Industrial Attachment Intramex Group Introduction Textile and garments sector is the biggest and fastest growing sector in Bangladesh. It is also the highest foreign currency earning sector in Bangladesh. Among this sector, Knit garment is growing very rapidly due to smaller investment requirement, greater backward linkage facility & higher profit than woven garments. That’s why export knit garments is increasing steadily for last few years and up to now. Industrial training is very much important for textile education. I have gathered a lot of information’s from this Industrial training which will help me to lead my future life and as well as the greater development in textile fields. 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 INTRAMEX GROUP, 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. General information about the company Name of the company: INTRAMEX GROUP Factory: INTRAMEX Group Laxmipura, Jaidebpur, Gazipur. Bangladesh Email: info@intramex group.com
Transcript
Industrial Attachment Intramex Group
Introduction
Textile and garments sector is the biggest and fastest growing sector in Bangladesh. It is also the highest foreign currency earning sector in Bangladesh. Among this sector, Knit garment is growing very rapidly due to smaller investment requirement, greater backward linkage facility & higher profit than woven garments. That’s why export knit garments is increasing steadily for last few years and up to now. Industrial training is very much important for textile education. I have gathered a lot of information’s from this Industrial training which will help me to lead my future life and as well as the greater development in textile fields. 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 INTRAMEX GROUP, 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.
General information about the companyName of the company: INTRAMEX GROUP
Name of The Buyer CountryMarks & Spencer U.KS.Oliver GermanyLi fung JapanGap U.S.APuma GermanyEsprit GermanyG-Star NetherlandPVH U.S.ACelio FranceAbercrombie& Fitch U.S.AGerry Weber Germany
Unit History, Location, Manpower & Item of Product
Unit Location Manpower Finished GoodsINTRAMEX Garments 1996
Laxmipura, Jaidebpur,Gazipur.Bangladesh
5500 Readymade Garments ( knit) + Embroidery)
INTRAMEX Fabrics 2002
Laxmipura, Jaidebpur,Gazipur.Bangladesh
1200 Knit Fabric ( Dyeing, finishing & washing)
INTRAMEX Spinning 2005
Laxmipura, Jaidebpur,Gazipur.Bangladesh
1100 Cotton Yarn
Interfab Shirt Mfg. Ltd 1998
Laxmipura, Jaidebpur,Gazipur.Bangladesh
2400 Readymade Garments (Woven)
Gothic Design Ltd. 2007
Laxmipura, Jaidebpur,Gazipur.Bangladesh
400 Printing of fabric
Fashion Plastic & Packaging Ltd.2003
Laxmipura, Jaidebpur,Gazipur.Bangladesh
100 Poly, Hanger & Button Poly,Hanger & Button
RAW MATERIAL Raw materialRaw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric.
Types of raw material:1. Yarn2. Fabric3. Dye stuff4. Chemical and auxiliaries
Name and source:
Yarn: The raw material (cotton yarn) used in Knitting are the product of INTRAMEX Spinning Ltd. They produce carded and also combed yarn according to their buyer requirement. The yarn count range vary for carded yarn from (34/1) to (7/1) Ne. The yarn count range vary for combed yarn from (40/1) to (20/1) Ne.
Mellange:Mellange is produced by blending different amount of top dyed fibre with grey fibre. Different types of mellange used in knitting are: Mellange
Jr. Executive (Yarn) (02) Jr. Executive (Grey Fabric) (03)
Store Asst. (Yarn) (03) Store Asst. (Grey Fabric) (07)
Loader (Yarn) (26) Batch Helper/Loader (35)
MANPOWER OF KNITTING SECTION:
Recommended points of buyer:When a buyer orders for fabric then they mention some points related to
Section No. of Person
Office staff 35
Q.C 30
Grey Store 35
Collar 15
Operators 107
Helper 27
Total 249
production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows-Diameter of the fabricDesign of the fabricGSM of the fabricTotal wt. of the fabricYarn countTypes of yarnColor of the fabricFinishing of fabric.Handling & fastness property
Machine List of Knitting Section in INTRAMEX GROUP :
Collect the approved sample and parameterAnalyze the work order and select yarnArrange yarn source and yarn in house in storeSet the cam designCollect yarn from yarn storeCone set the creel and yarn pass through the positive to the guide tensionSet the GSM/stitch (it control by VDQ pulley)Inspect the fabric after making approximately half matchIf ok, then continue the m/c be run
GSM Cutter Digital Balance Weight
If not ok, then identify the problem and solveRoll cut after making 20-25kgRoll making (Dia, GSM, Gauge Order no. Color, Buyer etc)Roll send to the inspection sectionAfter inspection roll grading according to the qualityThen it sends to the grey fabric storeFabric delivery from the store according dyeing batch card
Knitting:
The process in which fabrics are produced by set of connected loops from a series of yarns is called knitting.Warp knittingWeft knittingWhen fabric is produced by this method in weft direction then it’s called weft knitting & warp direction then it’s called warp knitting.
Loop formation of Knitting
Picture of knitting M/Cs:
Pilung Fukuhara Auto Stripe
Single Jersey Circular Knitting m/c:
Fig: Knitting m/c
DIFFERENT PARTS OF KNITTING MACHINE: Start/Stop/Inch buttons: This set of buttons is used to start/stop/slow running of machineRatchet lever: This lever permit the hand movement of the machine.Auto stop motion: Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicator lamps are on individual stop p motions & on the main control panel. While the yarn is broken we can find the location which is broken as well as to repair, meanwhile the motor can brake and stop operation at once to keep the security of the machine.Side creel: For each feed, there are two cones of yarn on the creel. Creel is used to place the coneTensioning device: The yarn goes to the feeder of the machine from the creel through different tensioning devices. These devices are used to maintain the proper tension ofthe yarn.Feeder: Feeder is used to feed the yarn.VDQ pulley: This is one of the important parts of the machine. VDQ pulley is used to control the GSM by controlling the stitch length. If the value of the VDQ pulley is increased, then the loop length of the fabric will be less and the GSM of the fabric will be high. Vice versa for make low GSM fabric.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.
Auto counter: Two shift revolution with display counter with predetermined stop, to settle freely the weight or yardage of fabric. Variable speed drive with machine break: Transistor inverter provided for free controlled, the process of V.S. motor-drive from slow operation to normal operation is quite & fast break to prevent damages in case of needles or yarn breakage.Fabric take up system: With variable speed control by a belt drive set can be adjusted the speed for different course of fabric-constant and uniform fabric tension.Rethom: These devise are used in Electrical Auto Striper Knitting machine.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
Typical Parameter at knitting section:Yarn count GsmStitch length
Points should be considered for GSM changing:VDQ (Variable Dia. Quality Control) pulley diameter.Yarn count.Machine gauge.Cam positionTake up motion
Factors that should be considered for changing of fabric design:Cam arrangement changing.Needle butt setting & needle dropping.Using of different colors in selected feeder.Using of jacquard mechanism.Size of the loop shape
YARN TYPES:
100%
COTTON YARN SOURCE:INTRAMEX Spinning Ltd.INTRAMEX Spinning an export oriented 40320 spindle ring & 1280 spindle rotor spinning industry equipped with all brand new state of the art European machines. It was established in the year 2004.MELANGE YARN SOURCE:Prime Spinning Ltd. 04. Shohagpur Spinning Ltd. Phartoli Spinning Ltd. 05. China
Single Jersey = 35Fleece = 10Double Jersey =19Auto Stripper (S/J) = 06Auto Stripper (Rib) = 02Flat Bed Knitting M/C = 25Fabric Inspection M/C = 03Grand Total = 100
Buyers: Buyers Logo: S. OliverG STARPUMAMarks & SpencerESPIRITPVH
Products of Circular Knitting Machine:
Single Jersey M/C:a) Plain jerseyb) Lycra jerseyc) Single Lacosted) Double Lacostee) Single Piquef) Double Pique g) Fleece (Three threads) h) Terry Fleece (Two thread)
Type of Collar:TippingSolid collarRaising collarFolding collarCuffEmboss
Faults, Causes & their Remedies in Knitting:
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.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.Sinker Mark: Causes:When sinker corrodes due to abrasion then some times cannot hold a new loop as a result sinker mark comes.If sinker head bend then sinker mark comes. Remedies:Sinker should be changedStar : 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.Drop Stitches: Causes:Defective needle.If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.
Take-down mechanism too loose.Insufficient yarn tension.Badly set yarn feeder. Remedies:Needle should be straight & well.Proper feeding of yarn during loop formation.Correct take up of the fabric & correct fabric tension.Yarn tension should be properly.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.07. 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.Pin hole : Causes:Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:Change the needleGrease stain: Causes:Improper greasing Excess greasing Remedies:Proper greasing as well as proper maintenance.10. 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 tightly during knit fabric production. Remedies:Blowing air for cleaning and different parts after a certain period of time.By cleaning the floor continuously.By using ducting system for cleaning too much lint in the floor.Over all ensure that lint does not attach to the fabric.11. Yarn contamination: Causes:If yarn contains foreign fiber then it remains in the fabric even after finishing,If lot, count mixing occurs. Remedies:By avoiding lot, count mixing.Fault less spinning. 12. Yarn Faults:
Neps.Slubs.Yarn count variations.Thick/Thin place in yarn.
Quality Assurance of knitting Section
Yarn Test after Receiving Yarn
Sample Fabric Preparation before Bulk Production
Online Quality Control
Offline Quality Control
Fabric Inspection using 4 point system
Measurement of Fabric Faults:
Four Point System: Defect Length Assigned Point 0-3” 1 point 3.1-6” 2 point 6.1-9” 3 point >9.1” 4 pointCalculation:Avg. Points/100 yds = total points /total inspected yds * 100
Maintenance:
During servicing or maintenance the following things are cheeked- NeedleSinkerCam BoxCylinderOilBelt Type of Maintenance:
Breakdown Maintenance Scheduled Maintenance
This is basically the servicing of the machine. This is done becauseTo maintain the quality of the fabricTo reduce the fabric faultRemoval of the lint from the machineCleaning the different parts of the machine
Production Calculation:
Production / shift in Kg at 100% efficiency:
Production / shift in Meter :
Fabric Width in Meter:
Efficiency : Actual production Calculated production 100Sample of various Type of Knitted fabric:
Fabric Type Sample Single jersey Lycra Single jerseySingle Lacost Double Lacost Fleece
Remarks & conclusion:Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good so that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements.
BATCH SECTION
(1*1) Rib(2*2) Rib Lycra Rib Stripe Single jersey
Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.
Function or Purpose of Batch Section:
To receive the grey fabric roll from knitting section or other source.Turn the grey fabric if require. To prepare the batch of fabric for dyeing according to the following criteria –Order sheet (Received from buyer)Dyeing shade (color or white, light or dark)M/C capacityM/C availableType of fabrics(100% cotton, PE, PC, CVC)EmergencyTo send the grey fabric to the dyeing floor with batch card.To keep records for every previous dyeing.
Proper batching criteria:
To use maximum capacity of existing dyeing m/c.To minimize the washing time or preparation time & m/c stoppage time.To keep the no. of batch as less as possible for same shade.To use a particular m/c for dyeing same shade.
Batch management:
Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency.
Machines in batch section
M/c quantity: 02
M/c Specification:
Machine Name : Air turning m/cM/c No : 01Brand Name : TaidaOrigin : ChinaM/c Speed : 300-500m/minModel : DF 200Max up clothing : 150 kgCompany : Shandong Taida Dyeing & Finishing Machinery Co.Ltd
Machine Name : Air turning m/cM/c No : 02Brand Name : Taida
1. Tearing Strength Tester:No. of m/c-01Brand Name: ElmatearOrigin : U.K
2. Button Strength Tester:No. of m/c-03Brand Name : TitanOrigin : U.KMax.Pressure: 10 barCapacity : 3000N
3. Bursting Strength Tester:No. of m/c-01Brand Name: TruBurstOrigin : U.K
4. Pilling Resistant Tester:No. of m/c-04Brand Name: ImpulseOrigin : U.K
5. Sprectra Flash:No. of m/c-01Brand Name: Data ColorOrigin : U.S.A
6. 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
7. Test Name : Dimensional Stability, Spirality, and Appearance after washing.Name of the m/c : Eltrolux wascator.Origin : U.KNo. of m/c : 01Test Method : ISO 6330, ISO 26330
8. Test Name : Shrinkage Test.Name of the m/c: Eltrolux Origin : U.KNo. of m/c : 01Test Method :
9. Test Name : Color Fastness to Wash Test.Name of the m/c: Gyro washOrigin : U.KNo. of m/c : 02Test Method : ISO 105-C06
Check & note the Lot no, Style no, Item no& Collar
Sample Preparation
Run the test
Physical test Wet lab
Color Fastness to wash Bursting strength Pilling Color Fastness to washing Crocking
Evaluate the sample Pre-production Sample Final sample
Report Making Test Test
Prepared the report prepared the report Pass Fail
Deliver Refinish Pass Fail Pass Fail
Need to test again Go for the final Refinish
Need to test again Dimensional stability.
Prepare the sample
Wash the sample according to buyer method.
Tumble dry
Keep the sample flat in the conditioned temperature at least four hours before, after measurement.
Measure the sample
Prepared the report
Pass Fail Ready to delivery Refinish
Need to test again Quality Management System The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. Objects of quality control:
Research.Selection of raw materials.Process control.Process development.Product testing.Specification test
Quality management system in INTRAMEX :
Online Quality control:
There are two types of online quality control. These are as follows: -Raw material control:Raw material control means control the quality of raw materials (e.g.- Quality of Grey fabric, Dyes, Chemicals and Auxiliary)Process control:Process control means the selection of right process and controlling of some parameters. Such as PH, Water hardness, water volume, Temperature, Reel Speed, Pump pressure, etc.
Laboratory:Laboratory is the heart of dyeing Industry. An efficient laboratory can increase the efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before bulk production a sample is sent to buyer for approval. Laboratory supplies the recipe to the floor. Purpose of Laboratory:Get color approval from buyer.Recipe supply to the floor.Shade correction.Minimize the deviation between bulk and laboratory. Laboratory line:Standard sample: At first recipe % of standard sample is measured by CCM (computer color matching) system.
QA
On-Line Off-Line
Laboratory Trial:Then by taking those recipe laboratory officers produce laboratory trial and match with standard according to buyer requirement.Approved Sample:Then sample swatch, which is matched with the standard, is send to buyer for approval.
Off-Line Tests:Off-Line tests for finished fabrics are divided into two groups. These are as follows:Physical testsChemical tests
Physical Tests:GSM of Fabric.Abrasion resistance / Pilling.Dimensional stability test.Spirality test.Color fastness to rubbing test (Dry / wet).Bursting strength test (For Knitted fabric).Tensile Strength test (For Woven fabric).
Chemical Tests:Color Fastness to washing.Color Fastness to light.Color Fastness to heat.Color Fastness to actual launderingColor Fastness to Chlorinated water.Color Fastness to water spotting.Color Fastness to perspiration.Color Fastness to Seawater.Flammability test.Fibre analysis.PH test.Spray test (water repellency).Phenolic yellowing. Quality standard:Here in the factory they are following ISO standards for their testing purpose. But testing standard depends on buyer requirements.
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: Size of specimen: Cut sample & multifibre at (10 × 2) cm then stitch.Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in distilled water & cooled at 20°C & measured PH (where necessary).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 Rinse the sample twice with cold water.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 tube. Then four tubes 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 the viewing cabinet & compare with standard photographs.
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 = ----------------------------------×100 Before wash
Width wise: After wash – Before wash = ----------------------------------×100 Before washSpirality test:
= × 100 %
Color fastness to water (ISO 105 EO1& EO2):
Sample size: Cut the specimen & multi-fiber at 10×2cm & sewn together.Solution: Wet in distilled water at room temperature & it will suck water.Place it in acrylic resin plates & put the weight on to the plates.Keep it in oven & keep the temperature at 37± 2°C for 4hrs.Open the specimen & dry it in the air hot exceeding 60°C.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 monohydrate5g/l of sodium chlorideThis solution is brought to pH -8 with 0.1 mole/l caustic solution. Acid solution:0.5 g/l of 1-histadine monohydrochloride monohydrate5g/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: 504) 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.
6.17 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.
RESPOSIBILITY OF OFF-LINE quality control: To check the following things:Inspection of fabric in the inspection M/C under 4-point system.Yarn count and lot no.Buyer.Design.Stitch length of grey fabric.Shade of grey fabric within one order.
RESPOSIBILITY OF ON LINE quality control: To check the following things:M/C Dia/GaugeBuyerDesignGrey fabric GSN & Stitch LengthYarn count & Lot noYarn whether approved or not by Q.C. DepartmentFinished dia & grey dia.Fabric quality checking under 4-point system.Responsibility of IN CHARGE of quality control:Making report.Supervise the grey Q.C.Check machine is running according to program or not Check program can meet the requirement. Which is mentioned in the order sheet or not.Check yarn is approved by Q.C. or not.
Maintain resister khata.Make daily batch re-process job card. Remarks & conclusion:Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good so that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements.
DYE
A colorant that becomes molecularly dispersed at some point during application to a substrate and also exhibits some degree of performance.
DYEING
The application of color producing agents to fibre, yarn, or fabric or part usually fibrous or flim, in order to impart a degree of color permanence demanded by the projected end use, usually by immersing in a bath of dye.
Specification of different machines: Bulk dyeing section:
Dyeing Machine. 01(Fongs):
Type Jet Dyeing MachineManufacturer name FONG’SCountry ChinaModel No. ECO-38-2TYear of manufacturing 2003Temp. Range 00-980CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 7
DGM/AGM
Manager
Planning
Asst.Manager
Sr.Executive/Executive
Jr.Executive
Sr.Supervisor/Supervisor
Production
Asst.Manager
Sr.Executive/Executive
Jr.Executivee
Sr.Supervisor/Supervisor
Store
Asst.Manager
Sr.Executive/Executive
Jr.Executivee
Sr.Supervisor/Supervisor
Washing
Asst.Manager
Sr.Executive/Executive
Jr.Executive
Sr.Supervisor/Supervisor
Production Capacity 500 KG
Dyeing Machine.02(Thies):
Type Jet Dyeing MachineManufacturer name THIESCountry GermanyModel No. D-48653 COESFELDYear of manufacturing 2004Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo Of Nozzle 04
Dyeing Machine. Thies-03:
Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653 COESFELDYear of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4
Dyeing Machine. THIES-04:
Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. ECOSOFT PLUSYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1
Dyeing Machine. THIES-05:
Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41350Year of manufacturing 2002Temp. Range 00-1400C
Used Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KGNo. of Nozzle 2
Dyeing Machine. THIES-06:
Type HTHP Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41354Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4
Dyeing Machine. FONGS-07:
Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 200 KGNo. of Nozzle 1Permissible Working Pressure
380 Kpa
Test Pressure 585 Kpa
Dyeing Machine. FONGS-08:Type Jet Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1Permissible Working Pressure
380 KPA
Test Pressure 585 Kpa
Dyeing Machine. FONGS-09:
Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-3TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 7Production Capacity 750 KGNo. of Nozzle 3Permissible Working Pressure
380 Kpa
Test Pressure 585 Kpa
Dyeing Machine. FONGS-10:Type High Speed jumbo Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 8Production Capacity 1120 KGNo. of Nozzle 4Permissible Working Pressure
350 Kpa
Test Pressure 520 KPa
Dyeing Machine. FONGS-11:
Type HSJ Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 8Production Capacity 840 KGNo. of Nozzle 3Permissible Working 380 Kpa
PressureTest Pressure 520 Kpa
Dyeing Machine.FONGS-12:
Type HSJ Dyeing MachineManufacturer name FONGSCountry ChinaModel No. HSJ-SR-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 3Production Capacity 560 KGNo. of Nozzle 3Permissible Working Pressure
380 Kpa
Test Pressure 520 KPaDyeing Machine.FONGS-13:
Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 6TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 1680KGNo. of Nozzle 6
Dyeing Machine.FONGS-14:
Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 840 KGNo. of Nozzle 3
Dyeing Machine.FONGS-15:
Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 1120 KGNo. of Nozzle 4
Sample Dyeing Machine.FONGS-01:
Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 25KGNo. of Nozzle 1
Sample Dyeing Machine.THIES-02:
Type Sample Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653-COESFELDYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Inhalt Capacity 523 LitreNo. of Nozzle 1
Sample Dyeing Machine.FONGS-03:
Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 9Production Capacity 30KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-04:
Type ALL FIT-120 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 120 KGNo. of Nozzle 1Sample Dyeing Machine.FONGS-05:
Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2006Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 30 KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-06:
Type ALL FIT-60 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 60 KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-07:
Type ALL FIT-60 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed
AirNo. of Motor 9Production Capacity 60 KGNo. of Nozzle 1
Dyeing Floor Area:
Total length of dyeing floor: 412 feetTotal width of dyeing floor: 34 feetArea of the dyeing floor: 412×34 = 14008 square feet.
Production capacity:
Sample Production: Sample dyeing machine = 07 pcsTotal machine capacity of sample m/c = 355 kgTotal production capacity of sample m/c = 275 kg
Bulk Production
Dyeing machine = 15 pcsTotal machine capacity = 11,710 kg /shift =35,130 kg/ dayTotal effective capacity* = 9,953 kg / shift = 29,859 kg/day* With 85 % machine loading For 100 % cotton fabric dyeing total capacity (2.5 batch/day) =24,883.75 kg/dayFor CVC dyeing total capacity (1.5 batch /day) = 14,929.5 kg / day
FEATURES OF FONG’S ATMOSPHERIC M/C:The M/C is designed for the pre-treatment, dyeing and after-treatment under atmospheric condition.Nozzle is sized for smooth passing through by the fabric and extensive exchange with the dyeing liquid. Two standard nozzle sizes with sufficiently large diameters are available.Circulation pump is sized for heavy fabricProduction capacity:500kgsMax temperature:98◦C Max pressure:1atm
Features of high temperature machine (Thies M/C):
The M/C is designed for the pre-treatment, dyeing and after-treatment which can Provide temperature up to 140◦c nozzle lead get interlock after temperature exceed 80◦C Loading per nozzle 250kgDesign pressure:350-550kpaDesign Temp :140◦CHydraulic Test Pressure:585Kpa Manufacturer: Germany(Thies),Taiwan (Fong’s)
No of nozzles:1-8Features of fong’s (hsj) machine:
Variable Loading (VL) storage chamber design gives extra capacity to carry loading up to 280 kg per tube. Heat Exchanger of extreme efficiency gives the largest heating rate with minimum heat loss to the environment.Multi Saving Rinsing System (MSR)Shortens the dye cycle and reduces the water consumption. Advanced Intelligent Rinsing System (MIR) controls the rinsing water consumption and shortens the rinsing process.Highly optimized machine structure reaches the lowest possible liquor ratio of 1:4.5 to run the machine.Dissolution pumps for proper circulation of liquor.Safety valve test: 350kpa.Maximum fabric speed: 400 m/min. Maximum working temperature: 140°C.Design pressure: 350kpa.Hydraulic test pressure: 510kpa.
Unique features of thies & fong’s m/c:Thies machine: Fong’s machine:CCR Function MIRWinch dia can be controlled MSROne addition tank Dissolution PumpNozzle pressure is 0.5-0.6 bar Two Addition TankVl chamber setting is not possible in thies ecosoft plus.*
Filter & Heat Exchanger Is In Same Shell Tube
Separate filter & heat exchanger Variable Chamber Setting Is PresentHeat exchanger is at vertical position Nozzle Pressure Is 8-8.50psi
Heat Exchanger Position Is HorizontalComparison between Fong‘s and Thies dyeing machine:Fong‘s Thies
Have heat-exchanger for preparation tank. Such facilities are not present.
Liquor pass through the filter & heat-exchanger
Filter and heat-exchanger are separate.
Have dissolution pump for mixing chemical in1:4 ratio.
Loading per nozzle 280 kg (HSJ). Loading per nozzle 250 kg
Winch speed can be above 450 m/min. Up to 350 m/min.
Technology of dyeing machine:
INTRAMEX dyeing unit used special types of dyeing machine. In these machine, the Jet and Winch technology is combined i.e. during dyeing, dye liquor circulate through the machine like jet dyeing machine also the fabric is circulated through the winch as like winch dyeing machine. This combination is made for better dyeing of the fabric.Main parts of dyeing machine:The main parts of the dyeing machine are-Main tankReserve tank/PT tankAdditional/Mixing tankMain pumpHeat exchangerFilter
The description of the main parts of the machine is as follows –Main tank:Main tank is the largest part of the dyeing machine. This is the main dye bath which contains the dye liquor & the fabric. The size of the tank depends on the capacity of the machine. Liquor & fabric circulates in the main tank during dyeing process. There may have different number of nozzle connected to main tank according to the machine capacity. Each nozzle may handle 300-900m of fabric.
Main tank
Reserve/ PTtank:This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for heating the water in the main tank which results in the reduction of total dyeing time.
Fig: Reserve/PTtankAdditional/Mixing tank:This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for heating the water in the main tank which results in the reduction of total dyeing time.
Fig: Mixing tank
Main pump:This is one of the essential parts of the dyeing machine. This is used for displacing of dye bath liquor causing a flow from main tank to heat exchanger through filter. That means the pump ensures the liquor circulation throughout the dyeing process.Heat exchanger:During the different stage of dyeing (also pre-treatment, after-treatment), there is a need of increasing or decreasing the temperature of dye liquor gradually. We cannot use liquor of required final temperature directly because there may be possibilities of thermal shocking of the fabric. So, the temperature should be increased or decreased in a controlled manner. This controlling is done by heat exchanger. Actually it is an indirect heater. During the circulation
of dye bath liquor, the liquor passes through the heat exchanger.
A heat exchanger is a device built for efficient heat transfer from one medium to another, whether the media are separated by a solid wall so that they never mix, or the media are in direct contact.Rate Of Heat Exchange IS Proportional To Temp Difference Between Hot Fluid And Cold Fluid *Counter Flow * Parallel Flow
Mechanism of Heat-exchanger:Heat-exchanger consists of no. of tubes surrounded by a shell body.Two fluids of different temperature flow through the heat exchanger. The fluids can be either gas or liquid on either the shell side or the tube side.One flows through the tube other flows through the shell.The temperature of the two fluids is different, so transfer of heat occurs from one fluid to another through shell.The fluids which flow through the tubes come in and pass out from the heat-exchanger on the same side. On the other hand the fluid used in shell comes in and pass out from the different side of the shell. Theory of Application of Heat exchanger:Two fluids, of different starting temperatures, flow through the heat exchanger.One flows through the tubes (the tube side) and the other flows outside the tubes but inside the shell (the shell side).Heat is transferred from one fluid to the other through the tube walls, either from tube side to shell side or vice versa.The fluids can be either liquid or gases on either the shell or the tube side. In order to transfer heat efficiently, a large heat transfer area should be used, so there are many tubes. In this way, waste heat can be put to use. This is a great way to conserve energy.
Heat exchanger control points-Steam Pressure 7 Bar (101.5 PSI)Cooling Water Temperature 25 ⁰C At 3 BarMax Heating 140 ⁰ C (HTHP)Cool Down Temp 85 ⁰C (HTHP)Filter:
During the treatment of fabric in the machine, lots of lose fiber is produced from the fabric. To eliminate these lose fibers, filter is used. It also reduces the lose fibers loads from the fabric. If they lose fibers are not eliminated, then the running of fabric is disturbed & entanglement can be occurred.
Fig.: FilterComponents-Filter Service DoorFiltration Section
Filter Type-Stainless Steel SieveFabric And Steel Sieve Filter Change-Filters Needed To Be Changed To Maintain The Accurate Nozzle PressureTo Supply Filtered Liquid To Heat ExchangerTime of Change-After Enzyme WashAfter Dyeing Bath DrainAfter Rinsing
Features of Filter:
The filter eliminates the loose fibres in the dye bath,consequently it reduces the loose fibre loads on the fabric.Changing and cleaning the filters is sometimes forgotten, with the result that the dyeing machine's nozzle pressure decreases, with the effect that running is disturbed and tangles can occur.
automatic self cleaning filter system-No cleaning of filter.No pressure variation in the nozzles due to lint buildup due to automatic regulation system.No lint on fabric due to 100 % filtration of the circulation liquor.
Additional Tank:Additional tank is used for-Color dosingSoda dosingSalt dissolvingAuxiliaries injectionChemical dosing
Ways of liquor flow from additional tank:Two ways-InjectionDosingLinear dosingProgressive dosingDecreassive dosing
Linear dosing Progressive dosing Decreassive dosing
Liquor circulation system:
During the treatment of fabric, the liquor is circulated throughout the machine. At first, the required amount of liquor is taken in the main tank. Then the liquor goes to the filter through pump and then it goes to the heat-exchanger. From the heat-exchanger, the liquor goes to the main tank through nozzle. The schematic diagram of liquor circulation system is given below-
Figure: Liquor circulation systemFunction of dissolution pump:Dissolution pump makes the chemical concentration (salt, soda, dye, auxiliaries) low before passing it to the main tank.This concentration is reduced in 1:4 ratios (liquor from additional tank: liquor from main tank).As a result rate of chemical dosing become slow which gives better fixation.Thus better color yield and even dyeing can obtain.
mixing zone
Liquor from main
Fig.: Dissolution pump
Nozzle:Controlling Points-Nozzle Pressure AdjusterNozzle Dia AdjusterPressure Range-Nozzle Pressure 0.5-0.6 bar In Thies M/C And 8-8.5 Psi In Fong’s M/CProblems-Fabric Entanglement*Fabric Slippage
Variable chamber:Function-Variable Chamber Settings Are Used To Avoid Fabric Entanglement
To Place The Fabric In “J” Box In Pile MannerControl points-Adjustable Gear Box Small Profile For S/J Large Profile For D/JIndicator with % GSM or linear density & Fig: Variable Chamber Chamber Size %*Take off roller & fabric plaiter:
Used to unload the fabricMove forward or reverse directionWith plaiter can plait the fabric
Fig.: Take off roller
Winch/ lifter reel:It is Used To Take Up The Fabric And Deliver It from the Storage Chamber Into Nozzle The Fabric Rope Passes To System Namely the Winch and the NozzleSpeed Synchronization Is NecessaryNo Tension Between Winch And Nozzle Fig.: Winch/ lifter reelKier chamber:Kier Service Door (open <45 ⁰C)Spray Cleaning Device Spot LightSteam Pressure ReleaserFabric Plaiter Fig.: Kier chamber
The control system of fong’s & thies:T 737 XL Controllers is available in THIES M/C. It can be used in centralized PC system like Orga Tex*. FC 28 Controller is available in Fong’s M/C. It can be used in centralized PC system like Orga Tex*. Fig.: The control system Of fong’s & thies
MIR Rinsing System:Multi-function intelligent rinsing system.If the temperature is below 80°C It is
a Low Level Continuous Rinsing Shorten Rinsing time.Save Rinsing Water.Fill and Drain at the same time at low level.
Fig.: MIR Rinsing System
MSR Rinsing System:Multi- saving rinsing system.If the temperature above 80°C it is Combined Cooling and Rinsing at high temperature. Save Steam in Hot Rinsing.Rinsing efficiency at higher temperature is faster, so rinsing time is shortened.
Orga tex:
Orga texis the Management & controller software for textile wet processing.Orgatex Includes Modules For-Program EditingRecipe ManagementStock ControlProduction PlanningCostingOnline Control Of Machine2th to 9th machine is under orgatex. Fig.: Orga tex
Raw materials for dyeing:
Raw materials used in the dyeing section are: 1. Grey fabrics 2. Dyes 3. Chemicals.Grey fabrics:Following types of gray fabrics are dyed:Single jerseySingle jersey with lycraPolo piqueBack PiqueSingle lacost Double LacostFleeceRib Rib with lycra1Χ1 rib2Χ2 rib
Different types of collar & cuff.
Different Types of Dyes Used In INTRAMEX With Their Brand Name:
Reactive Dyes:
BRAND NAME COUNTRY NAME NAME OF DYE STUFF
DY-STAR GERMANY
Remazol Golden Yellow RGBRemazol Deep Black RGB Remazol Deep Black GWF Gran Remazol Red RGB GranRemazol Turquoise Blue G133%Remazol Brilliant Blue R SpecRemazol Brilliant Blue BB 133% GranRemazol Ultra Carmine RGBRemazol Ultra Carmine RGB GRLevafix Rubine CA GranLevafix Red CA GranLevafix Olive CA GranLevafix Fast Red CA GranLevafix Brilliant Red E-4BA GranDianix Navy CCDianix Turquoise S-BG
IMPOCOLOR GERMANY
Imcozin Blue E-NRImcozin Blue V-CR 150%Imcozin Brilliant Red V-F3BImcozin Brilliant Yellow V-4GLImcozin Yellow E-3R 150%
BENZEMA SWITZER LANDBezaktive Blue S-GLD 150Bezaktive Yellow S-3R 150Bezaktive Red S-3B 150
CLARIANT SWITZER LAND Drimarene Yellow K-4G Cdg
HUNTSMAN SWITZER LAND
Terasil Red W-4BSTerasil Navy W-RSNovacron Red FN-R-01Novacron Yellow F-4G
JIHUA CHINA Star fix Black B 150%Star fix Red EP 150%
SUMIFIX JAPAN Sumifix Supra Blue E-XFSumifix Supra Yellow E-XF
SUN COLOR KOREA Sunfix Navy Blue MF-D
Different Types of Chemicals Used In INTRAMEX With Their Brand Name:
CHEMICAL NAME BRAND NAME COUNTRY NAMEWetting agent Feloson NOF GermanyLevelling agent A-41 ChinaAnti-creasing agent Kapavon CL Germany
Per Oxide StabilizerKapazon H-53
GermanyCBBRucorit Wez
Caustic Caustic ChinaSoda Ash Soda Ash ChinaH2O2 H2O2 China+Korea
Optical Brightening Agent
Uvitex-BMASwitzerlandUvitex-BHV
Uvitex-BBTSyno White 4Bk Korea
H2O2 Killer Kapatex-PKS GermanyAcetic Acid Acetic Acid India
Sequestering AgentSecuron-540 ChinaCSPolyclean-SP India
Enzyme Bio-ACE ChinaBiopolish-B41 Srilanka
Electrolyte / SaltSodium Sulphate Anhydrose IndiaGlubar Salt
Flow Chart for Dyeing:Process Flow Chart for Pretreatment:Scouring, Bleaching & Enzyme Treatment:
Fabric Load
Level in
Dyed Fabric Unloading from Fong’s Dyeing m/c
UnDyed Grey Mellange Fabric Loading To Thie’s m/c
Nof + Stabilizer (600C by injection)
Caustic Dosing (600C X10 min)
H2O2 Dosing (700C X10 min)
Temperature raise at 1050C Run time 30 min
Drain
H2O2 Killer hot wash (800C X10 min) Drain
Acetic Acid (600C X10 min)
MIR Rinse (10 min)
Acetic Acid (550C injection) Check PH-4.5
Enzyme Dosing (550C X 5 min) Run time 30 min Drain
CS hot washes (900C X10 min)
MIR Rinse (20 min) Pretreatment Curve for 100% cotton knit fabric in INTRAMEX ltd:
Flow Chart for CVC (blended fleece fabric) Dyeing: PREWASH
WATER FILL & FABRIC LOAD
HOT WASH WITH NOF (RUN 10´ AT 80°C)
RINSING
BATH DRAIN
Polyester part dyeing:
Acid (Injection) Run time (5 min x 450C)
PH Check (PH- 4.5)
Color dosing (15min x 450C) Dispersing agent
Raising Temp at 1300C Run time 45 min
Sample Check
Drain
Normal hot wash Drain
Reduction cleaning:
Caustic Dosing (600C X 6 min)
Raising Temp at 1300C
Hydrose injection Run time (10 min x 800C)
Drain
Normal wash Drain
Cotton part dyeing:
Level In (water from P.T)
Leveling agent injection
Salt dosing (10 min x 60˚C) Run time 20 minColor dosing (30 min x 60˚C) Run time 20 minSoda dosing (50 min x 60˚C) Run time 10 minCaustic dosing (30 min x 60˚C) Check pH Sample check
Normal hot wash
Drain
MIR rising 10 min
Bath drop
Dyeing Procedure for Light Color:
Water fill
PH Check (6.5-7.0)
Leveling agent (Inject & run 10 Min.)
Dye (Dosing 30 Min. & run 20 Min.)
Salt (Dosing for 10 min. & run 20 min.
Shade checkSoda (70% Pro Dosing 50´ & run 10´ & check PH sample check)
Shade check
Bath drain
Dyeing Curve for Light-shade:
Dyeing Procedure for Dark Color:
Water fill
Check PH (Req. 6.5-7.0)
Leveling agent (Inject & Run 10 Min.)
Salt (Dosing 10´ & Run 20´)
Dye (Dosing 30 Min. & Run 20 Min.)
Shade check
Soda (70% Progressive dosing 50´ & Run 10´ & Check PH)
Shade check
Bath drain
Dyeing process Curve for Dark Shade:
Dyeing Procedure for Turquoise Color:
Level In (Water from p.t at 800C) Check pHLeveling agent injection Run 10 minColor dosing linear (800 c x 40 min) Run 20 minSalt dissolving (800 c x 15 min) Run 200Soda dosing (70% Progressing) (800 c x 50 min) Check pHSample check
MIR rising 10 min
Bath drop
Dyeing Curve for Turquoise Color:
Flow Chart for OBA Treatment:
Level in (Water from PT)
NOF + H53 new
Fabric Load
Caustic Dosing 650 ×10 min Run 3 min
H202 Dosing 700 ×10 min
OBA Dosing 780 ×15 min
Temp Raise to 1050 C Run 60 min
Drain (B.D)
Level in (Water from PT)
Normal Hot 700 × 5 min
Drain (B.D)
Acid 500 × 10 min
Level In
CS HOT 900 × 5 min
Drain
Rinse 10 min
Acid
Drain Rinse 3min
UnloaDyeing Sequence for Black Shade:
Level In
Leveling agent injection Run 10 min
Salt dosing (600 c x 10 min) Run 15 min
Color dosing linear (600 c x 30 min) Run 20 min
Soda dosing (70% Progressing) (800 c x 50 min) Check ph
Sample check
MIR rinsing 10 min
Bath drop
Dyeing Sequence for 800 C Isothermal:
Level In (Water from p.t at 800C) Check pH
Leveling agent injection Run 10 min
Color dosing linear (800 c x 35 min) Run 20 min Salt dosing (800 c x 15 min) Run 20 min Soda dosing (70% Progressing) (600 c x 50 min)
Check pH Sample check
MIR rising 10 min
Bath dropDyeing Sequence for 80 0C Light Shade:
Level In (Water from p.t at 600 ) Check pHLeveling agent injection Run 10 min
Color dosing linear (600 c x 35 min) Run 20 min
Salt dissolving (600 c x 15 min) Run 20 min
Soda dosing (70% Progressing) (600 c x 50 min) Check pH Sample check
MIR rising 10 min
Bath drop
Dyeing Sequence for 800 C Medium Shade:
Level In (Water from p.t at 600 ) Check pH
Leveling agent injection Run 10 min
Salt dosing (600 c x 10 min) Run 20 min
Color dosing (600 c x 30 min) Run 20 min
Soda dosing (70% Progressing) (600 c x 50 min) Check pH Sample check
MIR rising 10 min
Bath drop
After treatment:
Water fill
MIR washes 10´
Normal Hot 70°C & run 15´
MIR wash 15
Acid at 45°C & run 10´
Hot with Nof + Soaping agent (Run 10´ at 80°C)
Sample check
Wash at 90°C for 10´
Sample check at 80°C
Rinsing
Fixing agent + Softener
Sample check
If OK then drain, If not OK then addition is given
Addition:
Dye (Dosing for 20´ & Run 20´)
Sample taken
If OK then bath drain & If not OK then Topping
Topping:
Bath drain
Water fill & Temp. Raised at 60°C
Check pH (Required 6.5)
Leveling agent (Inject & Run 10´)
Color dosing 30´ at 60°C
Salt dosing 10´ & Run10´
Sample check
If OK then ½ Soda Dosing 30´ & Run 20´ & then drain
If not OK then Addition is done
Stripping:
Water fill & Fabric load
NOF & Caustic dosing 10´
Temp. Raised to 90°C
Hydrose dosing 10´
Temp. Raised to 105°C & Run 40´
Hot wash at 90°C Bath drain
Common dyeing faults with their remedies:Uneven dyeing:Causes:- Uneven pretreatment (uneven scouring & bleaching).- Improper color dosing.- Using dyes of high fixation property.- Uneven heat-setting in case of synthetic fibers.- Lack of control on dyeing m/c
Remedies:- By ensuring even pretreatment.- By ensuring even heat-setting in case of synthetic fibers.- Proper dosing of dyes and chemicals.- Proper controlling of dyeing m/c
2. Batch to Batch Shade variation:
Causes:- Fluctuation of Temperature.- Improper dosing time of dyes & chemicals.- Batch to batch weight variation of dyes and chemicals.- Dyes lot variation.- Improper reel speed, pump speed, liquor ratio.- Improper pretreatment. Remedies:- Use standard dyes and chemicals.- Maintain the same liquor ratio.- Follow the standard pretreatment procedure.- Maintain the same dyeing cycle.- Identical dyeing procedure should be followed for the same depth of the Shade. - Make sure that the operators add the right bulk chemicals at the same time and temperature in the process.The pH, hardness and sodium carbonate content of supply water should check daily.
3. Roll to roll variation or Meter to Meter variation:
Causes:- Poor migration property of dyes.- Improper dyes solubility.- Hardness of water.- Faulty m/c speed, etc
Remedies:- Use standard dyes and chemicals.- Proper m/c speed.- Use of soft water.
4. Crease mark:
Causes:- Poor opening of the fabric rope.- Shock cooling of synthetic material.
- If pump pressure & reel speed is not equal.- Due to high speed m/c running.
- Lower rate rising and cooling the temperature.- Reducing the m/c load.- Higher liquor ratio.
5. Dye spot:
Causes:- Improper Dissolving of dye particle in bath.- Improper Dissolving of caustic soda particle in bath.
Remedies:- By proper dissolving of dyes & chemicals.- By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the large un-dissolved particles are removed.
6. 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.
7. Softener Mark:Causes: - Improper mixing of the Softener.
- Improper running time of the fabric during application of softener. - Entanglement of the fabric during application of 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.
Remark &Conclusion: We have seen that in dyeing different production parameters like temperature, time, PH, M:L ratio etc. are strictly followed. Sometimes the original dyeing process may not be found according to dyeing curve as they produce some complicated shade. One thing is clearly noticeable that production manager and officers are committed to try their best for reducing production time.
FINISHINGThe final processing of the fabric to increase the natural properties or attractiveness before the fabric is cut into apparel or made into any articles of textiles is called finishing. The finishing process depends on the properties required in the fabric with respect to its use.
Objective of finishing
To improve the attractiveness and service ability of textile material.To accestiate or inhabit some natural characteristics on textile materials,(such as softening , stiffing , delusture , etc)To impact new characteristics/properties to the textile materials(such as durable press, flame retardant)To increase life & durability of the textile material.To set the fabric, so that it can be maintaining its shape and structure. E.T.CTypes of Finishing
Two types of Finishing
Mechanical(Used to control dimension &To improve appearance and handle)CalendaringNapping & sue dingSanforizingBrushingShearingDolly pressTunnel press
Chemical(Used to make glossy protection & To improve performance or serviceability)Ant creasingSofteningStiffingSoil releaseAnti-staticRot-proofingAnti-bacterialResin finishesFiber retardant
Finishing process
Tubular Finish:
Dewatering
Dryer
Tube Compactor
Final Inspection
Open Finish:
Slitting
Stenter
Open Compactor
Final Inspection
Special Finish (Raising & Sueding):
Slitting
Stenter
Raising/Sueding
Stenter
Compacting
Final Inspection
Total M/C of Finishing Section
M/c Name Number of M/C Dewatering- 2Slitting- 2 Dryer- 2Open compactor – 2Tube compactor - 2Raising m/c – 3Sueding m/c - 1
DEWATERING MACHINE
Machine specification:
Brand name: HELIOT INTERNATIONAL MOIS: 06, ANNEE: 02
Company: France. Capacity: 3 tones/shift.Function of dewatering m/c:-Reduce water content-Apply chemicals-Apply overfeed to give some compaction-Open the fabric from the rope form
Working principle of Dewatering:
After completing the dyeing process from the dyeing m/c then the fabrics are ready for de-watering. In de-watering m/c tubular fabrics are mainly processed. There is a magnetic sensor which scene the twist of the fabric and its direction and turn the fabric in opposite direction to remove twist automatically. Here dewatering is performed De-watering is the process to remove the water from the fabric completely by squeezing and it is done by the padder. A suitable expander is used before the fabric is passed through the nip of the padders, which expands the fabric flat wise and adjust the width. The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%, Lacoste-40% wider than the required width. There is a pair of rubber coated padder, where water is removed from fabric when passed through the nip of it.
Normally squeezer contain single or double padders where, - One for removing water and - Other for applying finishing chemicals such as softener.But this finishing is done only for the tubular fabric. Open widths knitted fabrics are applied finishing treatment later in stenter. Here present the compressor which given compress air to form ballooning before passing through the padder. This balloon remove crease mark but not form the maximum balloon otherwise shrinkage increase
SLITTING MACHINE
Slitting Machine specification:
Dewatering Machine
No of Slitting m/c: 02
Slitting m/c-1: Brand name- Corino (SH) Country- Italy Year of manufacturing-2007 Capacity: 3 tones/shift.
Slitting:Slitting is a process that is applied for cutting the tubular fabric through the intended break Wales line on lengthwise direction prior to stenter processing.
Machine parts:
Rotary blade: To cut the fabric through break Wales line.
Ring: To help cutting.
Guide Roller: To guide the fabric to plaiting.
Plaiting: To plait the fabric.
Sensor: Sense for cutting through break Wales line.
Working principle: The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After dyeing completed and falling of water from fabric the fabric is fed in slitting m/c. So it is necessary to remove some water initially for the case of further processing in this m/c. The initial squeezer does this work. The de-twisting unit removes twists that may present in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2 feeler rollers with sensors. By these rollers it detects twist in fabric and removes by rotating rope fabric in opposite direction. Before slitting there is a blower which blows air to open the tubular fabric & makes it easy to pass over cigger. The cigger can be extended in circumference and opens the tubular fabric in full circumference. Slitting is done by using open mark detecting golden eye by around knife. Then the fabric passes through the padder where washing or chemical treatment is done. Squeezer is used to remove 60-70% of water. After removing water width is controlled by stretcher and fabric is delivered by folding device.
Operational parameter:
-Set the padder pressure as required (3-7bar) -Set the speed as much as possible (30-80m/min).Function of the Machine:
Used to remove excess water after pretreatment and dyeing.To slit the tube fabric by the knife for opening of the fabric and ready for stentering.Delivered fabric increase free state.Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer.It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism.
DRYER MACHINE
Two types of dryer machines are used in INTRAMEX Heliot machine (tube fabric)Santex machine (tube & open fabric)Santex machine (tube & open fabric)Machine specification:
Brand name: HELIOT INTERNATIONAL MOIS: 06, ANNEE: 02 Capacity: 8 tones/day.Made in France
Function of dryer-To dry fabric-To control GSM-To control fabric dia
Working principle of dryer: After de-watering, the fabric passed through the dryer. The main function of the dryer is given below:To dry the fabric.To control the overfeed system.To control the vibration which increase the G.S.M.This machine contains two chambers. Two mesh endless conveyors are placed lengthwise to the chamber named conveyor net and filter net, each chamber contain a burner, which supply hot air .This hot air is guided through the ducting line by suction fan .There are nozzles placed in between filter net and conveyor net .When the fabric pass on the conveyor net, hot
air is supplied to the wet fabric to dry it. There are exhaust fan which such the wet air and deliver to the atmosphere through the ducting line.The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric. If the m/c temp. is high then m/c speed also high and the m/c temp. is low then m/c speed also low . The vibration speed of the m/c for heavy fabric is 730 m/min and normal fabric is 480 m/min.
STENTER MACHINE
Two types of Stenter machines are used in INTRAMEX Sun superBruckner
Sun superM\c specification: Brand name: SUN SUPER. Country: KOREA. Capacity: 4 tones/shift.
Other specification: Speed range: Max: 110m/min. Use: 45 m/min. Temperature range: Max: 500 C Fig: Stenter machines (Sun super)
Use: 180 C (For heat set). Steam pressure: 2 bar Air pressure: 10 barMachine parameterPadder pressure =1.5 barSpeed=8m/minPick up=at least 75%Temp:1st chamber=120⁰c2nd chamber=150⁰cLast five chamber=170⁰cOver feed=full
Air pressure max. 10 bar Fig: Stenter machines (Bruckner)Capacity: 3 tones/shiftImportant parts of stenter:BurnerExhaust air fan(16)Overfeed rollerSuction fanNozzleChain arrangement
Function of stanter:-Drying-Shrinkage control-Heat setting-Width control finishing chemical application-Loop control-bowing control-Spirility control-GSM controlChecking points (m/c parts):To check m/c area cleanTo check m/c motorTo check burnerTo check blowerTo check chain & rollerTo check delivery roller
Brand name: HELIOT INTERNATIONAL MOIS: 06, ANNEE: 02Company: France. Type: HC99PI.Capacity: 3 tones/shift.Important parts:-Overfeed roller-Expander-BlanketOperational parameter-Set the temperature 120⁰c (as required)-Set the speed as much as possible (15-25m/min). GSM m/c speed.-Set the overfeed % as required; to increase GSM, overfeed need to increase to a certain limit.
Function:-Width control -Shrinkage control-GSM control
Brand name – LaferCountry – ItalyCylinder- 2Drum Speed - 110Drum Dia - 68 inchMachine Speed - 40 m/minPile Roller - 24Counter Pile Roller - 24Manufacturing Year –2002
FUNCTION OF RAISING MACHINE:
To produce the brush effect. To produce the fleece fabric. To raise the fibre on the fabric surface.
INSPECTION IN FINISHING SECTION
Process Flow Chart of Final Inspection :( Q.A.D)
After completing finishing process here firstly check the shade as per buyer standard with dimensional stability from lab.
Secondly check dia / width fabric weight or G.S.M
Thirdly check fabric surface or appearance as per buyer standard.
The every roll with every meter check as per four (04) point system.
Make a report.
If OK then ready for delivery.
If not OK then identify the fault.
If it is knitting fault then inform the knitting department by job card and mail, & requested the fabric for replacement.
If it is dyeing fault & If make sure that it is reprocess able then give job card to dyeing department correction. And if is not reprocess able then reject the fabric & inform the dyeing department to replace the rejected quantity.
Hand Cutter (20): Brand Name: Mack (10) Country: Japan Speed: 3000/3600 Volt: 220 Frequency: 50/60 Hz Phase:1 Blade: Straight bar blade Brand Name: Blue Streak (10) Country: USA Speed: 2850 Volt: 220 Frequency: 50Hz Phase:1 Blade: Straight bar blade
Auto Cutter (1): Brand Name: Gerber
Country: Germany
STANDARD OPERATING PROCEDURE OF CUTTING SECTION:
Cutting department receives Tech Pack from merchandiser and PP sheet of a style from IE.
Cutting department checks whether sample, master pattern and fabrics are ready or not.
If ready cutting department collects sample, marker and fabric (for size set) from the sample section, CAD section and fabric store.
Cutting department gives a lay for size set sample, cut, sew in the size set line, print, wash, embroidery all are done and measurement are taken in all the steps.
If it is found that an adjustment is required in the master pattern, than cutting manager, buyer QC and pattern master check and make necessary correction as per grading and informs pattern and CAD section.
Then cutting department collects fabrics for bulk production from store and checks whether the GSM of every roll is fine or not and check the width of fabric for that lot.
If fabric GSM is ok, cutting department sends information to CAD section containing in which width and ratio of fabric they are going to cut that particular cutting.
CAD prepares marker and sends it If in that style self fabric for neck is required, to the cutting section. Cutting in charge informs the spreading machine operator to keep particular amount of fabric from each roll.
Spreading starts and completed.
Marker is placed on the lay and then costape is attached. Cutting starts and completed.
Cutting parts are transferred to stickering A spread sheet containing number of Table. layer in that cutting, how many parts in a garment goes to the stickering Section by spreader machine operator. Stickers are made ready. Bundle cards are made ready. Stikering starts and completed and sticker attached parts are send to Bundle cards come to bundle area. bundling area. Bundling starts and completed. Rejection cutting starts and completed. If other operations are needed such as Print, Embroidery, cutting department sends the cut panels to Solid parts. the store and later collects them from the store and checks whether there is any alter or not. Print and Embroidery panels are checked and if some alter and rejects are found the bundle cards Store in the cutting input rack. are re-written making necessary adjustments.
SEWING SECTION
List of machines in Sewing Unit:
Machine name M/C quantity
Plain Stitching m/c 1290
Over Lock Stitching m/c 600
Flat Lock m/c 400
Button Hole m/c 25
Button Stitching m/c 25
Bar Tack m/c 40
Picoting m/c 02
Plain zig zig m/c 04
Kansai m/c 10
Two Needle Chain Stitching m/c 40
Two Needle Lock Stitching m/c 06
Suttle Stitching m/c 04
Fusing m/c 09
Heat Transfer m/c 13
9.4 Machine Specification:
Brand Name Country
Juki Japan Pegasus Japan Kansai Japan Brother Japan Pup Japan Sun Star Korea
GARMENTS FINISHING SECTION
Process Sequence of Garments Finishing:
Receive Garments
Steam Ironing
Folding Garments
Final Inspection
Attach Labels in the Garments
Packing with Tissue, Board & Hanger in Polybag
Metal Inspection in Metal Detector m/c
Cartooning the Garments
Store in the Wire House
Shipment
Layout of washing section: WestSouth North East
S. D. M/c-2
EXIT
G. D. M/c-04
G. D. M/c-03
Tumble Dryer-01
Tumble Dryer-04
Hydroex-tactor-01
Hydroex-tactor-02
Inspection Table
Tumble Dryer-06
Tumble Dryer-02
Tumble Dryer-05
Tumble Dryer-03
S. D. M/c-1
G. W. M/c-03
G. W. M/c-04
G.D-Garments dyeing m/c. G.W-Garments washing m/c
Washing / Garments Dyeing Machine Specification:
No. of Sample Garments Dyeing / Washing m/c: 02Brand Name: CosmotexOrigin: SpainCapacity: 20 KgMax. Temp: 100˚ C
No. of Garments Dyeing / Washing m/c: 08Brand Name: CosmotexOrigin: SpainCapacity: 200 KgMax. Temp: 100˚ C
No. of Sample Drying m/c: 08Brand Name: Green MacOrigin: ChinaCapacity: 10 KgMax. Temp: 110˚ C
No. of Drying m/c: 08Brand Name: Green MacOrigin: ChinaCapacity: 100 Kg
G. D. M/c-02
G. D. M/c-01
Gate
Office
Tumble Dryer-07
G. W. M/c-02
S.Dryer m/c
Tumble Dryer-08
G. W. M/c-01
Max. Temp: 110˚ C
Flow Chart for Garments dyeing (Medium / Dark Shade):
Garments Load– 2 Kg
Level In water 16 liter Wetting agent 0.5 g/l NOF ( 700 x 5’) Normal Wash
Leveling agent LDR ( 600 x 5’)
Color dossing (60˚C x 10’) {RG Yellow RGB- ( 0.44%) RG Red RGB- (0.254 %)
RG Blue RR - (0.898%)} Run 10’
Salt dossing {(50g/l) 600 c x (10’+10’)}
Soda dosing {(16g/l) (600 c x 10’)} Run Time 35’ (sample check)
A- acid (1 g/l x 5’)
Fixing agent (E.C) (1g/l) - ( 400 c x 5 min)
Raise temp. 500 c Run Time 5 min
Drain
Level in
Cold wash ( 270 c x 2min)
M: L-1:8
Flow Chart for Garments dyeing (Light Shade): Level in Raise temp ( 700 c x 5min )
Wetting +Detergent (NOF)
Leveling agent (LDR) 600 c x 5min
Color dosing {600 c x (10+10)} {CIBA Yellow FNR-0.048% CIBA Red FNR-0.048% CIBA Blue FNR-0.048%}
Salt dosing (24g/l)[600 c x (10+10)]
Soda dosing {(8g/l) (60˚c x 10’)}
Run Time 35 min (sample check)
Normal Wash
Acitic Acid (1g/l)
Cold wash
Fixing agent (E.C) (1G/L) - (400 c x 5 min)
Raise temp. 500 c Run Time 5 min
Drain
Level in
Cold wash ( 270 c x 2min)
Garments Washing Process:
Garments receive
Measurement checkCheck before washQuality check
Batch preparation
Load to washing M/C
Hydro extractor
Dryer
Measurement check Check after wash Quality check
Packing
Delivery Faults found in garments after washing
Needle damage
Fabric damage
Print problem
Spot
10.6 Picture of Washing Machi
PRINTING SECTION
Printing System:
Hand screen printingSereen Printing Automatic Flat (Revolving) screen printing
Specification (Automatic Flat screen printing)
M/C no -1 Brand name: Diamond back Red chili Country : USA No. of Head : 6Max. Color used : 5Drying head : 1
M/C NO:2Brand name: Diamond back Red chili Country : USA No. of Head : 8Max. Color used : 6Drying head : 2
M/C NO:3Brand name: Diamond back Red chili Country : USA No. of Head : 12
Garments Dyeing / Garments Washing m/c
Max. Color used : 8Drying head : 2
M/C NO:4Brand name: Diamond back Red chili Country : USA No. of Head : 8Max. Color used : 6Drying head : 2
Type of printing
Pigment Printing
Rubber Printing
Discharge Printing
High density Printing
Crack Printing
Pup Printing
Curing Temp:
Pigment -160-1700cRubber -150-1700cDischarge -2000cHigh density -1800c
Screen Preparation:
Mesh fabric tight with frame
Applied chemical TXR (sensitizing emulsion) on the mesh & dried 8 min in air.
Placed design paper under the mesh.
Light passes through the design paper & mesh fabric for 3-4 min.
Remove the colored TXR from the design area by water spraying.
Sequence of printing: Count garment parts
Screen preparation
Printing paste preparation
Applied garment part on the printing bed by (adhesive) gum in the marked portion
Printing the garment part by using screen
Drying the printed portion by hard dryer applying hot air flow
Curing the printed portion by passing through the conveyor dryer at 1600 - 1800 c
Inspection is done in qualify control department
Foil Printing:
Temp -1500c Pressure -100 psi Time -6 sec Pressing -2 times
Process for Foil Printing
Add adhesive on the require design by screen
Place the fabric part on to the Pressing M/C
Pressing the upper part of the M/C at 100PSi, Temp-1500 For-6 Sec
Picture of Printing Machine of INTRAMEX
EMBROIDERY SECTION MAINTENANCE SECTION
Maintenance:
Maintenance is a procedure by which we can maintain active functioning in operation according to the behavior and utility of a particular element. In engineering, we use this terminology for maintaining smooth and uninterrupted performance of machines, tools and metallurgical characteristics in practical uses. Objective of maintenance:To keep the factory plants, equipments, machine tools in an optimum working condition.To ensure specified accuracy to product and time schedule of delivery to customer.To keep the downtime of machines to the minimum thuds to have control over the production program.To keep the production cycle within the stipulated range.To modify the machine tools to meet the need for production.
Three types of maintenance are performed in INTRAMEX Group.Preventive Maintenance.Routine/ Schedule Maintenance.Breakdown Maintenance.
Preventive Maintenance: Actions performed periodically (or continuously) prior to functional failure to achieve the desired level of safety and reliability for an item. These actions are performed to prevent or reduce consequences of failures.
Schedule maintenance: It is time-based maintenance and pre-planned to perform on machine and equipments. This plan usually made on monthly basis.
Automatic Revolving Flat Screen Printing m/c
Breakdown maintenance: In this type of maintenance when the machine remains stop that time the maintenance is done.
Maintenance Tools, Equipments & their functions:
Name of Tools FunctionHammer To give shapeSlide Wrench Tightening and opening boltSpanner Tightening and opening boltPliers Cutting, Holding, Joining, wire, GrippingHacksaw CuttingPipe Wrench Tightening, opening, gripping pipeChisel Shaping, CuttingFile ShapingClamp GrippingVice
Name of Equipments FunctionGrinding m/c GrindingCutting m/c CuttingDrill m/c DrillingShaping m/c ShapingLathe m/c To make somethingBending m/c Bending
Maintenance Procedure:
Preventive Maintenance: They always follow preventive maintenance.
Breakdown Maintenance: When a problem occurred the operator informed the supervisor, then the supervisor informed the production officer, then the production officer called the maintenance officer. The maintenance officer visits the problem and takes necessary steps to solve the problem.
Flow chart of maintenance
Problem occurred
Operator
Supervisor
Production officer
Maintenance officer
Solution
Utility facilities available:The following utility facilities are available in INTRAMEX group:GasElectricityWaterSteamCompressed Air Generator houseThe list of machine:Generator 3Panel 3Distribution Board 1Generator Control Panel 1
1. Generator:To generate the power (volts & amps) for every section in the Factory.
2. Panel: To store the power (volts & amps) from the generator for every section in the factory.
There are two types of panel:
UTILITY
PFI (Power Factor Improvement) panelLT panelPFI panel: To store the power (volts & amps) from the generator for the boiler house, finishing section & dyeing section in the factory. Supply AC current. 4 Amps & 400 volts.
LT panel: To store the power (volts & amps) from the generator for the boiler house, finishing section & dyeing section in the factory. According there need. Supply AC current. 4 Amps & 400 volts.
3. Distribution:To supply the power (volts & amps) for the light, AC, fan etc in the different section.
Supply AC current. 4 Amps & 400 volts.
4. Generator control panel: To control the generator for generate power.
BOILER
Boiler: The equipment used for producing steam from water is called steam generator or
boiler. The boiler used for producing steam in GKL is Cochran boiler which is a fire tube type boiler. This produced steam is supplied by the steam line in different section. Simple vertical boiler of fire tube type is mainly used in small plant requiring small quantity of steam and where floor area is limited. Classification of boilers:
Fire – tube boiler( gas ) : Low pressure , low running cost , less chance of busting but greater risk of damage.
Water – tube boiler: High pressures, high running cost high chance of bursting & don’t damage the whole boiler.
As this factory used fire tube boilers and its description is given below.In boiler house, steam is produced at high temperature and pressure. This produced steam is supplied by the steam line in different section.Uses: Steam use for –
Power generation ( steam engine / turbine ) .Processing in industries ( dyeing & finishing mill , sugar mill , paper mill etc. ).Heating purposes ( houses , offices , hospitals etc in cold countries ).Hot water supply. Essentials of a good boiler:
Required pressure and quality at minimum fuel . Initial installation and maintenance cost low . Parts approachable for repairs .
Quick starting capacity .Conform to the safely regulations of boiler act .
Working principle:
The gas is fed through the front side to the furnace where fire created by electric spark.The blower move the fire into the flue pipe by compress air and then the flue gases enter through the combustion chamber which is lined with fire bricks on the outer wall of boiler. The hot gases passing through the horizontal smoke tubes give their heat to the water and convert water into steam. This steam gets accumulated in the upper portion of shell from where it can be supplied to the users. Finally, the flue gases are discharged to the atmosphere through the smoke box and chimney.
Figure: Steam produces procedure mechanism
The list of machineries:Three BoilersBoiler water softener plantDe-alkalizeFour Condensed pumpOne hot water tankOne water feed tank.
Boiler Specification:
Boiler No:01Machine Name (Functional) : Steam GenerateBoiler Type : Fire Tube BoilerBrand Name : OMNICAL BOILERModel Name : 20424Max. Steam Output : 6 t /hTest Pressure : 20.5 barVolume : 12540 L Year of Manufacture : 2008Country Name : Germany.
Feed water tank
Boiler Blower Burner Gas
Steam
Factory house
Boiler No:02Machine Name (Functional) : Steam GenerateBrand Name : SCHNEIDER-KESSEL BERLINModel Name : HDD-P5000-10Max. Working Pressure : 10 barMinn. Steam Temp. : 20˚C Max. Steam Temp. : 185˚CTest Pressure : 13.5 barVolume : 5200 LYear of Manufacture : 2006Manufacturer's Name : German Thai Boiler Manufacturing Ltd.
Boiler No:03Machine Name (Functional) : Steam GenerateBoiler Type : Fire Tube BoilerBrand Name : OMNICAL BOILERModel Name : 20424Max. Steam Output : 6 t /hTest Pressure : 20.5 barVolume : 12540 L Year of Manufacture : 2008Country Name : Germany.
WATER TREATMENT
The back wash & regeneration process:
The back wash process to clean the vessel no-1,2 & 3. The back wash process should be done after 8-12hrs. After 40-48 hrs later the regeneration process should be done. It should be done after back wash process. After back wash the common salt dissolved with water in to the STT (salt saturated tank) the solution of common salt is ringing the resin by the injector. The use of 18% salt in the total solution. (Suppose, 5000 lit of solution the amount of salt 600kg). The resin is activated by the salt rising. Here used cationic resin (NaHSO3). If the PH of the water increase or decrease it should be control by the dosing chemical (Sodium Hypochlorite) from the chemical tank.
Figure: Water treatment plant
A B C D E
Where, A=Hard water storage tank B=Stone filter C=Carbon filter D=Resin filter E=Soft water storage tank F= Pump Standard water quality for dye house:
Minimum standard Permissible concentrationColor ColorlessSmell No bad smellWater hardness < 50PH Value 7-8 NeutralDissolved solid < 1 mg/1Inorganic salt < 500 mg/1Iron (Fe) < 0.1 mg/1Manganese (mn) < 0.01 mg/1Copper (Cu) < 0.005 mg/1Nitrate (NO3) < 50 mg/1Nitrite (No2) < 5 mg/1
Hardness check:The hardness should be checked after every 6 hrs. It should be checked by the
hardness test kits. The using hardness test kits are Hanna Instrument. Made in Italy. If the hardness is going to be 0.5 on the syringe scale. Then have to do the regeneration process. The capacity of the vessel 115m3/ hr or 115 ton/hr.
14.10 Effluent treatment plant
Picture of E.T.P
E.T.P Plant of VIYELLATEX
Flow chart of ETP:
Effluent treatment plant (ETP)
Process: Biological.
Capacity: 110 m3 / hour.
The major sources of liquid discharge are:- scouring.Bleaching.Dyeing.Washing.Dye wastes content:Carbon, nitrogen, phosphorus.
EffluentWater from Dyeing
Equalizer Tank
Reaction Tank
Floccula- tion Tank
Aeration Tank
Secondary clarifier
PH
Control Tank
Primary Clarifier
Chlorination Tank
Sludge Bed
Multi filter
Reserve tank For Re-using Water.
Discharge Effluent
Bleaching:Dilute hypochlorite solution.H2O2
Raw materials:main raw material:- Cotton yarn.mixed yarnDyes Chemical
dye include: Reactive.Disperse.
Chemical includes:DetergentSoda ash Caustic soda.H2O2Stabilizer.Acetic acid. Step wise function of different unit of E.T.P
Equalizer Tank:Use chemical: Acid solution.Function: To neutralize raw waste water by dozing smaller particle.
PH Control Tank:Use chemical: Fe2So4, Fitcary. Function: To control PH.
Reaction Tank:Use chemical: Lime. Function: To agglomerate smaller particle. Flocculation TankUse chemical: Polyelectrolyte & alum. Function: To produce flock.
Primary Clarifier: Function: To monitor performance of flocculation clarifier & separate solid waste.
Sludge Bed:Function: Solid waste dried & send to outside for burial
Aeration Tank::
Use chemical: Bacteria, Urea, Cow dung.Function: Bio logical oxygen demand & Chemical oxygen demand reduced here & diffused aeration system ensures high oxidation efficiency.
Secondary Clarifier:Function: Remaining solid waste separate here. Reduced total solid.
Multi filter:Function: Extra suspended impurities separation by passing into the sand. Here removed suspended solution and correction the water color.
Conclusion:
First of all we want to give great thanks to ALLAH for successfully completed our industrial attachment in INTRAMEX group, which is a 100% export oriented composite textile industry. During the training period we completed our industrial attachment to a systematic routine which was provided by INTRAMEX group Ltd. We get help from different section, officers and workers which was helpful to gain a very good practical knowledge. Sometimes we operate machine for various jobs during operation. Last of all we give thanks all the officers and workers who helped us by co-operating & giving reliable information.
