Industrial Training & Practices”
1st June’09 to 12th July’09.
Introduction
Padma Poly Cotton Knit Fabrics Ltd. is one of the 100% export oriented industry in Bangladesh. 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.
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, despite all these industrial attachment help us to be familiar with the technical support of modern machinery, skill ness about various operation stages.
It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, production cost analysis, inventory management, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned can not e achieved successful 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.
I have prepared this report as required in completion of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for our future carrier. In Padma Poly cotton fabrics Ltd. I have completer 8 (eight) Weeks long industrial training in the sections, namely-Kilting, Dyeing, Finishing & Garments.
Location of the Mill.
Project Description
General Information about the mill:
| Objects | Description |
| Name of the company | Padma Poly Cotton Knit Fabrics Ltd. |
| Status | Private Limited Company. |
| Type | 100% Export Oriented Knit Composite Knit Dyeing Factory. |
| Year of establishment | 1995. |
| Location | Factory: North Begun-bari, |
131, Tejgaon I/A, Dhaka – 1208.
H. Office: 5, Rajuk Avenue Dhaka – 1000.
Tel: 9460917-20. Fax: 880956204
E-mail: Padma@bd.comOwner of the millMr. Khan Mohammod Amir (Director).InvestorsMrs. Parveen Sultana Khan.Annual production7200-8000 tones.CapacityKnit dyeing 25 tones / day.Actual productionKnit dyeing 20 tones / day (Approx.).Authorized capital100 cores taka.Total turn over20 Lac. US dollar / year (Approx.)
Vision:
To be one of the leading composite textile mill in Bangladesh.
To build a true marketing led enterprise with motivated workforce, innovative vision and more vale added produce portfolio, customer sails factiom and under standing global market.
Mission:
Padma Poly Cotton Knit Fabrics Ltd. Firmly believes that in final analysis, they are accountable to each of the constituents with whom they interact namely their employs, customers and business associates.
History of the Project:
First of all it was a printing press in 1993, then the owner planned to produce fabric specially knit fabrics in 1995, after that they started to dye the fabric in the middle of 1995. When they had got the approval of buyer. They started to produce the garments by subcontract. Then they decided to set up garments section.
In the year 1996 they started to produce garments by their own factory. In the year 1997 they started to print the fabric according to the buyer requirements. After that embroidery was started in the middle of 1997. Now they are self established. At present they plan to set – up spinning factory to produce yarn.
History of the project Development:
| Year | Details |
| 1995 | Establishment of the mill. 1st installment of the machinery. |
| 1999 | Installment of the 800 kg and 200 kg H.T.H.P m/c. |
| 2003 | Start of the construction of 3rd and 4th Floor. Installment of the 1800 kg H.T.H.P machine. |
| 2004 | Start of the construction of 4th and 5th floor. |
| 2005 | Installment of the 6 winch m/c and De-watering m/c. |
| 2006 | Starting a new project of dyeing and finishing and washing. |
| 2008-9 | Start of the construction of 6th floor and Mogbazar site. |
Physical Infrastructure:
The total area of this industry is 3.34,00 square feet. It is actually a sixth floor production unit. The ground floor is designed with dyeing and finishing section. The section is placed on the 1st floor.
The maintenance section is placed on the sixth floor. The batch section is also placed on the sixth floor. The other floors are designed with cutting, sewing, Printing, Embroidery and Garment finishing etc.
Production Capacity:
Knitting : 12 tones per day
Dyeing : 20 tones per day
Garment : 40,000 pieces per day.
Remarks:
The objects of the project are to produce knit wear and knit garments. The industry has the ability to maintain the finest quality products. To fulfill the buyer requirements the factory has strong management and modern machineries.
Manpower Management
Management System:
Padma Poly Cotton Knit Fabrics Ltd. has a central controller i.e. Chairman / Managing Director who controls the factory, besides these all the departments are controlled by respective departmental chief.
| General Manager (Production) |
| AGM Knitting | AGM Dyeing | Manager Lab | Manager Finishing |
| Manager Knitting | Manager Dyeing | In-Charge Lab-2 | In-Charge Finishing |
| Sr. Prod. Officer | Sr. Prod. Officer X2 | Asst. Technical Officer X3 | Sr. Supervisor X3 |
| Prod. OfficerX3 | Prod. OfficerX6 | Lab Asst. X6 | Supervisor X6 |
| Sr. supervisorX3 | Sr. supervisorX6 | Lab Helper X6 | Operator X20 |
| SupervisorX6 | SupervisorX8 | Helper X30 | |
| Feeder X12 | Operator X24 | ||
| Operator X40 | Helper X24 | ||
| Helper X40 |
Responsibilities:
General Manager (GM):
To plan, apply and administrative functions.
To set up price for the product.
To deal with the buyer and merchandiser.
To arrange necessary facilities for the buyers demand.
To follow up the instruction of managing director and chairman.
Manager:
To plan for the sequence of production.
To arrange necessary raw materials for the production.
To follow the production and give solution to the production problems.
To supervise the personal working under him.
To find out the possible reasons which are responsible for less production?
To follow fup the instruction of managing director and executive director as well.
Production Officer:
To follow up the instruction of production manager.
To follow up the production process.
To set instruction for the supervisors.
To guide the supervisors.
To find out the probable causes for less production.
Should discuss with the production manager about today’s production and tomorrows plan.
Shift in Charge:
To follow the worker’s movement.
Should discuss with the production officer about what is happening in the floor.
To maintain the production sequence.
To cheek the sample at certain time interval.
To set programs for the supervisions.
Supervisor:
To guide the operators and helpers working at the production unit.
To motivate the workers when necessary.
To check the sample.
To check the materials list whether they are at right quantity or not.
Total manpower with different departments:
| Section / Department | Number of People |
| Administration | 320 |
| Knitting | 176 |
| Dyeing | 202 |
| Dyeing & Finishing | 167 |
| Printing | 154 |
| Embroidery | 49 |
| Maintenance | 58 |
| Washing | 26 |
| Sewing | 1441 |
| Cutting | 214 |
| Quality | 250 |
| Finishing | 296 |
| Stuff | 164 |
| Security | 75 |
| Others | 8 |
| Total | 3600 |
Remarks: The management system plays a important role for an organization. The Padma Poly Cotton Knit Fabrics Ltd. has a very good organized management system. Padma Poly Cotton Knit Fabrics Ltd. gradually increasing the moreover of the factors
Machine Description
Dyeing Machine Description:
| Dyeing m/c type | Machine Quantity |
| Winch Dyeing Machine (H.T.T.P) | 06 |
| Winch Dyeing Machine (Sample) | 06 |
| Winch Dyeing Machine (Atmospheric) | 14 |
| Machine No. | 01 | 02 | 03 | 04 |
| Name of the m/c | Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c |
| Brand Name | THIES | KYUNG HUN | THIES | THIES |
| Origin | Germany | Korea | Germany | Germany |
| Capacity | 400 kg | 50 kg | 400 kg | 20 kg |
| Year of Manufacturing | 1995 | 1998 | 1995 | 1995 |
| No. of Nozzle | 4 | 1 | 4 | 3 |
| Nozzle Pressure | 0.5 Bar | 0.5 Bar | 0.5 bar | 0.5 bar |
| No. of Motor | 4 | 4 | 4 | 4 |
| Temp. range | Up to 980C | Up to 980C | Up to 980C | Up to 980C |
| Machine No. | 05 | 06 | 07 | 08 |
| Name of the m/c | H.T Winch Dyeing m/c | H.T Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c |
| Brand Name | THESIS | DILMENLER | THIES | THIES |
| Origin | Germany | Turkey | Germany | Germany |
| Capacity | 400 kg | 1800 kg | 600 kg | 400 kg |
| Year of Manufacturing | 1998 | 2003 | 1995 | 1995 |
| No. of Nozzle | 4 | 12 | 6 | 4 |
| Nozzle Pressure | – | – | 0.5 Bar | 0.5 Bar |
| No. of Motor | 4 | 13 | 8 | 4 |
| Temp. range | Up to 1350C | Up to 1350C | Up to 980C | Up to 980C |
| Machine No. | 09 | 10 | 11 | 12 |
| Name of the m/c | H.T Winch Dyeing m/c | H.T Winch Dyeing m/c | High Soft Winch Dyeing m/c | High Soft Winch Dyeing m/c |
| Brand Name | DILMENLER | DILMENLER | WOO YANG | WOO YANG |
| Origin | Turkey | Turkey | Korea | Korea |
| Capacity | 200 kg | 800 kg | 200 kg | 400 kg |
| Year of Manufacturing | 1999 | 1999 | 1995 | 1993 |
| No. of Nozzle | 2 | 8 | 2 | 4 |
| Nozzle Pressure | – | – | – | – |
| No. of Motor | 3 | 6 | 5 | 5 |
| Temp. range | Up to 1350C | Up to 1350C | Up to 980C | Up to 980C |
| Machine No. | 13 | New 1 | New 2 | New 3 |
| Name of the m/c | Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c |
| Brand Name | KYUNG HUN | DILMENLER | DILMENLER | DILMENLER |
| Origin | Korea | Turkey | Turkey | Turkey |
| Capacity | 100 kg | 100 kg | 450 kg | 300 kg |
| Year of Manufacturing | 1998 | 2004 | 2004 | 2004 |
| No. of Nozzle | 1 | 1 | 3 | 3 |
| Nozzle Pressure | 0.5 Bar | 0.5 Bar | 0.5 Bar | 0.5 Bar |
| No. of Motor | 3 | 3 | 3 | 3 |
| Temp. range | Up to 980C | Up to 980C | Up to 980C | Up to 980C |
| Machine No. | New 4 | New 5 | New 6 | New 7 |
| Name of the m/c | Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c | Winch Dyeing m/c |
| Brand Name | DILMENLER | DILMENLER | DILMENLER | KYUNG HUN |
| Origin | Turkey | Turkey | Turkey | Korea |
| Capacity | 150 kg | 100 kg | 200 kg | 450 kg |
| Year of Manufacturing | 2004 | 2004 | 2004 | 2001 |
| No. of Nozzle | 1 | 1 | 2 | 3 |
| Nozzle Pressure | 0.5 Bar | 0.5 Bar | 0.5 Bar | 0.5 Bar |
| No. of Motor | 5 | 3 | 3 | 3 |
| Temp. range | Up to 980C | Up to 980C | Up to 980C | Up to 980C |
| Machine No. | SI | S2, S3, S4, S5 | S6 |
| Name of the m/c | H.T. Sample Winch Dyeing m/c | Sample Winch Dyeing m/c | H.T. Sample Winch Dyeing m/c |
| Brand Name | THIES | BANGLA | HAB DONG |
| Capacity | 50 kg | 25 kg | 20 kg |
| Year of Manufacturing | 1995 | 2003 | 1995 |
| No. of Nozzle | 1 | 4 | 1 |
| Nozzle Pressure | – | 0.5 Bar | – |
| Origin | Germany | China | Korea |
| No. of Motor | 3 | 2 | 3 |
| Temp. range | Up to 1300C | Up to 980C | Up to 1300C |
FINISHING MACHINE
Finishing machine description:
| Machine Name | Hydro-extractor | De-watering m/c | Sutter Slitter | Dryer (tube) | Dryer (Open) |
| M/C No. | 02 | 02 | 03 | 02 | 02 |
| Model No. | DMS 07 | R 02 | 940727 | DMS 053 | |
| Serial No. | KC 1250 2003 | K2G 2400 20009 | |||
| Year of Mfg. | 2003 | 2005 | 1995 | 2003 | |
| Brand Name | DILMENLER | BIANCO | BIANCO | RUCKH | DILMENLER |
| Origin | Turkey | Italy | Italy | Germany | Tyrkey |
| Capacity | 125 kg | 8 tones/day | 8 tones/day | ||
| RPM | 60 m/min | 4-30 m/min | 4-30 m/min | ||
| No of Chamber | 2 | 3 | |||
| Application | Open width & Tube fabric | Open width & Tube fabric | |||
| Temperature | 110-2200C | 110-2200C |
STENTER MACHINE:
| Machine Name | BRUCKNER STENTER M/C |
| Machine No. | 1 |
| Model No. | – |
| Serial No. | 72276-0463 |
| Year of Mfg. | 1995 |
| Brand Name | BRUCKNER |
| Mfg. Country | Germany |
| Temperature | 500C – 2500C |
| Capacity | 8 tones / day |
| RPM | 15 – 30 m/min (knit) 15 – 80 min (Woven) |
| Used Utilities | Electricity, Water, Gas, Compact air. |
| No of Chamber | 3 – 7 |
| 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. |
COMPACTOR MACHINE:
| Machine Name | Open Compactor | Open Compactor (New) | Tube Compactor |
| M/C No. | 1 | 1 | 1 |
| Model No. | Compact_ck/240-a | Comptex /FV 200 | Comptex/FV |
| Brand Name | Sparta | Ferraro | Ferraro |
| Manufacturer | Italy | Italy | Italy |
| Temperature | 1100-1400 | 1100-1400 | 1100-1450 |
| Capacity | 4 tons / day | 4 tons /day | 8 tons / day |
| R.P.M | 13-22m /min | 13-22m /min | 16-35m /min |
| Used utilities | Electricity, Steam, Gas, Compact Air | Electricity, Steam, Gas, Compact Air | Electricity, Steam, Gas, Compact Air |
| Application | Open width fabric | Open width fabric | Tube fabric |
| Max. Width | 86” | 86” | 52” |
| Min. Width | 36” | 36” | 16” |
RAISING MACHINE:
| Machine Name | Raising machine |
| Brand Name | Comet |
| Manufacture Country | Italy |
| Temperature | 600-1000 C |
| Capacity | 4 tons / day |
| R.P.M | 20-30m/min |
| Used Utilities | Electricity |
| No. of pin roller | 24(pile-18,c-pile-6) |
| Cylinder R.P.M | 100 |
| Tension | 3 kg |
| Pin type | Both pile and country pile fabric |
Dyeing Lab Machine
The description of machineries of the dyeing lab of Padma Poly Cotton Knit Fabrics Ltd. are given below:
Laboratory Equipments:
Light box
Electronic Balance
Iron
Sample dyeing machine
Lab dip machine
GSM tester
Washing machine
PH tester
Dryer
Crock meter
Spectrophotometer
Light Box:
Issual assessment of color by reflectance and transmission.
Marilee used for shade matching.
4 types of light source are used.
Metamarism of the fabric is checked.
Sometime it may be more such as TL-84, CWD etc.
Brand Name : VITIVIDE
Model : CVC-60
Origin : U.K.
| Symbol | Full Meaning | Functions |
| Ultra Violet | Used for white color matching. | |
| F | Fluorescent light | Metamerism of the fabric is cheeked. |
| TL-84 | Tube light | Metamerism of the fabric is cheeked. |
| LD-65 | Artificial day light | Used for color matching |
Electronic Balance:
Fabrics, dyes, chemical and other auxiliaries can be measures accurately.
Wight range : 0.001 – 121 gm.
Accuracy : 0.001 gm.
|
Model : BL-310
Company : Jams H. Helal and Co. Ltd.
Origin : U. K.
Iron:
Mainly used drying the sample.
Wet sample is placed between the two white fabrics and pressure is given.
A dial is used to indicate the fabric type (Cotton, wool, silk etc.)
Sample Dyeing M/C:
Brand Name : ROACHES
Company : ROACHES
Origin : ENGLAND
No. of Machine : 03
Solvent : Glycerin
Model : HR
No. : 3800
Machine Type : H. T. M/C
Lab. Dip Machine:
Type of fabric processed : Cotton and Polyester.
Brand Name : Mathis Labomate
Company : Werner Mathis AG
Origin : Switzerland.
Features:
Sample can be dyed at 1000 c, 1300 c and more
Glycerin bath is used
18-24 holders are provided.
Main parts:
Program set panel
Glycerin bath
Holder
Holder carrier
Controlling points:
Time
Temperature
R.P.M
Gram Per Square Meter (G.S.M.) Tester:
Used to measure GSM of grey, dyed and finished fabrics.
100 cm fabric is cut and weighted in grams.
Took the final GSM.
Washing machine:
Washing condition and parameter can be controlled.
Model : RS 12 MS
Temperature : 1200 c
Solvent : Water + Glycerin
Brand Name : INDESIT
Company : INDESIT
Origin : Italy.
PH Tester : Digital PH Meter.
Crock meter:
Mainly used for rubbing fastness.
Rub may be wet / dry
Machine Specification:
Brand Name : GUVEN CELIK
Model : S 9011
Origin : Turkey
Dryer machine:
Mainly used for sample dry
Temperature may be up to 2000 c
27 pieces of sample can be easily dry
Machine Name: LAB TECH
Spectrophotometer:
Type : Spectrophotometer
Brand name : Data color
Model : SF 600 plus CT
Software used : Color tools QC, DCI match
Origin : USA
Function: Shade matching & Recipe formulation.
Raw Materials
In Padma Poly Cotton Knit Fabrics Ltd. raw materials used for production are –
Grey fabric
Dyes and
Chemicals.
Grey fabric:
The following of grey fabrics are dyed.
Single jersey.
Heavy jersey
Needle top Interlock
Lycra Single jersey
Single / Double Lacost
Collar & Cuff
RIB
Lycra rib
Fleece fabric
Polo pique
CVC (Chief Value of Colon. 60% Cotton + 40% Polyester = Blended fabric)
PC / TC (The more % of Polyester in the cotton part) (Such as 65%)
Mélange Fabric:
Mélange is a blended knitted fabric generally the blending of Cotton and Viscose. The one pare dyeing of CVC / PC, and then we get Mélange effect.
ECRO Mélange / Silver Mélange : 98% Cotton + 2% Viscose.
Grey Mélange : 85% Cotton + 15% Viscose.
Sources of yarn:
Arif Spinning Mills Ltd. Bangladesh.
Utah Spinning Mills Ltd. Bangladesh.
Square Spinning Mills Ltd. Bangladesh.
Shameen Spinning Mills Ltd. Bangladesh.
Prime Composite Mills Ltd. Bangladesh.
Motin Spinning Mills Ltd. Bangladesh.
New kids Spinning Mills Ltd. Bangladesh.
NRG Spinning Mills Ltd. Bangladesh.
Karim Spinning Mills Ltd. Bangladesh.
Malek Spinning Mills Ltd. Bangladesh.
Zarina Spinning Mills Ltd. Bangladesh.
Filament Yarn:
Polyester
Polyamide
Viscose
Spandex (Lycra)
Sources:
Sudhan, India.
Primayudha, Indonesia.
Sri Shanmugavel Mills, India.
Sources of Lycra Yarn:
Japan.
America.
Korea.
Dyeing Section:
100% Cotton Dyeing.
100% Polyester Dyeing.
100% Viscose Dyeing.
PC & CVC Dyeing.
Lycra mixed Dyeing.
Garments Sections:
Gent’s tops & bottoms.
Lady’s tops & bottoms.
Baby’s items.
• Dyes & Chemicals are imported from Germany, Switzerland, Singapore, India, China etc.
Annual Requirements:
To determine Annual requirement is very tuff. It mainly depends on the buyer order and sub contract order. The higher the buyer orders the higher the production and vice versa.
Padma Poly Cotton Knit Fabrics Ltd. uses the best Quality of raw materials. It produces fabrics from best quality yarn. They also use the best quality dyes.
Dyes and Chemical Name:
| SL. |
N0. Chemical NameSL.
N0. Chemical/Dyes NameSL.
N0.DyesDyes Name1Basic chemicalSalt56Soaping AgentAlcosper AD110SumitomoSumifix Sup.Scarlet 2GH2Soda ash57Lipotol PS-60111Sumifix Sup.T/Blue G3Caustic58Sadopur RSK112Sumifix Sup.Blue EXF4H2 O259Serisoap CA113Sumifix SupNavy Blue EXF5Hydrous60Rucogeu-NZA114Sumifix Sup.Red EFX6Bleaching Agent61Sequesteri-ng AgentInvatex CS115Sumifix Sup.Yellow EFX7Foming Agent62Neocrystal BGS116Sumifix Br. Blue R8Sodium Sulphate63Sirrix 2UD117Sumifix Br.Yellow 4GL9Antifoam-3064Seriquest DEM118Sumifix HF Yellow 4GL10Industrial Salt65Decoster-SQ119Sumifix HF Red G12Albatex FFC66Levelling AgentCibacel DBS120Sumifix HF Red 2813Contrioon S67Neocrystal 200B121Sumifix HF Navy 2G14NK-J-218(Soda Ash)68Drimagin E2R122Sumifix HF Blue 2R15AcidH2SO469Lyoprint RG123Sumifix HF Brown RL16Acetic Acid70Invadine-DIF124Sumifix Sup. Marine EXF17Fomic Acid71Setavin CO125Sumifix Sup. Navy Blue BF18Ruco Acid ABS72Sun Salt RM-400N126Sumifix Sup. Yellow 3RF19Oxalic Acid73Peroxide KillerBactasol AP127Sumifix Sup. Bri Red 3RF20Invatex AC74Invatex PC128Sumifix Orange 3R21Dyapol-Neu(acid)75Croaks N129Sumifix Dark Brown BRS22SiliconCrosoft76Rucorit WEZ130Sumifix Br. Violet B. SPI23Nepton SRE77EnzymeBio.ACE Razzor131ImperialTaifix Red SF 3BT24Ultratex UM New78Bio.Polish EC132Taifix Yellow SF 3RT25Silicon AMZ79Bio.Polish AL133Taifix Black SF BSDT26Ultraphil HMS80Enzyme B-50134Taifix Black SF BT27Cationic SoftenerSaleamine CWS81Bio.Polish SA-500135Taifix Br. Blue RTSPC28Sunsofton NK-0782StabilizerStabilizer Sifa136Taifix Br. Blue Rspecial29Softener JS-10083Neorate PH-100137Taifix Navy Blue BRNT30Crosoft-NBC84Rucostab EP138Evarzal Black-B31Siltoucl-HPJN85 139Evarzal Black GB32Nonionic (white)Sun Softer A30086BrightenerSyno White BNH140Evarzal Red 3BS33Supamine FPS87Syno White BYB141Evarzal Yellow 3RS34Softener ABN88Siba White142TerasilTerasil G/ Yellow W3r35Softener White89Uvitex BHV143Terasil Red W4BS36AnticreaseTexport Gl-50090Uvitex BBT144Terasil Red WWBFS37Texport D-60091Uvitex BAM145Terasil Blue WRBS38Texport D-90092Uvitex ERH146Terasil Blue BG-0239Ciba Fluid c93Scoumer BF-70147Terasil Black SRL40ROK-AC-31594G.S.S.148Terasil Blue BGE-0141Sakatuble STL-C95Ciba DyesCibacron yellow FN2R149Terasil Yellow 4G42Anticrease96Cibacron yellow G2H150Terasil Yellow W4G43Seritube 20097Cibacron Red FN-3G151Terasil Red R44Lubrifil-TFV ( C )98Cibacron Red FNR152Terasil Blue WBLS45Wetting AgentInvadine DA99Cibacron T/HGN153Terasil Navy WRS46Sun Mori CK-2100Cibacron Blue FNR154Terasil Blacks WNS47Pitchrunl 250k101Cibacron yellow F4G155Terasil Red WRS48Sandoelean PCLE102Cibacron Navy WBT156Terasil Red WFS49Nearpon BWLF-CK-1103Cibacron Navy H2G157Terasil Violet BL-0150FixingNeofix R-250(FDR)104Ciba Scarlet F-3G158Terasil Navy GRL-C51Cibafix ECO105Cibacron Br.Blue FNG159Terasil Orange 5RL52 106Ciba Black WHF160Terasil Yellow W5SI53BufferAmcrium Sulphide107Cibacron Orange161Protofix Red BBS54Cibatex AB-45108Cibacron Red HB/WR162Protofix Yellow 3RS55 109Ciba Dark Blue WR163Protofix Black B/GR
Dyes and Chemical Name:
| SL. |
N0.DyesDyes NameSL.
N0.DyesDyes Name164TaicronTaicron Yellow HW-T228VaritiesRemazol Deep Black GWF165Taicron Red XF-T229Remazol Br. Yellow 3GL166Taicron Black HW-T230Reactabond Yellow 3RN167Taicron Deep Red XF-T231Solazol Black GRN168Taicron Navy Blue HW-T232Remazol Green GB169Taicron Blue SE-2BT233Rifozal Black GR170Taicron Bri. Blue SE GLT234Rifofix Yellow 3RN171NakaNakajol Black B235Remazol Deep Red RGB172Nakajol Br.Blue RSPL236Sinofix Red ME6BL173Nakajol T. Blue G237Corazol G. Yellow MERP174Nakalon T. Blue G238Corfix Red ME4BP175Nakalon Red FB 200239Corfix Black BP176Nakalon Blue 2RLS240Corfix Black GDR177Nakalon Navy Blue SFS241Corfix Black GDG178Nakalon Black SFRD242Driming Blue CLBR179Nakalon Yellow 4GN244Driming T/CLB180Nakalon golden yellowGG245Driming Yellow HF 3GL181Naka Bri. Blue BGF246Polafix Red 3BS182Drimeriua Red K4BL247Polafix Yellow 3RS183Drimeriua Scarlet HF3G248Polafix Red 3BS184DiaonixDionix Navy XF249Polafix Black GR185Dionix Flovine XF250Polafix Black GRN186Dionix Blue XF251Novacon Yellow S3R187Dionix Red CBN SF252Novacon Deep Red SB188Dionix Black CCR253Novacon Red FN 2BL189VaritiesBezaktive Yellow S-3R254Novacon Black G190Bezaktive Red S-3B255Novacon Red S-2B191Bezaktive Black S-Max256Remazol Red F3B192Bezaktive Blue VRN257Amron Yellow HR2D193Indocron Yellow MERL258Amron Red HR2D194Indocron Yellow ME4GL259Amron Black HR2D195Indocron Orange ME 2RL 196Indocron Red ME6BL 197Impafix Orange ME2RL 198Impafix Golden yellow MERL 199Impazol Terquise Blue G 200Livafix Yellow CA 211Livafix Red CA 212Livafix Blue CA 213Livafix Fast Red CA 214Livafix Amber CA 215Livafix Rubine CA 216Livafix Br. Yellow RR 217Livafix Scarlet CA 218Remazol Yellow RR 219Remazol G. Yellow RGB 220Remazol Red RGB 221Remazol Blue RR 222Remazol Br. Blue RSPL 223Remazol Ultra Carmine RGB 224Remazol Red RR 225Remazol T/Blue G 226Remazol Br. Blue BB 227Remazol Navy RGB
Production Planning, Sequence & Operation
Production Parameters:
PH:
During H2O2 Bleaching PH : 9 – 11.
During Reactive Dyeing PH : 10.5 – 12.
During Disperse Dyeing PH : 4.5 – 5.5.
After Scouring add + Peroxide killer PH : 4.5.
Temperature:
For Cotton Scouring : 900C – 950C / 1100C
For Cotton Cold Wash : 300C – 400C
For Cotton Hot Wash : 700C – 800C
For Cotton Acid Wash : 600c – 700C
For Cotton Dyeing : 800C – 900C (Hot Brand)
: 400C – 600C (Cold Brand)
For Polyester Dyeing : 1000C – 1300C
Time:
For Scouring : 60 – 90 min
For Reactive Dyeing : 60 – 90 min
For Disperse Dyeing : 30 – 60 min.
M: L Ratio: For Reactive Dyeing M: L ratio maintained 1:10 (1:8)
Lab – Dip Procedure:
Lab – dip:
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.
Lab – dip plays an important role in shade matching & detaching the characteristics of the dyes and chemicals are to be used in the laree scale of production so this is an important task before bulk production.
In Padma Poly Cotton Knit Fabrics Ltd. also a well established laboratory with modern machineries and equipments. First of all the dye % of the Standard sample is measured by the data color and computer color matching system. Then by taking that recipe lab In – Charge produces lab trail and match with the standard according to buyer requirements after approving the sample, this sample is sent to bulk production with recipe
Washing for Colored fabrics:
Colored fabrics to be washed ate loaded in the m/c.
Required amount of water is taken.
PCLF (Detergents) added and washing continued at 800C for 20 min.
Cold washing.
Scouring & Bleaching:
Fabric to be scoured is loaded in the machine.
Required amount of water is loaded.
Detergence / washing agent is added (From recipe).
Steam pipes are on and scouting agent (Caustic soda / soda ash) added when the temperature reaches at 500C.
When the temperature reaches at 600C then stabilizer added.
Then H202 is added.
Temperature is then raised to 950C and the process then carried out for 60 – 90 min depending on the requirement.
Then the liquors are the drained.
Then Cold wash at 300C – 400C, Hot wash at 800C – 950C and Acid wash at 400C – 500C, (600C) is done.
After Scouring:
Added acid + Peroxide Killer
PH 4.5
Temperature 55 600C
Run Time 10 – 20 min
Then added Enzyme.
N. B.
ENZYME
(Depending on the buyer requirements.)
S. Oliver Fabric : 1.5 g/l.
Tom Tailor Fabric : 1.0 g/l.
S. Olive Fleece Fabric : 0.8 g/l.
Tom Tailor Fleece Fabric : 0.5 g/l.
Uses % of different fabrics:
| Fabrics: | Sun mori – CK – 1, II |
(Detergent):Ciba fluid – C
(Anti – creasing agent):Single jersey
Rib
Interlock
Fleece
S/J Lycra
Lycra Rib
Lycra Interlock
Lycra Terry Fleece0.5
0.5
0.5
0.5
0.8
0.8
0.8
0.81 – 1.5
1 – 1.5
0.4
–
1 – 1.5
0.4
0.3
0.2
Dyeing :
After acid wash all liquors are drained out.
Required amount of water is taken.
Then leveling agent, anti-creasing, de-foaming agents is added according to the requirement.
Then the temp is raised up to mark and after 10 – 15 min dyes are added.
Salts + Soda are added after another 30 min.
Then the temperature is raised slowly up to the mark.
The process is carried of and samples are taken after every 10 – 20 min to match with the target shade. It will be continue until shade matching.
If the sample is matched then the liquors drained out Cold wash at 400C – 500C, Hot wash at 700C – 800C, Acid wash at 400C – 500C is done.
Then softner is added at 450C for 20 – 30 min.
Fixer is applied for deep shade only before adding softner.
Re – dyeing:
When shade is not matched then fabric is treated again in dyeing m/c for shade matching is known as Re – dyeing.
Generally re – dyeing is done if the shade is deeper or lighter then target shade, If may occur when the fabrics absorb one or two color more or less.
Re – dyeing process is described below:
Drain the left off solution,
Hot wash at 700C – 800C.
Acid wash at 400C – 500C (400C = Light shade, 500C= Deep shade)
Soda washes at 900C – 1000C. For 60 min to reduce the depth of shade.
Acid wash at 600C.
Added to required dyestuffs.
Salt added.
Other operations are same as pervious described dyeing operations.
Sequence of operation for knit Dyeing:
Grey fabric from knitting
Grey fabric inspection
Batching
Fabric turning
Loading to the machine
Pretreatment (Scouring & Bleaching)
Dyeing
De – watering
-Tube form – Open form
– Tensionless – Slitting
– Compacting and Calendaring – Stentering
– Final Inspection – Compacting
– Packing – Final Inspection
– Delivery – Packing
– Delivery.
Depth of shade:
Padma Poly Cotton Fabrics Ltd. Produces 0.5%-5% Shade of goods in their dyeing section.
For Production ( Salt & S0da mistaken on the basis of shade % )
| Shade % | Salt % | Soda % |
| 0.00001- 0.01 | 7 | 5 (1:8) |
| 0.01- 0.08 | 10 | 6 (1:8) |
| 0.08 – 0.15 | 12 | 7 (1:7) |
| 0.15 – 0.8 | 15 | 8 (1:7) |
| 0.8 – 1.5 | 18 | 9 (1:7) |
| 1.5 – 2.0 | 20 | 10 (1:7) |
| 2.0 – 2.5 | 30 | 13 (1:7) |
| 2.5 – 3.0 | 40 | 15 (1:7) |
| 3.0-3.5 | 50 | 16 (1:7) |
| 3.5 – 4.0 | 60 | 18 (1:7) |
| 4.0 – 4.5 | 70 | 20 (1:6) |
| 4.5 & Above | 80 | 20 (1:6) |
Production parameters in knitting section:
The main Parameter controlled in knitting section are stitch are length, GSM, Fabric diameter etc.
Different parameters in knitting machine:
Machine pitch (t):
Is defined as the distance between the centers of two adjacent needle of the same needle row indicated in mm.
Pitch= 25.4 mm/ gauge (E).
Machine gauge (E):Machine gauge denotes the number of needles per inch,Arranged on the needle carrier and based on the nominal machine diameter.
Gauge (E) = 25.4 mm/Pitch
Loops: It is a basic unit consisting of a loop of yarn meshed at its base with previously basic unit.
Stitch: The smallest dimensionally stable unit of all knitted fabrics is the stitch, It consist of a yarn loop which is held together by being intermeshed with another stitch or other loops.
Stitch is composed by:-
Head
Side limbs or shanks
Feet
Interlocking
Stitch length: Stitch length is a length of cam which includes the needle loop & half the sinker loop on either side of it. Generally the larger the stitch length, the more extensible & the poorer the cover, capacity & bursting strength.
Basic knitting element:
Needle
Sinker
Cam
Needle:
Function of needles: Needle is raised to clear the old loop from the hook & receive the new loop above it on the needle steam.
Types of needles: In general there are three types of needles.
Bearded needle
Latch needle
Compound needle
CAM:
Function of CAM: The functions of CAM are as follows:
To produce motion to needles
To drive the needles.
Formation of loops.
Sinker:
Function of sinker:
It may one or