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Industrial attachment of MM KNITWEAR Ltd

Industrial attachment of mm knitwear

sheshir
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Industrial attachment of MM KNITWEAR Ltd

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  1. SOUTHEAST UNIVERSITY Department of Textile Engineering Report on 2 months Industrial Attachment As a curriculum in Wet Processing Technology (From 05th February to 06th April, 2011) At M M Knitwear Ltd. Konabari,Nilnagar, Gazipur. Supervising Teacher: Prof. Syed Fakhrul Hassan Murad Chairman Department of Textile Engineering Southeast University Submitted By : Kazi Mamun Hossain ID No: 2007100400024 Md.Azijul Haque ID No: 2007100400045 Dhaka, 16.05.2011

  2. ACKNOWLEDGEMENT At first my gratefulness goes to Almighty Allah to give me strength and ability to complete the industrial training and this report. You have made my life more bountiful. May you name be exalted, honored and glorified. Now I wish to take this excellent opportunity to thank a lot of people who have assisted and inspired me in the completion of my training period: I express my gratitude to Prof. Syed Fakhrul Hassan Murad, Head, Department of Textile Engineering, and my supervisor, to whom I am extremely indebted for his tremendous support and guidance throughout my training period. Being working with him I have not only earned valuable knowledge but was also inspired by his innovativeness which helped enrich my experience to a greater extent. His ideas and way of working was truly remarkable. I would like to thank the management of the M M Knitwear Ltd. for giving me the opportunity to do the industrial training successfully and also their valuable suggestions. My deepest appreciation goes to Mr. Nurul Islam, General Manager, M M Knitwear Ltd. for his permission to conduct my industrial training without which it would be uncompleted. The generous support is greatly appreciated. I would also like to thank executives, senior executives and other officials of M M Knitwear Ltd. for helping me to complete industrial training successfully. My gratitude also goes to all the employees of M M Knitwear Ltd. for their sincere co- operation, support and valuable advices. Last but not least, thanks go to my precious family for their never ending love and inspire at every stages of my life. Without their continuous support I realize that I would not be a person I am right now.

  3. TABLE OF CONTENTS CHAPTER – 1..................................................................................................3 1 Project Description............................................................................................5 1.1 COMPANY PROFILE....................................................................................................6 1.2 location:......................................................................................................................7 1.3 Basic lay-out of the factory .......................................................................................8 1.4 Vision and Mission...................................................................................................10 1.5 Different Departments.............................................................................................11 1.6 Remarks....................................................................................................................11 CHAPTER – II......................................................................................................13 2 Man power management.................................................................................14 2.1 Dyeing & Finishing Section.......................................................................................15 2.2 Knitting section.........................................................................................................16 2.3 Management System...............................................................................................17 2.4 Duties & Responsibilities of Production Officer.......................................................17 2.5 Duties & Responsibilities of Senior Production Officer...........................................18 2.6 Duties & Responsibilities of GM (Production).........................................................18 2.7 Remarks....................................................................................................................18 CHAPTER – III.....................................................................................................19 3 Machine Description........................................................................................20 3.1 Lay-out Of Dyeing & Finishing Section.....................................................................20 3.2 Dyeing Machinery....................................................................................................22 3.3 Finishing Machinery.................................................................................................27 3.4 Description of Machinery.........................................................................................28 3.4.1 Working principle of dyeing machinery............................................................28 3.4.2 Working principle of finishing machinery.........................................................29 3.5 Remarks....................................................................................................................41 CHAPTER – IV....................................................................................................42 4 Raw material.....................................................................................................43 4.1 Grey Fabrics..............................................................................................................43 4.2 Dyes..........................................................................................................................43

  4. 4.3 Chemicals.................................................................................................................45 4.4 Remarks....................................................................................................................45 CHAPTER-V........................................................................................................46 5 PRODUCTION PLANNING,SEQUENCES & OPERATION.............................47 5.1 Process flow chart of knit dyeing.............................................................................47 5.2 Dyeing work flow chart............................................................................................48 5.3 Dyeing Parameters...................................................................................................49 5.4 Description of production process...........................................................................50 5.5 Dyeing Recipe...........................................................................................................53 5.6 Finishing...................................................................................................................56 5.7 Finishing machine setting.........................................................................................57 5.8 Daily Production Report...........................................................................................59 5.9 Monthly Average Production...................................................................................59 5.10 Remarks..................................................................................................................59 CHAPTER – VI....................................................................................................60 6 QUALITY ASSURANCE SYSTEM...................................................................61 6.1 Quality Policy............................................................................................................61 6.2 Quality Assurance Procedure...................................................................................61 6.3 Inspection area.........................................................................................................62 6.4 PROBLEMs ENCOUNTERED IN DYEING....................................................................63 6.5 Process of Shade Matching......................................................................................65 6.6 List of Equipments....................................................................................................65 6.7 Quality Standard.......................................................................................................66 6.8 Remarks....................................................................................................................67 CHAPTER- VII.....................................................................................................68 7 Maintenance.....................................................................................................69 7.1 Maintenance of Machinery .....................................................................................69 7.2 Routine ....................................................................................................................69 7.3 Manpower Setup for Maintenance..........................................................................70 7.4 Maintenance Procedure...........................................................................................70 7.5 Maintenance Tools and Equipments.......................................................................73

  5. 7.6 Remarks....................................................................................................................74 CHAPTER- VIII....................................................................................................75 8 UTILITY SERVICES..........................................................................................76 8.1 Utility Facilities Available ........................................................................................76 8.2 Source of Utility........................................................................................................76 8.3 Capacity and Other Technical Details......................................................................76 8.4 Cost of different Utilities .........................................................................................79 8.5 Remarks....................................................................................................................79 CHAPTER – IX....................................................................................................80 9 STORES & INVENTORY CONTROL................................................................81 9.1 Scope of Inventory Control......................................................................................81 9.2 Frequency of Inventory Update...............................................................................81 9.3 Inventory Control System for Raw Materials...........................................................81 9.4 Inventory Control System for Finished fabric..........................................................82 9.5 Inventory Control System for Spare Parts................................................................82 9.6 Remarks....................................................................................................................82 CHAPTER-X........................................................................................................83 10 COST ANALYSIS............................................................................................84 10.1 INTRODUCTION......................................................................................................84 10.2 Costing elements....................................................................................................84 10.3 Knitting Charge of Different Fabrics.......................................................................84 10.4 Dyeing Charge of Different Fabrics........................................................................85 10.5 Finishing Charge of Different Fabrics.....................................................................85 10.6 COSTING OF THE PRODUCT....................................................................................86 10.7 Remarks..................................................................................................................86 CHAPTER – XI....................................................................................................87 11 MARKETING ACTIVITIES..............................................................................88 11.1 Consumer of Products............................................................................................88 11.2 Country of Export...................................................................................................88 11.3 Local Market...........................................................................................................88 11.4 Marketing Strategy.................................................................................................88 11.5 Duties & Responsibilities of Marketing Officer......................................................89

  6. 11.6 Remarks..................................................................................................................89 CHAPTER –XII....................................................................................................90 12 Effluent Treatment Plant (ETP).....................................................................91 12.1 Process Flow chart of Biological Effluent Treatment Plant....................................91 12.2 Function of different Unit of Biological Effluent Treatment Plant (E T P).............92 12.3 Product Quality Checked........................................................................................93 12.4 Remarks..................................................................................................................93 CHAPTER –XIII...................................................................................................95 13 Conclusion......................................................................................................96 13.1 SOME SUGGESTIONS..............................................................................................96 13.2 Limitations of the report........................................................................................97

  7. Industrial Attachment Introduction Introduction : Industrial attachment is the first step to professional life of student, especially of technical Side. It’s an indispensable part of study a practically running processing technology of an industrial unit for a student .In our university , processing machines are not in continuous running condition, so it would only provide demonstration of mechanical features & processing technology of the material in accomplishment of the theory there of but not of the situational variables to achieve practical knowledge. So two months industrial attachment program in a dyeing mill was arranged for us. Textile education can’t be completed without industrial training. Because this industrial attachment program minimizes the gap between theoretical and practical knowledge and make me accustomed to industrial environment. I got an opportunity to complete two month long industrial training in M M Knitwear Ltd , which is a 100% export, oriented composite Knit Dyeing Industry. It has well planned & equipped fabric and Knit dyeing-finishing units in addition to facilitate Knitting and Knit wear manufacturing. The rationale behind the existing structure and future expansion of M M Knitwear Ltd is to capture value-added at each stage of the textile manufacturing process. Despite Bangladesh’s lack of indigenous cotton production capacity, M M Knitwear Ltd has leveragedBangladesh’s labor cost advantage and export competitiveness to the Maximum. Southeast University Page | 1

  8. Industrial Attachment Objectives Objectives : ⇒ To familiarize with the factory and production. ⇒ To set the sequential work and factory layout ⇒ To keep a motel on the deviation between theory and industrial bulk production ⇒ To correlate between institutional and industrial working techniques and procedures ⇒ To observe the management system ⇒ To have a concept on production planning, costing, marketing techniques etc ⇒ To know about waste reduction and utilization ⇒ To know about how a technical person developed quality of products at various steps (knitting, dyeing, finishing and garments making) ⇒ To have a proper knowledge on the product development to customer handling Southeast University Page | 2

  9. CHAPTER – 1 PROJECT DESCRIPTION Southeast University Page | 3

  10. Industrial Attachment Project Description M M Knitwear LTD Southeast University Page | 4

  11. Industrial Attachment Project Description 1 PROJECT DESCRIPTION M M Knitwear Ltd has started manufacture and export of garments since 2001. The beginning M M Knitwear Ltd has a very good reputation as a financially sound and ethical business house. It has a long term association with selected factories, some of them are certified in terms of social and quality compliance by world’s highest rating bodies, and outstanding sourcing capabilities. Thus M M Knitwear Ltd has been able to prove itself to be a reliable supplier for knit item in any style and design Specializing in all kinds of knitted items. It is housed in its own building surrounding an area of 310,000 sq. ft. And 4,300 workers and stuff. The determination to achieve superior customer service and on time delivery has earned M M Knitwear Ltd recognition as an invaluable player and the desire to succeed in customer satisfaction with every order makes the M M Knitwear Ltd team even stronger it’s these fundamental that keep this unit in the game and wining every time. Buyers: Sl. buyers 1 NEW YOURKE 2 MERCURY 3 ROWA 4 VISAGE 5 WHITE STONE 6 LI & FUNG 7 SPRING FIEL GENEREL INFORMATIONABOUTTHE FACTORY Southeast University Page | 5

  12. Industrial Attachment Project Description 1.1 COMPANY PROFILE Name of the project : M M knitwear LTD. Type of the project : 100% Export oriented Knitwear industries Year of establishment : It was established in theJuly2001. Address : Factory, Ambag road, Konabari , Nilnagar Gazipur, Bangladesh. Head office : House #16, Road #10, Sector # 1,Uttara Model Town Dhaka-1230, Bangladesh : Md. Mofizul Islam, Managing Director Investors History of the project : M M Knitwear has started manufacture and export of garments since 2001. Project Cost : The project cost of M M Knitwear Ltd is nearly 100.croretaka. Annual production Capacity: The annual production capacity in MMKL ltd are given Below- Dyeing & Finishing Capacity : 7250 Tons. (Around) Knitting Capacity: 3250Tons. (Around) Sewing: 50000 pcs/day (Average) Area : 310,000 sq. ft. Southeast University Page | 6

  13. Industrial Attachment Project Description 1.2 location: M y m e N S in g hi gh w ay A M M M Knitwear B Gazipur Chowrasta Ltd. A G R O TANGAIL ROAD A AD RO UR ZIP GA KONABARI D y a w h g i Department of Textile Engineering h SEU a k a h d LOCATION OF M M KNITWEAR LTD Southeast University Page | 7

  14. Industrial Attachment Project Description 1.3 Basic lay-out of the factory W S N E 6 7 4 5 3 E E 2 X 1 N T R Y I T Vision & mission of the project: Southeast University Page | 8

  15. E X I T Industrial Attachment Project Description 1 : Security office. 2 : Administration office Fabrics Store (Gr.Floor)+Knitting (2ndFloor+3rd floor), . 3 : . Human Resources Department (HRD)(4thFloor), . Marchanding section (5thFloor), garments(6th Floor – 9th floor) Yarn store (Gr. Floor)+ +Garment section(1st Floor – 7th floor) 4 : 5 : Fabric dyeing & finishing section. 6 : Effluent Treatment Plant (ETP). 7 : Generator house, Water Treatment Plant(WPT), Maintenance building. Southeast University Page | 9

  16. Industrial Attachment Project Description 1.4 Vision and Mission The mission and vision of M M Knitwear Ltd. is to manufacture and deliver high quality readymade garments (RMG) to its customers. The core objective is to attain and enhance customer satisfaction by providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce. To attain these objectives, the management of M M Knitwear Ltd. has decided to adopt the following- 1. To increase awareness regarding customers requirements throughout the organization. By providing training to develop efficiency of the employee. To collect customer’s feedback regularly to know about their conception about their company and to take timely appropriate action. To reduce the percentage of wastage / rejection minimum by 2% per annum’s implement and monitor ISO 9001:2000 quality management system within the organization 2. 3. 4. Main Production : Basic T-Shirt, Tank top, Long Sleeve- Shirt, Polo Shirt, Shorts, Ladies & Kids Knitwear & all kinds of knit garments & Knit fabrics. Fax Number : + 880 – 2 – 8922483 E–mail Address : info@mmknitwear.com URL : http://www.mmknitwearbd.com Certification & awards : concern authority. Oeko Tex Standard 100 Certified by the Last year Export Turnover 18.50 Million U.S Dollars : : Workers and Stuff : 4,300 The annual Production capacity of M M knitwear Ltd is an approximate idea, it may vary. Southeast University Page | 10

  17. Industrial Attachment Project Description 1.5 Different Departments To ensure smooth running of various activities, some departments are available they are given bellow:  KNITTING SECTION: 1.Knitting 2.Inspection KNIT DYEING SECTION: 1.Batch section 2.Store house for dyes & chemicals 3.Dye house 4.Dyeing & QC lab 5.Finishing GARMENTS SECTION: 1.Merchandising 2.Sample 3.Production MAINTENANCE: 1.Electrical 2.Mechanical ACCOUNTS & COMMERCIAL SECTION ADMIN SECTION      Physical Infrastructure : Buildings- one ten storied building, one six storied building, and 1 dyeing shade. Buildings are made by brick. Total Area of Industry : 3,00,000 Sq.Ft 1.6 Remarks The company owns 300000 Sq. Ft. of high land property at Ambag,Konabari,Gazipur,Dhaka; which is 10 km from the Gazipur Chourasta. Charming sights along with natural beauty of rural areas with no hazards or air pollution attracts the foreign buyers during their visits. The company has the desire to achieve recognition of the project as the ‘M M Industrial Park’ and to set up within the park area industries and health care center in near future. Plans include for Acrylic Yarn manufacturing unit, Packaging unit, Designing unit and Hospital. Southeast University Page | 11

  18. Industrial Attachment Project Description Southeast University Page | 12

  19. CHAPTER – II MANPOWERMANAGEMENT Southeast University Page | 13

  20. Industrial Attachment Man power Management 2 The company has skilled administration, management and marketing team guided by proficient, dexterous & experienced leaders of offer right solution for the consumers with the right eminence & with the shortest lead-time for the export market in Bangladesh. The best use of continuous development of human resources by providing them standard equal opportunity is the keys for achieving comprehensive competence in all level of the organizational hierarchy. M.M. knitwear ltd the Managing Director/ Chairman who controls the entire factory. And the others respective department chief controls their department in this factory. In this below the organ grams of administration and the others department is showing: MAN POWER MANAGEMENT Managing director Director, H R Dept. Deputy Marketing Officer Store Deputy Account Officer Assistant General Manager Chief Egg. Manager Accounts Officer (ADMIN) Assistant Manager (ADMIN) Electrical Security Asst. Chief store Manager Mechanical Eng. Officer Egg. Assistant Sub assistant Sub assistant Assistant Asst. Officer Accounts Officer Administration Eng. Eng. Security Officer Officer Senior Clark Foreman Foreman Store officer Assistant Administration Security Havilder Officer Junior Clark Medical Officer .Security Foreman Administration Guard Assistant Peon Nurse Peon Southeast University Page | 14

  21. Industrial Attachment Man power Management 2.1 Dyeing & Finishing Section GM PM APM Lab SPO Batch Finishing In charge In charge In charge PO Sewing man Sewing man Lab Technician APO Turning m/c Squeeze Operator Q.C. Supervisor Operator Technician Helper Dryer Sr. Operator Helper Operator Asst. Operator Compactor Operator Operator Helper Southeast University Page | 15

  22. Industrial Attachment Man power Management 2.2 Knitting section AGM PO Store Incharge Supervisor Knitting Master Fitter man Fitter man Operator Operator Section-wise manpower Department Manpower 150 Knitting Dyeing & Finishing, Lab & QC ETPs Garments Power, Boiler, Utility & Maintenance Inventory 320 10 3590 50 10 Administration Security Others Total 77 55 44 4306 Southeast University Page | 16

  23. Industrial Attachment Man power Management Management Medium:  Intercom telephone  Fax  E-mail  Written letters & Papers  Oral 2.3 Management System ⇒ Buyer sample is send to G.M. ⇒ Matching is done by lab in charge. ⇒ Sample is prepared by dyeing master. ⇒ Sample is send to the buyer for approval. ⇒ Approved sample is returned and taken as STD. Sample for bulk production. ⇒ Asst. dyeing master gives responsibilities to production officer. ⇒ Then production officer, with the supervisors start bulk production. ⇒ On line and off line quality check is done by lab in charge and asst. dyeing master. ⇒ After dyeing finishing in charge controls the finishing process with the supervision of production officer. ⇒ After finishing, the material is checked by dyeing master. ⇒ Finally G.M. checks the result with dyeing master and decision is taken for delivery. 2.4 Duties & Responsibilities of Production Officer 1. To collect the necessary information and instruction from the previous shift for the smooth running of the section. 2. To make the junior officer understand how to operate the whole production process. 3. To match production sample with target shade. 4. To collect the production sample lot sample matching next production. 5. To observe dyed fabric during finishing running and also after finishing process. 6. To identify disputed fabrics and report to PM/GM for necessary action. 7. To discuss with PM about overall production if necessary. 8. To sign the store requisition and delivery challan in the absence of PM 9. To execute the overall floor work. 10. To maintain loading/ unloading paper. Southeast University Page | 17

  24. Industrial Attachment Man power Management 2.5 Duties & Responsibilities of Senior Production Officer 1. Overall supervision of dyeing and finishing section. 2. Batch preparation and pH check. 3. Dyes and chemicals requisition issue and check. 4. Write loading / unloading time from machine. 5. Program making, sample checking, color measurement. 6. Control the supervisor, operator, asst. operator and helper of dyeing machine. 7. Any other work as and when required 2.6 Duties & Responsibilities of GM (Production) 1. Overall supervision of dyeing and finishing section. 2. Check the sensitive parameters of different machines for smooth dyeing. 3. Check the different log books and report to management. 4. Check the plan to control the best output. 5. To trained and motive the subordinates how to improve the quality production. 6. Control the supervisor, operator, asst. operator and helper of dyeing m/c. 7. Maintenance the machinery and equipments. 8. Any other work as and when required 2.7 Remarks The manpower management system of M M Knitwear Ltd. is well arranged. Every officers & stuffs are responsible for their duty. But there are only three textile engineers in the industry (General manager, Production manager and Production officer). It is not sufficient for smooth production. More technical people is required. Southeast University Page | 18

  25. CHAPTER – III MACHINE DESCRIPTION Southeast University Page | 19

  26. Industrial Attachment Machine Description 3 MACHINE DESCRIPTION 3.1 Lay-out Of Dyeing & Finishing Section N W E S 12 13 13 16 17 13 13 16 17 13 13 16 13 17 15 13 13 17 14 13 15 13 17 9 11 10 10 18 6 5 4 ENTRY 8 3 7 2 Southeast University Page | 20 ENTRY

  27. ENTRY Industrial Attachment Machine Description 1. Office of PM ENTRY 2. Offline QC 3. Inspection table 4. Compactor 5. Tube-tex 6. Equalizer Dryer 7. Steenter 8. Calender 9. Slitting m/c 10. Squzzer m/c 11. Office of GM 12. Chemical store 13. Dilmelner high pressure Dyeing m/c 14. Office & Online QC 15. Bangla dyeing m/c 16. Korean dyeing m/c 17. Sample dyeing m/c 18. Turning m/c Southeast University Page | 21

  28. Industrial Attachment Machine Description 3.2 Dyeing Machinery In dyeing section of M M Knitwear Ltd, there are 22 Dyeing Machines, among of them 7 m/c’s are for sample dyeing and 15 m/c’s are for bulk production. Machine no.- 01: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-1 chamber : Sungmoo : Korea : 120 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Machine no.- 02: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-2 chamber : Sungmoo : Korea : 240 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Machine no.- 03 : Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-3 chamber : Sungmoo : Korea :350 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Machine no.- 04 : Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-4 chamber : Sungmoo : Korea :450 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Southeast University Page | 22

  29. Industrial Attachment Machine Description Machine no.- 05 : Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-1 chamber : Tongjeng : Taiwan :150 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Machine no.-06: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-1 chamber : Tongjeng : Taiwan :300 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Machine no.-07: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Semi-Automatic Vertical Winch-1 chamber : Tongjeng : Taiwan :900 kg/Batch : 80-90 % : 95 C (maximum) : Atmospheric : 1:8 0 Machine no.-08: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :50 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Southeast University Page | 23

  30. Industrial Attachment Machine Description Machine no.-09: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :1500 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Machine no.-10 : Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :1200 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Machine no.-11: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :900 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Machine no.-12: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :750 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Southeast University Page | 24

  31. Industrial Attachment Machine Description Machine no.-13: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :600 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Machine no.-14: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :450 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Machine no.-15: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Dms Ht Jumbo Jet Flow (HP Winch) : Dilmenler : Turkey :300 kg/Batch : 80-90 % : 135o C(maximum) : Water 4 bar and Steam 6 Bar : 1:9 Machine no.-16&17: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Sample Winch : Suntex : Chaina :15 kg/Batch : 80-90 % : 95o C(maximum) : Atmospheric : 1:8 Southeast University Page | 25

  32. Industrial Attachment Machine Description Machine no.-18&19: Name Brand Origin Capacity Efficiency Temperature Pressure Material : Liquor : Sample Winch : Suntex : Chaina :30 kg/Batch : 80-90 % : 95o C(maximum) : Atmospheric : 1:8 Machine no.-20: Name Origin Capacity Efficiency Temperature Pressure Material : Liquor : Sample Winch : Bangladesh :10 kg/Batch : 80-90 % : 95o C(maximum) : Atmospheric : 1:8 Machine no.-21: Name Origin Capacity Efficiency Temperature Pressure Material : Liquor : Sample Winch : Bangladesh :20 kg/Batch : 80-90 % : 95o C(maximum) : Atmospheric : 1:8 Machine no.-22: Name Origin Capacity Efficiency Temperature Pressure Material : Liquor : Sample Winch : Bangladesh :50 kg/Batch : 80-90 % : 95o C(maximum) : Atmospheric : 1:8 Southeast University Page | 26

  33. Industrial Attachment Machine Description 3.3 Finishing Machinery In finishing section of M M Knitwear Ltd, the machines which are available are listed below: Slitter m/c(1 set) Stenter m/c(1 set) Detwisting m/c(2 set) Natural Gas Dryer m/c(1 set) Compacting m/c(4 set) Air Turning m/c(1 set) Calendering m/c(1 set) 1. 2. 3. 4. 5. 6. 7. Slitting machine: Brand Origin Capacity : Bianco : Italy :12000 kgs/Day Sun-Supper ‘S’ Tenter(98″ Roller&8Chember) machine: Brand Origin Capacity : IIsung : Korea :10000 kgs/Day Pin chain compactor machine: Brand Origin Capacity : Laffer : Italy :6000-8000 kgs/Day Open width compactor machine: Brand Origin Capacity : Laffer : Italy :1200-1800 M/H Tube compactor calendar machine: Origin Capacity : Korea :7000 kgs/Day Tubular compactor machine: Brand Origin Capacity : Tubetex : USA :16000 kgs/Day Southeast University Page | 27

  34. Industrial Attachment Machine Description Soft Setting calendar machine : Origin Capacity : Korea :7000 kgs/Day Natural Gas Dryer Machine 3 Chamber machine: Brand Origin Capacity : Dilmenlar : Turkey :14000 kgs/Day Ait Turning machine: Brand Origin Capacity : Dongnam : Korea :12000 kgs/Day Auto-detwisting Ballooning Squeezer machine : Brand Origin Capacity : Dongnam : Korea :7000 kgs/Day Auto-detwisting Ballooning Squeezer machine : Brand Origin Capacity : Merson : Turkey :7000 kgs/Day 3.4 Description of Machinery 3.4.1 Working principle of dyeing machinery The dyeing m/c’s has a large tank where the fabric is loaded through out the nozzle. It has a good arrangement of water line (in let & out let), steam line, heat exchanger, liquor circulating motor and a chemical dosing tank. The loaded fabrics are circulating through out the nozzle continuously and the dyeing take place by the supplying of dye liquor by the liquor circulating motor when the fabric is passed over the drawing reel. It has also a control panel, which automatically control the production parameter. But it should firstly set manually. In case of low temperature machine it can raise up the temperature only 95oC (maximum) where as a low temperature machine can raise up the temperature up to140oC . During unloading of fabric drawing out reel is used. Southeast University Page | 28

  35. Industrial Attachment Machine Description Fabric Chemical dosing tank Fig: HTHP winch dyeing machine 3.4.2 Working principle of finishing machinery 3.4.2.1 Slitting machine 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 Southeast University Page | 29

  36. Industrial Attachment Machine Description 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. Slitting machine contains the following Parts  Basket  Slitter  Photo sensor  Twist opener  Padder squeezer  Squeezing unit 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 in crease 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  Southeast University Page | 30

  37. Industrial Attachment Machine Description Problem causes by the Machine  Photo sensor may failure  For that fabric may be cut to the other line  It may cause folding problem  Bowing  Spirality 3.4.2.2 Squeezing/Dewatering machine 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. Southeast University Page | 31

  38. Industrial Attachment Machine Description 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. In feed & Out feed traverses which present in albatros control the following functions by over feeding system. To control the width (dia) of the fabric. To control the spirality of the fabric. To control the crease mark of the fabric. To control the length of the fabric.     Different parts of dewatering m/c Tube tex dewatering machine contains two unit & two bath. One is for extraction and another for processing where softener or other chemical are applied for giving extra finish. Maintenance during operation  Proper balloon form by compressor air other wise crease mark appears.  Padder contract point a just perfectly according to the fabric construction otherwise accurate water will not remove.  Albatros must be clean every one or two hours later. Function  Reduce water from fabric  Fabric open from rope form  Dia/width control  Twisting and spirality control by twisting wheel  Apply chemical  Softening agent  Brightening agent Application of brightening agent / softening agent  Cationic  Non / anionic  Spamin Kl (white)  Ultra sot QM (dull)  Paranous Ic (PET) Southeast University Page | 32

  39. Industrial Attachment Machine Description Controlling parameter  Maximum pressure  For deep shade  For medium shade  For light shade  Squeezer pressure  Maximum speed : 45 PSI : 30-35 psi : 20-25 psi : 10-12 psi : 4kg (maximum) : 80m/min If pressure is increase, shade will be light. Problem causes by the Machine  Crease mark  Bowing  Twisting  Uneven padder setting causes uneven squeezing 3.4.2.3 Dryer After de-watering the fabric is passed through the dryer. 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 temperature 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. Southeast University Page | 33

  40. Industrial Attachment Machine Description Special feature of Tube Tex steam dryer        Steam dryer (two chambers). Vibration occurs in heating zone. Process air pressure switch present. Maximum temperature increase up to 2000C. Steam control switch present. Two burners present. Two conveyor belts are present. Maintenance during operation Temperature: Set the temperature between 1200C -1300C for white and 1500C -1700C for color fabric. If GSM is high then temperature will be high or, moisture content is high temperature will be high. Set the over feed up to 10~20% or as required to get finish G.S.M. Set the speed as much as possible (6~20m/min). if GSM is high then speed will be high. Function Dry the fabric GSM control Shrinkage control up to 3-3.5% 75% dries at 150oC Southeast University Page | 34

  41. Industrial Attachment Machine Description Controlling parameter Maximum temperature Minimum temperature For colored fabric White fabric : 2000C : 1100C : 1500C-1850C : 1200C-1300C The temperature of different chambers according to the shade of the fabric Shade Light Medium Deep Chamber-1 1200c 1350c 1500c Chamber-2 1300c 1400c 1700c Drying temperature depends on GSM of the fabric GSM 130 140 150 160 170 190-200 200-250 250-350 White 1200C 1350C 1400C 145-1500C 1550C 1600C 1750C 1850C Colored 1300C 1400C 1450C 1500C 1550C 1650C 165-1750C 1850C Problem causes by the Machine Shade variation due to uncontrolled temperature More roller speed caused the Wales distortion For Lycra heat setting is more necessary If heat is more Lycra fabric can be extended and create low GSM fabric Light shade due to high temperature 3.4.2.4 Stenter machine Stenter Machine is generally used to finish the open fabric. This stenter machine consists of eight chambers; each contains one burner, two blowers, two ducting line, nozzles and suction fan attach with the suction line. The burner produces hot flue gases which guided Southeast University Page | 35

  42. Industrial Attachment Machine Description though the ducting line by the help of blower. There are nozzles placed above and bellow the rail. When the fabric passed through the rail, then hot air is sprayed to the above and bellows the fabric with the help of nozzle. The hot air is circulating in the chamber and the moisture in the fabric is evaporated, which leave the chamber with the help of suction fan through the ducting line. Temperature of each chamber can control automatically by controlling the intensity of burner. Generally lower temperature is maintained the first and last chamber then other chambers. The speed of the fabric is maintained according to the moisture content of the fabric. After passing the fabrics to all the chambers, the fabric is collected for compaction. Delivery Roller Feed Roller Padding Rollers Padding Rollers Deliver ed Walkway Weft fabric Cooling Chamber Feed Six Chambers Straighter Chemical Tank Softener Tank Fabric Fig: Passes diagram of senter machine The performance of the stentering range depends on proper introduction of the cloth into the machine. The finer the fabric is being processed, the greater the significance of the correct, crease free and fault free fabric introduction. In stenter m/c the fabric first passed through different rollers including weft straightening device, uncurling device for proper feeding of the fabric into the machine. Then it passed through the selvedge detector which detect the selvedge and adjust the rail for proper gripping the fabric in the pin arrangement. This stenter m/c consists of both pin and clip arrangement. The fabric first grip by pin and gust before entering the chamber, pin are locked by clip arrangement. To maintain proper dimension of the fabric, length wise overfeed and width wise tension is given to the fabric. Southeast University Page | 36

  43. Industrial Attachment Machine Description Important parts - Burner (12) - Suction Fan (12) - Exhaust air fan (6) - Nozzle - Over feed roller. - Chain arrangement Different sections & their function of stenter machine Padder Section: In the padder section the fabric is treated with chemicals specially with softener and acid in two tanks. Weft straightner: The main function of Weft Straightner is to control the bowing & Skewnesss of the fabric. Width Setting Chamber: This Chamber control the width of the fabric by clip of 10 pin. Heatting Chamber: This chamber controls the shrinkage and the G.S.M of fabric. Temperature Range: Cotton- 1500C~1700C Polyester-1650C~1850C With Lycra -1750C~1900C Cooling Chamber: This chamber cooled the hot fabric before reach to delivery zone. Exhaust Motor: This specific part used to exit the steam produced in the chambers and also exit the extra temperature from the machine. Delivery Zone: This zone delivered the fabric in a folded form. In this zone the fabric has to Pass through several rollers in order to prevent the formation of crease mark in the finished fabric. Controlling parameter No. of chamber No. of burner No. of blower Padding mangle Exhaust fan Type Maximum production : 8 (without cooling chamber) : 8 : 16 : 2 : 8 : pin stenter : 5ton/day Southeast University Page | 37

  44. Industrial Attachment Machine Description Chamber to chamber distance Padder pressure : 3m : 3-4kg Temperature setting  Maximum temperature  Minimum temperature  Heat setting range  Lycra heat setting range : For Dyed fabric is done at 170˚c-175˚c : 200˚c : 130˚c : 175-185˚c : 175˚c -180˚c for finishing Temperature setting for different shade  For light shade  For deep shade  Pigment dyeing : Normal temp : High temp : 150˚c -160˚c Function of stenter machine 1. Apply chemicals 2. Apply softener 3. Drying of fabrics 4. Width control 5. Curing of fabric 6. GSM control 7. Shrinkage control 8. Spirality control 9. Heat setting on cotton/ Lycra 10. Pigment dyeing 11. Bowing effect control 12. Surface coating 13. Heat setting Problem causes by the Machine  Lycra may be decompose due to unbalanced heat  Elasticity may be loose due to dia extension caused GSM low  Color spot may be occurred due to lack of proper chemical mixing  Softener spot  Foaming spot  Iron spot Southeast University Page | 38

  45. Industrial Attachment Machine Description  Running shade may be seen due to difference between speed and heat  Crease mark may be appeared if expanding of the fabric is not accurate. 3.4.2.5 Compactor machine The main object of compactor is to make the fabric surface smooth, to control the residual shrinkage, G.S.M and if required fabric width also. To control the residual shrinkage the fabric is previously shrinkage artificially by gathering of loops of knitted fabric and it is set by heat and pressure. In tube & open compactor, the dried knitted fabric is face to steam when it passed through the Teflon coated conveyor belt. When a cotton fabric absorbs water, it swells and shrinks (particularly in length direction) because the absorbed water allows the cellulose chains to move relative stain free position. Then the fabric is passed through the expander. This m/c contains two compaction units to compact both side of the tubular fabric. Each unit contains a hot rotating cylinder, blanket which rotate in contact with the cylinder and Teflon cover .while passing the expander roller, the fabric is over feeded. The fabric is compacted with the pressure of blanket and Teflon cover while passing through the hot cylinder .Due to compaction stitch length is reduced. Then the fabric is passed through the counting device .Before packing, the fabric is inspected carefully. Important parts: • Over feed roller • • Steam sprayers Expander • Cylinder (2) Southeast University Page | 39

  46. Industrial Attachment Machine Description • • Blanket (2) Teflon covers Operational parameter Set the temperature at 110-1390C (as required) Set the overfeed % as required; to increase GSM, overfeed need to increase to a certain limit. Width control Length compaction We know that Compaction Percentage can be calculating as following formula Feedrollspeed-Deliveryrollspeed Compaction = ×100% Feedrollspeed Problem causes by the Machine  Cheats mark  Compaction mark  Fabric folding Southeast University Page | 40

  47. Industrial Attachment Machine Description  Side loose and tight Remedies  Properly compact the fabric  Properly compact the over feeding  Perfect pressures apply.  3.5 Remarks M M Knitwear Ltd is a well-equipped industry. It contains machinery of well known brands like Thies, Tubetex, Laffer, Bianco etc. The availability of these m/c’s are helpful to increase the productivity of the industry. The arrangement of machines is very beautiful and there is enough space for movement of the workers. Southeast University Page | 41

  48. CHAPTER – IV RAW MATERIAL Southeast University Page | 42

  49. Industrial Attachment Raw Materials 4 RAW MATERIAL M M Knitwear Ltd is a knit composite textile industry. In the industry the raw materials used for production are: 1.Grey Fabrics 2.Dyes 3.Chemicals 4.1 Grey Fabrics Following types of grey fabrics are processed→ Single jersey Single jersey/lycra Interlock Rib 1X1rib/lycra Combined rib Lacoste Terry & French terry polar Eyelet & mini-eyelet Mesh (warp knitted fabric) waffel Collar & cuff Pique Source→ 40% comes from the Knitting Department of Landmark Fabrics Ltd and other 60% comes from outward as sub-contract. Daily Fabric Production Capacity→ Item Quantity Single jersey, Pique Lacoste, Interlock Rib Collar & cuff 3800kg/day 1500 kg/day 1000 kg/day 6000 pcs 4.2 Dyes In M M Knitwear Ltd. the following types of dyes are used: Reactive dyes (cold brand & hot brand) Disperse dyes The commercial name of the dyes with their prices are collected from the dye stock report→ Sl. No. Name of the Dyes 01 Remazol yellow RR 02 Remazol blue RR 03 Remazol red RR 04 Remazol blue BB New • • Price in Tk/kg 195 520 420 380 Southeast University Page | 43

  50. Industrial Attachment Raw Materials 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Remazol G.yellow RGB Remazol blue RGB Remazol Ultra red RGB Remazol T/blue RGB Remazol red-RGB Rifa blue RSPL-N Solazol black-B Solazol red-SP3B Solazol blue R/SPL Solazol black-GRE Solacion navy blue-HEXL Solacion yellow-HE4RN Solacion red HE3B Evercion red-HE7B Evercion orange-HER Evercion navy-HER Dri. Turqouise L/P black-KAP/KNA L/P navy-NNA Syno white-4BK Sun white BVB San white 4BK Reactobond black-XL Reactobond blue BB Reactobond red BRF Reactobond blue H2R Reactobond red CRB Reactobond red F3B Kirazol yellow w 2BRL Kirazol blue EMRX Kirazol red EMX Taicron Billian blue SGLT Taicron yellow E3GT Taicron orange E3RT Taicron black SE-EXNT Taicron navy blue SE-EXNT Taicron red EF-BNT Taicron red WW2RT Taicron scarlet 320 350 460 600 466 1120 370 650 1242 210 800 1150 800 950 1050 900 520 315 450 550 480 900 850 620 750 950 880 Southeast University Page | 44

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