INDUSTRIAL ATTACHMENT OF rupa fabrics ltd.

1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF RUPA GROUP LTD.

2. Report On INDUSTRIAL INTERNSHIP Course Code: Tex -4036 Duration: 6 weeks RUPA FABRICS LTD. Kunia, Barobari, Gazipur. Page 2 of 121

3. Objective The main object of our training is to gather the practical knowledge on various textile processes related with the industry. During the training period we have tried to meet the gap between theoretical and practical knowledge. As we are the students of wet processing technology so our main concern was about knitting, knit dyeing, knit finishing & quality control of knitted fabrics?. We have also tried to gather knowledge about machine maintenance and various utility services. Page 3 of 121

4. TABLE OF CONTENT Chapter No. Title Chapter- 1 Introduction page no. 6-8 9 Chapter- 2 Project Description Management System Chapter-3 10-12 Chapter-4 Raw materials 12-15 Chapter-5 16-112 Production Planning & Sequence of operation: 16-34 1.Knitting 2. Batching 3. Laboratory 4. Dyeing Section (Knit Dyeing) 5. Finishing Section 6. Garments 35-36 37-541 42-57 58-71 72-80 Chapter-6 81-86 Quality Assurance System Chapter-7 Maintenances 87-90 Chapter-8 91-93 Utility Services Chapter-9 94 Safety Management Chapter-10 94 Store & Inventory Control Chapter-11 Cost Analysis 95 Merchandising &marketing Social & Environment Information Conclusion 96 Chapter-12 96-106 .Chapter-113 107-109 Page 4 of 121

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6. INTRODUCTION INTRODUCTION By means of practical knowledge it’s not possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equaled important in association with the theoretical knowledge. The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical Attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, stillness about various processing stages. It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, 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 be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at RUPA FABRICS LTD , which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing. Page 6 of 121

7. COMPANY PROFILE COMPANY PROFILE Name : Rupa Fabrics Ltd. Type : 100% Export Oriented Composite Knit Industry. Year of establishment : 2010(Dyeing Section) Investor : Md. Shahidul Islam Location : Kunia, Barobari, Gazipur. Certification & awards : ISO 9001:2000. Production capacity : Knitting: 4 tons/day Dyeing: 13 ton/day Sewing: 50,000 pcs/day Main Production : Basic T-Shirt, Long Sleeve, Sweater, T-Shirt, Polo Shirt, Pajama, Ladies, Kids Knitwear& all kinds of knit Garments & Knit fabrics. E–mail Address :rupa@citechco.net rupafash@bol-online.com Website : www.rupagroup.net Phone : 9292997, 9291704 Page 7 of 121

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9. History of the project: After successful operation in Rupa fabrics Ltd, the owner had decided to start a fully information & technology based along with the social accountability and quality controlled modern readymade composite knit garments industry in large scale. In this connection Shahidul Islam had decided in a resolution to start a company in Kunia, Barobari, Gazipur. Right from inception the policy of the company has been to provide total customer satisfaction by offering quality knitwear in time. To meet the commitments of quality and prompt delivery, Rupa fabrics Ltd Decided to integrate the manufacturing process in a planned manner. Over the years the entire process has been integrated by importing sophisticated machinery from world-renowned manufacturers. Vision & mission of the project The mission and vision of Rupa fabrics 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 Rupa fabrics Ltd. has decided to adopt the following- 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. Page 9 of 121

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11. Man Power Man Power O Organogram rganogram in RUPA FABRICS LTD. in RUPA FABRICS LTD. Knitting section AGM Dyeing & Finishing Section PM Store In charge Supervisor Knitting Master Fitter Fitter Operator Operator GM AGM PM SPO Batch Incharg Finishing Incharge Lab Incharg PO Sewing man Lab Sewing man Technician APO Squeeze Operator Turningm/c Operator Q.C. Technician Superviso Dryer Operator Helper Helper Sr. Operator Astt. Operator Compactor Operator Operator Helper Page 11 of 121

12. 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. Designation & their Responsibilities: General Manager: Report to: Reports to the Board of Directors. Position objective: To direct promote & coordinate the operations of the cooperative in a manner that will optimize the cooperative market share & savings, improve the cooperatives efficiency, help cooperative’s mission & goals making result in outstanding customer service. Position responsibilities: The General Manager’s responsibilities involve supervision, public relation, marketing, profitability & sales, service, reporting, capital requirements & other duties as assigned by the board of directors. Dyeing Manager: Report to: Reports to the General Manager. Position objective: To direct promote & coordinate the operations of the cooperative in a manner that will optimize the cooperative market share & savings, improve the cooperatives efficiency, help cooperative’s mission & goals making result in outstanding customer service. Page 12 of 121

13. Position responsibilities: To promote and managing the safety of their employees and their work environment. Overall supervision of dyeing & finishing section & quality control. The dyeing manager will maintain a positive attitude that promotes team work within the cooperative & a favorable image of the cooperative. Managers also must report failures to follow safety standards by others outside of their departments and take immediate actions to implement controls for situations that are clearly unsafe. Production Officer: Report to: Dyeing Manager. Position objective: To plan execute & follow up the production activities & control the quality production with related activities. Position responsibilities: Overall supervision of dyeing & finishing, dyes chemicals requisition issue & check, program making, sample checking, color measurement. Page 13 of 121

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15. Raw materials Raw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric. Types of Raw Materials: 1. Yarn 2. Fabric 3. Dye stuff 4. Chemical and auxiliaries Raw Materials Sources: Cotton Yarn: 1. ARMAN Spinning Mill. 2. RISING Spinning Mill. 3. THERMAX MELANGE Spinning Mill. 4. NZ Spinning Mill. Polyester Yarn: India Lycra : Singapore, Indonesia, Korea, Japan Fabric : 01. RUPA Fabrics Ltd. 02. Cotton Club (BD) Ltd. Types of fabrics: Single jersey Single jersey with lycra pique Polo pique. Single lacoste Double Lacoste Fleece Rib Rib with lycra 1×1 Rib 2×1 Rib CVC. Polyester. PC. Different Types of Dyes Used In RUPA FABRICS LTD with Their Brand Name: Page 15 of 121

16. Reactive Dye BRAND NAME COUNTRY NAME NAME OF DYE STUFF Remazol Blue RR Remazol Yellow RR Remazol Deep Black GWF Remazol Red RR Remazol Turquoise Blue G Remazol B/Yellow3GL Remazol Blue BB new Remazol Orange RR Remazol Blue RSPL Levafix Rubine CA Gran Levafix Red CA Gran Levafix Olive CA Gran Levafix Fast Red CA Gran Levafix Brillant Red E-4BA Gran Dianix Navy CC Dianix Turquoise S-BG Imcozin Blue E-NR Imcozin Blue V-CR 150% Imcozin Brilliant Red V-F3B Imcozin Brilliant Yellow V-4GL Imcozin Yellow E-3R 150% Bezaktive Blue S-GLD 150 Bezaktive Yellow S-3R 150 Bezaktive Red S-3B 150 Drimarine Yellow K-4G Cdg Terasil Red W-4BS Terasil Navy W-RS Novacron Red FN-R-01 Novacron Yellow F-4G Starfix Black B 150% Starfix Red EP 150% Sumifix Supra Blue E-XF Sumifix Supra Yellow E-XF Sunfix Navy Blue DY-STAR. GERMANY IMPOCOLOR GERMANY BENZEMA SWITZER LAND CLARIANT SWITZER LAND HUNTSMAN SWITZER LAND JIHUA CHINA SUMIFIX JAPAN UN COLOR Different Types of Chemicals Used In Rupa Fabrics Ltd With Their Brand Name: KOREA Page 16 of 121

17. CHEMICAL NAME Wetting agent Levelling agent Anti-creasing agent BRAND NAME FELSON NOF N.D.L.S. Con Marla KT Kapazon H-53 CBB Rucorit Wez Caustic Soda Ash H2O2 Uvitex-BMA Uvitex-BHV Uvitex-BBT Syno White 4Bk Catazyme 200L Acetic Acid MS SIRIX 2UD P cone BIOPOLISH,AVOCEF Cellzyme 335i Sodium Anhydrose Glubar Salt Marla OLS KRCP Rukozen-NZA Dekol ISN Erapon R Nerosoft-JS(an-ionic) Nerosoft-NI(non-ionic) Kappa Soft BD Sandofix-EC Marla PS 100 COUNTRY NAME Germany Switzerland Germany Per Oxide Stabilizer Germany Caustic Soda Ash H2O2 China Chaina Chaina+Korea Switzerland Optical Agent Brightening Korea Germany India H2O2 Killer Acetic Acid China Sequestering Agent India China India Enzyme Sulphate Electrolyte / Salt India Germany Switzerland Germany Detergent Soaping agent China China Softener Bangladesh Stabilizer Germany Disperse Dye Black EX SF Yellow K 4GB Blue KFBL Crimson-XFT D-Red-XFT Orange-HWT Blue BBL Orange F-3R Red KRB Page 17 of 121

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19. Production Planning & Sequence of Operation Production of the industry describe to the below sequentially given which may expresses the working principle of every operation: KNITTING SECTION Knitting: Knitting is the method of making fabric by transforming continuous strands of yarn into a series of interloping loops, each row of such loops forms the one immediately preceding it. Flow chart of knitting Section: Yarn in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device. Knitting Withdraw the rolled fabric and weighting Inspection Numbering Machine Description of Knitting Section: Page 19 of 121

20. No. of m/c 1 M/C Dia 30” M/C Gauge 24 No. Of Feeder 60 No. Of Needle 2256 M/C Type D/J Brand Origin PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG PAI LUNG Taiwan Taiwan Taiwan 2 38” 24 76 2856 D/J 3 34” 24 72 2544 D/J 4 32” 24 64 2400 D/J Taiwan 5 42” 24 126 3168 S/J Taiwan 6 38” 24 114 2856 S/J Taiwan 7 38” 24 114 2856 S/J Taiwan 8 36” 24 108 2712 S/J Taiwan 9 36” 24 108 2712 S/J Taiwan 10 32’’ 24 64 2400 S/J Taiwan 11 36” 24 108 2712 S/J Taiwan Flat Bed machine M/C No : 04 Flat : 54 inch Feeders No : 06 Gauge : 14 Page 20 of 121

21. Image of knitting M/c Raw materials for knitting: Type of yarn Count Cotton 24S, 26S, 28S, 30S, 32S, 34S, 40S Polyester 75D, 72D,100D Spandex yarn 20D,40D, 70D Grey Mélange (C-90% V-10%) 24S, 26S PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S CVC 24S, 26S, 28S, 30S Page 21 of 121

22. Image of Knitting action RUPA FABRIC’S Ltd. produce the following product- Single jersey- a. Single Jersey (Plain) b. Single lacoste c. Double lacoste d. Polo pique Double jersey- a. 1×1 rib (normal) b. 1×1 rib (lycra) c. 2×1 rib . Flat Bed- a. Plain collar b. 3×2 rib. c. Cuff Page 22 of 121

23. Image of Dust Removal Fan of Knitting M/c Interlock M/C: a) Interlock pique b) Mash fabric c) Face/Back rib Page 23 of 121

24. Image of Grey GSM setting cylinder Rib M/C: a) 1*1 Rib fabric b) 2*2 Rib fabric Considerable points to produce knitted fabrics: When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows- - Type of Fabric or design of Fabric. - Finished G.S.M. - Yarn count - Types of yarn (combed or carded) - Diameter of the fabric. - Stitch length Page 24 of 121

25. Image of needle action with yarn Operation procedure: Sample analysis: After receiving an order first step is analysis the fabric. A sample is analysis as per following system. a) Design analysis:- Example: 1 2 3 4 1 2 1 2 Cam set up: Here, = Knit loop = Tuck loop = Miss loop Page 25 of 121

26. 1 2 3 4 Needle arrangement: - 1 2 3 4/ 1 2 3 4// This fabric can by produced by two tuck cam Optimum cam set up: 1 Optimum needle: - 1 2 1 2/ 1 2 1 2// In BKL most of the fabrics are produced by using three track cam. The truck cam set up for different fabric that is usually produced in BKL single jersey knitting machine are given below: S.T.B – PK B – PK In BKL for double jersey machine two Truck cam are generally used to produce Rib, Interlock Thermal, Mini-Thermal, Waffle, Mini-Waffle etc fabric. Inter lock Rib D D 2 Page 26 of 121

27. C Fabric: Single jersey NOTATION DIAGRAM     C                 CAM SETTING ARRANGEMENT ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ Page 27 of 121

28. Image of Cam with Cam box CAM SETTING ARRANGEMENT ∆ ∆ ∆ ∆ ∆ ∆ D ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ C ∆ ∆ ∆ ∆ ∆ ∆ Page 28 of 121

29. Image of Cam box NEEDLE ARRANGMENT HL HL L LS 11 11 22 22 N.B: ∆ = Knit cam H =High butt needle L = Low butt needle 1 = One butt needle 2 = Two butt needle Page 29 of 121

30. Image of Cam setting to the Cylinder Fabric: 2  2 Rib CAM SETTING ARRANGEMENT ∆ ∆ ∆ ∆ ∆ ∆ D ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ C ∆ ∆ ∆ ∆ ∆ ∆ Page 30 of 121

31. Image of Knitting M/c By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed. A. By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. B. By using machine of higher gauge: The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased. C. By imposing other developments: a) Using creel-feeding system. b) Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage. c) Using yarn feed control device. d) Using auto lint removal. Page 31 of 121

32. Image of rolled fabric Production calculation: Production/shift in kg at 100% efficiency: of No RPM     . . ( ) Feeder . 3527 No of Needle SL mm  80 Yarn count Production/shift in meter: / min cm . Course  / Course   cm   . 60  12 RPM No of Feeder Efficiency  / 100 Course Fabric width in meter: . cm Total no of wales   / 100 Needles Wales . Total no of used in knitting   / 100 Wales cm Page 32 of 121

33. Some points are needed to maintain for high quality fabric: a) Brought good quality yarn. b) Machines are oiled and greased accordingly. c) G.S.M, Stitch length, Tensions are controlled accurately. d) Machines are cleaned every shift and servicing is done after a month. e) Grey Fabrics are checked by 4 point grading system Changing of GSM:  Major control by QAP pulley.  Minor control by stitch length adjustment.  Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley moves towards the positive direction then the G.S.M. is decrease. And in the reverse direction G.S.M will increase.  Other m/c in Knitting Section: 01.Gray Inspection M/c, Brand : UZU fabric inspection machine 02.Electric Balance for Fabric Weight. 03.Electric Balance for GSM check. 04.Compressor 2 pieces Image yarn insertion Production Parameter: Machine Diameter; Machine rpm (revolution per minute); No. of feeds or feeders in use; Machine Gauge; Count of yarn; Required time (M/C running time); Machine running efficiency. Relationship between knitting parameter: Page 33 of 121

34. Stitch length increase with decrease of GSM. If stitch length increase then fabric width increase and Wales per inch decrease. If machine gauge increase then fabric width decrease. If yarn count increase (courser) then fabric width increase. If shrinkage increases then fabric width decrease but GSM and Wales per inch increase. for finer gauge, finer count yarn should use. Considerable points to produce knitted fabrics: When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows- -Type of Fabric or design of Fabric. -Finished G.S.M. -Yarn count -Types of yarn (combed or carded) -Diameter of the fabric. -Stitch length -Color depth. Effect of stitch length on color depth: If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted then. Similarly in case of light shade loop length should be relatively smaller Factors that should be change in case of fabric design on quality change: a)Cam setting b)Set of needle c)Size of loop shape Methods of increasing production: By the following methods the production of knitted fabric can be increased – A. By increasing m/c speed: Page 34 of 121

35. Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed. By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. By using machine of higher gauge: The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased. By imposing other developments: a) Using creel-feeding system. b) Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage. c) Using yarn feed control device. d) Using auto lint removal. B. C. E. Faults &Remedies of knitting fabrics 1. Hole Mark: Causes: Holes are the results of yarn breakage or yarn cracks. During loop formation the yarn breaks in the rejoin of the needle hook. If the yarn count is not correct on regarding structure, gauge, course and density. Badly knot or splicing. Yarn feeder badly set. Remedies: Yarn strength must be sufficient to withstand the stretch as well as uniform. Use proper count of yarn. Correctly set of yarn feeder. Knot should be given properly. 2. Needle Mark Causes: When a needle breaks down then needle mark comes along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies: Needle should be straight as well as from broken latch. 3. Sinker Mark Causes: When sinker corrode due to abrasion then some times can not hold a new Page 35 of 121

36. loop as a result sinker mark comes. If sinker head bend then sinker mark comes. Remedies: Sinker should be changed. 4. Star Mark Causes: Yarn tension variation during production. Buckling of the needle latch. Low G.S.M fabric production. Remedies: Maintain same Yarn tension during production. Use good conditioned needles. 5. Drop Stitches Causes: Defective needle. If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook. Take-down mechanism too loose. Insufficient yarn tension. Badly set yarn feeder. Remedies: Needle should be straight & well. Proper feeding of yarn during loop formation. Correct take up of the fabric & correct fabric tension. Yarn tension should be properly. 6. Oil stain Causes: When oil lick through the needle trick then it pass on the fabrics and make a Line. Remedies: Ensure that oil does not pass on the fabrics. Well maintenance as well as proper oiling. Dear Madam or Sir: 7. Pin hole Causes: Due to break down or bend of the latch, pin hole may come in the fabric. Remedies: Change the needle. 8. Bairre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) stripe(s). Causes: Page 36 of 121

37. This fault comes from yarn fault. If different micro near value of fiber content in yarn. Different lusture, dye affinity of fiber content in yarn. During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics. In draw fame different similar classes sliver is mixed and make one sliver. Remedies: We can use this fabric in white color. 9. Fly: Causes: In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies: Blowing air for cleaning and different parts after a certain period of time. By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor. Over all ensure that lint does not attach to the fabric. 10. Yarn contamination Causes: If yarn contains foreign fiber then it remains in the fabric even after finishing, If lot, count mixing occurs. Remedies: By avoiding lot, count mixing. Fault less spinning Yarn Faults: Neps. Slubs. Yarn count. Thick/Thin place in yarn. Hairiness. Batching Batching is the process to get ready the fabrics that should be dyed and processed for a Particular lot of a Particular order. Batch Management: Page 37 of 121

38. Primarily Batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing Manager. Some time Planning is adjusted according to m/c condition. Batch process follow-up: Grey fabric inspection Batching Fabric Turning Storing for dyeing Purpose of Batch Section: To receive the grey fabrics roll from knitting section or other source. To turn out the tubular fabric in its grey stage and to safe the face side of the fabric from any type of friction during the time of dyeing. To prepare the batch of fabric for dyeing according to the following criteria- Order sheet (Receive from buyer) Dyeing shade (Color or white, light or Dark) M/c available Type of fabrics (100% cotton, PC, CVC) Emergency To send the grey fabric to the dyeing floor with batch card. To keep records for every previous dyeing. Criteria of proper batching: -To use maximum capacity of existing dyeing m/c. -To minimize the washing time or preparation time & m/c stoppage time. -To keep the no. of batch as less as possible for same shade. -To use a particular m/c for dyeing same shade. Page 38 of 121

39. Fabrics Faults Identification: Hole Mark: Five are acceptable. Needle Mark: five are acceptable. Visualize on the face side of the fabric. Sinker Mark: These problems are not acceptable. It is Visualize on the back side of the fabric. Patta: acceptable for only white color producing. Star Mark: Five are acceptable. Thick and thin place. Lycra out. Loop hole. Oil spot.  Drop Stitches LABORATORY Lab department: Lab dip is a process by which buyers supplied swatch is matched with the varying dyes percentage in the laboratory with or without help of “DATA COLOR” Page 39 of 121

40. Lab dip plays an important role in shade matching & and detaching the characteristics of the dyes and chemicals are to be used in the large scale of production so this is an important task before bulk production Lab Working Procedure: Lab dip receive ↓ Input id number entry ↓ By reference ←Recipe making→ from data color ↓ Recipe calculation ↓ Pipetting ↓ Fabric weighting & fabric input ↓ Fabric input into dye bath for dyeing ↓ Unloading ↓ Cold wash ↓ Hot wash→ with chemical ↓ Hot wash→ normal water ↓ Acid wash→ normal water ↓ Dryer ↓ Ironing ↓ Shade matching ↓ Shade ok ↓ Lab dip cutting ↓ Submit to buyer ↓ Buyer approval OK Send to floor . Not OK Page 40 of 121

41. Available Stock Solutions: Red – 0.1%, 0.5%, 1.0%, 2.0% (very common) Yellow – 0.1%, 0.5%, 1.0%, 2.0% (very common) Blue - 0.1%, 0.5%, 1.0%, 2.0% (very common). Preparation: To prepare 0.1% Stock solution, it is necessary to mix 0.1 g dye and 100 cc water. To prepare 0.5% Stock solution, 0.5 g dye stuff is mixed with 100 cc water. To prepare 1.0% & 2.0% Stock solution similar procedure is followed. To prepare 10% Stock solution of Soda ash, 10 g Soda is mixed with 100 cc water. Depth of shade: Rupa Fabrics Ltd. Produces 0.1% to 5% shade for the goods. 2.0%for deep shade. 1.0%for medium shade. 0.5%for deep shade. 0.1%for light shade.  Usually following calculations are followed :- Recipe % × Sample Weight Dye Solution = (cc). Stock solution % Recipe % × Liquor) Salt = (gram per liter). 1000 Recipe % × 100 × Liquor) Page 41 of 121

42. Soda Solution = (cc). (1000 × Stock solution %) SAMPLE CALCULATION FOR 0.5% SHADE Sample wt. = 5 mg Material liquor ratio = 1: 10 Total liquor (5  10) = 50 cc 5  0.5%  Dye solution required = ------------------- = 2.5 cc 1 % 50  25 Salt solution required = ------------------- = 6.25 cc 20  10 50  10 Soda ash solution required = ------------------- = 2.5 cc 20  10 Water required {50 - (2.5 + 6.25 + 2.5)} = 38.75 cc Procedure for100 % cotton fabric: 1.Calculate the recipe. 2.Weight the fabric. 3.Take the beaker keep the fabric into the beaker. 4.Then the dyes, chemicals & required amount of water take in to the beaker by the digital pipetting. 5.Then weight the salt by the electric balance and add in to the beaker. 6.Then the beaker set in to the lab dyeing machine for dyeing. 7.Start the program for dyeing the whole dyeing time 60 min at 60 °C temperature. (The dyeing time and temperature depends on which classes of dyes are used for dyeing.) Page 42 of 121

43. 8.After 30 min add the then add the soda ash. By pipetting. 9.Again run the program next 30 min at the same temperature. 10. Finished the dyeing time then the sample taken from the beaker first Hot wash & then cold wash. 11. Then acid wash as for neutralization. 12. Then soaping required soap solution 10 min at 90° C temperature. 13. After the fabric again cold. 14. Then dry the lab dip and compare with the standard. LABORATORY MACHINERIES WITH ITS SPECIFICATION: Machine Type : Color Fastness to Rubbing (Crook Meter) Brand : ATLAS Test Method : ISO 105-C06, ISO105-F09 Machine Type : Spectra Photo meter Brand : Data Color Manufacturer : U. S. A Test Name : Color fastness to Wash (Rota Wash). Brand : ATLAS No.of m/c : 01 Test Method : ISO 105-C06, ISO105-D02 Test Name : Color Fastness to Perspiration Brand : Paramount Origin : U.K No.of m/c : 02 Test Method : ISO 105-C06 Test Name :PH (Ph Meter) Brand :HANNA Origin :ROMANIA Lab Dip m/c: Brad name : Starlet Origin : U.S.A Page 43 of 121

44. M/C No : 02 Color Matching Cabinet (Light box): Light Box no: 02 Brand : Verivide Origin : U.K Light Source: Day Light (D-65) UV TL-84 * CWF Machine Type : Washing M/C. Brand : SIEMENS Manufacturer : JARMAN Machine Type : Weight Balance M/C Brand : KERN Dyeing Page 44 of 121

45. Section DYEING: Dyeing is the process of imparting colors to a textile material in loose fiber, yarn,cloth or garment form by treatment with dyes. General Classification of dye stuff (Dyers Point of view): Water soluble Mineral Coloring matters Dyes Pigment Mineral Water insoluble Vat Azoic Page 45 of 121

46. Direct Acid Vat Sulpher Disperse Basic Reactive Optical whitener Flow Chart For Dyeing: Grey fabric receive from knitting section Batching Select m/c no Fabric loading Select production program Pre treatment Select recipe for dyeing Recipe confirm by D.M / S.P.O Dyeing Post treatment Unload MACHINE DESCRIPTION DYEING FLOOR Dyeing Machines: The RUPA Fabrics Ltd. There are 14dyeing machines. Among them 5 are sample dyeing machine and 9 are bulk dyeing machine.The description and specifications of the machine are given below- Machine Type 01 Name of the machine : Sample Dyeing Machine Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 10 Kg Page 46 of 121

47. Hydraulics Test Pressure : 540 KPa Design pr. : 350 KPa Design temp. : 1400C Machine Type 02 Name of the machine : Sample Dyeing Machine Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 30 Kg Hydraulics Test Pressure : 540 KPa Design pr. : 350 KPa Design temp. : 1400C Machine Type 03 Name of the machine : Sample Dyeing Machine Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 10 Kg Hydraulics Test Pressure : 520 KPa Design pr. : 350 KPa Design temp. : 1400C Machine Type 04 Name of the machine : Sample Dyeing Machine Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 30 Kg Hydraulics Test Pressure : 540 KPa Design pr. : 350 KPa Design temp. : 1400C Machine Type 05 Name of the machine : Sample Dyeing Machine (ALLFIT – 1T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 120 Kg Hydraulics Test Pressure : 840 KPa Design pr. : 350 KPa Design temp. : 1400C Page 47 of 121

48. Machine Type 06 Name of the machine : Winch Dyeing Machine (Innoecology) Brand Name : Brazzoly Manufacturer :Italy Capacity : 1000 Kg Hydraulics Test Pressure : 250 KPa Design pr. : 350 KPa Design temp. : 1400C Machine Type 07 Name of the machine : Winch Dyeing Machine (ECO -1T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 250 Kg Hydraulics Test Pressure : 250 KPa Design pr. : 350 KPa Design temp. : 1400C Machine Type 08 Name of the machine : Winch Dyeing Machine (ECO – 2T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 500 Kg Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell),ATM KPa (tube) Design temp. : 1700C Machine Type 09 Name of the machine : Winch Dyeing Machine (ECO -3T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 750 Kg Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell), Design temp. : 1700C Machine Type 10 Name of the machine : Winch Dyeing Machine (ECO -4T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Page 48 of 121

49. Capacity Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell), Design temp. : 1700C Machine Type 11 Name of the machine : Winch Dyeing Machine (ECO -6T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 1500 Kg Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell), Design temp. : 1700C Machine Type 12 Name of the machine : Winch Dyeing Machine (HSJ -1T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 280 Kg Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell) Design temp. : 1700 Machine Type 13 Name of the machine : Winch Dyeing Machine (HSJ -2T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 560 Kg Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell) Design temp. : 1700C Machine Type 14 Name of the machine : Winch Dyeing Machine (HSJ -3T) Brand Name : Fongs Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD. Capacity : 840 Kg Hydraulics Test Pressure : 1100 KPa (Shell) Design pr. : 700 KPa (Shell) Design temp. : 1700C : 1000 Kg Page 49 of 121

50. Image of dyeing machine Pretreatment Process of SCOURING/ BLEACHING: Fabric Load ↓ Chemical Dozing (Detergent+Anticreasing+Stabilizer+Sequstering) at 50 0C (5 min) ↓ Caustic Soda 500C (10min) ↓ H2O2 700C (5min) ↓ Run time at 98 0C (60min) ↓ Cooling at 780C ↓ Scouring sample check Page 50 of 121