INDUSTRIAL ATTACHMENT OF BISWAS GROUP LTD

1

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

BISWAS GROUP LTD.

2

TABLE OF CONTENTS

Serial No. Topic Page No.

01 Introduction 05

02 Company Profile 06

03 Knitting Section 12

04 Quality Control 30

05 Batch Section 33

06 Dyeing Lab 35

07 Dyeing 39

08 Finishing Section 68

09 Fabric Inspection 75

10 Quality Assurance system 77

11 Maintenance 79

12 Utility 85

13 Effluent Treatment Plant 89

14 Conclusion 91

3

INTRODUCTION

By means of practical knowledge its not possible to apply the theoretical knowledge

in thepractical field. For any technical education, practical experience is almost

equal importance 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 provide 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, skillness about various

processing stages.

It is also provide us sufficient practical knowledge about production management,

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

of machinery and their operation techniques etc.

Textile education cannot be completed without industrial training. Because this

industrial training minimizes the gap between theoretical and practical knowledge

and make us accustomed to industrial environment. We got an opportunity to

complete our industrial training at BISWAS SYNTHETIC LTD. It has well planned &

equipped fabric dyeing-finishing and printing unit in addition to facilitate knitting

and knitwear manufacturing.

4

COMPANY PROFILE

GENERAL INFORMATION ABOUT THE COMPANY:

Biswas Group was established in 1985 Biswas Group deals in Apparels, Textile and Accessories. Biswas Group have 9 fully automated garments factories in Dhaka. 7 associate factories in Dhaka.

Product Range- Men's Women's Boys, Girls, Kids and Toddlers, T-Shirts, Polo Shirts, Woven Women's Blouses, Men's Shirts, Pants/Shorts Casual/Denim Men's, Women's and kids, Jogging Suits, Swimwear, Nighwear, Winter Wear and All kinds of Accessories.

Monthly Capacities : 43000 pcs woven bottoms, 300000 pcs woven tops, 380000 pcs pants, 600000 pcs knit tops, 30000 pcs knit bottoms.

Work force - 9000 employees Sewing Lines : 100 Sewing Machines : 4567 Knitting Machines : 220 Weaving Machines : 300 Dying Machines : 47

Head office:

J.S. Bhaban, 95, BirUttam C.R. Dutta Road (New)299/2A Sonargaon Road (Old), Dhanmondi, Dhaka-1205, Bangladesh

Tel: 9668835-7,8611796,8610685,9673065

Fax: 88028613367

Email: [email protected]

5

Web: www.biswasgroup.com

Project location:

6

7

Buyer:

Aldi - Germany

C & A - UK

Calvin Klein- USA

Carrera - Italy

Defacto - Turkey

Ecko– USA

H & M - Sweden

Hurley -USA

Inditex - Spain

JC Penney - USA

Kenneth Cole - USA

Kik - Germany

LC Waikiki - Turkey/France

Li & Fung - Internalional

Lidl - Germany

Oshkos -USA

Roca Wear - USA

Sol's - France

Sears/K-Mart - USA

Tema - Turkey

Wal- Mart - Europe

Zara – Spain

8

General Manpower Organogram:

Chairman

Director

Executive Director

Production QualityAdminAccounts MarketingMaintenance Utility store security

Production QualityAdmin Accounts Marketing Maintenance Utility store security

ManagerManagerManagerManagerManagerManager Mngr. Mngr.officer

Assistant Senior AdminAccountsMarketingMaintenanceUtilitystore Assist

Manager Officer OfficerOfficerOfficer Engineer Engineer Officer Officer

Senior Assistant Cashier Fore man Assistant Helper security

Production Officer Admin Engineer Guard

Officer Officer Fitter man Worker

Production Lab Helper Worker

officer Assistant

Assistant Lab Worker

Production Boy

officer

Machine

Operator

Helper

Worker

9

Shifting:

In Biswas Synthetic Ltd. the whole day production time is divided into 2shift. Per shift 12 hours.

Shift Duration

Shift A

8:00 am- 8:00 pm

Shift B

8:00pm – 8:00 am

Responsibility of Production officers:

1. To give dyeing program slip.

2. To match production sample with target shade.

3. To collect production sample lot sample matching next production,

4. To observe dyed fabric during finishing running & also after finishing.

5. To identity disputed fabrics & report to P.M/G.M. for necessary actions.

6. To discuss with P.M about overall production if necessary.

7. To sign the store requisition & delivery challan in the absence of P.M.

8. Also to execute overall floor works.

9. To maintain loading'/unloading khata.

10. Any other assignment given by higher authority.

Title :Production Office

Report To : Sr. Production Officer.

Job Summary:

To plan, execute & follows up the production activities &. control the quality … production

with related activities.

Duties & Responsibilities:

Overall supervision of dyeing, finishing production.

Batch preparation & pH I chock.

Dyes & chemical requisition issue & check.

Write Fabrics loading & unloading time from m/c

Program making, sample checking, colour measurement

Control the supervisors,operator, ass. operator and helper of

10

Dyeing m/c.

And also any other over work as & when required by the management.

Title : Sr. Production Office

Report To :Manager

Job Summary:

To plan.execute& follows up the production activities & control the quality production with

related activities.

Duties & Responsibilities:

Overall supervision of dyeing, finishing production.

Checks the sensitive parameters of different machine for smooth dyeing

Checks the different log books of different areas & report to management

Checks out the plan to control the best output from supervisors & workers.

To trained up& motive the subordinates how to improve the quality production.

Control the supervisor, operator, Asstt. Operator & helper of dyeing.

11

KNITTING SECTION

12

Knitting section layout:

Office

Store

QC

Wash

room

13

Process flow diagram of knitting:

MERCHANDISER

SAMPLING

TESTING

ORDER PLACEMENT BY BUYER

YARN PROCURED & STORE

FABRIC MADE (YARN TESTING)

PRE-PRODUCTION

SAMPLE

PRODUCTION

QUALITY INSPECTION

14

Process control of knitting:

Yarn in cone form

Creels

Pipe

Knot catcher

Tension disk

Inlet stop motion

Yarn guide

PF Wheel

Out let stop motion

Guide

Needle

Fabric

Fabric take up roller

Inspection

Numbering

15

Knitting:

Knitting is the method of creating fabric by transforming continuous strands of yarn into a series

of interlocking loops, each raw of such loops hanging from the one immediately preceding it.

The fundamental structure unit of a knitted fabric is the loop. Any circular knitted fabric is

composed of row after row of intermeshed loops. Different types of fabric are made of different

method of intermeshing the loop. The gross dimension of knitted fabric is simply a relation of

average shape and size of individual loop. There are several key variables in the production

which affect the average shape and size of the loop. After knitting the grease fabric is dyed to

required shade and finished to required weight and width.

Classification of knitting:

Warp knitting:

A method of making a fabric by normal knitting means is which the loop made from each

warp thread is formed substantially along the length of the fabric. Characterized by the fact that

each warp thread is feed more or less in the line with the direction in which the fabric is

produced.

Weft knitting:

A method of making a fabric by normal knitting means is which the loop made from each

weft thread formed substantially along the length of the fabric. Characterized by the fact that

each warp thread is feed more or less in the line with the direction in which the fabric is

produced.

Knitting

Weft knitting Warp knitting

Flat knitting Circular knitting

Double jersey Single jersey

16

Single jersey:

A fabric in which all the loops of the Wales are intermeshed in one direction is called

single jersey. Only cylinder is used to make single jersey fabric.

Double jersey:

A fabric in which all the loops of the alternate wales/wales are intermeshed in one direction and

all the loops of the other wales knitted t the same course are intermeshed in the other direction is

called the double jersey. Dial and cylinder are used to make this type of fabric.

Primary knitting elements:

Needle:

The needles are the most important stitch forming elements. They are displaced vertically up and

down and are mounted into the tricks or cuts of the knitting cylinder.

There are three types of needles namely:

1) Latch Needle.

2) Spring bearded Needle and

3) Compound Needle.

The main function of needle is loop formation.

Cams:

Cam is the second primary knitting element. The cams are the mechanical device which convert

the rotary machine drive into a suitable reciprocating action for the needles or other elements

came are carefully profiled to produce precisely time movement and dwell periods.

Types of knit cam:

1.Knit cam

2.Tuck cam

3.Miss cam

17

Sinker:

Sinker is a thin metal plate with action at right angles to and fro between adjoining needles.

Functions of Sinker:

1) Loop formation: The main objects of a sinker are to assist the needles in loop formation by

sinking or knitting the newly laid yarns into a loop.

2) Holding down: It also holds down the loops at a lower level of the needles stems and

prevents the old loops from being lifted as the needles raise to clear them for their hooks.

3) Knocking over: The function is knocking over at which the needle passes through the old

loop by drawing a new loop.

End Products of Single Jersey Circular Knitting Machine:

1.S/J Plain 2.Single Lacoste

3.Double Lacoste 4.Single pique

5.Double pique 6.Terry

7. Fleece

End Products of Rib Machine:

a) 1x1 Rib

b) 2x2 Rib

c) Honeycomb

18

Cam arrangement:

▲→ Knit Cam

Π→ Tuck Cam

=→ Miss Cam

Single Jersey: ▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲

Rib Stracture:▼ ▼ ▼ ▼ ▼ ▼

▼▼▼▼▼▼

▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲

Interlock:▼=▼=▼=

=▼=▼=▼

= ▲ = ▲ = ▲

▲ = ▲ = ▲ =

Single pique: Π▲Π▲Π▲

▲Π ▲ Π▲ Π

Double pique:ΠΠ ▲▲ ΠΠ ▲▲

▲ ▲ ΠΠ ▲ ▲ΠΠ

Single Lacoste:Π▲ ▲ ▲ Π ▲ ▲

▲ ▲Π▲ ▲ ▲Π

Double Lacoste:ΠΠ▲ ▲ ▲ ▲ ΠΠ ▲ ▲ ▲

▲ ▲▲Π Π▲ ▲ ▲▲Π Π

Fleece fabric: = ▲ Π= ▲ Π▲ Π=

= ▲ Π= ▲ Π▲ Π=

= ▲ ΠΠ▲= ▲ΠΠ

19

Machine profile of knitting section:

Knitting Machine (Single Jersey)

SL M/C Dia/Gauge M/C Quantity Capacity (Per Day) Origin Brand

1 17x24 GG 1 Set 200 Taiwan Min Hua




5 23x24 GG 1 Set 220 Taiwann Min Hua





Total= 9 Set 1990 kg

Knitting Machine (rib Interlock)


1 30x18 GG/24 GG 1 Set 300 Taiwan Min Hua






Knitting Machine (Micro-Polar)


1 26x18 GG 7 Set 1750 Taiwan SandaDask


3 28x19 GG/24 GG 19 Set 5320 Taiwan SandaDask







20

Knitting Machine

CVC Fleece (Cross/Straight Terry)





Flat Rib

1 60x20 GG 6 Set 2400 Pcs Chaina Sen Huang

Total= 6 Set 2400 pcs

21

Knitting variables:

Yarn count

Yarn twist

Spinning system

No. of ply of the yarn

Stitch length

Yarn tension

Required time (M/C running time);

Take down tension

Yarn quality

Machine gauge

Machine Diameter

Machine rpm

No. of feeds or feeders in use

Machine running efficiency.

Machine pitch (t) : Is defined as the distance between the centers of two adjacent

Needle of the same needle row indicated in mm.

25.4

Pitch = m.m

Gauge(E)

Machine gauge (E) : Machine gauge denotes the number of needles per inch , arranged

On the needle carrier and based on the nominal machine diameter .

25.4

Gauge (E) = mm.

Pitch

Loops : It is a basic unit consisting of a loop of yarn meshed at its base with

previously Basic unit .

Stitch : The smallest dimensionally stable unit of all knitted fabrics is the stitch . It

consists of a yarn loop which is held together by being intermeshed with another stitch or

other loops

Stitch length:Stitch length is a length of yarn which includes the needle loop & half the sinker

loop on either side of it. Generally the larger the stitch length, the more extensible & lighter the

fabric & the poorer the cover, opacity & bursting strength.

22

Raw materials for knitting:

Key accessories used in Circular knitting:

Yarn feeder guide

Needle

Sinker

Cam

Cylinder

VDQ pulley

Pattern wheel

Sinker cam cap

Sinker trick ring

Dial

Needle retaining spring

Cam box

cam plate

Inventor

Belt

Type of yarn Count

Cotton 20S, 22S,24s,26s,28s,30s,32s, 34S, 40S

Polyester 75D,150D

Lycra yarn 20D,40D

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

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

23

Production calculation:

A. Production/shift in kg

B. Efficiency:

24

Relationship between knitting parameter:

1. Stitch length increase with decrease of GSM.

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

Decrease.

3. If machine gauge increase then fabric width decrease.

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

5. If shrinkage increases then fabric width decrease but GSM and Wales

Per inch increase.

6. For finer gauge, finer count yarn should use

7. Grey GSM should be less than finish GSM

Yarn Twist and Yarn Count:

The amount of twist is an important factor in finished consumers’ goods. It determines the

appearance as well as the durability

and serviceability of a fabric. Fine yarns require more twist than coarse yarns. If the yarn twist

increase, the yarn strength increase up to certain level after that yarn strength decrease.

The twist factor for combed cotton yarns for knitted fabrics should not exceed 3.7, whereas in

case of carded yams, a twist factor up to 3.9 is tolerated of yarns for knitted fabrics .

In case of knitting yams a part of the yarn strength has to be sacrificed for a better and softer

handle

Yarns with low twist are used for knitted fabrics, yarns with high twist are used for crepe yarns

Yarnswith average twist are used for regular woven fabrics.

25

Effect of stitch length on color depth:

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

with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted

then. Similarly in case of light shade loop length should be relatively smaller

Knitting defect & remedies :

Fault name Causes Remedies image

1. Hole Mark

# yarn breakage or yarn

cracks.

# If the yarn count is not

correct on regarding

structure, gauge, course

and density.

# Badly knot or splicing.

# Yarn feeder badly set.

# If yarn tension too

high

#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

# When a needle breaks

down.

# If a needle or needle

hook is slightly bends .

# If needle does not

catch yarn .

# Needle should be

straight as well as

from broken latch.

3.Star Mark

# Yarn tension variation

during production.

# Buckling of the needle

latch.

# Low G.S.M fabric

production

# Maintain same

Yarn tension during

production.

# Use good

conditioned needles.

26

4.Drop

Stitches

# 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.

#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.

5.Bariness

# Use of irregular yarn

having higher long term

irregularities.

# Using different count

thread.

# Remove irregular

yarn

# Use proper yarn

count

#We can use it for

white fabric

6.Loop

# If needle latch is hard

or curve.

# if yarn tension is loose

.

# Clean or change

the needle.

# Set proper yarn

tension

27

7.Lycra out

Cause by If lycra is

missed or Lycra attach

with the yarn

Check the feeder and

attatchlaycra.

8.Seat up

(cloth

fallout)

# if needle latch is not

work properly/jaum

# Causes by thick yarn

# Improper/large knot

Make sure all the

latches of needle are

closed with feeding

yarn after a drop

stitch.

9.Oil mark

# Excessive oil flow in

the needle

# Leakage of oil line

# Ensure that oil does

not pass on the

fabrics.

# Well maintenance

as well as proper

oiling.

28

10.Fly

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.

# 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

# If yarn contains foreign

fiber then it remains in

the fabric even after

finishing,

# If lot, count mixing

occurs

# By avoiding lot,

count mixing.

# Fault less spinning.

12.Sinker

Mark

# 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

Sinker should be

changed

29

Quality Control

Quality assurance system of knitting division:

The quality assurance department is assigned to maintain consistently uniform quality of the

material in process and various stages of its manufacturing. After collecting fabric rolls from

different machines, these fabrics need to inspect thoroughly by the quality inspectors to assure

required quality before dying. Quality assurance of knitted grey fabric is described here.

Quality control

On-lineOff-line

Quality control equipment:

Following equipment are used to ensure proper quality of the produced fabric

Yarn tension meter

Stitch length meter

Magnifying glass

GSM cutter etc

On- line:

1. Grey GSM of the fabric

2. Grey inspection

3. Stitch length

4. In coming good quality check

Off- line:

1. Check diameter, GSM, unevenness, dead fiber, hairiness, thick and thin place, and

contamination

2. Shrinkage %

3. Spirality

Body inspection:

All rolls are kept in front of the inspection m/c time to time and are inspected over the inspection

m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre

effect, fall out, contamination, fly, holes, oil lines, needle line, slubsetc are recorded in inspection

report to classify the fabric based on the four point system.

30

Collar & cuff inspection:

Collar& cuff are inspected visually under the light box, any major or minor fault in collar/cuff

like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly

counted and recorded.

Quality Control Standard Value:

Fabric inspected by 4-point system.

Shortly describe about 4-point system.

This is the universal system for the inspection of grey and finished fabric. In this system, we

count penalty point for different kind of defect as well as according to the defect size. Different

types of defect may come from yarn fault, manufacturing fault, transportation fault.

Parameter of penalty point:

Hole-H

Rus Stain-RS

Oil Stain-OS

Missing Yarn-MY

Fly/Contamination-F/c

Slubs-S

Needle drop-ND

All holes, regardless of size will be penalized 4 point.

Four point grading system

Size of defects Penalty

3 inches or less 1 point

Over 3 inch but not over 6 inch 2 point

Over 6 inch but not over 9 inch 3 point

Over 9 inch 4 point

Any hole 4 point

31

Calculate points per 100 square yards fabric:

= 100widthActual

36

lengthRollActual

countedpointsActual

= points/ 100 sq. yards

Classification of Inspection Fabric:

< 40 points = A

41-60 points = B

61-80 points = C

80 above = Reject.

Acceptance:

Generally any piece of fabric with 40 points or less faults per 100sq. yard is

allowed to pass however for a roll, the average value should not exceed 18point per

100sq.yard.More than 40points faults per 100sq yard is recorded as “REJECT”.

Defects For Rejection:

Patta-P

Continuous Star-CS

Sinker Mark-SM

Wrong Design-WD

Poor Elasticity-PE

Major thick

Needle Line NL

32

Batch section

Batching:

Primarily batching is done by batching section which is supervised by dyeing manager. The main

function of batching section is to prepare the batch for dyeing according to machine capacity,

order and emergency. This section receive the grey fabric from knitting section and make batch

according to order for particular shade. Then this batch delivers to dyeing section for dyeing.

Function or purpose of Batch section:

To receive the grey fabric roll form knitting or other source.

Turn the gray fabric if require.

Prepare the batch for dyeing according to the following criteria:

Order sheet (Received from buyer)

Dyeing shade ( light or dark, color or white)

Machine capacity.

Type of fabric ( 100% Cotton, CVC, Stripe fabric)

Emergency order.

Fabric construction (single jersey, Rib, Lycra Rib, Lacost, Pique etc.)

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

To keep record.

Proper Batching Criteria:

To use maximum capacity of existing dyeing machine.

To minimize preparation time & machine stoppage time.

To use a particular machine for dyeing same shade.

Batching Ratio Calculation;

Batching Ratio = (Fabric Dia × Batch quantity) / Total quantity

33

Process flow chart of Batch preparation:

Deliver the Fabric to dyeing section

Receive the order sheet from in-charge

Make the batch card on the priority of shipment

date

Take the Batch card which order have to deliver

first

Check the availability of the fabric

Turn off the fabric (if necessary)

Distribute the collar/cuff or Rib in each rope

equally ensuring equal length.

Take collar/cuff as per size and keep the total

weight

Take require quantity of body fabric from the

store

Stitch the fabric

Write down weight against roll no. in the back

side of the Batch card

Write the total weight in the batch card

Fill up the Production report form

34

Dyeing Lab

In every dye house, a laboratory equipped with machines & equipment is essential. It assists in

production prediction, minimization of time consumption and wastage reduction. It is also

producing the product of desired quality.

Prior to the bulk production, laboratory plays a vital role in shade matching & detecting the

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

In Biswas Synthetic Ltd. dyeing Lab is divided into two section.

Chemical Lab

Quality Lab

Quality Lab:

Quality lab performs all testing on finished fabric.

Chemical lab:

Chemical lab performs all shade matching and other chemical tests for Bulk dyeing Production.

Lab dip:

Lab dip is a process by which buyers supplied swatch is matched with the varying dyes

percentage in the laboratory with The help of “DATA COLOR” or see the previous matching

sample or give the recipe by the practical experience, Lab dip plays an important role in shade

matching & and detaching the characteristics of the dyes and chemicals are to be used in the

large scale of production so this is an important task before bulk production.

Key accessories for Lab:

Data color computer

Lab, receive file

Electronic Blench

Plastic/Glass beakers

Steel stirrer

Scissors

Stainless reference & dyeing beakers

Dryer

Variable light box

Electric Heater

35

Lab Dip Procedure to Dyeing Floor Or Bulk Production:

Receive swatch

Spectrophotometer inspection

Ref. recipe

Stock solution preparation

Sample measuring

Dyeing

Unload and wash in cold water

Hot wash with detergent

Wash in cold water

Squeeze and Dry

Preparing Lab dip

If not ok send to buyer if ok

Send recipe for sample dyeing

Sample Dyeing

Available Stock Solutions:

For dyes:

Red –0.01, 0.1%, 0.5%, 1.0%, 2.0%

Yellow – 0.01, .01, 0.1%, 0.5%, 1.0%, 2.0%

Blue - 0.01,0.1%, 0.5%, 1.0%, 2.0%

For chemical:

NaOH – 10% stock solution

Salt – 25% stock solution

Soda - 25% stock solution

36

Range of Salt and Soda according to the shade %:

Shade % Glauber

salt(g/l)

Soda ash(g/l)

.001 – 0.5 20 6

0.51 – 1.0 30 8

1.01 – 2.0 40 10

2.01 – 3.0 50 12

3.01 – 3.5 60 15

3.51 – 4.2 70 18

4.21 - 5.10 80 20

5.11 above 100 20

Recipe Calculation:

Total Liquor=4x50=200 cc

Dye solution=(sample weight x recipe amount% )/stock solution% cc

Salt required=(total liquor x recipe %)/ (1000 x stock solution%) cc

Soda Solution =(total liquor x recipe %)/ (1000 x stock solution%) cc

SAMPLE CALCULATION FOR 1% SHADE:

Sample wt. = 5 mg

Material liquor ratio = 1: 8

Total liquor (5 8) = 40 cc

37

5 1%

Dye solution required == 5 cc

1.0%

40 30

Salt solution required = 4.8 cc

1000 25%

40 8

Soda ash solution required = = 1.28 cc

1000 25%

Water required {40 - (5 + 4.8 + 1.28)} = 28.92 cc

Machine profile of Lab section:

Laboratory Machine

SL Machine Name M/C Quantity Origin Brand

1 MSI 1 Set Taiwan Mingscape International

2 Multi Light Color Compersion

Cabinet 1 Set Taiwan Model: CT-100

3 Spector Photo Meter(Data color) 1 Set U.S.A Spectra flash SF-300

4 Rapid 4 Set Taiwan Labortex co. ltd

5 Dexter 2 Set Taiwan Yuan Shein

6 Labtec 1 Set Taiwan Newave lab equipment

7 Dryer 1 Set Taiwan Labortex co. ltd

Total= 12 Set

38

DYEING

39

Layout of Dyeing section:Dyeing m/c Symbol

Folding m/c

Folding m/c

Folding m/c

Office

Dyeing lab

Washing

m/c

Batch

section

Chemical Store

office

Office

Office

Office

Office

squeezer

Squeezer

Fabric

store

Fabric

store

Office

Squeezer

Squeezer

Squeezer

40

Machine specification:

Knit Dyeing Machine

SL Machine Name Capacity

(Per Day)

M/C

Quantity Origin Brand

1 Dyeing M/C 300 1 Set Taiwan Toonggeng



4 Dyeing M/C 150 1 Set Taiwan Hsiang Fu

5 Dyeing M/C 150 1 Set Taiwan Hsiang Fu

6 Dyeing M/C 150 1 Set Taiwan HuanJenn

7 Dyeing M/C 90 1 Set Taiwan HuanJenn

8 Dyeing M/C 1800 1 Set Taiwan Tong wutaiwan






14 Dyeing M/C 3000 1 Set Taiwan Ak





19 Dyeing M/C 1800 1 Set Taiwan Tong geng



22 Dyeing M/C 4500 6 Set Taiwan Taiwan

Total= 29040 yds 27 Set

41

Woven Dyeing Machine

Sl Machine Name Capacity

(Per Day)

M/C







6 Dyeinng M/C 1800 1 Set Taiwan Tong geng



Jigger Dyeing Machine

SL Machine Name Capacity (Per

Day)

M/C


1 Jigger Dyeing M/C 3600 yds 4 Set Korea Sung Moo Korea

2 Jigger Dyeing M/C 6000 yds 4 Set Korea Shink Wang Kore

3 Jigger Dueing M/C 6000 yds 4 Set Korea Sung Moo Korea


42

Process Flow Chart:

Scouring & bleaching

Hot wash

Cold wash

Peroxide killing

Neutralization

Enzyme wash

Enzyme killing

Normal wash

Dyeing

Soaping

Acid wash

Softening

43

Dyeing: Dyeing is the process of imparting colors to a textile material through a dye (color). Dyes are

obtained from flowers, nuts, berries and other forms of vegetables and plants as well as from

animal and mineral sources. These are known as natural dyes. The other classes of dyes are

known as synthetic dyes. These are based on a particular type of chemical composition. Some of

these dyes are- Acid (Anionic) dyes, Basic (Cationic) dyes, Neutral dyes, sulfur dyes, vat dyes,

reactive dyes, pigment dyes etc.

Pretreatment:

The term “pretreatment” covers all operations of preparing textile material for subsequent dyeing

and finishing processes.

Objective: The preparation of goods for dyeing and printing is a far important process than the production

of white goods. Textile material to be dyed or printed must have the following properties:

To increase the uniform absorbency all over the goods as much as possible.

To remove all types of impurities as much as possible with minimum damage to fibres

To make fibres fit for dyeing.

Fit for dyeing is a concept that explain a material which is completely ready for dyeing both

externally & internally & conforms several requirements. Like-

Required uniform absorbency

Required Ph level.

Required H2O2 level

Required bi-carbonate level

Minimum damage of fibre structure.

Degree of whiteness:

In the past, it was customary to regard the degree of whiteness as the most reliable criterion for

judging the quality of the pretreatment. But now there are other factors governing the results

obtained in subsequent operations. Today, therefore, the object of pretreatment is not a full

bleach, but only a partial bleach as necessary to ensure good purity and brilliance of shade in

subsequent dyeing or printing.

Hydrophilic properties:

High and uniform absorptive of the goods is essential. It is the hydrophilic properties that govern

the evenness of uptake of the dyes and chemicals, particularly in cases where these are applied

continuously

44

Scouring:

The main purpose of scouring textile material is to remove natural as well as added impurities of

essentially hydrophobic character as completely as possible and leave the material in a highly

absorptive condition without undergoing chemical or physical damage of fibre or fabric.

Objective:

1. To remove natural as well as added impurities.

2. To produce hydrophilic characteristics.

3. To make goods cleaner.

4. To leave the material in a highly absorptive condition without undergoing chemical or

physical damage.

Basic principle:

The scouring process of cotton consists of an alkali treatment in the presence of wetting and

sequestering agents, in order to convert the impurities, other than natural coloring matter, into

products which can be removed by aqueous washing.

The processes occurring during the scouring are:

• Saponifiable oils and free fatty acids are converted into soap.

• Proteins are degraded to simple soluble amino acids or to ammonia.

• Mineral matter is dissolved.

• Unsaponifiable oils are emulsified by the soaps formed during the hydrolysis of the

saponifiable matter.

• Adventitious dirt is removed and retained in suspension by the soap.

Factors involved in scouring:

When cleaning soiled surfaces, five variables become involved that interact during scouring and

they are as follows:

1. The nature of the surfaces to be cleaned.

2. The nature of the dirt or soil.

3. The chemicals to be used.

4. The nature of the water or solvent.

5. The nature of the detergent or soap.

45

Bleaching:

In the bleaching process the colored material is destroyed and thus to confer a pure white

appearance to the fabric. Bleaching should also decolorize or remove any residual impurities left

by scouring.

An efficient bleaching process must ensure:

1. A pure and permanent white.

2. Level dyeing properties.

3. The fabric does not undergo tendering (chemical damage or degradation, which results in loss

in tensile strength and hence the durability is affected) during bleaching.

Objectives:

Bleaching of cotton is carried out with two objects in view:

1. To achieve a high degree of whiteness, for goods that are to remain white or to be dyed in

pastel shades; for goods to be dyed in dark shades, bleaching improves the brilliance.

2. To improve the even appearance of the goods by removing the husks.

Enzyme wash:

Enzymes are biological catalysts, mainly proteins, generated by an organism to speed up

chemical reactions. They have an active site on which the substrate is attached, and then broken

up or joined.

Biopolishing is an enzymatic process for finishing of cellulosic materials such as cotton, linen,

viscose, ramie and their blends with synthetic fibres. It is a process that removes fuzz and

eliminates pilling in cellulosic garments.

The enzyme performs a controlled hydrolysis of the cellulosic fibres in order tomodify the fabric

surface. This keeps the garments looking new even after repeated washes. It also enhances color,

feel and drapability. Its effects are permanent, without involving chemical coating of the fibre.

Function:

Improved resistance to pilling.

A clearer and fuzz less surface structure.

Superior finish with improved drapability and

Softness

46

Classes of dyes on the basis of suitability of dyeing different fibers:

Sl.

No

Name of dyes Suitable for Fibers

01 Acid dyes Wool, silk and Nylon

02 Basic dyes Nylon, Acrylic, Acetate Rayon, Silk, Wool and

Jute

03 Direct dyes Cotton, Viscose Rayon, Linen, Nylon, Wool and

Silk

04 Azoic dyes Cotton, Viscose and Linen.

05 Vat dyes Cotton, Viscose and Linen.

06 Sulpher dyers Cotton, Viscose and Linen.

07 Reactive dyes Cotton, Viscose, Linen, Wool, Silk and Nylon.

08 Disperse dyes Polyester, Nylon, Acrylic, Acetate Rayon and

Triacetate Rayon.

Winch dyeing machine : A dyeing machine consisting essentially of a dye vessel fitted with a driven winch ( usually

above the liquor level) which rotates and draws a length of fabric, normally joined end to end,

through the liquor.

Winch dyeing machines are a low cost design that is simple to operate and maintain, yet versatile

in application proving invaluable for preparation, washing or after treatments as well as the

dyeing stage itself.

Description and Dyeing Method on Winch Dyeing Machine:

The basic principle of all winch dyeing machines is to have a number of loops or ropes of the

fabric in the dye bath, these ropes are of equal length , which are mostly immersed in the liquor

in the bath. The upper part of each rope runs over two reels which are mounted over dyebath. At

the front of the machine , above the top of the dye liquor , is a smaller reel, which is called

jockey or fly roller. The fly roller remain free wheeling along with fabric rope. At the back of

winch tank is the winch wheel, which pulls the fabric rope from the dye bath over the jockey reel

for dropping in the dye bath for immersion. From the dropped location , the fabric rope travels

back . to be lifted and fed to winch wheel.

The dyeing process on winch dyeing machines is based on higher M:L as compared with other

dyeing machines. The process is conducted with very little tension . The total dyeing time is

lengthier as compared to other machines.

47

Advantages of Winch Dyeing :

a. Construction and operation of winch are very simple.

b. The winch dyeing machines are suitable for types of wet processing operations

c. The winch dyeing machine is suitable for practically all types of fabrics ,which can withstand

creasing in rope form processing.

d. The tension exerted on winch is less than jigger, the material thus dyed is with fuller hand.

e. The appearance of the dyed goods is clean and smooth on winch dyeing machines.

Raw Material Used for Dyeing:

Gray fabrics

Dyes

Chemicals

Gray fabrics: Following types of gray fabrics are dyed:

Single jersey

Single jersey with lycra

Lycra Rib

Rib

1 x 1 Rib

2 x 2 Rib

2 x 1 Rib

Polo Pique

Interlock

Fleece

Micro fleece

Polar fleece

48

Dyes, Chemicals & Auxiliaries Used in Biswas Synthetic Ltd

Auxiliaries

1 Peroxide killer geizyme OEM

2 Peroxide tesbilizerSR/Stopa-52 chemical

3 Polyester leveling Melevel -lpf

4 Polyester leveling Melevel-BFR

5 Sequestering austol

6 Soaping asugal-ALBI

7 Wetting agent –proder-SCPC/LF

8 White softener gensoft

9 Fixing ecofix DR/SR

10 Leveling drimegen W2R/ Texotech

11 Anticrease-Pac(8460)

12 Genifoam NS

Special Chemicals

1 Brightener Leucophor BSB

2 Brightener sun white

3 Enzyme producto _EAPS-A/Genincor-Bf-1600/3500

4 Silicon softener Dowsil-DMAX

5 Silicon softener silipinwor HD/MAttaX/Tubingal/get soft –SA852

6 Silicon softener Adilin NI

7 Silpure FBR-5

Others

1 Other apritonnchemichel

2 Other binder mtb chemical

3 Other bleaching powder

4 Other formic Acid

5 Other glycerin

6 Other oxalic acid

7 Other pocket clear

8 Other power wash Ne

9 Other sandozin EH

10 Other sodiamhydrose chemical

11 Other ultra phor BN chemical

12 Other urea chemical

13 Jintex eco GD CONE

14 JINTEX eco GS CONE

16 Benlon2900(buffer acid)

17 Chemical amound

49

Dyes

1 Ciba blue FNR Dyes

2 Ciba brill Blue FNG FyesFGFN

3 Ciba red FN3G Dyes

4 Ciba red FNR Dyes

5 Ciba red WB Dyes

6 Ciba Navy SG

7 Ciba Red C2BL

8 Ciba Navy WB

9 Ciba yellow CRG Dyes

10 Ciba yellow S3R

11 Ciba yellow H2G

12 Ciba Navy FNB

13 Ciba Yellow F4G Dyes

14 Ciba Yellow DN2R Dyes

15 Ciba Orange FNR Dyes

16 Ciba Orange W3R Dyes

17 Dianix black CCR Dyes

18 Dianix Blue SSB Dyes

19 Dianix Navy CC Dyes

20 Dianix Yellow SEG Dyes

21 Drimarine Blue HFRL Dyes

22 DrimarineBlueCLBRDyes

23 Drimarine Red CL5B Dyes

24 Drimarine Red RH3b Dyes

25 DrimarineScariate HF3G Dyes

26 DrimarineTarquise CLB Dyes

27 Drimarine Yellow CL2R Dyes

28 Drimarine Yellow HFR Dyes

29 Reactive G. Yellow 3RS/MERL

30 Reactive black B Dyes /AB/5

31 Reactive Red ME4BL Dyes

32 Reactive Yellow H4GL Dyes

33 Reactive Super black G Dyes/AG

34 Reactobond yellow HW Dyes/AEY

35 Reactobond Red Hw Dyes

36 Reactive Navy WB

37 Reattofex orange ME2RL

38 Remazol Navy RGB Dyes

39 Remazol Red RGB Dyes

40 Remazol Blue RSPL Dyes

41 Remazol RED RR Dyes

42 Remazol Blue RR Dyes

43 Remazol Yellow RR Dyes

44 Imcozin Blue VCR

50

Typical Process Flow Chart for Knit Dyeing:

Process Flow Chart Scouring &Bleaching:

Fabric Loading

Machine filling with water

Chemical Inject at 40 0C

Caustic Soda dozing at 600c for 10 min

Run time 10 min.

H2O2 Dozing at 700c dozing for 10 min

Heating at 105 0C

Run time 45 min.

Cooling at 80 0C

Drain Bath

Normal hot wash at900c for 10 min

Cold wash for 10 min

Drain

Process Flow Chart for Enzyme:


Acetic acid dozingat 40 0C

Run 10 min

Heating at 55 0C

Dozing enzyme

Run time 45 min.

Drain

PH Check

51

Process Flow Chart for Dyeing :


Heating at 40 0C

Chemical dozing

Run time 10 min.

Salt dozing

Run time 10 min

Dyes dozing for 40min

Run time 20 min.

Soda dozing for 40 min

Run time 10 min.

Color Steam at 600C for 60min

Bath drop

Drain

Process Flow Chart for softening :


Heating at 40 0C

Softener dozing

Run time 20 min at 450C

Drain

PH Check

PH Check

Sample check

after 10 min

PH Check

52

Fabric specification & Recipe (White color): Fabric : Single Jersey Quantity : 592 kg

GSM : 160 M: L - 1:7

Color : White Water - 4100 lit

Recipe :

Sl.

No

Commercial

name of Dyes &

Chemicals

Origin name Amount

(g/l or %)

Total amount

Pretreatment:

01 NOF Detergent 0.7 g/l 2.900 kg

02 BLB Sequestering

agent

0.2 g/l 820 gm

03 OKB Stabilizer 0.8 g/l 3.280 kg

04 B.PAC Anti-creasing

agent

0.6 g/l 2.40 kg

05 Caustic soda Scouring agent 3.0 g/l 12.300 kg

06 H2O2 Bleaching agent 10 g/l 41.00 kg

07 4BK OBA 0.35% 2.072 kg

08 Acetic Acid 1.0 g/l 4.100 kg

09 NOF Detergent 0.5 g/l 2.00 kg

10 Soda 2 g/l 8.200 kg

11 Hydroze For reduction

cleaning

0.2 g/l 820 gm

12 Acetic Acid 0.4 g/l 1.600 kg

13 Bio polish Enzyme 0.3% 1.800 kg

14 T.S.W Softener 0.5% 2.960 kg

53

Process flow chart for White color:

Fabric loading

Machine Fill with required water

Detergent +sequestering agent+ Peroxide stabilizer +

Anti creasing agent Inject at 45°C Temperature.

Caustic soda dosing at 60°C Temperature for 10 minuets

H₂O₂ dosing at 70°C Temperature for 10 minuets

Optical brightening agent dosing at 80°C Temperature

Machine runs 30 minutes at 105°C Temperature

Cooling at 80°C Temperature

Sample check if not ok

if ok

Normal hot wash at 90°C Temperature for 10 min.

Cold wash for 10 min

Drained water & Machine Fill with required water

Detergent+ Soda ash + H₂O₂ dosing for Reduction clearing



Acetic acid dosing for neutralization



Cold wash for 10 minuets


Acetic acid dosing at 40°C Temperature

Enzyme dosing

Ph 6.0-7.0

Ph 4.5-5.5

54



if ok

Hot wash is done for enzyme killing



Softener dosing for softening


Drained water

Unload

Fabric specification & Recipe (Green color):

Fabric : Pique (PK) Quantity : 1310 kg

GSM : 200 M: L - 1:7 (During Pretreatment)

1.8 (During Dyeing)

Color : 13-024 texGreen Water - 9200 lit (Pretreatment)

10500 lit (During Dyeing)

Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(g/l or %)

01 NOF Detergent 0.5

02 BLB Sequestering agent 0.2

03 OKB Stabilizer 0.4

04 B.PAC Anti-creasing agent 0.8

05 Caustic soda Scouring agent 3.0

06 H2O2 Bleaching agent 2.75

07 Acetic Acid 1.0

08 Ultra Per-oxide killer 0.5

09 Acetic Acid 0.4

Ph5.5

55

10 Biopolish Enzyme 1.0



13 Texotech Leveling agent 1.0

14 Yellow 4GL Dye 0.08% - 5%

15 Rea. Blue Dye .064% + 10%

16 Rema blue RR Dye .0068% + 5%

17 Salt 30

18 Soda 8

19 Acetic Acid 1.0

20 RSK Soaping agent 0.6

21 KWL Softening agent 0.7%

Dyeing process for Light shade(Green):

Fabric loading









if ok


Cold wash for 10 min.


Peroxide killer dosing


56






Enzyme dosing



If ok





Sequestering agent+ Anti creasing agent Inject at 45°C Temperature

Leveling agent dosing at 45°C Temp for 10 min.

Gluber salt dosing at 45°C Temp for 10 min.

Color dosing at 45°C Temp. for 40 min.

Machine runs 10 minutes


if ok

soda dosing at 45°C Temperature for 40 minuets

Color steam at 60°C Temp. for 60 min.


if ok

Rinse for 10 min. & then Drain

Acid wash at 45°C Temperature for 10 minuets

Soaping is done at 80°C Temperature for 10 minuets

Ph 6.0-7.0

Ph 4.5-5.5

Ph11.0- 12.0

57


if ok




Final Sample check if not ok

if ok

Unload

Fabric specification & Recipe (Black color):

Fabric : Single jersey Quantity : 1000 kg

GSM : 160

M: L - 1:7 (During Pretreatment)

1.8 (During Dyeing)

Color : Black

Water - 7000 lit (Pretreatment)


Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(g/l or %)

01 Jintex GD Detergent 1.0

02 Jintex GS Sequestering agent 0.2

09 Acetic Acid 0.4





14 RB. Yellow-HW Dye 1.10% + 0%

15 RB. Red-HW Dye 0.90% - 20%

16 Rea. S. Black-KGD Dye 4.80% - 20%

17 Salt For exhaustion 80

18 Soda For fixation 8

Caustic For fixation

Ph 6.0

58

19 Acetic Acid 1.0



Dyeing process for Dark shade(Black):

Fabric loading


Detergent +sequestering agent Inject at 45°C Temperature.




if ok





Enzyme dosing



If ok






Leveling agent dosing at 45°C Temp for 10 min.

Gluber salt dosing at 45°C Temp for 10 min.

Color dosing at 45°C Temp. for 40 min.

Ph 4.5-5.5

59

Machine runs 10 minutes


if ok

soda&NaOH dosing at 45°C Temperature for 40 minuets

Color steam at 60°C Temp. for 60 min.


if ok





if ok





if ok

Unload

Fabric specification & Recipe (Critical color Turquoise blue):

Fabric : Single jersey Quantity : 570 kg

GSM : 160

M: L - 1:7 (During Pretreatment)

1.8 (During Dyeing)

Color : Black

Water - 4000 lit (Pretreatment)


Ph 6.0

Ph11.0- 12.0

60

Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(g/l or %)

01 NOF Detergent 0.5


03 OKB Stabilizer 0.4


05 Caustic soda Scouring agent 3.0


07 Acetic Acid 1.0

08 Ultra Per-oxide killer 0.5

09 Acetic Acid 0.4





14 Rema Red RR Dye 0.04%

15 Rea.Turq. Blue Dye 0.32%

16 Sola blue RSPL Dye 0.82%

17 Salt 40

18 Soda 10

19 Acetic Acid 1.0



Dyeing process for Critical color (Turquoise Blue ):

Fabric loading




61






if ok



Peroxide killer dosing







Enzyme dosing



If ok






Leveling agent dosing at 45°C Temp. for 10 min.

Gluber salt dosing (1st half) at 45°C Temp. For 10 min.

Ph 6.0-7.0

Ph 4.5-5.5

62

Gluber salt dosing (2nd half) at 45°C Temp. For 10 min.

Color (critical & another 1st) + urea dosing at 45°C Temp. For 30 min.

(e.g. Turkish blue + rema red + urea)

Run time 10 min.

Color (remaining another color) dosing at 45°C Temp. For 20 min.

(e.g. blue RSPL)




if ok

soda dosing at 60°C Temperature for 40 minuets

Run time 10 min.

Color steam


if ok





if ok





if ok

Unload

Ph11.5

Ph6.0

63

Fabric specification & Recipe ( Pink color, reserve dyeing):

Fabric : Single Jersey(CVC)Lycra attached Quantity : 800 kg

GSM : 200 M: L - 1:7 (During Pretreatment)

1.8 (During Dyeing)

Color : Pink Water - 5600 lit (Pretreatment)


Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(g/l or %)

01 APB-XP Detergent 1.00

02 ALBA-C 1.00

03 2146 Anti-creasing agent 0.50

04 CAUSTIC Scouring agent 3.00

05 SIFA Peroxide stabilizer 0.50


07 Acetic Acid 0.50

08 Acetic Acid 0.4

09 RTM Dispersing agent 1.00


11 HELO:G-yellow-

FW3R

Dye 0.075%

12 HELO:RED-FB Dye 0.17%

13 Hydrose 0.4

14 Caustic 0.4

15 Acetic acid 0.4

SAMPLE:

64

Fabric specification & Recipe ( Pink color, reserve dyeing):

Fabric : Polar Fleece Quantity :419 kg

GSM : 215 M: L :1.9 (During Dyeing)

Color : Olive Green Water :3500 lit (During Dyeing)

Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(kg/l or %)

01 Acetic Acid 1.00

02 RTM Dispersing Agent 3.00


04 BLM Leveling Agent 2.00

05 Tai-Y-3GT Dye 0.56%

06 Lon-R-FB Dye 0.04%

07 Lon-N.B-EXSF Dye 0.56%

08 Caustic 6.00

09 Hydrose 6.00

10 Acetic Acid 1.00

SAMPLE:

65

Fabric specification & Recipe ( Black)

Fabric : Panama Quantity :566kg


Color : Black Water :4000 lit (During Dyeing)

Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(kg/l or %)

01 Oxalic Acid 8.00

02 Jef 0.8

03 Mut Acid 6.00

04 BFT 6.00

05 REMAZAL JET 10.00

06 LIDABUST 2.00

07 Long-Yellow Mugl Dye 0.2%

08 Tana-Red-R Dye 0.15%

09 Tana-Black-SFTCR Dye 5.00%

10 Hydrose 6.00

11 Caustic 6.00

SAMPLE:

66

Fabric specification & Recipe (Olive)

Fabric : Polyester 190 FDY Quantity :148kg


Color : Olive Water :1200lit (During Dyeing)

Recipe :

Sl.

No

Commercial name of

Dyes & Chemicals

Origin name Amount

(kg/l or %)

01 Acetic Acid 1.5

02 RTM Dispersing Agent 4.00

03 BLM Leveling Agent 4.00


05 Lon:Yell:M4GL Dye 0.14%

06 Lon-Red-RB Dye 0.065%

Helo:R/Blue-NN Dye 0.18%

SAMPLE:

67

Dyeing faults Causes and Remedies

Uneven dyeing:

Causes:

Uneven Pretreatment

Improper addition of color

Improper addition of chemical

Using dyes of high fixation properties

Less control of dyeing machine

Less circulation time

Remedies:

By ensuring even pretreatment

By proper addition of color and chemicals

Correct circulation time

By controlling the dyeing machine properly

Batch to batch Shade variation

Causes:

Using improper dyes and chemicals

Incorrect pretreatment procedure

Batch to batch weight variation of fabric

Batch to batch chemicals and dyes variation (lot variation)

Improper dosing of dyes and chemicals

Remedies:

By using standard dyes and chemicals

By correcting the pretreatment procedure

By maintaining batch to batch weight variation

By avoiding lot mixing of dyes and chemicals

By correcting the dosing time of dyes and chemicals

By following different dyeing parameter.

68

Dark colored spots:

Causes:

Dyestuff precipitation during dyeing

Incompatibility of dyestuff used for producing combined shade

Too high dyestuff concentration in the dye bath

Precipitation of unabsorbed dyestuff during after treatment

Remedies:

By ensuring proper dyeing condition

By selecting proper dyestuff

By checking the solubility limit of the dyestuff before dyeing

By ensuring proper after treatment

Patchy dyeing:

Causes:

Due to hardness of water

Due to faulty color addition

Due to faulty injection of alkali

Due to improper salt addition

Due to improper PH of solution

Remedies:

By using proper sequestering agent

By correcting the color addition

By correcting the salt addition

By proper injection of alkali

By maintaining the PH level of the solution

Crease mark:

Causes:

Poor opening of the fabric rope

Due to high speed of machine running

Unequal pump pressure and reel speed

69

Remedies:

By maintaining proper pump pressure and reel speed.

By controlling the speed of the machine.

Correct opening of the fabric rope.

Roll to roll variation:

Causes:

Poor migration property of dye.

Hardness of water.

Improper dyes solubility.

Faulty machine speed.

Remedies:

Use standard dyes and chemicals

Proper machine speed.

Using soft waste.

70

Finishing section

Introduction of Finishing:

Textile finishing involves treating a textile material in such a way that the product has the desired

properties required for its intended useand therefore has great market value. The desired

properties may include the fabric dimensions and their stability, its weight, drape, appearance,

softness and handle, as well as any required functional properties such as resistance to creasing,

flame, water, oil, dirt or bacteria. Textile finishing is therefore an extremely diverse field

involving an extensive range of chemicals.

The degree of permanency of a particular finish for a fabric depends on its intended use. The

chemicals used may weigh the fabric to make it easy to slide and handle, or allow smooth

penetration of a sewing needle to minimize needle breakage.

Anyone involved in textile coloration must be aware of the influence of preparation process on

the dyeing behavior of the fabrics as well as the finishing chemicals on the final color of the

goods and on their color fastness properties. Without this knowledge, nobody can ensure the

ultimate color and its fastness properties.

The techniques of finishing depend on the following:

Nature of the fabric, i.e. chemical composition, state etc. this determines the appearance,

i.e. transparency, luster, fullness, weight, whiteness etc.

After dyeing, knit fabric is required to finish. During dyeing all knit fabric are dyed in tubular

form. According to buyer's requirement knit fabric are finished in Open form or tubular form.

The tubular and open finishing sequences of Biswas synthetic Ltd. Is given bellow:

71

Flow Chart of finishing for tube fabric:

Dyed Fabric

Tube Squizer

Tube Dryer

Tube Compactor

Final Inspection

Delivery to Garments

Flow Chart of finishing for Open Width fabric:

Dyed Fabric

Open Squizer

Stenter

Ultrasoft

Compactor

Final Inspection

Hydroextractor

Tumble dryer

Delivery to garments

72

Specification of Finishing Machines:

(Floor A)

SL Machine Name M/C

Quantity

Capacity

(Per Day) Origin Brand

1 Compactin M/C 1 Set 12000 kg Italy Ferraro

2 Stenter M/C 2 Set 26000 kg Taiwan Cheng Fu

3 Stenter M/C 1 Set 12000 kg Taiwan Tung Yung

4 Stenter M/C 1 Set 12000 kg Taiwan Hung Jyi

5 Stenter M/C 1 Set 12000 kg Taiwan LK & LH

6 Stenter M/C 1 Set 12000 kg Taiwan Tung yung

7 Brushing M/C 18 set 15000 kg Taiwan Yantu

8 Brushing M/C 14 Set 8000 kg Taiwan Yantu

9 Semi Brushing M/C 2 Set 7000 kg Taiwan Yantu

10 High Speed Brushing M/C 2 Set 8000 kg Taiwan Chienlun

11 Shearing M/C 4 Set 40000 kg Taiwan Yantu

12 Hi Combing M/C 3 Set 40000 kg Taiwan Yantu

13 Tumbler M/C 21 Set 30000 kg Taiwan Peacock

14 Tumbler M/C 12 Set 30000 kg Taiwan Ta-Ting

15 Folding M/C 3 Set 40000kg Taiwan

16 Slitting M/C 4 Set 45000 kg Taiwan

17 Fabrics Inspection M/C 5 Set 45000 kg Taiwan Hong Chi

Total= 95 Set

(Floor B)

Sl Machine Name M/C


1 Washing Machine 2 Set Korea+Taiwan Woo Yang+FulutaEleg

2 Stenter M/C 1 Set Taiwan Lk& LH

3 Peach M/C 2 set Taiwan I Khang

4 Fabrics Inspection & Rolling M/C 2 Set Taiwan Shiaw tai tong

5 Fabrics Folding M/C 1 Set Taiwan shiaw tai tong

6 Calander M/C 2 Set Korea Chan sain

7 WR Coating M/C 1 Set Taiwan Fun tay Electric

8 Fabrics Tention M/C 1 Set Taiwan Shiaw tai tong

9 Sweing M/C 4 Set Taiwan Maqi

Total= 17 Set

73

Observation of Different Finishing M/C:

Squeezer or De-Watering M/C:

After dyeing process from the dyeing machine then the fabrics arc ready for dc-watering. This is

the process to remove the water from the fabric partially by squeezing. This is the main function

of the squeezing machine. But here also control the some important factor of the fabric quality.

Important parts: • Twist detector

• Expander

• Paddcr

The basic function of the squeezing m/c: To remove the water from the fabric.

To control the width of the fabric.

To control the length of the fabric.

To control the over feeding system.

To increase the softness of the fabric.

To remove the crease mark of the fabric.

Controlling points:

• Diameter setting must be accurate.

• Excess padder pressure may cause fabric damage. Padder pressure depends on fabric

construction.

• Speed must be optimum.

• Higher the fabric speed leads less removal of water.

• Overfeed.

Dryer

Drying is defined as a process where the liquid portion is evaporated from the fabric.

Important Parts: o Conveyor net

o Chamber

o Burner

o Exhaust air fan

o Over feed roller

o Filter net

o Fan

o Nozzle

74

The basic function of the dryer: • To dry the fabric.

• To control the over feed system (Shrinkage control)

• To control the GSM of the fabric.

Controlling Points

• Overfeed (%): It depends on fabric structure

• Temperature: It depends on color.

• Speed: It depends on fabric construction and color. For higher GSM lower the speed.

TUBE COMPACTOR:

Important parts: Overfeed roller

Expander

Blanket

Steam sprayers

Cylinder

Teflon covers

The basic functions of the Tube compactor machine: • To control the GSM. (Increase & decrease).

• To control the dia.

• To control the shrinkage. (Increase & decrease).

Controlling Points a. Temperature : It depends on construction and composition &color of the fabric.

b. Speed : It depends on temperature and fabric construction.

c. Blanket Pressure : Fabric smoothness depends on blanket pressure.

d. Over feed : Over feed should be optimum. It increases GSM but higher over feed

leads to the formation of crease mark.

Observation of tube compacter setting for different fabric:

Fabric

parameter

Single jersey

1 x 1 Rib

Compaction 18 30

Overfeed 5 12

Padder pressure 30 bar 30 bar

Speed 18 m/min 18 m/ min

Temperature 100oC 100

oC

75

Slitting Machine

Important parts: • Twist detector

• Cutting knife/device

• Padder

Main Function of Slitting m/c To open the tube forms of fabric

To squeeze the fabric and remove the extra water in the fabric.

Controlling Points • Pressure: The paddcr pressure should be according to requirement.

• Specd-Thc speed should be optimum (30-80 m/min)

Stenter Machine:

Important parts Burner (Oil)

Chamber (6)

Overfeed roller

Nozzle

Chain arrangement

The basic functions of the stenter machine:

To control width.

To control GSM.

To control shrinkage.

To control spirality.

Drying of fabric.

To remove the crease mark of the fabric

To increase the better shade properties

To give belter finishing result of the fabric

Controlling Points

a. Temperature : It depends on color construction and composition of the fabric. For S/J

the temp is 150°C and 170°C for stripe fabrics.

b. Over feed : Over feed increases the GSM of the fabric.

c. Width setting : Higher width setting reduces the GSM

d. Speed : It depends on construction and amount of moisture on the fabric.

76

Observation of stenter setting for different fabric:

OPEN COMPACTOR:

Important parts:

• Overfeed roller

• Blankct

• Steam sprayers

• Cylindcr

• Tell on covers

The basic functions of the Open compactor machine:

• To control the GSM. (Increase & decrease).

• To control the dia.

• To control the shrinkage. (Increase & decrease).

Controlling Points:

a. Temperature : It depends on construction and composition & color of the fabric.

b. Speed : It depends on temperature and fabric construction.

c. Blanket Pressure: Fabric smoothness depends on blanket pressure.

d. Over feed :Over feed should be optimum. It increases GSM but higher over feed

leads to the formation of crease mark.

Fabric

parameter

Single jersey

L – Rib

P.K.

F/T

Required Dia 88’’ 80” 54” 80”

Actual Dia 90.5” 88” 67” 84”

Required GSM 160 240 210 240

Actual GSM 148 218 185 232

Temperature 170oC 170

oC 170

oC 170

oC

Overfeed 60% 45% 60% 40%

Machine speed 45 45 45 45

Dia setting 2310 mm 2400 mm 1720 mm 2150 mm

77

Observation of open compactor setting for different fabric:

Fabric

parameter

Single jersey

CVC S/J

L – Rib

P.K.

F/T

Required Dia 88’’ 92” 80” 104” 80”

Actual Dia 90” 94” 84” 108” 84”

Finished Dia 89” 93” 82” 106” 82”

Required GSM 160 180 240 200 240

Actual GSM 150 170 210 190 230

Finished GSM 155 175 220 200 240

Overfeed 12 12 10 12 10

Temperature 80oC 80

oC 80

oC 80

oC 80

oC

Machine speed 20 20 20 20 20

78

Fabric Inspection

Fabric Inspection:

The finished fabric may have different kinds of faults. This may occur during Knitting, dyeing or

finishing. If the fabric delivered then the quality of the fabric may not be good and the buyer will

reject the finished garments. For this reason careful inspection of this finished fabric is so

important. In finished fabric the following faults are generally found:

Faults Appearance Indicating slayable

Uneven shade US

Crease mark CR

Needle line NL

Neps N

Thick thin TT

Barre mark MB

Hairiness H

White specks WS

Penalty Points Indicating slayable

Hole H

Fly Yarn Fy

Fly contamination FC

Dye stain DS

Oil stain OS

Chemical stain CS

Dirts D

Slubs S

Water spot Ws

Lycra Out LO

Insect Spots IS

Rub mark RM

Rust stain RS

79

Biswas Synthetic Ltd. 4 points system is used for calculating fabric acceptance:

4-points system:

In four points system the points are defined on the basis of defect size as shown below:

Size of the defect Penalty

7.5 cm or less 1 points

Over 7.5 cm but less than 15 cm 2 points

Over 15 cm but less then 22.5 cm 3 points

Over 22.5 cm 4 points

Any hole 4 points

Acceptance Calculation:

Roll length in meter = A

Total points found = B

Acceptance Value = B/A x 100 points per 100 meter

Acceptance range:

Range Grade

<40 points A

41 – 60 points B

61 – 80 points C

Above 80 points Reject

If the fabric is found within acceptance limit then it is delivered to Garments section. But if the

fabric fault is so high that cross the acceptance limit then it is rejected

80

Quality Assurance system

Quality assurance system can be divided into following steps:

1. On line Quality assurance system and

2. Off line Quality assurance system.

On Line QC:

GSM of the Fabric;

Exact Diameter and Width;

Grey Fabric Inspection (4 point);

Shade Check;

Bias and Bowing;

Visual appearance (Enzyme performance);

Stripe.

Off Line QC:

After dyeing the material is received by the finishing section. Before receiving the following

things are checked:

1. Shade condition.

2. Wash fastness.

3. Condition of softening.

4. Condition of enzyme wash.

Before delivery the finished fabric to the customer it should be pass against the requirements.

The following tests are done-

GSM check.

Shrinkage test.

Shade check.

Rubbing test.

Wash fastness test.

Color fastness to perspiration.

81

1. GSM Check: GSM of the finished fabric essentially should be check according to the

buyer’s requirement.

Checking time : at finished state.

Equipment used : GSM cutter.

Sample area : 100 sq.cm.

Manufacturer : Local brand.

2.Shrinkage and SpirilityTest:

Shrinkage and Spirility both are very important for control the quality of fabric. Buyer considers + 5%

allowance for both Shrinkage and spirility. The scale is 50 cm long. The supplied the instrument use for

this Purposes are

washing m/c, measurement tape, scissors etc. The measurement Calculation of shrinkage and Spirility test

are given below:

Before wash - after wash

Shrinkage % = x 100

Body Width

Left twisting - Right twisting

Spirility % = x 100

Body Length

3. Rubbing fastness test: Equipment used : Crockometer.

Test method : BS EN ISO 105x12. Dry rub & wet rub is including in this method.

Testing time : Finished fabric.

4. Wash Fastness test: Equipment used : Wascator washing m/c.

Chemicals used : 4 g/l detergent (NOF)

40 min; 60C

then the shade change is measured by color change scale & staining scale.

Test Method : ISO 105 C06.

5. Color Fastness to Perspiration: Equipment used : Rota-Wash.

Test Method : ISO 105E04.

82

Maintenance

Maintenance:

Maintenance is a process by which equipment is looked after in such a way that trouble free.

Service and increased machine life can be ensured and specific product quality required by the

customers is sustained.

On time maintenance increase m/c lifetime & ensures trouble free services.

Maintenance of machineries is very important for any type of industries and it is must for a knit

composite factory. All machines and machine parts of knitting, dyeing and garments are

maintainedwith extreme care. Because production quality and quantity, both depends on the

maintenance with regularity.

Objective of Maintenance:

To keep the factory plants, equipments, machines. Tools in an optimum

working condition.

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

customer.

To keep the machine down time to minimum thus to have control over the

production program.

To keep the production cycle within the stipulated range.

To modify the machine settings to meet the need for the production.

83

Maintenance Of Machinery:

Preventive Maintenance:

Preventive Maintenance is a predetermined routine activity to ensure on time inspection /

checking of facilities to uncover conditions that may lead to production break downs or harmful

depreciation.

Corrective Maintenance:

In this case, repairs are made after the equipment is out of order it cannot perform its normal

function.

Maintenance

Preventive Maintenance Break Down Maintenance

Mechanical

Maintenance

Electrical

Maintenance

Mechanical

Maintenance

Electrical

Maintenance

Mechanical

Maintenance

Periodic

Maintenance

Mechanical

Maintenance

84

Periodic Maintenance:

Maintenance of different machines is prepared by expert engineer of maintenance department

for a period of time. Normally in case of dyeing machine maintenance after 30 days complete

checking of different important parts are done.

Maintenance Tools & Equipment:

1. Combination Tools/Spanner: Function: Tightening & loosening of nuts & bolts.

2. Socket Ratchet Set: Function:Tightening & loosening of nuts & bolts.

3. SlideRange: Function: Tightening & loosening of nuts & bolts.

4. Pipe Threat Cutting Tools: Function: To cut the threat in pipe.

5. Bearing Puller: Function: To assist the opening of bearing from shaft.

6. PipeRange: Function: Tightening & loosening of pipe joint.

7. Pipe Cutting Tools Function: For Pipe cutting.

8. Hole Punch: Function: Punching the hole.

9. Divider: Function: For circle marking on metal &wood.

10.Easy Opener: Function: To open the broken head bolts.

11.External Threat Die: Function: Forexternal Threat cutting.

12.Heavy Scissor: Function: Cutting of gasket & steel sheet.

13.Oil Can: Function: Oiling of moving parts.

14.Srill M/C: Function: For drilling.

15.Grease Gum: Function: Greasing of moving parts.

16.Grinding M/C: Function: For grinding& cutting of mild steel.

17.Welding M/C: Function:For welding.

18.Spirit Leveler: Function: For perfect leveling.

85

19.File: Function: For smooth the metal surface.

20.Hammer: Function:For scaling & right angling.

21. Hacksaw Blade: Function: For metal cutting.

Maintenance Procedure:

Normally preventive maintenance is done here. During maintenance procedure following points should

be checked:

Checklist for Different Machine:

Machine : Dyeing Machine

Check the main pump oil level.

Check all bearings, seals, gaskets.

Check all mechanical seal flush pipes.

Discharge the water from air filter.

Check all m/c flange & platform bolts.

Grease RCR rotary joints every 2 weekly

Clean & check the control panel.

Check the adjustment of catch basket mechanism and plaiter system.

Machine : Squeezer Machine

Maintenance: Mechanical

Grease squeezer bearings.

Grease all the bearings.

Check oil level of pneumatic oilers.

Check oil level of gearboxes.

Check magnetic spreader adjustment.

Machine : Compactor

Maintenance:Mechanical

86

Nuts of width adjustment spindles for wear

Check all spindle bearings for free running

Free running of guide rollers, deflection rollers & contact rollers

Pressure springs of chain tensioner

Perform visual inspection: -

Gear box oil level

Belts, pulleys

Machine :Stentcr


Crease all bearing with stuburg NBU-12, energrease 1002

Complete cleaning of the machine

Check all belt and belt tension

Check all door sills

Check gear box of platting and its oil.

Check all pin bars & clean

Check chain and give oil if required .Clean exhaust blower & duct

All chamber blowers check and clean

Chamber nozzle cleaning

Check gas pressure, adjust if required

Machine : Boiler:


Check and clean fluff & dart at all machine.

Feed pump servicing.Main boiler servicing.

Cheek all temperature & pressure gauge meter.

Cheek gas strainer.

Clean gauge glass &change if required.

Clean feed tank.

Clean fire tube.

Clean all safety valves.

Check all steam valves.

Check all gas regulators.

Remarks:

Maintenance of m/c’s are very essential to prolong the m/c life and good maintenance is important consideration.

In this industry maintenance program is done by expert maintenance team. So very few times production are

stopped due to m/c problem.

87

Basic Procedure Of Production Planning &Control:

A planned work brings success. Without planning nothing is complete within the required time. So

planning has its own importance which is intolerable. Planning gives a scheduled task and control

completes it successfully. But production planning and control is not an easy task. Its basic working

procedure is as follows-

Taking order form marketing division, Analyzing the orders Planning for knitting the fabric

Planning for dyeing the fabric Planning for finishing the fabric

It is only a basic procedure. It may change according to the type of order. Sometimes the order is planned

only for finishing the materials or only for dyeing the goods. Then some steps are minimizing for

planning.

Taking order from the marketing division: N. A. Z Bangladesh Ltd. marketing division supplied fabric orders to the planning and control division by

a specific format.

Analyzing the orders: After getting the fabric order, this section analyzes the orders according to buyers order quantity, type of

orders (i.e. type of fabric, color to be dyed etc.) delivery date etc. This section plans for required quantity

of fabric to be knitted, knitting balance, fabric to be dyed, dyeing balance RFD (ready for delivery), RFD

balance, delivery fabric & delivery balance.

Planning for knitting: This section plans for knitting production. It selects m/c for knitting the fabric, no of m/c to be used, type

of yarn used, from which source of yarn will be collected, required GSM, width etc. It also gives delivery

date of knitted fabric.

Planning for dyeing of the fabric: Production planning for dyeing is called "Batch Plan". Batch plan is prepared according to m/c capacity,

no. of nozzle batch no, fabric construction, color, width, GSM and priority of delivery etc. and written in

a batch card.

Planning for finishing of the fabric: Finishing schedule is same as dyeing. After dyeing, materials go to the finishing section with the batch

plan. The fabric can be finished in the open line finish or tube line finish. Finishing line will be selected

according to the type of the fabric to be finished. Finishing data is written to the batch card and is

informed to the planning section. However this section always forces to all the departments to finish all

the workwithin the delivery time given by the buyers. Thus, it plays a very important role in the

success of the company.

88

Utility

Available Utility Facilities Biswas Synthetic Ltd. is a large project. So it requires adequate utility services. In Biswas

Synthetic Ltd. the following utility services are available –

Electricity

Gas

Water

Compressed air

Steam

Electricity:

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

very much essential to ensure smooth production. In Biswas synthetic Ltd. the whole demanded

electricity is generated by Own Generator.

Generator Specification:

Type : Gas generator

No. of generator : 2

Manufacturer : DEUTZ

Local Supplier : KALTIMEX ENERGY BANGLADESH LTD.

Capacity :

Generator No Capacity

Generator No-1 1010 KW

Generator No-2 1344 KW

Electricity Consumption :

Season Total Consumption/Day

In Summer 1400 KW

In Winter 1100 KW

Overall efficiency :80%

89

Stroke of engine : 4 Stroke

Engine RPM : 1500

No of Cylinder :

Generator No No of Cylinder

Generator No-1: 12

Generator No-2: 16

Cooling System : Open Cycle

Ignition System : Auto

Gas

The gas is supplied to Gas Generator, Boiler .

The source of gas is TITAS GAS LTD.

Water

Continuous supply of water for Biswas synthetic Ltd. is ensured by Water pump. The deep well water is

subjected to Water Treatment Plant (WTP) to make sure the water qulity parameter suitable for Textile

Wet Processing.

Water Treatment Plant (WTP)

The goal of all water treatment process is to remove existing contaminants in the water, or

reduce the concentration of such contaminants so the water becomes fit for its desired end-use.

Some common contaminants in raw water (deep well water) is iron,Ca, Mg etc.

The water treatment plant is a vital part of the dyeing section where the supply water of the

dyeing floor is treated and cured for proper dyeing. The supply water contains various soluble

effluents like dissolved solids, metal compounds and other impurities which can lead to any sort

of fabric fault during dyeing the knitted fabrics

Optimum Hardness for Dyehouse water is 1-3 ppm.

In Biswas synthetic Ltd. water treatment is done in three steps by three filter tanks. The

circulation of water at different stages are controlled by different bulbs. Backwash bulbs are used

when the tank needs washing, Drain bulbs helps to drain out the water and Supply bulbs are used

to control the water supply among the filter tanks.

90

Water Treatment Procedure:

Multi Grade Filter:

The multi grade filter is used for removing the residual iron contained in the treated

water.

Activated Carbon Filter:

The activated carbon filter is used for removing the remaining metals and other

impurities by passing the water flow through rocks of different sizes arranged in different

layers of the tank. At first there is a layer of small rocks and next is a layer of medium

rocks and finally comes a layer of big rocks. The tank contains a carbon layer in middle.

Softener Tank:

The heart of a water softener is a mineral tank. It's filled with small polystyrene beads,

also known as resin or zeolite. The beads carry a negative charge.

Calcium and magnesium in water both carry positive charges. This means that these

minerals will cling to the beads as the hard water passes through the mineral tank.

Soft Water Reserve Tank:

The processed soft water is reserved in the soft water reserve tank.

Brine Water Tank

The brine tank is just what its name suggests, a plastic tank that contains a brine, water

saturated with salt. The brine solution is typically made with salt or sodium.

The brine tank holds a salt solution that flushes the mineral tank, replacing calcium and

magnesium ions with sodium.

Calcium and magnesium in water both carry positive charges. This means that these minerals

will cling to the beads as the hard water passes through the mineral tank. Sodium ions also

have positive charges, albeit not as strong as the charge on the calcium and magnesium.

When a very strong brine solution is flushed through a tank that has beads already saturated

with calcium and magnesium, the sheer volume of the sodium ions is enough to drive the

calcium and magnesium ions off the beads. Water softeners have a separate brine tank that

uses common salt to create this brine solution.

91

Regeneration :

In normal operation, hard water moves into the mineral tank and the calcium and magnesium

ions move to the beads, replacing sodium ions. The sodium ions go into the water. Once the

beads are saturated with calcium and magnesium, the unit enters a 3-phase regenerating cycle.

First, the backwash phase reverses water flow to flush dirt out of the tank. In the recharge phase,

the concentrated sodium-rich salt solution is carried from the brine tank through the mineral

tank. The sodium collects on the beads, replacing the calcium and magnesium, which go down

the drain. Once this phase is over, the mineral tank is flushed of excess brine and the brine tank

is refilled.

Test Performed to Ensure the Water Quality:

Harednes Test

Iron Test

Silica Test

PH Test

Compressed Air:

In Biswas Synthetic Ltd. Compressed air is generated with air compressor.

Machine Name : SWAN Air

Compressor

No. Of Comepressor : 2

Manufacturer : Tong Chen Iron Works

Co. Ltd.

Model : SWP-415

Max. Working Pressr : 9kg/cm2

Machine Name : Foam Liquid Storage

Tank

Manufacturer : Kashiwa Co Ltd.

Origin : Japan

Capacity : 3.7 M

92

Steam:

Pure steam with required temperature must be produced to meet the continuous demand of steam

in different sections. In Biswas Synthetic Ltd. Steam is generated using 2 fire tube boiler.

Boiler No-01: Boiler No-2:

Brand : Cochrn Boiler

Manufacturer : Cochran Boiler Ltd.

Origin : Scotland

Capacity : 10 ton

Brand : DMX1-900P

Manufacturer : Dapang Industry

Origin : Korea

Capacity : 9 ton

93

ETP (Effluent Treatment Plant)

ETP (effluent treatment plant ) is used to process waste water.

There are two type of effluent treatment plant is present:

BOD (Biological Oxygen demand)

COD(Chemical Oxygen Demand)

In Biswas Synthetic Ltd.BOD (Biological Oxygen demand) system is used to treatment

effluent water.

Principle:

Simple bacteria (cells) eat the organic material present in the wastewater. Through

theirmetabolism, the organic material is transformed into cellular mass, which is no longer

insolution but can be precipitated at the bottom of a settling tank or retained as slime onsolid

surfaces or vegetation in the system. The water exiting the system is then muchclearer than it

entered it.

A key factor is the operation of any biological system is an adequate supply of oxygen.Indeed,

cells need not only organic material as food but also oxygen to breathe, just likehumans. Without

an adequate supply of oxygen, the biological degradation of the wasteis slowed down, thereby

requiring a longer residency time of the water in the system. Fora given flow rate of water to be

treated, this translates into a system with a larger volumeand thus taking more space.

94

95

Process flow chart:

Effluent water

Filtration

Equalization Tank

Ph correction Tank

Biological Oxidation Tank

Primary clearer

Water Recycle to the

Flocculation tank

Secondary clearer 01

Water PIT

Secondary clearer 02

Out

Ph 6 - 8

De-colorant

dosing here

Aeration for proper

oxygenation

Date post:	07-Jul-2015
Category:	Engineering
Upload:	mazadul-hasan
View:	512 times
Download:	7 times

INDUSTRIAL ATTACHMENT OF BISWAS GROUP LTD

Engineering