Industrial Training & Practices” 1st June’09 to 12th July’09

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Industrial Training & Practices”

1^st June’09 to 12^th 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:

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:

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 1^st 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.

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:

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:

FINISHING MACHINE

Finishing machine description:

STENTER MACHINE:

COMPACTOR MACHINE:

RAISING MACHINE:

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

P^H 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.

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.

P^H Tester : Digital P^H 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:

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:

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:

P^H:

During H₂O₂ Bleaching P^H : 9 – 11.

During Reactive Dyeing P^H : 10.5 – 12.

During Disperse Dyeing P^H : 4.5 – 5.5.

After Scouring add + Peroxide killer P^H : 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

P^H 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:

(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 % )

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