCTION CALCULATION:

A. Production/shift in kg at 100% efficiency

countYarnmmSLNeedleofNoFeederofNoRPM

80.3527

)(..

B. Production/shift in meter

100/1260.

/.min/

cmCourseEfficiencyFeederofNoRPM

cmCourseCourse

C. Fabric width in meter:

100/.

100/.

cmWalesknittinginusedNeedlesofnoTotal

cmWaleswalesofnoTotal

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2.10 PRODUCTION PARAMETER:1. Machine Diameter2. Machine rpm (revolution per minute)3. No. of feeds or feeders in use4. Machine Gauge5. Count of yarn6. Required time (M/C running time)7. Machine running efficiency

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2.11 FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:

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 loop as a result

sinker mark comes. If sinker head bend then sinker mark comes.

Remedies: Sinker should be changed.

4. Star

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

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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.

7. Rust stain

Causes: If any rust on the machine parts.

Remedies: If any rust on the machine parts then clean it. Proper 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

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9. Grease stain

Causes: Improper greasing Excess greasing

Remedies: Proper greasing as well as proper maintenance

10. Cloth fall- out

Causes: Cloth fall- out can occur after a drop stitch especially when an empty needle with an

empty needle with closed latch runs into the yarn feeder and remove the yarn out of thehook of the following needles.

Remedies: Make sure all the latches of needle are closed with feeding yarn after a drop stitch.

11. Barre:

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

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.

12. Fly dust: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 tightlyduring 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.

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13. 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.

14. Yarn Faults: Neps. Slubs. Yarn count variations. Thick/Thin place in yarn. Hairiness.

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LABROTORY

3.1 LABORATORY MACHINERIES WITH ITS SPECIFICATION:

1. Brusting Strength Tester:No. of m/c-01Name of the m/c : TruBurstBrand Name : James H HelalOrigin : U.K

2. Pilling & Snagging Resistant Tester:No. of m/c-01Brand Name : SDL ATLASOrigin : U.K

3. Data color M/c:No.of m/c-01Brand Name : Ahiva-600Origin : U.S.A

4. Test Name : Colorfastness to Washing, Dry cleaning.Name of the m/c : Rota WashOrigin : U.KNo.of m/c : 02Test Method :ISO105-C06, ISO105-D02

5. Test Name : Colorfastness to RubbingName of the m/c : Crock MasterBrand Name : James H HelalOrigin : U.KNo.of m/c : 01

6 Test Name : Dimensional Stability, Spirality, Appearance after washing.Name of the m/c : Eltrolux wascator.Brand : SDL ATLASOrigin : U.KNo.of m/c : 02Test Method : ISO 6330, ISO 26330

7. M/C Name: Datacolor AutoLab TF Gravimetric Lab dispenserNo.of m/c-01Brand Name : Ahiva-600Origin : U.S.A

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8. Lab Dip m/c:No.of m/c: 02M/C NO- 01Brand name : Ahiba Nuance Lab Dip Dyeing m/cOrigin : U.S.A

3.2All Buyer Test Manual:

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Washing M/CRubbing Fastness Tester M/C

Data Color M/CTruBurst M/c29 | P a g e


Data Color M/CTruBurst M/c29 | P a g e


Data Color M/CTruBurst M/c

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Washing M/C Wash Fastness Testing M/C

Lab Dip M/C Pilling or Snagging M/C

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3.3 SOME TEST PROCEDURE

Color fastness to rubbing (wet & dry):

Procedure:

At first take a sample of size (14 × 5) cm at Wales & Course wise. Put the crocking cloth on to

the finger & stag by finger clip & run 10 times in 10 seconds manually & assess the crocking

cloth with gray scale.

Place the crocking cloth on the water, it will sucked some water and then squeeze the crocking

cloth. Then place the wet rubbing cloth on to the finger and stag with finger clip and run 10 times

in 10 seconds manually. Then assess the crocking cloth by gray scale for wet rubbing. Wet and

dry rubbing are checked according to buyer’s requirement.

Color fastness to washing. (ISO/05-CO6):

Procedure:1. Size of specimen: Cut sample & multifibre at (10 × 2)cm then stitch.

2. Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in distilled water &

cooled at 20°C & measured PH (where necessary).

3. Run the program in the following way: -

Test no. Temp°C Liq.volume ml Time min. Steel balls Adjust pH

C2S 60°C 50 30 25 10.5±1

4. Rinse the sample twice with cold water.

5. Dry at 60°C by hanging or by flat iron pressing but temperature should not less more than

150°C.

Pilling test:

Procedure:Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using template. Then sewn

the fabric so that it can be firmly fit in the tube a moulded polyurethane tubes. Then fourtubes are placed in a box & start 60±2 rev/min for 5 hrs or according to buyer requirement.Here mainly used 3hrs(1100 cycle). Then assess the pilling by putting tested specimen on theviewing cabinet & compare with standard photographs.

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Shrinkage & Spirality test:

Buyer’s requirements:

Template size: 50cm & 35cm, 25.5cm &18cm (use after quick wash).

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 35cm at 3 places. 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

= ----------------------------------×100Before wash

Width wise:After wash – Before wash

= ----------------------------------×100Before wash

Spirality test:

=M)&HforthLength(wid

2sideRightsideLeft

× 100 %

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Color fastness to water (ISO 105 EO1& EO2):

1. Sample size: Cut the specimen & multi-fiber at 10×2cm & sewn together.

2. Solution: Wet in distilled water at room temperature & it will suck water.

3. Place it in acrylic resin plates & put the weight on to the plates.

4. Keep it in oven & keep the temperature at 37± 2°C for 4hrs.

5. Open the specimen & dry it in the air hot exceeding 60°C.

6. Assess the staining & shade change with gray scale.

Color fastness to perspiration Alkaline & Acid solution (Method: ISO 105 E04):

1) Procedure:Cut the specimen & multifibre at 10×2cm & sewn together.

2) Prepare solution:

Alkaline Solution:

0.5g/l of 1-histadine mono hydrochloride monohydrate

5g/l of sodium chloride

This solution is brought to pH -8 with 0.1 mole/l caustic solution.

Acid solution:

0.5 g/l of 1-histadine monohydrochloride monohydrate

5g/l of sodium chloride.

2.2 g/l of sodium dihydrogen orthophosphate dehydrate.

This solution is brought to pH-5.5 with 0.1 mole/l caustic solution.

3) M: L = 1: 50

4) Wet the specimen in flat dish containing acid & alkaline solution & keep for 30min. Then take

the specimen & squeeze the excess solution by two glass rods.

5) Put the specimen in to the acrylic resin plates & put wt. on the plates.

6) Keep it in the woven at 37°C ± 2°C for 4hrs.

7) Open the specimen 6 multi fibre & dry separately in the air temperature not exceeding 60°C.

8) Access the staining & shade change with grey scale.

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PH Test:

Procedure:

Take 2gm sample fabrics and cut into small pieces. Then put it conical flax with 100cc water (M:

L -1:50). Then shake it 15 min, then place it in a shaker m/c for 1 hour. Then check PH by PH

meter.

GSM TEST:

Procedure:

GSM is the most important factor. There is a GSM cutter. The sample cut by the GSM

cutter is weighted in the electronic balance. The reading (in gm) from the balance is multiplied

by 100 to get the value of GSM.

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Dyeing Section4.1 Dyeing Machine Capacity :SampleNo. of High temperature sample dyeing machine = 06 pcsTotal machine capacity of sample m/c = 190 kgsTotal production capacity of sample m/c = 150 kgs

ProductionNo. of High temperature dyeing machine = 11 pcsTotal Machine capacity on dyeing floor = 6750 kgsTotal Production capacity on dyeing floor = 16 metric tons/day

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4.2 Dyeing Machine Specification:No.of Machine :11Machine no-01

Machine name : Thie’s (High temperature machine).Origin : GermanyCapacity : 250 kgNumber of nozzle : One (01)Max. working Temperature : 140°CWorking Pressure : 0.35 MpaTest pressure : 0.55 MpaYear of Construction : 2002

Machine no. -02


Machine no-03


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Machine no-04


Machine no-05


Machine no-06


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Machine no-07

Machine name : Thie’s (High temperature machine).Origin : GermanyCapacity : 750 kgNumber of nozzle : Three (03)Max. working Temperature : 140°CWorking Pressure : 0.35 MpaTest pressure : 0.55 MpaYear of Construction : 2002

Machine no-08


Machine no-09


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Machine no-10

Machine name : Thie’s (High temperature machine).Origin : GermanyCapacity : 750 kgNumber of nozzle : Two (02)Max. working Temperature : 140°CWorking Pressure : 0.35 MpaTest pressure : 0.55 MpaYear of Construction : 2002

Machine no-11

Machine name : Thie’s (High temperature machine).Origin : GermanyCapacity : 1000 kgNumber of nozzle : Two (02)Max. working Temperature : 140°CWorking Pressure : 0.35 MpaTest pressure : 0.55 MpaYear of Construction : 2002

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Sample Section

Specification Of Sample Dyeing Machine:No. of Machine : 06

Machine no-01Machine name : Thie’s (High temperature machine)Origin : GermanyCapacity : 60 kgMax. Variable Temperature : 160°CMax. Operating Pressure : 400 KpaYear of Construction : 2002

Machine no-02Machine name : Thie’s (High temperature machine)Origin : GermanyCapacity : 30kgMax. Variable Temperature : 160°CMax. Operating Pressure : 400 KpaYear of Construction : 2002



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4.3 Raw materials for dyeing:

Raw materials used in the dyeing section are:1. Grey fabrics2. Dyes3. Chemicals.

Grey fabrics:Following types of gray fabrics are dyed: Single jersey Single jersey with lycra Polo pique Back Pique Single lacoste Double Lacoste Fleece Rib Rib with lycra 1Χ1 rib 2Χ2 rib Different types of collar & cuff.

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4.4 Flow Chart For Dyeing :

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

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4.5 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/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

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 andtemperature in the process.- The pH, hardness and sodium carbonate content of supply water should check

daily.

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3. Patchy dyeing effect:

Causes:- Entanglement of fabric.- Faulty injection of alkali.- Improper addition of color.- Due to hardness of water.- Due to improper salt addition.- Dye migration during intermediate dyeing.- Uneven heat in the machine, etc

Remedies:- By ensuring proper pretreatment.- Proper dosing of dyes and chemicals.- Heat should be same throughout the dye liquor.- Proper salt addition.

4. 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

5. 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

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6. 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, sothat the large un-dissolved particles are removed

7. 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

8. 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

Remedies:- Maintaining proper reel sped & pump speed.- Proper Mixing of the softener before addition.- Prevent the entanglement of the fabric during application of softener

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Finishing Section5.1 Machine List of Finishing Section:

Machine Name Machine Quantity

Slitting m/c 02

Hydro Extractor 02

Dryer 02

Stenter 02

Open Compactor 01

Tube Compactor 01

Single Drum Raising m/c 01

Double Drum Raising m/c 01

Sueding m/c 01

5.2 Flow chart for tube fabric finishing:

Tube fabric

Dewatering

Dryer

Compactor5.3 Flow chart for open fabric finishing:

Open fabric

Slitting

Stenter/Dryer(santex)

CompactorsRaising/Sueding

Stenter/Dryer(santex)

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5.4Function of Different Finishing M/C:

Objectives of De-Watering M/C: Remove excess Water Application Of GSM To control the crease mark of the fabric.

Hydro Extractor M/C: To extract excess water.

Slitting M/C:

To open tube fabric according to specific needle mark.

Dryer M/C: To dry the fabric. To control the overfeed system To control the vibration which increase the GSM

Compactor M/C: Shrinkage control Width control

Stenter M/C: Heat setting Width control, Finishing chemical application Loop control GSM control Drying Shrinkage control

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Printing Section

6.1 Different Types of Printing:

Pigment Printing Rubber Printing Flocking Printing Glitter Printing Emboss Printing Screen Printing

6.2 Chemical Used:

Thickener (PG): It is a main compound for making a paste.

Binder: Hold color on to the fabric surface.

Pigment: It is a coloring substance.

6.3Printing Process Sequence:

6.4 Pigment Printing:Recipe:

Thickener-2%Binder-8%Fixer-2%Water-90%

Sequence:Table Preparation

Fabric Plaited on the table

Pigment Printing paste apply with the help of screen

Curing at 160’c (Belt speed 6.50 m/min)

Delivery

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6.5 Faults in Printing:

Fatting: If the pigment printed fabric is fatted (on printed portion) after washing, then this fabricis rejected. So it is a major fault in printing.

Cracking: If the rubber printed fabric is braking (on printing portion) after elastration

Machine Used in Printing Section:

Machine Name Brand Origin Machine Quantity

Tunnel Dryer Sujou-Yuhui Chaina 01

IR dryer Sujou-Yuhui Chaina 04

Exposer Sujou-Yuhui Chaina 01

Heat press M/C Sujou-Yuhui Chaina 03

Screen Frame Binder Sujou-Yuhui Chaina 01

Mixture M/C Sujou-Yuhui Chaina 01

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.Picture Gallery

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.Picture Gallery

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.Picture Gallery

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Garments Section

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7.1 Sample Section:7.2.1 Types of Sample: Photo sample Fit sample Size set sample Pre Production sample Salesman sample Counter sample Shipping sample

Quality Checking of SampleProduct

Sample Garments

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Sample Garments

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Sample Garments

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7.3 Cutting Section:

MARKER MAKING: It is a thin paper which contains all the necessary pattern pieces for allsizes for a particular style of garments. It gives special instruction for cutting. It can be done bothmanually and computerized. In padma PolyCotton computerized and manual method are used.

CONSIDERABLE POINTS BEFORE MARKER MAKING: Fabric width (1/2) higher than marker width Fabric length higher than marker length (1” + 1”) The grain line should be parallel to the line of Wales in knit fabrics. All the pattern pieces of garments should be along the same direction when laid on an

asymmetric fabric. Considered garments production planning.

COMPUTERISED MARKER MAKING: There are two systems for marker making

1. Digitizing system.2. Automatic system.

FACTOES RELATED TO MARKER EFFICIENCY:

Marker planer Size of garments Marker length Pattern engineering Fabric Characteristics Marker making method Marker width. Style of garments.

MARKER EFFICIENCY: The marker planner measures his success by the efficiency of themarker plan. The following formula is used to measure the efficiency:

Marker efficiency=Area of the pattern in the marker plan/ Total area of the marker plan X 100%.

MINIMIZATION OF FABRIC WASTAGES OUTSIDE THE MARKER:

There are four points for the fabric minimization outside the marker

1. Ends of ply losses.

2. Loss of fabric in roll.

3. Selvedge loss.

4. Purchase loss.

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FABRIC SPREADING:Spreading is the process of superimposing lengths of fabric on a

spreading table or cutting table or specially designed surface in preparation for the cuttingprocess. A spread is the total amount for a single marker.

EQUIPMENT OF FABRIC SPREADING:

Spreading equipment consists of: Spreading surface. Spreading machines. Fabric controlling device. Fabric cutting devices.

The appropriate type of spreading surface is determined by the type, spreadingequipment, cutting method, cutting equipment, and the industry’s quality standards.

The fundamental purpose of a spreading machine is to superimpose layers of the fabric ina smooth, tension –free manner for accurate and efficient cutting.

Fabric control devices at higher rates of travel, it is an operate to monitor more than oneaspect of the operation ; therefore ,edge sensing devices; lap counters , with monitors,and out-of –cloth sensors simply the operation so the operator’s primary concern is thefabric being spread.

Objects of fabric spreading:

To place the number of plies of fabric to the length of the marker plan correctly alignedas to length and with and without tension.

To cut the garments in bulk and saving in cutting time per garment that result fromcutting many plies at the same time.

TYPES OF SPREADING:

There are two types of spreading1. Flat spreading.2. Stepped spreading.

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MEHODS OF FABRIC SPREADING:

1. Manual method.2. Mechanical method.

a) Semi automatic.b) Full automatic.

9.3.12 REQUIRMENTS OF FABRIC SPREADING:

1. Alignment of fabric ply. 6. Elimination of static electricity.2. Correct ply tension 7.Matching checks and stripes.3. Fabric must be flat. 8. Easy separation of cut lay into bundles.4. Elimination of fabric flaws. 9. Avoidance of fusion of plies during cutting.5. Correct ply direction and stability. 10. Avoidance of distortion in Spread.

TYPES AND NAME OF CUTTING MACHINES:There are many kinds of cutting machine are used in our country. Cutting machine is as follows:

1. Straight knife cutting machine.

2. Band knife cutting machine.3. Round Knife cutting machine.

4. Die cutting machine.5. Automatic Straight Knife cutting Machine.

Fabric Cutting

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Fabric Cutting

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Fabric Cutting

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Garments Cutting Section

M/C Specification:

Auto Spreader (1):M/C No.: 01Brand Name: JutexCountry: GermanyYear of Manufacturing: 2006

Hand Cutter (20):Brand Name: Mack (20)Country: JapanSpeed: 3000/3600Volt: 220Frequency: 50/60 HzPhase:1Blade: Straight bar blade

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SEWING SECTION

There are 38 sewing line under three sewing unit in Aman Tex. All the sewing macine in AmanTex are Juki brand which origin is Japan. The whole set-up work for the production of 100%export oriented knit product.

7.4.1 Machine List that used in the Factory:

Sl. No. Name of Machine Brand

01 1 needle Lock Stitch JUKI

04 Over Lock 6 Thread JUKI




10 Flat Lock JUKI

13 Zig Zag JUKI

15 Back Top JUKI

20 Snap Button JUKI

22 Button Stitch JUKI

23 Button Hole JUKI

27 4 Needle Feed of the arm JUKI

29 Plain M/C JUKI

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7.4.2 SEWING SEQUENCE OF BASIC T-SHIRT IN AMAN:

Serial Operation Machine used

1. Front part gathering Plain M/C(2)2. Solder Joint Over lock M/C(1)Thread

no.43. Neck rib make

Plain M/C(1)4. Neck joint Over lock M/C (1)

5. Main+Size level joint Plain M/C(1)

6. Level joint Plain M/C (1)

7. Sleeve gathering Plain M/C(2)

8. Sleeve joint Plain M/C ()

9. Side seam Over lock M/C(2)

10. Cuff rib make Plain M/C(1)

11. Bottom make Over lock M/C(1)

12. Bottom joint Plain M/C(1)

13. Loop make Plain M/C(1)

14. Loop top seam Over lock M/C(1)

15. Loop attachment Plain M/C(3)

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7.4.3 Sewing Sequence of Long Sleeve T-Shirt:

Serial Operation Machine used1. Solder joint Over lock Machine.2. Neck rib tuck. Plain Machine.3. Neck rib loose stitching. Plain Machine.4. Neck rib joint. Over lock Machine.5. Size + main level joint. Plain Machine.6. Back tape joint. Plain Machine.7. Back tape top stitch. Plain Machine.8. Neck top stitch. Flat lock Machine.9. Sleeve joint. Over lock Machine.10. Sleeve top stitch. Flat lock Machine.11. Side seam. Over lock Machine.12. Sleeve hem. Flat lock Machine.

13 Body hem. Flat lock Machine.

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6 Thread over lock M/C

Plain Stitch M/C

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Plain Stitch M/C

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Plain Stitch M/C

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Ironing

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Ironing

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Ironing

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Button Attaching M/C

Button Hole M/C

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Button Hole M/C

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Button Hole M/C

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7.5 FINISHING / PRESSING SECTION:

The term garments finishing mainly applies to pressing, Folding, and Packing of garments. Aftercompleting pressing, the garments have to be folded. After Completing pressing, the garmentsare folded with a predetermined area. Garments are folded according to the direction of Buyersrequirements or in a standard area.7.5.1 Pressing/Ironing:

This is a finishing process done by subjecting a cloth to heat & pressure with or without steamto remove unintended creases and to impart a flat appearance to the or garments. Also, pressingis done to introduce creases in the garments, in garments industries, pressing is called Ironing.

7.5.2 Objects of Ironing/ Pressing:

1. Remove of unwanted creases and crinkles.2. To apply creases where necessary.3. Shaping.4. Under pressing.5. Under pressing.6. Final pressing.7.5.3 List of Accessories Used in Finishing Section: Main Level Size Level Care Level Hang Tag Bar code Sticker Poly Bag Tag Pin Carton Hang Tag String Clip Paper Gum Tape Silica Jel Tissue Paper

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Quality Assurance

8.1 Quality Assurance System:

The Quality Assurance Department is assigned to maintain consistently uniform quality of thematerial in process and various stages of its manufacturing.

Objective of quality control: Research Selection of raw material Process control Process development Product testing Specification test

Aman Tex Ltd. Assures the quality of the products of dyeing section in the following three steps:

1) In Laboratory2) In Dyeing Section3) In Finishing Section

Procedures are described below:

In Laboratory: Swatch card from buyer according to their requirement Recipe prediction for sample dyeing Sample dyeing until matching with swatch card Fastness & other tests of the fabric or yarn are done here

In Dyeing: According to the buyer’s sample, sample dyeing is done in sample dyeing machine in

dyeing shed & again matched with the approved sample. If result is ok, then bulk production. During dyeing sample are taken until accurate shade matching. The interval may be 30-

40 minutes. After dyeing sample is collected after softening matching is done. Last of all, sample is collected after fixation & matched. Then allowed the fabrics to be finished.

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In finishing: By using a series of finishing machines correct width, softness & appearance are

maintained according to requirements. Then sample is done for several times to testGSM, shrinkage & fastness properties. Finally fabric is inspected & prepared fordelivery.

8.2 Quality Standards:

Padma Poly cotton knit fabrics Ltd. Follows the quality standard: ISO-9001:2000.

8.3. Fabric Inspection:

The inspection of fabric is a procedure by which the defects of fabric are identified and fabric isclassified according to degree or intensity of defects. The fabric inspection is done for both greyand finished fabric.

8.3.1Grey Fabric Inspection:

Grey fabric inspection is performed according to 4-point system.

8.3.2Finished Fabric Inspection:

4 point numbering system is followed for finished fabric inspection. Defects found in the finalinspection.

1) Uneven shade2) Oil Spot3) Neps4) Crease Mark5) Machine stoppage mark6) Listing7) Line mark8) Double yarn9) Fly yarn contamination

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Conclusion :

9.1 Limitation of the Report:

Because of secrecy act the data on costing and marketing activities has not been supplied& hence this report excludes these chapters.

I had a very limited time in spite of my willing to study more details it was not possibleto do so.

Some of the points in different chapter are not described as these were not available. Because of some security reason adequate amount of pictures could not be attached or

shown in this report.

9.2 Lastly…..I have completed my Industrial Training successfully by the grace of Allah.

Industrial Attachment send me to the expected destiny of practical life. AMAN TEX is a well

know factory in the textile field of Bangladesh. The completion of the two months industrial

attachment at AMAN TEX gave me the inspiration that factory is one of the appropriate destiny

to implement the theoretical knowledge. From this industrial attachment I got the details idea

about the factory environment, production process, total management, etc.

AMAN TEX GROUP are well equipped and the working environment is excellent. The relation

between top management to bottom level is so nice.

I am lucky to get the opportunity of having training in this mill.

The factory runs by a number of efficient Textile Engineers, Skilled technical & Non-technicalpersons.

All the Textile Engineers, technical & Non-technical persons are very sincere, co-operative andhelpful.

I wish good luck of them and also for this factory.

It was really a productive practical learning besides my four year academics, so we wish I

will be able to implement our learning and methodological knowledge successfully in the

textile industry and the betterment of the economy of my country.

Date post:	06-May-2015
Category:	Engineering
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