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Industrial attachment of reedisha knitex ltd.

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Industrial attachment of reedisha knitex ltd.

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Reedisha Knitex Ltd

  2. CONTENTS CONTENTS Topics Page no. Acknowledgement……………………………………………………..2 Introduction………………………………………………………………3 Chapt-1: Project Description………………………………………….4 Chapt-2: Man-power management………………………………..10 Chapt-3: Machine Description……………………………………….15 Chapt-4: Raw Materials………………………………………………..29 Chapt-5: Production Planning , Sequences & Operations…….. 33 Chapt-6: Quality Assurance System…………………………………56 Chapt-7: Maintenance………………………………………………...62 Chapt-8: Utility Services………………………………………………...65 Chapt-9: Store & Inventory Control………………………………….73 Chapt-10: Cost Analysis………………………………………………..76 Chapt-11: Marketing Activity…………………………………………78 Chapt-12: Conclusion…………………………………………………. 81 2

  3. INTRODUCTION INTRODUCTION Reedisha Knitex Limited. one of the countries leading knit composite factories. The factory is equipped with the latest facilities of modern time to meet up the global demand of knit garments. It is a 100% export oriented factory so quality is the first consideration above all. After establishment it has made it reputation to such extent that it has got some of the finest buyer who depends on the quality of the product of this factory. The list of buyers is a long one, that composed of ZARA, WALMART, H&M, KIABI, BENETTON, LIE & FUNG and many others. From the list of buyers we can certainly make an assumption of the quality they maintain. The harmonically mix of man and machine and the boost of powerful management made this factory run so smoothly. The skilled and technical manpower and devoted labor force made the factory a success. With the quality of product the factory and management always feels the liabilities to the environment as well as to the public health, as a result effluent treatment and chemical used are very strictly maintained. As a result the factory got the CONFIDENCE IN TEXTILE CHEMICAL and WRAP certification. Considering all the above features to learn about technology of textile manufacture as well as management to ensure such quality Reedisha Knitex Limited was a good choice. We feel very lucky to complete our industrial attachment with this mill. 3

  4. Chapter One PROJECT DESCRIPTION 4

  5. PROJECT LOCATION The project is located in Dhanua, Sreepur under the district of Gazipur, about 50km distance from the intertnational airport Dhaka, Bangladesh. A well developed road communication is there to reach the factory from the airport as well as from the Dhaka city. The head office of the project is located in the heart of the of Dhaka City in tejgaon industrial area. Location map: Reedisha Knitex Ltd. Naynanpur, Dhanua, Shreepur Mauna chaurasta Gazipur National Park Gazipur chaura sta Zia international Airport 5

  6. PROJECT AT A GLANCE PROJECT AT A GLANCE Name of the mill Type Status Year of establishment Location : Reedisha Knitex Limited. : 100% export oriented knit composite : Private limited company. : 2003 : Location map is attached. Address: Factory address Reedisha Knitex Ltd. Dhanua,Nayanpur, Gazipur. Tel : 01713-013126 Fax: 01713-013127. Head office: 36 Shaheed Tajuddin Ahmed Sarani Tejgaon Industrial Area , Dhaka-1208. Tel: 9897816, 9897817-20. Fax: 880-2-8826086. Sponsor: KOHINOOR GROUP of company LTD. Product mix: a) Knitted grey fabrics : Plain single Jersey, Heavy jersey, Polo pique, Lacoste, Rib & Interlock double jersey, Drop needle, 2/3 Thread fleece( Brushed/ Unbrushed), Stripe fabric, French terry, Collar & cuff etc. 100% cotton, 15% viscose + 85% cotton,10% viscose + 90% cotton, 30% viscose + 70% cotton, 100% polyester, Spandex etc. b) Knit Garments: T-shirt, polo shirt, sweat shirt, Golf shirt, cardigan, Jogging suit, Short/ Trouser, Legging, Children wears & Fashion dress etc. 6

  7. Poduction capacity: Production capacity Production actual Production capacity Actual Production Production capacity : : : : : 12tons/day (Knitting). 7-8tons/day. 15tons/day (dyeing). 13-14tons/day. 1600000 pcs/month(Garments) Final product: Long sleeve/ Short sleeve T-shirt, Polo shirt, Ladies wear, Sports Wear, Tank tops, Kids wear, Trouser, Pants, Jacket, Children Wear etc. Project area: 25 acre(land premises), 415000sqft(Industrial building area) Total manpower at a glance: 1800(Technical&professional) Different departments: 1.Production oriented department : Knitting. Batching. Dyeing lab. Dyeing floor. Chemical house. Finishing. Quality control. Finished ware house. Maintenance. Utility. 2. Supporting department : Procurement.  Marketing.  HRD.  Finance & accounting. Personnel administration.  Security. 7

  8. Physical infrastructure: Physical infrastructure of REEDISHA KNITEX LTD. is a simple one. It is fabricated by steel structure, somewhere it is R.C.C & brick wall structure. Building wise location list : Sl no. Name of building Name of floor Name of unit Single storied building 40,000 sqft 05 generators, 02 boilers, 05 compressor and others 01. Utility Dyeing Single storied building 70,000 sqft Dyeing, chemical store and laboratory 02. Ground floor Circular knitting and grey fabric store 03. Knitting 90,000 sqft 03 storied buliding 1stfloor(master unit) Cutting, sewing , finishing and quality 2ndfloor Sample section, accessories store and finished cartoon Security building 6,000 sqft 03 storied buliding Ground floor Security officer and visitors room 04. 1stfloor Mens prayer hall and security officer rest room 2ndfloor Officers mess Adminstrative building 9,000 sqft Ground floor Admin and store office 05. 1stfloor Directors chamber 2ndfloor Conference room and rest house 8

  9. 3rdand 4thfloor Officers dormitory Warehouse 02 storied building 22,000 sqft Ground floor General engineer and fabric store 06. 1stfloor Fabric and Ex fabric store Ground floor Embroidery and chemical store 07. Garments building 07 storied building 1,89,000 sqft 1stto 5thfloor Separate an complete garments unit 6thfloor Workers dining and canteen Finished cartoon store, training room, women’s prayer hall Printing section Shed building-08, 12,00 sqft Printing shed 08. Shed Building-09 Wastage godown 09. Shed Building-10 Security forces rest room 10. Shed Building-11 ETP building 11. Shed Building-12 Day care centre 12. Remarks: Reedisha Knitex Ltd. is a member concern of Kohinoor Group of companies, a leading house & Commerce in Bangladesh,having printing & packaging Industry, paper manufacturing unit,country wide network of color film processing laboratory units, representing world famous Fuji color Film products, personal,hygiene products manufacturing & real estate development etc. 9

  10. Chapter Two MAN-POWER MANAGEMENT 10

  11. ORGANOGRAMS ORGANOGRAMS Adminstration: Chairman & Managing Director Director Finance Executive Director Deputy general manager General manager Manager Executive officer Adminstrative officer Computer section Store Time section Security section Transport section 11

  12. Production: General Manager(Dyeing) A.G.M (Dyeing) A.G.M (Knitting) Dyeing Manager Senior Production officer Senior Production officer Production officer Production officer Finance: Director Finance Manager (Commercial) Accounts officer Purchase officer Import officer Export officer 12

  13. Management system: The company has skilled administration, management and marketing team guided by proficient, dexterous & experienced leaders to 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 International standard environment & equal opportunity is the keys for achieving comprehensive competence in all level of the organizational Hierarchy. Shift change 3 shift per day. a) Day shift b) Afternoon shift c) Night shift : from 8 A.M.-3 P.M. : from 3 P.M – 11P.M : from 11P.M.-8 A.M. Shift is changed for each employee in the production floor after every 7 days. Responsibilities of production officer: 1. To give dye-line or the programme slip according to daily production plan. 2.Batch preparation and Ph check. 3.Control of supervisor, operator, asst.operator & helper of dyeing floor. 4.To match shade in connection with fabric quality. 5.To find out fabric fault as early as possible. 6.To rectify the finished fabric which rejected from quality control department. 7.To check daily production report. 8.To study dye & chemicals nature delivery by the manufacture and apply them correctly to the production to get best product. Job description: Title Dept./section Report to Job summary : Production officer. : Dyeing. : Sr.Production officer. : To plan, execute & follow up the production activities & control the quality production with related activities. Title Dept./section : Dyeing. Report to Job summary : Sr.Production officer. : Dyeing manager. : To plan ,execute & follow up the production activities & control the quality production with related activities. 13

  14. Technical personnel in dyeing floor: In total there are 13 textile engineers in the dyeing floor. The posts they are occupying are mentioned below 01. General Manager 02. Asst. General Manager 03. Manager(2 posts) 04. Senior Production Officer(5 posts) 05. Production Officer(4 posts) Remarks: In this dyeing plant all the P.O , S.P.O & P.M. are technical person. Thats why, efficiency of this section is very high. 14

  15. Chapter Three MACHINE DESCRIPTION 15

  16. FLOOR LAYOUT FLOOR LAYOUT Reedisha Knitex Limited. at first started the project with only a dyeing floor with 14 dyeing machine and one finishing line only. With the extending demand for their quality fabric products all around the world there was a need for expanding their available capacity. From this thought a new floor of atmospheric pressure dyeing machine floor was developed. Both these floors are running in full swing to give the most of the production it can handle. Reedisha Knitex Limited. is equipped with the worlds most advanced dyeing and finishing equipments. Among them the worth to be mentioned are the world famous brand names like the “Thies”, “Fong’s”, “Dilmenler”, “Monforts”. The machines are all set according to a definite plan to increase the productivity. The layout plans are done by very professional and skilled persons. To understand the machinery functions it’s very important to know their location in then factory. For this purpose the layout of two floors are given in the following section. Layout description of old floor: 01. Maintenance department 02. Dilmenler Dyeing m/c 03. Dilmenler Dyeing m/c 04. Fong’s Dyeing m/c 05. Fong’s Dyeing m/c 06. Dilmenler Dyeing m/c 07. Thies Dyeing m/c 08. Dilmenler Dyeing m/c 09. Fong’s Dyeing m/c 10. Thies Dyeing m/c 11. Thies Dyeing m/c 16

  17. 12. Thies Dyeing m/c 13. Thies Dyeing m/c 14. Thies Dyeing m/c 15. Fong’s Dyeing m/c 16. Color kitchen 17. Manager’s room 18. Batch section 19. Slitting machine 20. L.K & L.H Stenter 21. Ferraro compactor 22. Fabric inspection table 23. Q. C department 24. Toptex dryer 25. Monforts stenter 26. Montex compactor Lay out description of new floor: 1. Toilet zone 2. Dilmenler Dyeing m/c 3. Dilmenler Dyeing m/c 4. Dilmenler Dyeing m/c 5. Dilmenler Dyeing m/c 6. Dilmenler Dyeing m/c 7. Dilmenler Dyeing m/c 8. Atta sample dyeing m/c 9. Atta sample dyeing m/c 10. Bianco squeezer 11. Enzyme room 12. Dilmenler dryer 13. Tubetex 14. Inspection table 17

  18. MACHINERIES AT A GLANCE MACHINERIES AT A GLANCE Total machineries: Department Total no. of m/c M/c Type No. of m/c Batching 02 Turning m/c 02 Grey inspection 02 Grey inspection m/c 02 Dyeing 22 Winch m/c 08 Finishing 08 Hydro extractor m/c 01 Open Squeezer 01 Slitting m/c 01 Open Compactor 01 Tube Compactor 01 Dryer 02 Padder 01 18

  19. Machineries of Dyeing(Old floor): M/c sl. no. Name Brand Make Capacity(Kg) 01 Sample dyeing m/c Dilmenler Turkey 25 02 Sample dyeing m/c Dilmenler Turkey 25 03 Sample dyeing m/c Fong’s Hong kong 10 04 Sample dyeing m/c Fong’s Hong kong 60 05 Sample dyeing m/c Dilmenler Turkey 25 06 Sample dyeing m/c Thies Germany 50 07 Winch Dilmenler Turkey 150 08 Winch Fong’s Hong kong 250 09 Winch Thies Germany 250 10 Winch Thies Germany 500 11 Winch Thies Germany 500 12 Winch Thies Germany 750 13 Winch Thies Germany 1000 14 Winch Fong’s Hong kong 1500 19

  20. Machineries of dyeing (New Floor): M/c Sl. No. 01 Name Brand Atta Make Taiwan Capacity(kg) 10 Sample Dyeingm/c Sample dyeing m/c Winch Winch Winch Winch Winch Winch 02 Atta Taiwan 10 03 04 05 06 07 08 Dilmenler Dilmenler Dilmenler Dilmenler Dilmenler Dilmenler Turkey Turkey Turkey Turkey Turkey Turkey 150 300 300 450 600 900 Machineries of Finishing: SL. No 01 02 03 04 05 06 07 08 Name Brand Bangla Bianco Bianco Bianco Monforts Dilmenler Monforts Tube-tex Make Local Italy Germany Italy Germany Turkey Germany U.S.A Hydro extractor Slitting m/c Open squeezer m/c Padder m/c Dryer Tensionless dryer Open compactor Tube compactor Main parts of a dyeing machine: 1. 2. 3. 4. 5. Kier.(Dye-bath) Heat exchanger. Filter. Hot water reserver. Addition tank. 20

  21. MACHINE SPECIFICATION MACHINE SPECIFICATION Machine number: 01 Machine function: Dyeing (HT) Machine brand: Dilmenler Machine capacity: 25kg Country of origin: Turkey Machine number: 02 Machine function: Dyeing (HT) Machine brand: Dilmenler Machine capacity: 25kg Country of origin: Turkey Machine number: 03 Machine function: Dyeing(HT) Machine brand: Fong’s Machine capacity: 10kg Country of origin: Hong Kong Machine number: 04 Machine function: Dyeing(HT) Machine brand: Fong’s Machine capacity: 60kg Country of origin: Hong Kong Machine number:05 Machine function: Dyeing (HT) Machine brand: Dilmenler Machine capacity:25kg Country of origin: Turkey Machine number: 06 Machine function: Dyeing(HT) Machine brand: Thies Machine capacity: 50kg Country of origin: Germany Machine number:07 Machine function: Dyeing (HT) Machine brand: Dilmenler Machine capacity: 150kg Country of origin: Turkey 21

  22. Machine number:08 Machine function: Dyeing (HT) Machine brand: Fong’s Machine capacity: 250kg Country of origin: Hong Kong Machine number:09 Machine function: Dyeing (HT) Machine brand: Thies Machine capacity: 250kg Country of origin:Germany Machine number:10 Machine function: Dyeing (HT) Machine brand: Thies Machine capacity: 500kg Country of origin: Germany Machine number: 11 Machine function: Dyeing (HT) Machine brand: Thies Machine capacity:500kg Country of origin:Germany Machine number:12 Machine function:Dyeing(HT) Machine brand: Thies Machine capacity: 750kg Country of origin: Germany Machine number: 13 Machine function: Dyeing(HT) Machine brand: Thies Machine capacity:1000kg Country of origin: Germany Machine number:14 Machine function: Dyeing(HT) Machine brand: Fong’s Machine capacity: 1500kg Country of origin: Hong Kong 22

  23. Dyeing machine features: M/C no Brand Capacity (Kg) Minimum liquor reqd. 160 Addition tank capacity(LT.) 40 Reserve tank capacity(LT.) Winch speed Pump speed 01 Dilmenler 25 - 100 90 02 Dilmenler 25 160 40 - 100 90 03 Fong’s 10 80 15 - 100 90 04 Fong’s 60 200 50 - 150 90 05 Dilmenler 25 160 40 - 130 90 06 Thies 50 180 30 - 150 90 07 Dilmenler 150 500 150,150 900 230 80 08 Fong’s 250 800 80,150 1500 250 80 09 Thies 250 800 130 2000 250+ 80 10 Thies 500 1600 250 3100 250 80 11 Thies 500 1600 250 3100 250 80 12 Thies 750 2500 500 5000 250 85 13 Thies 1000 3500 500 6000 250 85 14 Fong’s 1500 6000 450,900 8000 300 80 Specification of finishing machineries: 01.Hydroextractor m/c Model R.P.M Year of made : 2003. Extraction% : Local. : 250-300.s : 60%(apprx.) 23

  24. 02.Slitting m/c Brand Capacity Country of origin : BIANCO : 12,000kg/day : Italy Function: 1.To cut the tubular fabric for opening. 2.Rubber pressure roller removes a slight amount of water. Utility used: Electricity. Controlling points: - Maximum slitting speed is 92 m/min. -For single jersey fabric slitting speed is maintained as 90m/min. -For rib fabric slitting speed is maintained as 60-70m/min. -Production capacity is10 tons/day. 03. Squeezer(Tube form): Brand Capacity Country of origin :Bianco :8,000 kg/day : Italy Main parts: -Squeeze roller(dewatering) -Over feeding roller(to delivers as per feed) -Folding device(to delivers the fabric in folded form) -Softener tray.(to impart soft finish) Utilities used: Electricity. Compressed air. Padder pressure: 5-7 bar. Pressure of 2ndpadding zone: Enzyme wash fabric: 1 bar. 1x1 Rib or Interlock: 2 bar. Main parts : -Revolving platform. -J-box squeezer. Application of softener : In the 2ndpadding zone chemicals are applied when fabrics are seems to be hard. 24

  25. Maximum line speed: 80 m/min. Chemicals used: Detergent, Anti creasing aagent, Softener. Pressure of 1stpadding zone: Enzyme wash fabric Controlling of diameter: Dia is controlled by stretcher & maximum 2-3 inch width can be increased. 05.Dryer There are two dryers are available for the finishing purpose of the knit fabric. 01. Brand Capacity Country of origin : Montex(MONFORTS) :10,000 kg/day : Germany 02. Brand Capacity Country of origin Function: : Dilmenler :10,000 kg/day : Turkey To dry the fabric properly. To dry the fabric without tension. Main parts: 1.Heat chamber. 2.Burner. 3.Blower. 4.Exhaust fan. 5.Synthetic blanket. 6.Folding device. Heating system: Gas fired(Monforts), Steam(Dilmenler). Utility used: -Gas -Electricity -Compressed air -Steam Air pressure: 4 bar (avg) 25

  26. Maximum line speed: 60 m/min. Setting according to fabric construction: Temperature(C) Fabric type Speed (m/min) Overfeed speed(%) 20 Single jersey 15 140 Interlock 10 140 25-30 Rib 10 140 15-20 T/C,P/C,Viscose 20-23 130 40-45 Lacoste 30 140 40-45 Collar 20 140 40-45 Lycra fabric 17 130 45-50 O6.Tube Compactor : Brand Capacity Country of origin : Tube Tex :8,000 kg/day : U.S.A Maximum line speed: 100 m/min Maximum dia: 62". G.S.M : Maximum 20% increase after compacting. Shrinkage: ±5%(max) M/c temperature: 95ºC Production capacity: 8 tons per day. Main function: 1.Dia control 2.G.S.M. controlling 3.Shrinkage removing Utility used: 26

  27. -Gas. -Electricity. -Steam. Sensor position: -On the stretcher. -After compacting unit. -On the conveyor. -Delivery position. 07.Stenter m/c: There are two stenter machines are available. 01. Brand Capacity Country of origin :Monforts :10,000 kg/day : Germany 02. Brand Capacity Country of origin : LK & LH :10,000 kg/day :Taiwan Features: -Heat setting is available only for Lycra fabric. -Width is set in such a way so that it gives the required GSM & shrinkage. -Suitable for open compactor. -Course and wales become align and even distribution by Mahlo in the feed side. -Bowing of fabric become straight. -4 burner,4 chamber,8 blower. -In case of heavy fabric temp 210C and for light fabric it is 180-190C . -Maximum width is not used because pin penetration is difficult and chains are locked. -Over feed speed is maintained as per delivery speed so that it can give the desired quality. -Temperature control depends on shade condition. -In every chamber fabric width should be same. Controlling points: 1.Fabric speed. 2.Fabric width, 3.Temperature. 4.Over feeding speed. Utility used: 1.Gas 2.Electricity. 3.Steam. 27

  28. Settings: Temperature (C) 140-150 180 160 180 190 140-150 Fabric type Single jersey Rib Interlock Lacost T.C Pique **For heat-setting overfeed% is kept 20%. **For heat-setting temp. is kept 180-185ºC. **Overfeed %  Fabric tension  Shrinkage  GSM. Over feeding (%) Max.50% Max.50% Max.50% Max.50% Max.50% Max.50% Speed (m/min) 20-30 20-30 20-30 20-30 20-30 20-30 08. Open compactor : There are two compactors available to finish wide range of knit fabrics. 01. Brand : Toptex(MONFORTS) Capacity :8,000 kg/day Country of origin : Germany 02. Brand Capacity Country : Ferraoro :8,000 kg/day :Italiy Functions: 1.To impart dimensional stability. 2.To obtain required width and G.S.M. Main parts: -Heated cylinder(steam) -Steaming device. -Blanket. -Teflon roller. -Sensor. Overfeed %: upto 50%. Steam pressure: 5-6 bar. Remarks: All the machineries are of state of the art technology so the quality of product is naturally the best. 28

  29. Chapter Four RAW MATERIALS 29

  30. RAW MATERIALS US RAW MATERIALS USED ED To run the production smoothly raw material is a unparallel substances in a oriented textile industry .Materials that goes into final products i.e. raw materials can be categorized as follows: -Grey fabric. -Dye-stuffs. -Chemicals & auxiliaries. Fabric used: Different types of knitted fabrics are dyed in the dyeing floor according to the buyer’s requirements. In the knitting floor fabrics are knitted on specific machines according to design. Then passing the batching section the fabrics come to the dyeing floor. The type of fabrics dyed in the floor is mentioned below: Types: -Single jersey. -Lycra single jersey. -Interlock. -Double jersey. -Polo pique. -Melange. -Rib -Fleece fabric. -Auto-stripper. -Single & Double lacost. Dye-stuffs Used: Different dyes of different brands and tones are used to produce a specific color. There is a comprehensive list of used dyestuffs are given below: 30

  31. Sl no. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Name of dyes used Kirazol BlackB Kiractive BlackB Chemifix Blue F2R Kiractive G. Yellow MERL Kiractive Red ME6BL Bezactive Red S2B Bezactive Blue SFR Drimarine Blue CL5B Drimarine G.Yellow K2R Dromarine Turquoise K2B Remazol Red RR Remazol Blue RR Remazol Yellow RR Imcozin Yellow V4GL Imcozin Blue ERL Disperse Yellow 4G Disperse Yellow F5GL Kiractive Red ME5BL Bezactive Cosmos-S-MAX Drimarine Navy CL-GN Chemicals used: Different types of chemicals and auxiliaries are used. A comprehensive chart is given below: Sl. no Name of chemical used Basic chemicals 1. 2. 3. 4. 5. 6. 7. Salt or Electrolyte 1. 2. 3. Detergent and Scouring Agent 1. 2. Anti foaming Agent 1. Anticreasing Agent Acetic acid(India) Acetic acid(China) Acetic acid(Thailand) Neutracid NVM 200 Soda Ash Hydrogen Peroxide 50% Caustic Soda Salt(Common) Salt(Gluber )Taiwan Salt(Gluber) China Sandoclean PCLF Paste Felosan NOF/NG Anitmussol HTS 31

  32. 1. 2. 3. Premazol JET Setavin ECS Lubatex ECS Peroxide Stabilizer 1. Sequestarent and stabilizer 1. 2. Washing Agent 1. 2. Reactive fixing Agent 1. 2. 3. Reducing Agent 1. Enzyme finishing Agent 1. 2. 3. Optical brightener for cotton 1. 2. 3. Softener weak (Cationic or non-ioninc) 1. 2. 3. 4. Softener non-ionic(Silicon) 1. 2. Dyebath leveling Agent 1. 2. Stabilizer SOF Sirrix 2UD Optavon 4UD Reactive W Claracup S Cibafix ECO Gemfix RNK Permafix RDX Hydrosulphite/Hydrose Biopolish AL Epy Ace Olive x Retrocel PLX Cyno white 4BK Lucophor BMB Cyno white BYB Alcaamine CWS Sapamine CWS Crosoft NBC pearl-CWS Tubingal 1112 Adasil SM/1913 Adasil ME Gemsol SQD Secho SQD Remarks: The annual requirement was not determined because the project’s age was not a year at the time of our training. Annual requirement of dyes & chemical depend on the order of production .But for various reasons such as improper weighting, carelessness of operators ,hydrolysis of dyes, uneven process control, wrong recipe formulation, incorrect batching, improper storage facilities& for different unwanted expenditure , extra dye consumption increased dye & chemical requirement. 32

  33. Chapter Five PRODUCTION PLANNING, SEQUENCES & OPERATIONS. 33

  34. FLOW PROCESS OF PRODUCTION FLOW PROCESS OF PRODUCTION Grey fabric inspection Batching Pretreatment Dyeing Dewatering Tube form Open form Dring Slitting Compacting Drying Inspection Stentering Packing Compacting Delivery Inspection Packing Delivery 34

  35. PRODUCTION PROCESSES PRODUCTION PROCESSES Production parameters: Temp. (C) 100 Process Scouring- bleaching Enzyme wash Time(min) 30 M:L ratio 1:8 PH 10.5 50 70 60 5 30 10 60 1:8 Reactive dyeing light shade Reactive dyeing med. to dark shade Turquise color dyeing Polyester stripping Cotton stripping Polyester dyeing Cotton whitening 10.5 1:6 60-65 10.5 60 1:6 70-80 10.5 90 1:6 90 4.5 30-45 1:8 100 11 30 1:8 130 4.5-5.5 60 1:8 100 30 1:6 BATCHING: Batching instruments: -weight m/c. -Turner m/c. -Sewing m/c. -Trolley. Must be checked in a batching card: -Order no. -Buyer’s name. -M/c no. for each batch. -Lot no. 35

  36. -Turning requirements. -Length of fabric in each tube should be same. Process description : Batch preparation is the process where visually inspected grey fabric are divided into different batches with reasonable quantity in order to make them suitable for dyeing operation. For fabric dyeing batching is very important. Fabric is weighted according to m/c capacity. So that equal amount of fabric is passed through each nozzle of the m/c. for batching it is important-  To make a batch (body, cuff, collar, rib) from the same raw material.  Accurately weighted for correct recipe formulation to avoid dye & chemical wastage. SCOURING & BLEACHING: -Scouring-bleaching is carried out in the same bath and at the same time simultaneously. -Bleaching is not carried out for black shade. -Scouring is carried out for every type of shade. Scouring-Bleaching chemicals: Agent Brand Wetting agent Alkali Ant creasing agent Bleaching agent Felosan NOF/NG Caustic soda Lubatex ECS H2O2 Stabilizer Acid Optavon 4UD Acetic acid Procedure of Scouring-Bleaching process: 1. 2. 3. 4. Firstly the fabric is load on to the bath. Required amount of water is taken to the bath. Wetting agent i.e.NOF, & anticreasing agent i.e.ECS is added. Steam pipes are on & scouring agents (i.e., caustic soda/soda ash) added by the aid of dosing when the temperature reaches at 60C. When the temperature reaches at 60C, then stabilizer is added. Then H202 is added by the aid of dosing system in 10 mins in 70ºCand the material is run for 10-15 mins to reach the temp. 100C. Temperature is then raised to 100C & the process is then carried out for 60 mins depending on the requirements. The liquors are the drained at 75C at 1.5 grade. 5. 6. 7. 8. 36

  37. 60 min 100C 5 min 70C ECS H202 50C NOF Caustic Stabilizer Curve: SCOURING-BLEACHING . Procedure of Hot wash: 1.Water is taken to the bath from hot water reserver. 2.Steam inlet pipes are on for heating dye-bath to 90C 3.Material is run for 10-15 mins. & cooling start & at 75C the bath is drained. Procedure for Acid –Wash: 1.Again new water is taken from hot water reserver. 2.At 60C acid is dosed & run for 15 mins. Then the fabric is rinsed about 5 mins & then bath is dropped. ENZYME WASH: Objects: ٠ To remove hairiness from the material. ٠ This treatment can be done before dyeing & after dyeing. Sometimes double enzyme treatment occurs if buyer wants. ٠ The fabric knitted with carded yarn always requires enzyme wash for obtaining combed effect by biopolishing. This process is very sensitive to PH(4-5) & temperature. Chemical used: Biopolish-AL(1 g/l) 70C x10´ Curve(Enzyme wash): 55C x 60´ 5´ drain Phcheck Enzyme dosing Process: 1.Firstly the Phof the liquor should be checked & it should be within 4 to 5 . 2.Dosing of enzyme in 5 mins. 3.The material runs at 55C for 60 mins. & at 70C for 10 mins. 37

  38. DYEING: Dyeing process that is practiced in Reedisha Knitex Ltd. can be described as following: Cotton Dyeing: Cotton dyeing is the main concern of the factory, mainly cotton dyeing is done in the factory very frequently. Enormous no of different color shades are matched everyday. Some of the most frequent color names are mentioned below: Deep shade: Navy, Red, Black, Green, etc. Medium shade: Khaki, Yellow, Blue, Orange, Olive, Royal, etc. Light shade: Sand, Beige, Stone, Pink, Rose, Purple, Rose petal, etc. Sensitive shade: Red, Black, and Turquoise. Dyeing Programme: As an established factory Reedisha Knitex has developed some exquisite dyeing programs. According to color development the programs are set into the dyeing machine. The programs are given below: M/C programme and S/L number: SL no. Name Pretreatment time(Min) Color dosing time(Min) Runtime(Min) Soda dosing time(Min) 40 40 25 30 40 25 30 Turquoise color 80ºC Critical color 60 ºC L.S.J Light color 60 ºC L.S.J Deep color 60 ºC L.S.J Critical color 60 ºC Any Light color 60 ºC Any Deep color 65 ºC Any Normal white L.S.J White C.V.C Polyester part 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. L.S.J Deep color 65 ºC 12. L.S.J Critical color 65 ºC 13. Critical color 65 ºC 14. Topping normal color 15. Topping Critical color 16. Stripping Color 17. Any Average 60 ºC 18. Any Average 65 ºC 19. L.S.J Average 60 ºC 20. L.S.J Average 65 ºC 60 60 60 60 60 40 40 30 20 15 20 20 15 20 25 25 20 25 25 20 25 60 60 60 20 20 20 25 25 25 30 40 40 40 40 60 60 15 15 15 15 25 25 25 25 30 30 30 30 38

  39. Details dyeing procedure: To understand different dyeing processes here some programmes are described below for 1.Light shade 2.Medium shade 3.Extra deep shade 4.Viscose dyeing The processes are given below: 1.Procedure of Light shade dyeing: Color Fabric type : Pantone number-07000 : 1cm Drawsting Recipe: Chemical g/l % Pre treatment NOF ECS 4UD Caustic H2O2 4BK Acetic Acid 1 0.5 1 2.5 2.5 0.63 1 Dyeing 0.5 0.25 15 SQD ECS Gluber Salt Rema Blue RR Rema Red RR Rema Yellow RR Soda Acetic Acid CCS 0.0416 0.0128 0.03 3 1 0.5 After Treatment 1.5 0.1 CWS Acetic Acid Dyeing flow procedure of Pantone no-07000 color: Water added at 60 º C NOF, ECS and 4UD is added 39

  40. Caustic is added at 60º C Then H2O2 is added at 70 º C Tempeature is raised to 100 º C Runtime 10 min Cooling at 75 º C Water drain Water collect Hot wash Drain Acid wash is given at 60 º C temp for 15 min Drain Water collect PHcheck(PH=4-5) Bio –AL and NOF is added at 55 º C for 60 mins Then temp is raised to 70 º C for 10 mins Rinsing with cold water Sample is cut Water drain Rinse with hot water at 90 º C for 10 min Temp decrease to 80 º C Rinse Drain Water is taken at 80 º C Then ADM and SQD is added at 80 º C Salt is added at 80 º C PHcheck(PH= 6) 40

  41. Runtime for 10 mins Color dosing at 80 º C for 10 min Runtime for 25 mins Soda dosing at 80 º C for 30 min Runtime 40 mins After 20 min a sample is cut Again after 20 mins another sample is cut Bath drop Cold wash Normal hot at 55 º C for 15 mins Rinse Acetic acid and Netra-acid is given at 50 º C for 15 mins Cold rinse ECS & CCS is given at 90 º C for 15 mins then hot wash is given Acetic acid & Netra-acid is given PHcheck(PH=4-5) CWS and ECS at 45 º C for 20 mins Unloading Process curve: Levelling Agent 15 min 15 min 25 min 60ºC PHcheck Runtime20’ Salt Color Soda Dosing Dosing Drop with rinse 10” 41

  42. Rinse: 10 min Acid: 15 min 10 min Acid Hot Wash: 20 min 90ºC 10 min Rinse: 10 min Procedure for medium shade dyeing: Color Fabric type : PORCELAIN. : Lycra single jersey. Recipe: Chemical g/l % Pre treatment NOF ECS 4UD Caustic H2O2 Acetic Acid Bio Al NOF 1 1 1 2.5 2.5 1 1.25 0.1 Dyeing 0.25 0.5 40 ADM SQD Gluber Salt Dri Turquooise CLB Dri Blue HFRL Dri Yellow HF3GL Soda Acetic Acid CCS ECS 0.27 0.192 0.12 8 1 0.5 0.3 42

  43. After Treatment CWS 2 Acetic Acid ECS 0.1 0.3 Dyeing flow process of PORCELAIN color: Water loaded at 60 º C NOF, ECS and 4UD is added Caustic is added at 60 º C Then H2O2 is added at 70 º C Temperature is raised to 80 º C Temperature raised to 100 º C Runtime 60 min Cooling at 80 º C Rinse Water drain Normal Hot wash at 90 º C for 15 min Temperature decrease to 80 º C Rinse Drain Acid wash is given at 60 º C temp for 15 min Rinse Drain Water collect PHcheck(PH=4-5) Bio –AL and NOF is added at 55 º C for 60 mins Then temp is raised to 70 º C for 10 mins Rinsing with cold water Sample is cut 43

  44. Water drain Rinse with hot water at 90 º C for 10 min Temp decrease to 80 º C Rinse Drain Water is taken at 80 º C Then ADM and SQD is added at 80 º C Runtime 10 min G.Salt is added at 80 º C for 15 min PHcheck(PH= 6) Runtime for 10 mins Color dosing at 80 º C for30 min Runtime 25 mins Salt sample cut after 15 min soda dosing at 80 º C for 45 min Runtime 60 mins After 30 min a sample is cut Bath drop (50 mins) Acid wash at 40 º C for 15 min Cold wash ECS & CCS is given at 90 º C for 15 mins Then hot wash is given Acetic acid is given PHcheck(PH=4-5) CWS and ECS added at 45 º C for 20 mins unloading 44

  45. Process curve: Levelling Agent 15 min 30 min 40 min 10’ 10' 80ºC Runtime25’ Salt Color Soda Dosing Dosing Drop with rinse 10” Normal hot: 50ºC Rinse: 10 min Rinse: 10 min Acid: 15 min 10 min Acid Hot Wash: 15 min 90ºC 10 min Rinse: 10 min 45

  46. Procedure for extra deep shade dyeing: Color Fabric type : NOIR CAVIA. : Lycra single jersey. Recipe: Chemical g/l % Pre treatment NOF ECS 4UD Caustic H2O2 Acetic Acid Bio Al NOF 1 1 1 2.5 2.5 1 1 0.1 Dyeing 0.5 0.5 0.2 100 SQD ECS ACID Gluber Salt Kira Black GRE Kira Red ME6BL Kira Yellow MERL Soda Acetic Acid CCS ECS Netracid 6 1.25 1.7 25 1 1 0.3 1 After Treatment 1.5 0.1 0.3 0.2 CWS Acetic Acid ECS Netracid Dyeing flow process of NOIR CAVIA color: Water added at 60 ºC NOF, ECS and 4UD is added Caustic is added at 60 ºC Then H2O2 is added at 70 ºC Temperature is raised to 80 ºC Temperature is raised to 100 ºC Runtime 60 min 46

  47. Temperature is decreased at 80 ºC Cold rinse Water drain Water collect Hot wash at 90 ºC for 15 mins Temperature is decreased at 80 ºC Rinse Drain Acid wash is given at 60 ºC temp for 15 min Rinse Drain Water collect PHcheck(PH=4-5) Bio –AL and NOF is added at 55 ºC for 60 mins A sample is cut at 55 ºC temp Water drain Rinse with hot water at 90 ºC for 10 min Temp decrease to 80 ºC Rinse with cold water at 50 ºC for 10 mins Drain Water is taken at 50 ºC Then SQD and ECS is added M/C run time for 10 mins G. salt is added at 50 ºC PHcheck(PH= 6) Runtime for 10 mins 47

  48. Color dosing at 60 ºC for 20 min runtime 25 mins soda dosing at 50 ºC for 40 min Temperature is raised to 65 ºC Run time for 60 mins After 30 min a sample is cut Bath drop Normal hot at 50 ºC for 15 mins Rinse Acetic acid is given at 40 ºC for 15 mins Cold rinse ECS & CCS is given at 90 ºC for 15 mins Rinse Acetic acid is added PHcheck CWS and ECS at 45 ºC for 20 mins Unloading Process curve: Levelling Agent 15 min 20 min 30 min 65ºC 90ºC PHCheck Runtime25’ Salt Color Soda Dosing Dosing Drop with rinse 10” Normal hot: 50ºC 10 min 48

  49. Acid: 15 min 10 min Acid Hot Wash: 15 min 90ºC 10 min Rinse: 10 min Procedure for viscose dyeing: Color Fabric type : 4569. : Lycra single jersey viscose. Recipe: Chemical g/l % Pre treatment NOF ECS 4UD 1 1 1 3 1 1 1 Viscocolor NOF ECS Acetic Acid Dyeing ADM SQD ECS ACID BRR 1 0.25 1 0.2 0.013 2.142 2.076 Kira Red ME4BL Kira Orange ME2RL G.Salt Soda 80 20 After Treatment 0.5 CCS Acetic Acid ECS 1 0.3 49

  50. Dyeing flow process of 4569 color: Fabric loading at 60 ºC Runtime for 5 min Viscocolor dosing for 10 min Runtime 30min in 80 ºC Rinse for 10 mins Drain Water taken NOF & ECS added Runtime of 10 min at 80 ºC Rinse for 10 min Drain Water taken Acid added at 50 ºC for 15 min Drain Water taken and temperature rise to 60 ºC ADM & ECS is added Runtime for 5 min PH check Dye dosing for 35 min Runtime for 15 min Salt dosing for 45 min Runtime 30 min Soda dosing for 90 mins Runtime for 30 min Shade cut 50

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