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Industrial attachment of newtex composite textiles ltd.

Industrial attachment of newtex composite textiles ltd.

sheshir
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Industrial attachment of newtex composite textiles ltd.

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF Newtex Composite Textiles Ltd. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 1

  2. ABSTRACT: By means of the practical knowledge it’s possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge. In this report describe about our entire internship period. By this industrial attachment we can know about Impress-Newtex composite Textiles Ltd basic information. The internship paper provides knowledge about Knitting, planning, wet processing lab, dyeing, finishing, quality & dry lab. It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to accustomed with the industrial atmosphere & improve courage & inspiration to take self-responsibility. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 2

  3. CONTENT Topics name Page No. 1.CHAPTER -I....................................................................................................7-9 COMPANY PROFILE 1.1 General information About the Mill 1.2 Buyers of Impress-Newtex Composites Textile Ltd. 1.3 Site Location 2.CHAPTER -II.............................................................................................10-11 STRUCTURE OF THE ORGANIZATION 2.1 Organ gram of Impress-Newtex Composite Textiles Ltd 2.2 Shift Classification 2.3 Responsibilities of the officer 3.CHAPTER -III………………………………………………………………...12-26 KNITTING DEPARTMENT 3.1 Knitting 3.2 Raw materials 3.3 Lay-out of knitting section 3.4 Specification of knitting department 3.5 Production flow chart of knitting section 3.6 Description of production process in Impress-newtex composite textiles ltd 3.7 Production parameter 3.8 DESCRIPTION OF IMPORTANT MACHINE PARTS 3.9 Types of fabrics produce in Impress-Newtex Composite Textiles Ltd. 3.10 Production Calculation 3.11 Knitting faults, causes & their remedies Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 3

  4. 4.CHAPTER -IV………………………………………………………………...27-29 PLANNING DEPARTMENT 4.1 Planning department 4.2 Batch section 4.3 machines used in batch section 5.CHAPTER -V……………………………………………………………….....30-31 WET PROCESSING LAB 5.1 Dyeing laboratory 5.2 Lab Dip 6.CHAPTER -VI…………………………………………………………….......32-47 Dyeing 6.1 Raw-materials 6.2 Production planning, sequence & operations 6.3 sequence of operation for knit dyeing 6.4 Dyeing process 6.5 Process sequence of stripping 6.6 Lay out plan of Dyeing Shed 6.7 Specification 7.CHAPTER -VII……………………………………………………………….48-54 FINISHING 7.1Finishing 7.2Process flow chart of knitting finishing 7.3 Lay out Plan of Finishing Shed 7.4Specification of Finishing Section 7.5Objects of finishing machine used in Impress-Newtex composite Textiles Ltd. 7.6Data for Tumble machine 8.CHAPTER -VIII……………………………………………………………....55-58 QUALITY CONTROL 8.1 Quality Management System 8.2 Objectives of quality control 8.3 Quality Management system in Impress-Newtex Composite Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 4

  5. Textiles Ltd. 8.4 Analysis of different types of faults 8.5 Four (4) point system 9.CHAPTER -IX…………………………………………………………………59-63 DRY LAB 9.1 Different types of machine used in finishing lab 9.2 Short note on some tests 10.CHAPTER -X………………………………………………………………64-69 WTP & ETP 10.1 Water treatment plant 10.2 Standard water quality for dye house 10.3 Flow chart of ETP 10.4 Step wise function of different unit of E.T.P 11.CHAPTER -XI……………………………………………………………….70-73 MAINTENACE & UTILITY SERVICES 11.1 Maintenance 11.2 Utility servicess 12.CHAPTER -XII……………………………………………………………..........74 CONCLUSION 12.1Comments 12.2Some suggestions Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 5

  6. CHAPTER-I COMPANY PROFILE 1.1 General information About the Mill Name of the Company Type Year of Establishment Location Address: Factory Head Office : Impress-Newtex Composite Textiles Ltd. : 100% Export oriented Knit Dyeing Factory. : 1996. : Gorai, Mirzapur, Tangail. : Gorai industrial area, Mirzapur, Tangail. : “Evergreen Plaza”(6th Floor) 260/B, Tejgaon Industrial Area, Dhaka-1208 Project Cost Capacity Annual Turnover Physical Infrastructure: : 100crores taka. : Knit Dyeing 22-24 tons per day :Around 10 Lac U.S Dollar/year. Physical infrastructure of Impress-Newtex Composite Textiles Ltd. is simple one. It is constructed by steel structure; outside is brick wall, somewhere it is R.C.C. & brick wall structure. Vision: 1.To be one of the best leading composite mill in Bangladesh 2.To build a true marketing led enterprise with motivated workforce, innovative vision & more value added product portfolio, customer satisfaction & understanding of global market. Mission: Each of our activities must benefit and add value to the common wealth of our society. We firmly believe that, in the final analysis we are accountable to each of the Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 6

  7. constituents with whom we interact; namely, our employees, our customers, our business associates, our fellow, citizens. Medical facility: Trained team of medical are formed in case of any emergency. Working environment: An excellent working environment exits in the factory with proper ventilation & light. No child labor work in the factory Certification & Award: ISO 9001:2008 certified Company. 1.2 Buyers of Impress-Newtex Composites Textile Ltd. Name/logo Country SWEDEN NETHERLAND Germany AUSTRALIA Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 7

  8. 1.3 Site Location Nabinagor Mirzapur Cadet College Impress- Newtex Group Karnafully Knit-Industries Ltd. Dhaka- Tangail Road West South North East Dhaka-M anikgonjRoad Chandra Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 8

  9. CHAPTER-II STRUCTURE OF THE ORGANIZATION 2.1 Organ gram of Impress-Newtex Composite Textiles Ltd. Impress-Newtex Composite Textiles Ltd. is well equipped with highly efficient team of management, which is very essential for smooth running of a factory. Chairman Managing Director Director Executive Director Senior General Manager General Manager Deputy General Manager Manager Deputy Manager Assistant Manager Senior Executive Executive Junior Executive Supervisor Operator Assistant operator Helper Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 9

  10. 2.2 Shift Classification There are three shifts per day in Impress-Newtex Composite Textiles Ltd. So each shift contain eight hour. Shift A B C General Start 6:00 A.M. 2.00 P.M. 10:00 P.M. 9.00 AM End 2.00 P.M. 10:00 P.M. 6:00 A.M. 5.00 PM The factory runs 24 hours a day & 365 days a year. It maintains a strong working schedule which is shown in the chart below- Section No. of shift Dyeing Knitting Finishing Inspection Staff & Commercial General shift(9am to 5pm) Top management General shift(9am to 5pm) 2.3 Responsibilities of the officer General Manager (G.M): Deals with the buyers & merchandiser. Setting up price for the product Planning, applying & controlling all administrative functions. Following up the instructions of the Managing Direction & Chairman. Arranging necessary facilities for the buyer’s demand. Manager: Planning for the sequence of operation. Organizing necessary raw materials for the production To follow the production & provide solution to the production problems. Indicating reasons which are liable for less production. Executive: Follows the worker’s movement Discuss with the manager what is going on the floor Maintain production sequence Check the sample at a certain time interval. Setting program for the supervisor Duration 8 hours each 8 hours each 8 hours each 8 hours each 8 hours 8 hours 3 shifts 3 shifts 3 shifts 3 shifts Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 10

  11. CHAPTER: III KNITTING DEPARTMENT Fig: Knitting machine 3.1 Knitting Knitting is considered to be the second most frequently used method of fabric construction, after weaving. It is one of the several ways to turn thread or yarn into cloth. It is similar to crochet in the sense that it consists of loops pulled through other loops. In other words, knitting is the process of construction of a fabric made of interlocking loops of yarn by means of needles. The loops may be either loosely or closely constructed, according to the purpose of the fabric. The loops or stitches are interlocked using a needle which holds the existing loop and a new loop is formed in front of the old loop. The old loop is then brought over the new loop to form the knitted fabric. Knitting is different from weaving in the sense that a single piece of yarn can be used to create fabric. The knitted fabric consists of horizontal rows known as courses and vertical columns of loops known as wales. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 11

  12. 3.2 Raw materials 3.2.1 Types of raw material 1.Yarn 2.Lycra Yarn: Natural and synthetic, Cellulosic and non-cellulosic all kind of yarn are used as raw materials in this mill. Generally, Cotton, Polyester, Viscose are mostly used in knitting departments. Fiber composition Count Yarn type Cotton 7, 10, 12, 13, 16, 20, 30 Carded 16, 20, 30, 40, 50, 60, 80, 100/2, Combed 80/2, 20/2, 30/2, 40/2, 50/2, 60/2 PC 16, 20, 30, 45 Carded or Combed CVC 12.5, 20, 30, 38, 40, 45, 26/2 Combed Viscose 16, 20, 30, 40 Combed Spandex 20D, 40D Polyester 70D, 75D, 100D, 120D, 150D Fig: Yarn Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 12

  13. 3.3 Lay out of knitting section Fig: Lay out of knitting section 3.4 Specification of knitting department 1. Machine no: Brand: Origin: Model: Size: 1 PRECISION FUKUHARA WORKS LTD. Japan DXC-35 20 Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 13

  14. 2. Machine no: Brand : Origin: Model: Size: 2 PRECISION FUKUHARA WORKS LTD. Japan DXC-35 20 3. Machine no: Brand : Origin: Power: No. of phases: Frequency: 3 ORIZIO PAOLO S.p.A ITALY 45V 3 50-60 Hz 4. Machine no: Brand : Origin: Power: No. of phases: 4 ORIZIO PAOLO S.p.A ITALY 45V 3 5. Machine no: Brand: Origin: Power: No. of phases: Frequency: 5 ORIZIO PAOLO S.p.A ITALY 45V 3 50-60 Hz 6. Machine no: Brand: Origin: Power: No. of phases: Frequency: 6 ORIZIO PAOLO S.p.A ITALY 45V 3 50-60 Hz 7. Machine no: Brand: Origin: Model no: No. of needles: Diameter: Feeder: 7 JIUNN LONG MACHINE CO. LTD. TAIWAN JLS-4 1740T 23’’ 69F Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 14

  15. Gauge: 24G 8. Machine no: Brand: Origin: Model no: No. of needles: Diameter: Feeder: Gauge: 8 JIUNN LONG MACHINE CO. LTD. TAIWAN JLS-4 2400T 32’’ 96F 24G 9. Machine no: Brand: Origin: Model no: No. of needles: Diameter: Feeder: Gauge: 9 JIUNN LONG MACHINE CO. LTD. TAIWAN JLS-4 2712T 36’’ 108F 24G 10. Machine no: Brand: Origin: Model no: No. of needles: Diameter: Feeder: Gauge: 10 JIUNN LONG MACHINE CO. LTD. TAIWAN JLS-4 1740T 23’’ 69F 24G 11. Machine no: Brand: Origin: Model no: No. of needles: Diameter: Feeder: Gauge: 11 JIUNN LONG MACHINE CO. LTD. TAIWAN JLS-4 1584T 21’’ 63F 24G 12. Machine no: Brand: Origin: Model no: 12 JIUNN LONG MACHINE CO. LTD. TAIWAN JLS-4 Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 15

  16. No. of needles: Diameter: Feeder: Gauge: 1440T 19’’ 57F 24G 3.5 Production flow chart of knitting section Sample fabric Design analysis Machine selection Setting machine for the specific design Sample knitting Sample approval Bulk production Grey fabric inspection 3.6 Description of production process in Impress-newtex composite textiles ltd. In every mill, there maintains a sequence in production processing. It is also followed in this mill where I was in industrial attachment. The process sequences are in list below: 1.Firstly, knitting manager gets a production sheet from merchandisers as accordance as consumer requirements. Then he informs or orders senior production officer about it. 2.Senior production officer informs technical in charge and knows about m/c in which the production will be running. 3.Technical in charge calls for leader of mechanical fitter troops, they two take decision about m/c for production considering m/c condition, production capacity, maintenance complexity etc. 4.Production officer with experienced mechanical fitter adjusts required stitch length and grey GSM (gram per square meter) for required final GSM. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 16

  17. 5.Supervisor check daily production regularity and make operators conscious about finishing in due time. 6.Operators operate machine in highly attention as if there were no faults in the fabrics. If he is sure about any fabric fault, then he call for mechanical fitter in duty. Mechanical fitter then fixes it if he can or he informs technical in-charge. He then comes in spot. 7.After required production and final inspection in 4-point system, they are sent in dyeing section 3.7 Production parameter: During production of fabric in circular knitting machine following parameters must be maintain: 1. Machine Diameter; 2. Machine RPM (Revolution/Minute); 3. Number of feeds or feeders in use; 4. Machine Gauge; 5. Count of yarn; 6. Required time (Machine running time); 7. Machine running efficiency. 3.8 DESCRIPTION OF IMPORTANT MACHINE PARTS Creel: Creel is a part of a knitting machine. Hear yarn package are store and ready to feed in the machine VDQ pulley: It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley moves towards the positive directive then the G.S.M. is decrease. And in the reverse direction G.S.M will increase. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 17

  18. Pulley belt: It controls the rotation of the MPF wheel. Brush: Its clean the pulley belt. Tension disk: It confront the tension of the supply yarn Inlet and outlet stop motion: It is a important parts of the machine. It stops the machine instantly when a yarn is break. Yarn guide: Its help the yarn to feed in the feeder. MPF Wheel: Its control the speed of the MPF. Pulley belt gives motion to the wheel. MPF: Its isMamenger positive feed. Is is also an important parts of the machine. It’s give positive feed to the machine. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 18

  19. Feeder ring: It is a ring. Where all feeders are pleased together. Feeder: Feeder is help yarn to feed in to the machine. Needle: It is a principal element of the knitting machine. Its help the yarn to create a loop. And by this way fabric are produce. Prior to yarn feeding the needle is raised to clear the old loop from the hook, and received the new loop above it on needle stem. The new loop is then enclosed in the needle hook as the needle starts to descend. Needle track: Where all needle is placed together in a decent design. Sinker: It is most important element of the machine. Its help to loop forming, knocking over and holding down the loop. Sinker ring: Sinker ring is a ring. Where all sinkers are pleased together. Cam box: Where the cam are set horizontally Cam: Cam is device s which converts the rotary machine drive in to a suitable reciprocating action for the needles and other elements. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 19

  20. Lycra Attachment: Lycra is placed hear. And feeding to the machine. Sensors: It is one kind of stop motion to stop the machine when the lycra is break. Cylinder: Needle track are situated hear. Cylinder Balancer: It helps the cylinder to set in a proper alignment. Screen: it is a digital screen. Which show the all machine information and we can give command to the machine. Automatic oiler: Its give the machine oil all the time properly and automatically. Inverter: Its is the heart of the circular knitting machine. Its control the speed of the machine. Power Switch: To give the power to the machine. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 20

  21. ON/OFF Switch: It help the m/c to start and stop. Manual drive: To drive the machine manually. Machine motherboard: All the Electronic parts are placed hear. 3.9 Types of fabrics produce in Impress-Newtex Composite Textiles Ltd. single Jersey Single Lacost Double Lacost P/C Lycra Baby Tery Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 21

  22. Fleece fabric Terry Fleece Pique Lycra single jersey Stripe fabric Grey Mélange (5%,10%,15% viscose) 3.10 Production Calculation: A. Production/shift in kg at 100% efficiency :( formula)      . . ( ) 60 12 RPM No 10 No  of . 2 of Feeder  54 Feeder 3527 No 840 No  of  . Needle 2046 . 2 Needle of SL mm   .    36 Yarn SL  count mm ( ) RPM  . 80 Yarn count B. Production/shift in meter: (formula) / min cm . Course  / Course   cm   . 60  12 RPM No of Feeder Efficiency  / 100 Course C. Fabric width in meter: (formula) . cm Total no of wales   / 100 Needles Wales . Total no of used in knitting   / 100 Wales cm D. Let, Fabric Type: Number of Feeder: R.P.M. of Machine: Machine Diameter: Machine Gauge: Count of Yarn: Single Jersey Plain 90 30 30 24 24/1 Ne Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 22

  23. Stitch Length: Efficiency: Production/8 hours shift = (90*30*60*8*0.85*3.14*30*24*2.74)/ (10*2.54 *36 *840*24*2.2046) = 168 Kg Actual production Efficiency = Calculated production =138/168×100 = 82 % E) G.S.M calculation [G.S.M gm/m2]: GSM means grams per square meter. In knitting fabric it is the main parameter. It is controlled by loop length. If loop length increases GSM will decrease and vice versa. It is measured by GSM cutter & electric balance. It may also be calculated as below. tex l s   2.74 85 % × 100% GSM = Where, S = wale per cmcourse per cm. = wpc cpc. l = loop length in mm. 100   590 s l GSM = Ne Industrial Calculation of Impress-Newtex Composite textiles ltd: Collect sample (s/j) by G.S.M cutter and weighted from the weighting balance. e.g.; form balance we get 1.838g grey fabric so, Gray G,S.M=1.838 / 100 m g  =183.8gm/m2 Calculate Finish G.S.M as like procedure By calculation finish G.S.M =235g/m2 From finish G.S.M calculating grey GSM, SL, count: 2 Suppose a fabric involve 180 finishes G.S.M FinishG 180 . M S . 138 So, gray G.S.M= = 3 . 1 4320 3 . 1 4320  So, count= = 24/s G . S . M . 180 F Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 23

  24. 95351  5 . GSM G 95351  5 .   28 78 . So, S.L = cm=2.9 mm . 24 138 count 3.11. Knitting faults, causes & their remedies Faults Causes Remedies Holes are 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 & density. Badly knot or splicing Yarn feeder badly set Yarn strength must be sufficient to withstand the stretch as well as uniform. Use proper yarn count. Correctly set of yarn feeder. Knot should be given properly. Hole Mark When a needle breaks down then needle mark comes along with the fabrics. If a needle or needle hook is slightly bends then mark can be obtained. When sinker corrode due to abrasion then sometimes can’t hold a new loop as a result sinker mark comes If sinker head bend the sinker mark can be obtained. Yarn tension variation during production Buckling of needle latch. Low GSM Needle straight. Needle Mark should be Sinker changed Sinker mark should be Maintain tension production Use good conditioned needle Star Mark same yarn during Defective needle If yarn is not properly fed during loop formation then causes drop stitch. Too loose take down mechanism Insufficient yarn tension Badly set yarn feeder Needle straight & well Proper feeding of yarn during loop formation Yarn tension should be proper Drop Stitch should be When oil lick through the needle trick then it pass on the fabrics & makes a line Ensure that oil does not pass on the fabric. Oil Mark Well maintenance as well as Proper oiling. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 24

  25. Due to break down or bend of the latch, pin hole may come in the fabric Improper greasing Excess greasing Change the needle Pin Hole Proper greasing as well as proper maintenance Grease Mark   If yarn contains foreign fiber then it remains in the fabric even after finishing Count mixing can causes this fault By avoiding lot count mixing Yarn Contamination Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 25

  26. CHAPTER –IV PLANNING DEPARTMENT 4.1 Planning department Mainly planning department of the factory divided into 2 sections 1.Store section 2.Batch section Fig: Planning department Objective of Store section: To receive the grey fabric from knitting department or other sources. To store the grey fabric according to order number & fabric type To update the daily grey fabric store report 4.2 Batch section Production planning for dyeing is called batch plan. According to the batch no, color, width, style & construction the batch plan is made. Batch preparation sequences: Receive batch card from grey in charge Made the priority as per dyeing plan Take one specific batch card Read the batch card for own understanding Check the availability of fabric Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 26

  27. Take require quantity of the body fabric from ware house Make required no. of rape maintaining equal length Take collar as per size, keep the total weight Distribute the collar/ cuff or rib in each rope equally ensure equal length Stitch the fabric Write down the weight against roll no. in the back side of the batch card Write the total weight in the batch card Put signature & data Fill up the production report form. Information checks point: Order no Color Yarn count Yarn lot Yarn brand Machine no Roll no Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 27

  28. 4.3 machines used in batch section 1. Machine name: Fabric inspection machine Brand: Uzu Fig: Fabric inspection machine 2. Machine name: Air turning machine Model no: DNAT-400 Brand: DONG NAM INDUSTRIAL CO., LTD Origin: Korea Fig: Air turning machine Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 28

  29. CHAPTER -V WET PROCESSING LAB 5.1 Dyeing laboratory Lab is the most important section of a dyeing industry. Higher precision lab can aid easily to achieve the goal of the organization. Before bulk production a sample for the approval from industry is sent to buyer. As per requirement of the buyer the shade is prepared in a lab considering the economic aspects. 5.2 Lab Dip A lab dip is a swatch of fabric test dyed to hit a color standard. It is a process by which buyer’s supplied swatch is matched with the varying dyes percentage in the laboratory with or without help of spectrophotometer. Lab dip plays an important role in shade matching & this is an important task before bulk production. In previous article of this author we have to learn on flow chart on dyeing lab. 5.2.1 Object of Lab Dip: The main objectives in lab dip are as follows: 1.To calculate the recipe for sample dyeing. 2.To compare dyed sample with swatch by light Box or Spectrophotometer. 3.To calculate revise recipe for sample dyeing. 4.Finally approved Lab Dip (Grade: A, B, C & D) 5.2.2 Process Sequence of Lab Dip: Lab dip plays an important role in dyeing process. Bulk dyeing process completely depends on the lab dip development work. Lab dip is completely managed as the following sequence. Lab Dip Requisition from buyer ↓ Entry in the computer ↓ First recipe is given by swatch/pantone number ↓ First correction Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 29

  30. ↓ Second correction ↓ Grading of sample (A, B, C, D) ↓ Yarn and knit sample send to buyer ↓ Approved by buyer ↓ Order for bulk production ↓ Production card with approved sample and recipe send to production section. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 30

  31. CHAPTER -VI DYEING 6.1 Raw-materials: In impress-Newtex Composite Textiles Ltd., the raw materials used for production are –  Grey Fabric  Dyes  Chemicals 6.1.1 Grey Fabric: The following type of Grey Fabric are dyed-  single Jersey Lycra single Jersey Interlock Lacoste Rib Lycra Rib 1x1 Rib& others collar & cuff polyester Fabrics Source: The required single jersey grey Fabrics &it’s derivatives are produced in this industry & double jersey & it’s derivatives are bought from others factory. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 31

  32. 6.1.2 Dyes & Chemicals Used in Impress- Newtex Composite Textiles Ltd: Aids Chemicals name General Chemicals Caustic Soda ash H2O2 Hydrose Antifoam-39 Gluber salt(anhydrose) H2SO4 Acetic Acid Formic Acid Invatex AC Oxalic Acid Aikamine CWS Sun Soflon FK-21 Acid Cat-ionic softener Non-ionic (white) Sun SofterA300 SupamineFPS TexportD-900 Anticrease Ciba Fluid C Texport GL-500 Wetting Agent Invadine DA Sun Morl CK-1 SandocleanPCLF Neofix R-250(FDR) Fixing Agent cibatex ECO AmoniumSulphide cibatex AB-45 Alcosper Ad Lipotol PS-60 SadopurRSk Invatex CS Neocrystal BGS Sirrix 2Ud Cibacel DBC Neocrystal 200B Drimagin E2R Lyoprint RG setamal BL Buffer Soaping Agent Sequestering Agent Leveling Agent Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 32

  33. Per-oxide killer Invatex PC Croaks N Bio-polish EC Bio-polish AL Tinozyme 44L Enzyme Stabilizer Stabilizer Sifa Neorate pH-100 Siba white Uvitex BHV UvitexBBT Naka white Leucopher BMB Brightener 6.1.3 Dyes used in Impress- Newtex Composite Textiles Ltd Dyes Solazol Black sp GRI Reactofix Red ME 4BL Cottofix Red ME 4BL Reactofix orange ME 4RL ReactofixN.ME2GL Reactive yellow H4GL Reactive Deep Black N Cottofix Black B Reactive Blue R (SP) Remazol Red RR Remazol yellow RR Remazol Blue RR Remazol Blue BB NEW Remazol T. Blue G Remazol B. yellow 3GL Remazol Red RGB Cibacron Red FN2BL Cibacron Red FB Cibacron RedFN3G Cibacron Red WB Cibacron Blue FNR Cibacron Blue FGFN Cibacron Navy WB Drimarin yellow CL2RL Drimarin Red CL5B Drimarin VIOLET K2RL Drimarin Navy CLB Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 33

  34. Drimarin Blue CT2R Bezaktrive yellow S3R Bezaktrive yellow SLE Bezaktrive yellow VGL Diss yellow F5GL Diss Red BF Diss Blue FRL Diss Navy 2GL Diss Black EXNSF Terasil Black WNS Terasil Red FB Terasil Red WFS Terasil Red W4BS Sunfix Supra Scarlet 2GL SunfixSupraT/ Blue G Sunfix Supra Blue EXF Sunfix Supra Navy Blue EXF Sunfix Supra Red EXF Sunfix Supra yellow EXF Sunfix Br. Blue R Sunfix Br. yellow4GL Sunfix HF yellow 3R Sunfix HF RedG Sunfix HF Red 2B Sunfix HF Navy 2G Sunfix HF Blue 2R Sunfix HF Brown RL Sunfix Supra Marine EXF Sunfix Supra Navy Blue BF Sunfix Supra yellow 3RF Sunfix Supra Br. Red 3BF Sunfix Red 4BNF Sunfix orange 3R Sunfix Br. yellow 3GF Sunfix Supra BlueBRF Sunfix Supra Red GF Sunfix Dark Brown BRS Sunfix Br. violet B.SPI Taifix Red SF3BT Taifix yellow SF3RT Taifix Black SFBSDT Taifix Black SFBT Taifix Br. Blue RTSPC Taifix Br. BlueR special Taifix Navy Blue BRNT Taifix Black GRNT Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 34

  35. 6.2 Production planning, sequence & operations 6.2.1 Production parameters: A. pH: - During H2O2 bleaching pH 9-11 - During reactive dyeing pH 10.5-12 - During disperse dyeing 4.5-5.5 B. Temperature: - For cotton scouring 900 -950C - For cotton cold wash 300-400C - For cotton hot wash 700-80C - For cotton acid wash 600-700C - For cotton dyeing at 800-900C ( For hot brand ) 400-600C (For cold brand) - Polyester dyeing: 1000-1300C C. Time: - For scouring 60-90 mins - For reactive dyeing 60-90 mins -for disperse dyeing 30-60 mins D. M:L ratio -for reactive dyeing M:L ratio maintained 1:8 Description of production process: Washing for colored fabrics: -The colored fabrics to be washed is loaded in the machine - Required amount of water is taken -PCLF ( detergents ) added and washing continued at 800C for 20 mins -Cold washing Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 35

  36. Scouring – bleaching: -Fabric to be scoured is loaded in the machine . -Required amount of water is loaded . -Washing agent / detergent is added. -Steam pipes are on and scouring agent ( i.e caustic soda/ soda ash ) added when the temperature reaches at 500C. -When the temperature reaches at 600C then stabilizer is added . -Then H2 O2 is added. -Temperature is then raised to 950 C and the process is then carried out for 60-90 mins depending on the requirements. -The liquors are then drained . -Then cold wash at 300-400 C, hot wash at 80-950 C and acid wash at 40-500 C is done. Dyeing: -After acid wash all liquors are drained out. -Required amount of water is taken. -Then leveling agents, anti – creasing agents, de-foaming agents are added according to the requirement. -then the temp. is raised up to mark and after 10-15 mins dyes added. -Salts are added after another 30 mins. -Then soda ash after another 30 mins. -Then the temperature is raised slowly up to the mark. -The process is carried on and sample are taken after every 10-20 mins to match with the target shade. It continues until shade matching. -If the sample is matched then the liquors drained out. -Then cold wash at 300-400 C, hot wash at 700-800 C, acid wash at 40-500 C is done. -Then softener is added at 450 C for 20-30 mins. -Fixer is applied for deep shade only before adding softener. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 36

  37. Re-dyeing: When shade is not matched then fabric is treated again in dyeing machine for shade matching is known as re-dyeing. Generally re-dyeing is done if the shade is deeper or lighter than the target shade. It may occur when the fabrics absorb one or two colors more or less. One re-dyeing process is described below. -Drain the let off solution. -Hot wash at 700-800 C. -Acid wash at 40-500 C ( 400 for light shade and 500 C for deep shade ) -Soda ash washes at 900-1000 C for 60 mins to reduce the depth of shade. -Acid wash at 600 C -Addition to required dyestuffs. -Salt addition. -Soda ash addition. -Other operations are same as previous described dyeing operations. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 37

  38. 6.3 SEQUENCE OF OPERATION FOR KNIT DYEING: Grey fabric inspection Batching Fabric turning Loading to the machine Pre-treatment (Scouring &Bleaching ) Dyeing Dewatering Drying Compacting & Calendaring Final inspection & packing Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 38

  39. 6.4 Dyeing process Maple process: Every chemical are applied at low temperature such as at 400c & color steam in between 40 to 60oc. Scouring temperature= 98oc & scouring time 30 minutes Turquoise process: Every chemical are applied at 600c & migration is done from 60 to 90oc & cooling temperature is 60oc. Scouring temperature= 110oc & scouring time 60 minutes Taupe process: Every chemical are applied at low temperature such as at 600c & color steam 60oc. Scouring temperature= 98oc & scouring time 60 minutes 6.4.1 Dyeing flow chart for 100% cotton: Leveling: 60 for 10 min. Color (600C X20min) Salt, Soda, Caustic: (600C X 20 min) Color Steam: 20 min. Color wash: 10 min. Normal hot (80 0C X 20’) Ringe: 15’ Add Acetic Acid------1% (Run time 10’) Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 39

  40. Hot wash (800C X10’) Add softener (900C X25’) Unload 6.4.2 Process sequence of polyester dyeing Fabric load Water level as required Rise temp. to 600C Addacidat 600C Rise temp. to 950C (Run time 10’) Drain Water level as required Rise temp. to 450C Hot wash With PS-60------1% Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 40

  41. (980C X 10’) AdddyesDosing(45 0C x 10’)(Run time15’) Rise temp. to 1300C (Run time 30’) Cooling to 700C if shade ok then BD Drain Water level as required Add Hydrose + caustic (800C x 10’) Hot wash(800C X10’) AddAcetic Acid&softener(450C X 10’) COLD wash(300C X10’) Unload 6.5 Process sequence of stripping Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 41

  42. Fabric loading Loading hot – 900C for 10 min Washing at 40OC for 10 min Drain & filling Leveling run at 400C for 10 min Caustic dosing for 400 C for 10 min Steam up at 400C to 1000C Steam up at 1000C to 1300C Run time 70 min Cooling Normal hot at 900C for 10 min Drain & filling Acid run at 400C for 10 min Washing at 400C for 10 min Drain & filling Lab test & unloading 6.6 Lay out plan of Dyeing Shed Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 42

  43. 5 4 15 13 1 6 2 7 7 16 S-8 3 Diesel Genera tor S-9 17 14 S- 10 S- 11 : 6.7 Specification 12 Fire Tube Boiler B B Godown Gas Generator Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 43

  44. Dyeing Machine type Machine Quantity 13 4 Winch dyeing Machine Winch dyeing Machine(SAMPLE) Winch dyeing Machine(Atmospheric) Machine no. 01 02 03 04 Name of the Machine Winch dyeing Machine Sclavos Greece 1200kg 2008 Winch dyeing Machine Winch dyeing Machine Winch dyeing Machine Brand name Tong gene Taiwan 800kg Tong gene Taiwan 1200kg Tong gene Taiwan 250kg Origin Capacity Year of manufacturing No. of Nozzle 1995 1995 1995 4 Up to 1420C Tgru-Half 1-5 4 6 4 Temp. range Up to 980C Up to 980C Up to 980C Model Tgru-Half 1-15 Tgru-Half 1-25 Tgru-Half 1-50 Machine no. 05 06 07 12 Name of the Machine Winch dyeing Machine Sclavos Greece 1500kg 2008 Winch dyeing Machine Winch dyeing Machine Winch dyeing Machine Brand name Fong’s Fong’s Fong’s Origin Honkong Honkong Honkong Capacity 450kg 650kg 600kg Year of manufacturing No. of Nozzle 1995 1995 1995 6 DIN-EN-729-3 4 4 4 Model BS-5500 BS-5500 BS-5500 Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 44

  45. Machine no. 9 10 11 8 Name of the Machine Winch dyeing Machine(Sample) Winch dyeing Machine(Sample) Winch dyeing Machine(Sample) Winch dyeing Machine(Sample) Brand name Dilmenler Fong’s Honkong 25kg 1999 Tong Gene Tong Gene Origin Turkiye Taiwan Taiwan Capacity 35kg 20kg 10kg Year of manufacturing No. of Nozzle 1999 1995 1993 1 1 14 1 1 Machine no. 13 15 16 Name of the Machine Winch dyeing Machine Winch dyeing Machine Winch dyeing Machine Winch dyeing Machine Brand name Tong gene Fong’s Honkong 800kg 2001 Tong gene Tong gene Origin Taiwan Taiwan Taiwan Capacity 600kg 1000kg 600kg Year of manufacturing No. of Nozzle 1998 2001 2001 3 4 6 3 Machine no. 17 Name of the Machine Winch dyeing Machine Brand name Origin Tong gene Taiwan 1000kg 1998 Capacity Year of manufacturing Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 45

  46. No. of Nozzle 6 Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 46

  47. CHAPTER –VII FINISHING 7.1 FINISHING Any operation (other than preparation and coloring) that improves the appearance and/or usefulness of fabric after it leaves the loom or knitting machine. Finishing is the final series of operations that produces finished textile fabric from grey goods. The word "finish" means all the different treatments applied to a fabric to change such things as its • Appearance, • Feel or hand, • Wear ability or care requirements. 7.2Process flow chart of knitting finishing For Tubular form: Hydro-extractor De-watering Dryer Tubular compactor For open form: Hydro-extractor De-watering Dryer Slitter Stenter Compactor Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 47

  48. 7.3 Lay out Plan of Finishing Shed Notation A Open compactor I Physical test Lab. B Platinum J Supervisor’s room Stenter m/c C bianco Slitter K Hydro-extractor D De-watering m/c L Information desk E Dryer M Chemical Lab. F Tube compactor G Finishing table Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 48

  49. 7.4Specification of Finishing Section Machine name Hydro- extractor De-watering m/c Sutter Slitter Dryer (tube) Dryer (open) m/c no. 02 DMS 07 (centifuge) Model no. R 02 940727 DMS07 KC1250 2003- 02 Serial no. DMS053k2G 2400 2003- 09 Year of Mfg 2003 2005 1995 2003 Brand name Dilmenler Bianco Bianco RUCKH Dilmenler Manufacturing country Turkey Italy Italy Germany Turkey Total power 16.12kW Capacity 125kg 8 tons/day 8 tons/day 4-30 m/min. 4-30 m/min. R.p.m 60m/min No. of motor 03 No of chamber 2 3 Open width& tube fabric Open width& tube fabric Application 1100C - 2200C Temp. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 49

  50. Machine name Platinum Stenter m/c m/c no. 1 Model no. Serial no. 72276-0463 Year of Mfg 1995 Brand name BRUCKNER Mfg country Germany Temp. 50-2500C Capacity 8 tons/day R.p.m 15-30m/min.(knit) 15-80m/min.(woven) Used Utilities Electricity, Water,gas,Compact air No of chamber 3 Application Open width fabric Max. width 102” Min. width 30” Steam Pressure 2 Bar Air Pressure 10 Bar Extra attachment Mahlo attachment for Bowing control Open compactor(new) Machine name Open compactor Tubecompactor m/c no. 1 1 1 Model no. compacta_ck/240-a comptex/Fv 200 comptex/Fv Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 50

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