Beximco Industrial Park, Sarabo, Kashimpur, Gazipur
Executive summery
Bextex Ltd. (the “Company”) was incorporated in Bangladesh as a Public Limited Company with limited liability on 8 March 1994 and commenced commercial operation in 1995 and also went into the public issue of shares and debentures in the same year. The shares of the Company are listed in the Dhaka and Chittagong Stock Exchanges of Bangladesh. Bextex Ltd. is the most modern composite mill in the region. Bextex Ltd. has an installed capacity of 288 high-speed air-jet looms in its weaving section and a high-tech dyeing and finishing section with a capacity of 100,000 yards of finished fabric per day. This company is located at the Beximco Industrial Park. Bextex Ltd. has a state of the art composite knit fabric production mill, which serves the growing needs of high-quality knit garments exporters in Bangladesh. The project was set up as a state of the art knit fabric knitting, dyeing and finishing facility. During the year the Company produced and sold high quality of knit fabrics and bringing forth all the latest in hard and soft technologies in knitting, dyeing and finishing of knit fabric. Bextex Ltd. also has cotton and polyester blended yarn-spinning mill, with 122,000 spindles is one of the largest spinning mills of the country. The mill was set up to feed the country’s export oriented industries.
COMPANY PROFILE
Company name : BEXTEX LIMITEDCorporate headquarter : Bel TOWER, 17, Dhanmondi R/A, Dhaka-1205, Bangladesh
Operational headquarter : Beximco Industrial Park, Sarabo, Kashimpur, Gazipur, Bangladesh.
Factory : Sarabo, Kashimpur, Gazipur
Date of incorporation : 30 May, 1984
Commercial production : 1990
Business line : Manufacturing & Marketing of Yarn Woven, Knit and DenimListing status : Public listed company
Stock Exchange listing : Dhaka & Chittagong
Authorized capital in Taka : 3,000 million Taka
Paid up capital in BDT : 1,882.50 million Taka
Number of Shareholders : 37,929
Number of Woven loom Installed : 293
Number of Spindles Installed : 119,520
Number of Denim Looms Installed : 56
Number of Circular knit Machine Installed : 30
Production Capacity : 28 Million Linear Meters
Number of Employers : 5,181
Factory Equipment : different types of weaving, knitting. Dyeing Cutting, Sewing, Finishing & Generator machines Supplied by mostly Germany, Italy, Japan, Taiwan, U.K, USA, Singapore etc
Production Capacity : 12 to 18 tons/day (Knit dyeing)Web site : www.beximco.org
Mission of the company:
BEXTEX Ltd. is a full service vendor with strong vertically integrated production facilities as well as creative & analytical capabilities which clearly sets us apart from most other South Asian vendors. Vision of the company:
• Gain market leadership in high value added apparel in USA & Europe. • Use “Innovation” & “Speed” as prime drivers, rather than cotton & cheap labour. • Dominate these markets in high quality: Men’s, Women’s, Children Shirts (Dress & Casual) Blouses (formal & casual), Skirts, Jackets Jeans & Casual non – denim bottoms Knitted tops & bottoms
Way from city university to bextex:
Plant layout of Bextex:
Organogram of manpower
Shifts:
Eight hours shift.
A shift : 06:00 A.M – 02:00 P.MB shift : 02:00 P.M – 10:00 P.MC shift : 10.00 P.M – 06:00 A.MGeneral shift : 9:00 A.M – 5:00 P.M
Layout of Beximco Knitting Ltd.
Sequence of Operation
Knitting Section:
Knitting is the method of fabric formation continuous strands of yarn into a series of interlocking loops, each raw of such loops hanging from one immediately preceding it.Yarn is the main raw material of knitting section.
Sources of raw materials:
Main source of yarn is Padma Spinning Ltd.
Other sources of raw material are as follows:-
? Jamuna Spn. Mill Ltd,? Advance Group? Utha Spn. Mill Ltd? Amber Spn. Mill Ltd? Hanif TEX ? Square Spn. Mill Ltd? Prim Spn. Mill Ltd? Sahin tex? Phartali tex(Indian)? Munnu tex? Youth Spn. Mill Ltd Material sources also collected from overseas like India, Pakistan and Lycra from South Korea, China, Singapore, Taiwan, India etc.
Consumer of the products:
Beximco knitting LTD. is a100% export oriented industry. All the goods produced in this industry are exported into various foreign countries. Name of the main buyers of the products of the industry are given below:
• ZARA?CALVIN• ENYCE• COOGI• MOTHER CARE• ZOO YOCK• S-OLIVER• TEMA.• RIVER ISLAND• T. LAND.• CHARTER HOUSE• BERSHKA• MAVI FASHION• JC PENNY• WEARE APPAREL• CALVIN• KLEIN• US POLO• ROCAWEAR • DEREONRecommendable points of a buyer:
Diameter of the fabric Design of the fabric GSM of the fabric Total wt. of the fabric Yarn count Types of yarn Color of the fabric Finishing of fabric. Handling & fastness property.
Production flow chart of knitting section:
Knitting program from merchandising department
Yarn selection according to fabric& GSM
Selection of M\C diameter according to fabric diameter
Change the cam setting according to fabric design
Set the yarn into creel and join to the needle
Run the M\C with desire RPM of M\C
Knitted fabric
Knitting variable:
Yarn count: – Yarn count indicates the fineness of yarn. It varies according to weight with length of the yarn. Yarn twist: – It is the torsion of yarn which helps the fibers to ad hear with each other. Spinning system: – This is the systematic way of giving torsion to the fibers. Yarn ply: – It is the number of ply of the yarn which depends on the required gsm of the fabric. Stitch length: – It is the length of the yarn which forms a single loop in a knitted fabric. If stitch length is increased, fabric gsm is decreased & vise versa.
Yarn tension: – It is the given tension on the yarn during feeding in circular knitting machine. It depends on the required gsm of the fabric. If yarn tension is increased, then stitch length is decreased and fabric gsm is increased. And if yarn tension is decreased, then stitch length is increased and fabric gsm is decreased. Take down tension: – It is the tension created by increasing fabric take up roller speed. Yarn quality: – Fabric quality depends on the yarn quality. As for example, for producing slub single jersey we need slub yarn. Machine gauge: – It the number of needle in one inch area of a cylinder. G.S.M (gm/m2): For knitting it is the main parameter. It is controlled by loop length. If loop length increases GSM will decrease and vice versa. It is measured by GSM cutter & electric balance. It may also be calculated as below.
Classification of Knitting
Circular knitting machine specification:
M/C NO M/C GAUGE M/C DIA MODEL NO ORIGIN NO. OF FEEDER M/C RPM ODUCTION PER DAY(app.)Kg01 20 30 1995 UK 90 25-28 60002 20 30 1995 UK 90 25-28 60003 28 30 1995 UK 90 25-28 60004 18 30 1995 UK 90 25-28 60005 24 30 1995 UK 90 25-28 60006 24 30 1995 UK 90 25-28 60007 24 30 1995 UK 90 25-28 60008 24 30 1995 UK 90 25-28 60009 24 30 1995 UK 90 25-28 60010 20 30 1995 UK 90 25-28 60011 28 30 1995 UK 90 25-28 60012 24 30 1995 UK 90 25-28 60013 24 30 1995 UK 90 25-28 60014 24 30 1995 UK 90 25-28 60015 24 30 1995 UK 90 25-28 60016 24 30 1995 UK 90 25-28 60017 18 30 1995 UK 90 25-28 60018 20 30 1995 UK 90 25-28 60019 20 30 1995 UK 90 25-28 60020 28 30 1995 UK 90 25-28 60021 28 30 1995 UK 90 25-28 60022 20 30 1995 UK 90 25-28 60023 20 30 1995 UK 90 25-28 60024 20 30 1995 UK 90 25-28 60025 20 30 1995 UK 90 25-28 60026 18 30 1995 UK 90 25-28 60027 18 30 1995 UK 90 25-28 60028 20 30 1995 UK 90 25-28 60029 18 18 1995 UK 36 17-20 15030 16 18 1995 UK 36 17-20 15031 18 30 – GERMANY 50 17-20 24033 22 30 – GERMANY 50 17-20 24034 18 30 – GERMANY 50 17-20 24035 18 30 – ENGLAND 48 17-20 10036 18 30 – ENGLAND 48 17-20 10037 18 30 – ENGLAND 48 17-20 10038 18 30 – ENGLAND 48 17-20 10039 18 30 – ENGLAND 48 17-20 10045 14 34 – TAIWAN 36 20-25 12049 20 26 – JAPAN 36 15 10050 20 26 – JAPAN 36 15 10051 20 26 – JAPAN 36 15 100
Single jersey machine Double jersey machine
Wale knitting: –
A method of making fabric by normal knitting means in which the loops are made from each wale thread are formed substantially along the length of the fabric characterized by the fact that each warp thread is fed more of us in the line with the direction in which the fabric is produced.
Coarse knitting:-
A method of making a fabric by normal knitting means in which the loops made by each coarse thread are formed substantially across the width of the fabric, characterized by the fact that each weft thread is fed more of less at right angle to the direction in which the fabric is produced.
Single jersey: –
A fabric in which all the loops of the Wales are intermeshed in one direction is called single jersey. There is only cylinder in single jersey machine.
Double jersey:-
A fabric in which all loops of the alternate Wales are intermeshed in one direction and all the loops of the other Wales knitted at the same course intermeshed in the other direction is called double jersey. Dial and cylinder are used to make this type of fabric.Materials used for knitting process:
The main material used for knitting is yarn. Following are the different qualities of yarn that are used for knitting process:
Yarn CountCotton 40/1 Ne36/1 Ne34/1 Ne30/1 NeTC 34/1 Ne30/1 Ne28/1 Ne26/1 Ne20/1 NeCVC 26/1 Ne34/1 Ne30/1 Ne
Mélange 26/1 Ne22/1 Ne20/1 Ne
Spandex 40 Denier75 Denier
polyester 150 Denier75 Denier
Cotton yarn in creel
Yarn count used according to grey gsm:
Name of required fabric Grey gsm Finish gsm Yarn count Stitch length(mm) Lycra count(D) Machine gauge Machine diameter
Single jersey 90 90 50/s cc 2.45 24 30Single jersey 105 120 36/s cc 2.61 28 30Single jersey 145 160 26/s cc 2.77 28 30Single jersey 185 200 20/s cc 2.90 20 30Single jersey 260 275 30/2 kc 3.10 18 30Single jersey 135 150(silicon finish) 28/s kc 2.62 24 30Single jersey (3% viscose) 165 180(after wash 190-200) 24/s kc 2.74 20 30Slub single jersey(organic cotton) 100 110 40/s 2.61 24 34Lycra single jersey 175 190 34/s cc 3 20 24 30A/Stripe single jersey 195 210(after peach finish) 18/s cc 2.96 20 26Multi feeder single jersey 195 ” 20/s cc 3 24 36STBPQ 165 180 28/s pc 2.55 24 30STBPQ 185 200 24/s kc 2.68 24 30STBPQ 215 230 20/s kc 2.96 24 30Y/D STBPQ 210 220 18/s kc 3.10 20 30Suede jersey 265 280 30/2 kc 3.10 18 30Lycra fleece 245 260/270 30/s cc 2.8 20 24 30Lycra Twill fleece 210 220 34/s cc 3.05 75/D poly 24 30Frency 245 260 20/s kc 3.10 20 30Lycra F/Terry 225 240 30/s cc 2.80 20 24 30Thermal 210 220 26/s kc 3 18 30Thermal 225 240 24/s kc 3.20 18 301×1 Normal Rib 210 220 28/s cc 2.70 18 30H/F Lycra 2×1 Rib 385 400 20/s kc 2.87 70 18 402×1 Rib 225 240 24/s kc 2.75 18 30Polo PQ 185 200 26/s 2.60 24 30
Relation between Grey GSM & Finish GSM:
Finish process/Color shade % (%)Percent increase/decrease1) White 15% to 18% increase2) Light color (0.5% – 2%) 18% to 20% increase 3) Medium color (2% – 3.5%) 20% to 23% increase4) Deep color (3.5 %– 6%) 23% to 25% increase5) Extra deep (6%- 9%) 25% to 30% increase
Finish G.S.M. Count (Ne)160-180 34/s180-200 30/s200-220 28/s220-235 26/s235-245 24/s
FOR DOUBLE JERSEY (INTERLOCK)
Finish G.S.M. Count (Ne)180-200 40/s200-220 34/s220-240 30/s240-260 28/s260-280 26/s
Relation between fabric diameter and machine diameter:
Count Finish GSM Grey fabric diameter increases then machine diameter30 142 5-8%28 155 8-12%26 165 12-15%24 180 15-20%20 200 20-25%
Knitting Calculations:
Production calculation:
Production per hour = Here,R.P.M = Machine speed (Revolution per minute)N.F = Number of feederN.N = Number of needleS.L = Stitch lengthM.E = Efficiency of machine
Some conversions:1 cm = 10 mm1 inch = 2.54 cm1 yd = 36 inch1 hank = 840 yd1 kg = 2.2046 lb
Stitch length meter measurement for 28 gauge machine:
Length of 4 yarns ( ) are taken by stitch length meter for 5 revolution. Then stitch length is calculated as bellow:
= = 35.35= = 7.07 × 1000= = 2.67 mm
Measurement with stitch length meterLet,
Finish GSM = 200So, Grey gsm will be = = 153.84Yarn count should be used = = 21.6Stitch length should be maintained = = 2.869 cm
Calculation for total number of needle of a machine = G × D × ?
Here, G = Machine gaugeD = Machine diameter
G.S.M calculation [G.S.M gm/m2]
GSM means grams per square meter. In knitting fabric it is the main parameter. It is controlled by loop length. If loop length increases GSM will decrease and vice versa. It is measured by GSM cutter & electric balance. It may also be calculated as below. GSM = GSM =
Procedure: 1. Industrial Calculation of BKL:
Collect sample (s/j) by G.S.M cutter and weighted from the weighting balance.
e.g.; form balance we get 1.838g grey fabric
so, Gray G,S.M=1.838 =183.8gm/m
Calculate Finish G.S.M as like procedure1 By calculation finish G.S.M =235g/m
2. An industrial calculation about lb/100yd2=13.85[From calculation of 10 reading average]
So, 100 yd -weight=13.85lbSo, 1 yd –weight= So, 1 yd =62.2gm ) =62.2 gm =0.1385
So, G.S.M calculation rule,G.S.M= weight in lb]So, S.D= =.316
CV% %
From finish G.S.M calculating grey GSM, SL, count
Suppose a fabric involve 180 finishes G.S.MSo, gray G.S.M= = So, count= = 24/s
So, S.L = cm=2.9 mm
Calculation of S.L where yarn count = 24
S.L=16.66d =16.66 =16.66 =.308 cm =3.08mm
Calculation if fabric width = no. of needle fabric specification D = machine diameter=( )=( G = machine gauge
For cotton count
Fabrics produced from single jersey machines are given below:
Plain jersey Polo pique Single lacoste \ single tuck back pique Double lacoste \ double tuck back pique Herringbone Pop corn Bubble knit Lapiqe Honey comb Slub terry Fred Perry Two tone pique Fleece
Fabric that are produced from Double jersey m/c:
1×1 Rib 2×2 Rib 3×1 Rib 6×2 Rib Thermal Mini thermal Interlock Waffle Design jersey
Key accessories used in Circular:
Yarn feeder guide Needle Sinker Cam Cylinder VDQ pulley Pattern wheel Sinker cam cap Sinker trick ring Dial Needle retaining spring Cam box Cam plate Inventor Belt Creel MPF wheel
Operation procedure:Sample analysis:
After receiving an order first step is analyzing the fabric. A sample is analyzed as per following system.Design analysis:- Example: Here, = Knit loop ? = Tuck loop 1 2 3 4 = Miss loop 1 2 1 2Cam set up:
1,2,3,4
Needle arrangement: – 1 2 3 4/ 1 2 3 4//
This fabric can be produced by two tuck cam
Optimum cam set up: 1 2 Optimum needle: – 1 2 1 2/ 1 2 1 2//
In BKL most of the fabrics are produced by using three tuck cams.
The tuck cam set up for different fabric that is usually produced in BKL single jersey knitting machine are given below:
S.T.B – PQ B – PQ
P – PQ FLEECE
In BKL for double jersey machine two Tuck cams are generally used to produce Rib, Interlock Thermal, Mini-Thermal, Waffle, Mini-Waffle etc fabric.
Inter lock Rib D D C C
Thermal waffle D D
C C Mini waffle Mini thermal
D D C C Flat knitting:
Flat knitting machine: –
The machine is of flat from in shape is called a flat knitting machine. It is also known as v bed knitting machine. This machine is used to produce collar, cuffs, cardigans etc.
Types of Flat knitting:
Flat knitting
Plain semi jacquard JacquardPlain:
The machines which produce only plain collar & cuff are called plain flat knitting machine. Four feeder cams are used at a time.
Semi jacquard:-
The machine which has a greater flexibility collar & cuff called semi-jacquard machine.
Jacquard:- The machine which can produce any type of design for collars and cuff is called jacquard flat knitting machine. Each individual’s needle can be controlled in the machineEquipment used:The following equipment is used for production:
Name Fabric type Manu. Model Gauge Length No. of m/c.STOLL semi-jacquard Germany ——– 14 84 inch 2MATSUYA Plain Japan M-100 14 100 cm 26MATSUYA Plain Japan M-70 14 70 cm 22KAUO HENG Semi-jacquard Taiwan KH-313 14 54 inch 17MATSUYA Semi-jacquard Japan 14 64 inch 2Total machines = 69
Note: Collar & cuff prepared is mainly rib fabric. Tipping is also used in the collar & cuff. ‘Tipping’ is stripe design mainly knitted by Polyester yarn.
Flat bed knitting machinesType of collar/cuff:
Beximco knitting Ltd is able to produce high quality collar/cuff with greater flexibility to produce a wide range of design. The main products are:-a) Plain collar/cuff.b) Welted collar/cuff.c) Herring bone collar/cuff.d) Hill collar/cuffe) Raising collar/cufff) Picot collar/cuff.g) Tipping cuff cup to (color).h) Racking design.
Collars
Knitting Faults:? Barre or stripe ? Press off? Miss stitch/ drop stitch ? Needle mark? Sinker mark ? Oil stain? Crease mark/Edge mark ? Holes? Excessive slubs ? Spirility? Broken needle ? Pin hole? Tight course ? Missing Yarn, etc.
Greige Inspection
Set fabric roll in machine
Run the machine
Check the faults
Record the faults
Accept/Reject
Send for next process
To detect and identify the fault in fabric by the knitting, visual assessment on Inspection m/c.Machine used:
(Front side) (Back side)
Inspection m/c (Calator Sweden, Model no: 1095622) Inspection table.M/C set up (Inspection m/c):
M/C set up Parameter range Set valueRoller speed 0-40 m/min 25-30 m/minLight Not applicable Artificial day lightLength measuring unit Not applicable Attached with m/c.Following faults are detected:
Faults:
H= Hole OS= Oil stain BN= Broken needleDS= Drop stitch. WD=Wrong Design PH= Pin HoleNL = Needle line. S = Stripe TC= Tight CourseTT = Thick & Thin yarn. S = Slub MY= Missing YarnSM = Sinker Mark. WP=Wrong Ply, etc.
FOUR – POINT SYSTEM:
Size of defect Penalty3 inches or less 1 pointsover 3 but not over 6 2 pointsOver 6 but nor over 9 3 pointsOver 9 inches 4 pointsAcceptance calculation: Total point per 100 square yards = = Points/100 square yards.Classification of Inspection Fabric:< 40 points = A41-60 points = B61-80 points = C80 above = Reject. Acceptance: Generally any piece of fabric with 40 points or less faults per 100sq. yard is allowed to pass however for a roll, the average value should not exceed 18point per 100sq.yard.More than 40points faults per 100sq yard is recorded as “REJECT”
Collar & cuff inspection:
Collar & cuff inspection is a process of identifying quality fault in knitted collar & cuff from flat knit m/c.
Batch Preparation
Batch preparation is the process where visually inspected grey fabrics are divided into different batches with reasonable quantity in order to make them suitable for further operation.
Inspection & Batch Preparation lay out :
Raw materials:
Collar & cuff. Body
M/c for Batch preparation:
Two types of machines are used for Batch preparation
Turning m/c ( Jusa, Portugal) Plaiting m/c ( Bangladesh) Sewing machine
Turning machine Plaiting machine
Function or Purpose of Batch Section:
– To receive the grey fabric roll from knitting section or other source.- Turn the grey fabric if require. – To prepare the batch of fabric for dyeing according to the following criteria –• Order sheet (Received from buyer)• Dyeing shade (color or white, light or dark)• M/C capacity• M/C available• Type of fabrics(100% cotton, PE, PC, CVC)• Emergency- To send the grey fabric to the dyeing floor with batch card.- To keep records for every previous dyeing.
Loading Capacity:-
In dyeing machine, 125-140 kgs of fabric can be one nozzle through dyeing machine. Normally, for the fabric with high G.S.M and large width, maximum load can be done.Considering the fabric quality, the recommended loading capacity of each machine is shown in following table.
Machine No. MinimumCapacity (in kgs) MaximumCapacity (in kgs) Usually Loaded1 450 600 5502 450 600 5503 450 600 5504 450 600 5505 35 75 456 175 275 2007 450 600 5508 450 600 5509 190 340 30010 350 480 45011 50 70 6012 10 20 1513 5 10 714 120 150 13015 200 250 20016 350 450 38017 350 450 38018 8 15 1719 7 15 10
NOZZLE:- Each batch is divided into 1-4 stacks, which are termed as nozzle, generally each nozzle weight 125-140 kgs
Rolls: Each nozzle is further divided into 1 to 5, which are termed as rolls. Usually each roll weight about 22-27 kgs.
Batch calculation:Batch quantity = kg
Process sequence of Batch preparation:-
Receive batch card from Grey In-charge
Card for own understanding
Check the Make the priority as per dyeing plan
Take one specific Batch card.
Read the Batch availability of fabric
Take required quantity of body fabric from ware-house.
Make required no. of Rope maintaining equal length.
Take collar/cuff as per size, keep the total weight.
Distribute the collar/cuff or Rib in each rope equally unsure equal length
Stitch the fabric
Write down the weight against roll no. in the back side of the Batch Card.
Write the total weight in Batch card
Put signature & date.
Fill up the production report form.
Lab
Laboratory work sequence flow chart:
Order received
Dye selection
Lab dip making
Lab dip submit
Lab dips approval/reject
Pre production making
Equipment used:
1. Ahiba Nuance Top speed.2. Ahiba Spectra dye3. AG Machine4. Automatic electrical pipette5. Verivide Light box.
Light sources: ? Artificial day light D65? TL 84? F(Filament)? UV (Ultra violet) light etc.
Manufacturer: James H. Heal & Company, Halifax, England.
Lab
Pilot plant Q.C side
Offline On linePilot plant:-
Laboratory matching is a color development processes of a given shade of the specified material by formulating a recipe from selected dyes, though the aid of color computer recipe. Combinations using the appropriate dyeing process with available sample dyeing machine until the closed matched are achieved.
Dyeing process:
Fabrics are dyed based of their quality and blending and to the buyers standard sample appearance. The dyeing processes used in BKL are:-
Reactive dyeing:
Cotton part eyeing at temperature range of (60-90) oC in alkali medium (in accordance to existing dyes)
Disperse dyeing:
Polyester part is dyeing in acid medium at 132 oC temperature. There are different processes for blended fabrics such as pc or CVC.
Two bath process:-
This is a process where at first the polyester part is dyed, matched and reduction clearing (if needed) is done, and then proceeds to cotton part dyeing using different bath.
One bath process:-
Putting disperses and reactive dyes together and other chemical in one bath but dyeing the polyester part first proceed with cotton dyeing. In this process selected dyes which are compatible with each other are used. Disperse & Reactive are suitable for the process.
Chemicals & Auxiliaries Used:
Chemicals are main ingredients used with dyes and auxiliaries means the aids or helper to get better results like levelness, absorption, crease free and other quality parameters, but water is the important ingredient need in all dyeing.
Chemicals used in lab are given bellow:
1. Jinsofter ACN (Anti creasing agent)2. Jintex QSE (Sequestering agent)3. Soda ash (Dye fixer)4. Glauber salt (Electrolyte)
Chemical chart For Reactive Dyeing:
SOAZOL/REACTOBOND:
Dyes % up to 0.25% 0.26-0.75 0.76-1.5 1.6-2.5 2.6-3.5 3.6-5.0 L5.0Salt g/LSoda g/LCaustic g/L 103- 205- 307.5- 4010 5050.3 6050.7 8050.7
LEVAFIX/ SYNOZOL:
Dyes % up to 0.25% 0.26-0.5 0.51-1.0 1.1-2.0 2.1-3.0 3.1-4.0 4.6-60Salt g/LSoda g/LCaustic g/L 102- 105- 205- 307.5- 4010- 5010- 6010-
SOLACION/ PROCION (HOT BRAND):
Dyes % up to 0.25% 0.26-1.0 1.1-2.0 2.1-3.0 3.1-3.5 3.6-5.0 L5.0Salt g/LSoda g/LCaustic g/L 205- 307.5- 4010- 5010- 6012- 7015- 9020-Lab dips making process follow up:
100% cotton single tuck back pique (STBPQ) of 235 gsm.In lab and production floor 1:8 liquor ratio is taken. For lab 10 gm fabric sample is taken. The sample color was orange. The sample was matched with previous record and got the recipe.
Color recipe:
1% sola orange 10.20 ml1% sola yellow 8.00 ml0.1% sola blue 1.30 mlTotal 19.5 ml
Chemicals used:
Jinsofter ACN (Anti creasing agent) 4 ccJintex QSE (Sequestering agent) 6 ccTotal 10 cc
Shade% calculation & get salt, soda, caustic amount from above charts:
Shade% =
Sola orange 1.02Sola yellow 0.80 Sola blue 0.013Total 1.833
From chart we get 40 g/l salt and 10 g/l soda
Salt & Soda calculation:
Amount of salt = = 3.2 gm
Amount of soda = = 8 cc
Here, 80 is the total amount of water. And soda ash is taken from 10% stock solution.
Required amount of water = {80 – (Total color + Chemicals + Alkali)} = {80 – (19.5 + 10 + 8)} = 42.5 mProcedure:
First stainless steel tube is taken in tube holder. Then colors are taken by measuring with electronic pipette in tube. Salt is taken measuring with electronic balance. Required amount of water is taken in the tube. Fabric sample is taken in the tube. Tube is set inside the Ahiba nuance machine and kept for 30 minutes at 600c. It is called salt program. After salt program soda ash is added to the tube. Then the tube is kept for 1 hour at 600c temperature. Then the tube is poured off and fabric is washed. After cold wash the sample is washed at 1000c called hot wash. It is continued until bleeding is stopped. Then fabric is washed with cold water and dried. Then shade is checked in verivide light box at required light source.
Laboratory dyeing procedure:
Reactive dyeing for cotton partDiagram: For Reactive dyeing (Cold brand)
60oc 30’ 60 min
B 2 min Unload & wash A A= 1) Fabric 2) Dye 3) Chemical 4) Salt B= Soda ash Procedure:
Add required amount of dyes, Chemical, water and salt in the dyeing beaker Add the fabric in the dyeing beaker. Place the dyeing pot into the dyeing machine at room temperature & circulate the dyeing beaker. Raise the temp of the dyeing machine at 60oc and run the machine for 30 min Then add soda ash in the dyeing pot and run the machine for 60 min. Unload & wash.
Diagram: for Reactive dyeing (Hot brand). 82oc 40min
60oc 2 min Unload & Wash B
A A= 1) Fabric B= Soda ash 2) Dye 3) Chemical 4) Salt
Procedure:
1) Add required amount of dyes, chemical, water & salt in the dyeing beakers.2) Add fabric to the dyeing beaker.3) Place the dyeing beaker into the dyeing machine at room temperature.4) Circulate the dyeing beaker in the dyeing machine and raise temp at 60oc and run the machine for 30 min.5) Then add soda ash in the dyeing beaker raise the temp at 82oc and run the machine for 40 min6) Decrease the temp & unload.
For Disperse Dyeing:
Chemical and auxiliaries in disperse dyeing in all brands are similar and dyeing temperature mostly is 132oc
1) Dispersing agent – PALAGAL SFD – 0.5g/L JINLEV RLF 349 – 0.3 g/L
2) PH adjusted – Eulysin – 0.23 gm/L (Buffer solution)3) PH required and to be maintained = 4.5 – 5.0
For medium & dark shades reduction clearing is required after dyeing
Sl. No Chemicals Medium shade Dark shad01020304 Detergent Caustic sodasodium hydroseAcetic Acid(For neutralization) 0.5 g/L1.0 g/L2.0 g/L0.5 g/L 0.5 g/L2.0 g/L4.0 g/L0.5 g/L
Diagram for Disperse dyeing:
130oc 30min
50oc 5min Unload & wash Dyes +water + Auxiliaries Procedure: Add required amount of dyes, water Auxiliaries and water in the dyeing beakers Add the fabric in the dyeing beakers & check the PH Place the dyeing beaker into the dyeing machine at room temperature Circulate the dyeing beaker into the dyeing machine and raise the temperature of the machine at 130oc and run the machine for 30 min Then Decrease the temperature at 60oc Then unload, reduction clearing,& wash
One bath dyeing process of polyester & cotton blend:
1) Add required amount of dyes (reactive + Disperse) auxiliaries (Reactive + Disperse), salt and water in the dyeing beaker.2) Add fabric to the dyeing beaker3) Place the dyeing beaker in the dyeing machine at room temp and run the machine for 5 min 4) Circulate the dyeing vessel and raise the temp at 130oc and run the machine for 30 min5) Decrease the temp at 82oc and run the machine for 10 min6) Add soda ash to the dyeing beaker and run the machine for 40 min7) Decrease the temp at 60oc then unload and wash.
130oc 30 min
10 min 40 min
82oc 50oc B Unload & A wash
A = 1) Dyes (Reactive+Disperse) 2) Auxiliaries (Reactive+Disperse) 3) SaltB = Soda ash
Dyestuff strength test:
This test result is identified by comparing the visual appearances of two dyed samples are dyed with different dyestuffs at same condition. For this test two different fabric samples are taken from same fabric which is ready for dye. Then two samples are dyed with different dyestuffs which to be tested with same auxiliaries and chemicals at same time, temperature and other conditions. After dyeing and drying both sample are compared with each other visually. According to their depth of shade and appearance decision is taken which dyestuff is more economic.
Salt test:Equipments used1. Distilled water (as required)2. Salt 500 gm3. Pot4. Stirrer5. Filter paper6. Electronic balance7. DryerProcedure:
First 500 gm salt is taken in a pot. Then it is fully melted in required amount of distilled water with a stirrer. Then filter paper is weighted and the weight is recorded. Then the salt solution is filtered by the filter paper. All the dust particles are gathered at the surface of the filter paper. Then the dust containing paper is dried. After drying weight of the dust containing filter paper is measured with the electronic balance. Then the weight of the dust is calculated subtracting the previous measured filter paper value from the present value. Then percentage of dust is calculated in the salt.
Soda, Caustic, Acid and Peroxide testing equipments (common) are given bellow: Pipette Conical flask Burette Volumetric flask BeakerSoda/Caustic test:Chemicals used: Distilled water Sulphuric acid = 4.9gm Soda ash = 5.3 gm Methyl orange = 1 dropProcedure:
First stock solution is made taking 50 cc distilled water and 4.9 gm sulphuric acid. Stock solution is made taking 50 cc distilled water and 5.3 gm soda ash. Then a conical flask is taken and 10 cc distilled water, 10 cc stock solution of soda ash and 1 drop methyl orange is taken in the conical flask and stirred. The solution appearance is yellow color. Sulphuric acid stock solution is poured in a burette at the amount of 100cc. Then the conical flask is set under the burette and sulphuric acid is taken drop by drop in the flask and stirred. The color of the solution of the flask is observed very carefully. After falling a certain amount of acid in the flask the color of the solution is changed from yellow to pink. Then the burette valve is turned off. Certainly color changing indicates the neutralization point. The amount of sulphuric acid gone to the flask is calculated from the burette.Result:
If the amount of lost sulphuric acid from burette is more than 10 cc, then the soda is rejected. Otherwise it is accepted for use.Acetic acid test
Chemicals used:
Distilled water Acetic acid = 6% Caustic soda = 4% Methyl orange = 1 dropProcedure:
First 10 cc distilled water is taken in the conical flask. Then 10cc acetic acid is taken from the 6% stock solution in the flask. And 1 drop methyl orange is taken in the conical flask and stirred. The solution appearance is pink color. Caustic soda stock solution is poured in a burette at the amount of 100cc. Then the conical flask is set under the burette and Caustic soda is taken drop by drop in the flask and stirred. The color of the solution of the flask is observed very carefully. After falling a certain amount of caustic in the flask the color of the solution is changed from pink to yellow. Then the burette valve is turned off. Certainly color changing indicates the neutralization point. The amount of caustic soda is gone to the flask is calculated from the burette.Result:
If the amount of lost caustic soda from burette is more than 10 cc, then the acid is rejected. Otherwise it is accepted for use.Peroxide testChemicals used:
Distilled water Potassium permanganates (KMnO4)= 3.16 gm Sulphuric acid (H2SO4) = 2.94 gm Hydrogen peroxide (H2O2) = 1.7 gmProcedure:
First stock solution is made taking 50 cc distilled water and 3.16 gm potassium permanganates (KMnO4). Stock solution is made taking 50 cc distilled water and 2.94 sulphuric acids (H2SO4). Stock solution is made taking 50 cc distilled water and 1.7 gm hydrogen peroxide (H2O2). Then a conical flask is taken and 10 cc distilled water, 10 cc stock solution of hydrogen peroxide (H2O2) and 10cc sulphuric acid (H2SO4) is taken in the conical flask. The solution appearance is pink color. Potassium permanganates stock solution is poured in a burette at the amount of 100cc. Then the conical flask is set under the burette and potassium permanganates is taken drop by drop in the flask and stirred. The color of the solution of the flask is observed very carefully. After falling a certain amount of potassium permanganates in the flask the color of the solution is changed from pink to yellow. Then the burette valve is turned off. Certainly color changing indicates the neutralization point. The amount of potassium permanganates gone to the flask is calculated from the burette. Result:
If the amount of lost potassium permanganates from burette is more than 10 cc, then the Fiber Identification:
Fiber Burning orMelting Shrinkage from flame Odor ResidueCotton Burns only No Burning paper, leaves or wood Fine, grey ashViscose Same as cotton Same as cotton Same as cotton Same as cotton
Wool Burn only Yes Strong odor like hair burn BlackNylon Burn &melt Yes Celery Hard, Crimp color beadPolyester Burn &melt Yes Sweet chemical Hard, Crimp color beadAcrylic Burn &melt Yes Broiled fish Hard shaped beadAcetate Burn &melt Yes Burning paper & vinegar Dark, hard, solid beadJute Same as cotton Same as cotton Same as cotton Same as cotton
Carbonizing test:Blend type Solution use CarbonizedFiber UnchangedPC/CVC 70% Sulphuric acid Cotton PolyesterViscose 30% Sulphonic acid Viscose CottonLycra cotton 50% Sulphuric acid Cotton LycraDye House
Layout of the dye house:
Machine specification:
Dyeing Machineries:
Machine No : 1, 2, 3, 4, 7, 8Machine Name : Jet Dyeing Machine (Eco-soft)Company Name : Theis, GermanyNo. of Nozzle : 4Machine Capacity : 500-600 kgEconomic loading capacity: 550 kgPressure : 500-600 m.barRope speed : 200-250 m/minType of Machine : HTHP
Machine No : 5Machine Name : Jet Dyeing Machine (Mini-soft)Company Name : Theis, GermanyNo. of Nozzle : 1Machine Capacity : 30-80 kgEconomic loading capacity: 50 kgPressure : 500-600 m.barRope speed : 150-200 m/minType of Machine : HTHP
Machine No : 6Machine Name : Jet Dyeing Machine (Eco-soft)Company Name : Theis, GermanyNo. of Nozzle : 2Machine Capacity : 200-250 kgEconomic loading capacity: 200 kgPressure : 500-600 m.barRope speed : 200-250 m/minType of Machine : HTHP
Machine No : 9Machine Name : Jet Dyeing Machine (Luft-roto)Company Name : Theis, GermanyNo. of Nozzle : 2Machine Capacity : 250-350 kgEconomic loading capacity: 300 kgPressure : 500-600 m.barRope speed : 200-250 m/minType of Machine : HTHP
Machine No : 10Machine Name : Jet Dyeing Machine (Luft-soft)Company Name : Theis, GermanyNo. of Nozzle : 3Machine Capacity : 400-500 kgEconomic loading capacity: 400 kgPressure : 500-600 m.barRope speed : 200-250 m/minType of Machine : HTHP
Machine No : 11Machine Name : Sample Dyeing MachineCompany Name : Beximco, BangladeshMachine Capacity : 70 kg Economic loading capacity: 60 kgPressure : 200-300 m.barRope speed : 100-150 m/minType of Machine : Atmospheric
Machine No : 12Machine Name : Sample Dyeing MachineCompany Name : Beximco, BangladeshMachine Capacity : 10-20 kg Economic loading capacity: 15 kgRope speed : 100-150 m/min
Machine No : 13Machine Name : LocalCompany Name : Beximco, BangladeshMachine Capacity : 5-10 kg Economic loading capacity: 7 kgRope speed : 100-150 m/min
Machine No : 14Machine Name : Jet Dyeing Machine Company Name : Theis, GermanyNo. of Nozzle : 1Machine Capacity : 120-150 kgEconomic loading capacity: 130 kgPressure : 300-500 m.barRope speed : 150-200 m/min
Machine No : 15Company Name : Theis, GermanyNo. of Nozzle : 1Machine Capacity : 250-250 kgEconomic loading capacity: 200 kgPressure : 300-500 m.barRope speed : 150-200 m/minType of Machine : Atmospheric
Machine No : 16, 17Company Name : Theis, GermanyNo. of Nozzle : 3Machine Capacity : 350-450 kg Machine No : 18, 19Company Name : LocalMachine Capacity : 8-15 kgEconomic loading capacity: 7 kgType of Machine : Atmospheric
Dyeing machine
Raw materials used:
Fabric Water Chemical Dyes Steam
Production flow chart:Singing
Mercerizing
Scouring
Bleaching
Enzyme wash
Dyeing
Washing
Rinse
Hot wash
Cold wash
UnloadPre-treatments
Singeing: It is the process of burning of the fabric hairs projection through the fabric surface.
Mercerization: Mercerization is a process of treatment of cellulosic textile yarn or fabric form with a concentrated solution of caustic alkali whereby the fibers swollen, the strength lusture and dye affinity of the materials increased, and their handle is modified.
Scouring: Boiling off process with detergent & alkali (Soda ash/Caustic soda). Greige fabrics contain fats, waxes& other impurities .the absorbency of the fabrics adversely effected due to the presence of these impurities. This leads to improper dyeing, printing & finishing in subsequent process.
Bleaching: Bleaching is a process for removing natural nitrogenous coloring matters e.g. dirt, dust, husk, broken seeds, protein, leaf etc from the fabric & make it white by oxidizing or chemical treatment.
Objects of scouring & Bleaching:
1 To remove fats, wax, impurities from the fabrics.2 To increase absorbency of fabric3 To remove natural coloring materials, dirt, dust, broken seed by oxidizing of chemical treatment4 To obtain pure & permanent color.5 To whiten the fabric.6 It changes the textile materials which are hydrophobic in nature. 7 It helps to produce an even shade during dyeing operation. 8 To impart the wet ability of the fabric this is necessary for further treatment and domestic uses.
Materials & chemicals used for scouring & bleaching:
Steam: To heat up the water.Compressed air: To operate the machine.Caustic soda: For controlling PH of the dye bath.Hydrogen peroxide: To bleach the fabric.Stabilizer: It is buffer solution and maintains PH at a stable point.Wetting agent: To wet the fabric for even dye application.Detergent: To wash the fabric.Sequestering agent: To remove the hardness of water.Acid: To maintain PH.Anti-creasing agent: For reducing crease mark at the fabric during washing, dyeing and other processes.
Enzyme wash: It is the process of washing fabric with enzymes to remove hairiness of the fabric.
Demineralization of water: Beximco use underground water for all wet processing activities. This water contains different types of minerals.Total dissolved solid (TDS)| Arsenic (As) Cadmium (Cd) Lead (Pb) Chloride (Cl) Nitrate (NO3) Nitric (NO2) Cyanide (Cn) Fe II
Among these only Iron is removed by sand bath filtering process in water treatment plant. Other material remains at sustainable limit.
Composition of cotton materials:
Particles PercentageCellulose 88 – 96Facts &waxes 0.45 – 1.0Mineral substances 0.7 – 1.0Pectin’s 0.7 – 1.2Protiens 1.1 – 1.9Various organic compound 0.5 – 1.0
Dyeing process:
White Shade:
Whitening is a chemical treatment process; this process is used white the fabric at a desired level by bleaching & OBA treatment.Batch weight: 400Kg
Recipe Name: RN7121 WHITE calvin 2×2 RibChemical Name g/l KgAcetic acid 0.700000 2.240000Phenolas CLN.20 1.507500 4.824000Phenozyme 1000 0.500000% 2.000000Chimistone Nilf 1.004900 3.21568Phenolas Crease-10 1.000000 3.200000Chemical 540 1.500000 4.800000Chimistab FG 0.400000 1.280000Caustic Soda 2.500000 8.000000Hydrogen per oxide 2.010000 6.432000Bluetone 2B 0.40700% 2.198000Skywhite BVB 0.08050% 434.700gSQA-6 000000 2.500000Acetic acid 0.525656 1.620992Process steps and procedure:
Fabric is loaded in the machine. 3200 liter water is added in the dye bath. As liquor ratio is 1:8. Temperature is raised at 550c & fabric is circulated for (3-5) minutes. Acetic acid is added for maintaining pH at 4.5 for enzyme wash. Fabric is circulated for (3-5) minutes. Then enzyme and enzyme catalyst is added and fabric is circulated for about 60 minutes at 550c. Then bath is drained off and fabric is washed about 800c for 10 minutes. Then rinse wash is done. Take water at required level. The temp at 500c & continue circulating the fabric. Add sequestering agent, anti creasing agent, detergent & stabilizer. Circulate the fabric for 3-5 min at constant temperature. Add Caustic Soda at linear dosing for about 20 minutes & raise the temp at 600c. Add H2O2 at curve dosing for about 40 minutes & run the m/c for 5 min at 700c. Raise the temp at 800c & add OBA & continue circulate the fabric for 5 min. Raise the temp at 1000c & continue circulate the fabric for 60 min and maintaining pH at 10.5. Decrease the temp at 600c. Drain. Add acetic acid at 60oc & run for 10 min Unload the fabric. Curve:
For Enzyme Wash: 800c × 10 min
550c × 60 min hot wash
A B pH Check C 600c Cooling + Drain Here,A= WaterB= Acetic acidC= Enzyme WashpH = 4.5
For Bleaching: 1000c × 30 min 800c × 5 min 700c × 10 min 600c × 10 min E 600c Cooling 500c × 10min D + Drain CA B
Here,A= Water + FabricB= ChemicalC= Caustic SodaD= Hydrogen per OxideE= Optical Brightening Agent.
For acid Wash: 600c × 10 min
Water Acetic acid DrainLight Shade:
Batch weight: 480 Kg
Recipe name: RN7152 arena zara 2×2 TIV
Chemical Name g/l KgChimistone Nilf 1.000000 3.200000Phenolas Crease-10 1.000000 3.200000Chemical 540 1.000000 3.200000Chimistab FG 0.400000 1.280000Caustic Soda 1.800000 5.750000Hydrogen per oxide 2.010000 6.432000Sodium Thiosulphate 1.020000 3.264000Acetic acid 0.700000 2.240000Acetic acid (enzyme) 0.262500 840.0000gPhenolas CLN.20 1.507500 4.824000Phenozyme 1000 0.500000% 2.400000Glaubers Salt 10 38.400000Phenolas Crease-10 1.000000 3.200000Chimisperse FA 1.005000 3.859000Phenolas LVA Plus 1.500000 5.760000SQA-6 00000000 4.000000Levafix Yellow CA 0.032000% 153.6000gLevafix Red CA 0.007600% 36.48000gLevafixBlue CA 0.107000% 51.36000gLVA 00000000 2.000000SQA6 00000000 2.000000Soda Ash 2.000000 7.680000Acetic acid 0.420525 1.615000Chimisperse RK 0.500000 1.920000Phenolas Crease-10 0.500000 1.920000
Process steps and procedure:
Fabric is loaded in the machine. 3840 liter water is added in the dye bath. As liquor ratio is 1:8. Temperature is raised at 600c & fabric is circulated for (3-5) minutes. Add sequestering agent, anti creasing agent, detergent & stabilizer. Add Caustic Soda at linear dosing for about 10 minutes. After 5 minutes add H2O2 at curve dosing for about 40 minutes at temperature 700c & run the m/c for 5 min. Raise temperature at 1000c. Maintaining pH at 10.6 Fabric is circulated for 30 minutes at 1000c. Add Sodium thiosulphate (peroxide killer) dosing for 10 minutes & run for 10 minutes. Decrease temperature at 600c and then drain. Take water and add acetic acid and raise temperature at 600c and run for 10 minutes then drain. Again take water and add acetic acid to maintain pH 4.5 Then enzyme and enzyme catalyst is added and fabric is circulated for about 60 minutes. Then bath is drained off and fabric is washed about 800c for 10 minutes.
Then rinse wash is done. Take water at required level. Raise the temp at 600c & circulate the fabric. Add sequestering agent, anti creasing agent, fixing agent & leveling agent. Maintaining pH at 6.6 Circulate the fabric for 3-5 min at constant temp. Then color is added by linear dosing for 20 minutes and run for 10 minutes. Then glauber salt is added by linear dosing for 10 minutes and run for 20 minutes. Then soda is added by curve dosing for 30 minutes then run for 30 minutes. Then shade check. Drain. Take water at required level the take acetic acid and run for 10 minutes and drain. It is called neutralization. Then drain. Take water at required level and add soaping agent, anti creasing agent. Then raise temperature at 850c and run for 10 minutes. Decrease the temperature at 600c and then drain and rinse the fabric. Unload the fabric.
Curve:For Bleaching:
1000c × 30 min 700c × 10 min E 600c × 10 min 500c × 10min D 600c Cooling + Drain C A B
Here,A= Water + FabricB= ChemicalC= Caustic SodaD= Hydrogen per OxideE= Sodium thiosulphate (Killer)For acid Wash: 600c × 10 min
Water Acetic acid Drain
For Enzyme Wash: 800c × 10 min
600c × 60 min hot wash
A B pH Check C 600c Cooling + Drain
Here,A= WaterB= Acetic acidC= Enzyme WashpH = 4.5
For Dying:
600c 10 min run 20 min run 30 min run
A B pH Check C D E Shade Check Drain
Here,A= WaterB= ChemicalC= Color Dosing (20 min)D= Salt Dosing (10 min)E= Soda Ash Dosing (30 min)pH = 6.6
For Sopping: 500c × 10 min
Water Acetic acid Drain 850c × 10 min
500c × 10 min
Water Sopping Chemical Drain
450c 10 min
Water Rinse Complete Sample Drain
Medium Shade:
Batch weight: 470kg
Recipe name: RN7157, CAMEL 751 Slub Single jersey, zara.
Chemical Name g/l KgChimistone Nilf 1.000000 3.760000Phenolas Crease-10 1.000000 3.760000Chemical 540 1.000000 3.760000Chimistab FG 0.400000 1.504000Caustic Soda 1.800000 6.768000Hydrogen per oxide 2.010000 7.558000Sodium Thiosulphate 1.020000 3.835000Acetic acid 0.700000 2.632000Acetic acid (enzyme) 0.262500 987.0000gPhenolas CLN.20 1.000000 3.760000Phenozyme 300 0.200000% 940.0000Glaubers Salt 40 150.4000Phenolas Crease-10 1.000000 3.760000Chimisperse FA 1.005000 3.799000Phenolas LVA Plus 1.500000 5.64000SQA-6 0000000 4.000000Kiractive Yellow 3RS 1.10000% 5.170000Kiractive Red 3BS 0.30000% 1.410000Kemafix Blue × F2R 0.433000% 2.035000LVA 00000000 2.000000SQA6 00000000 3.000000Soda Ash 10.000000 37.60000Acetic acid 0.525656 1.976000Chimisperse RK 0.500000 1.880000Phenolas Crease-10 0.500000 1.880000LVA Plus 0.500000 1.880000Phenolas FAX-33 1.000000 3.760000
Process steps and procedure: Fabric is loaded in the machine. 3760 liter water is added in the dye bath. As liquor ratio is 1:8. Temperature is raised at 600c & fabric is circulated for (3-5) minutes. Add sequestering agent, anti creasing agent, detergent & stabilizer. Add Caustic Soda at linear dosing for about 10 minutes at temperature 600c. After 7 minutes add H2O2 at curve dosing for about 10 minutes at temperature 700c & run the m/c for 7 min. Raise temperature at 1000c. Maintaining pH at 10.6 Fabric is circulated for 30 minutes at 1000c. Add Sodium thiosulphate (peroxide killer) dosing for 10 minutes & run for 10 minutes. Decrease temperature at 600c and then drain. Take water and add acetic acid and raise temperature at 600c and run for 10 minutes then drain. Again take water and add acetic acid to maintain pH 4.5 Then enzyme and enzyme catalyst is added and fabric is circulated for about 60 minutes.
Then bath is drained off and fabric is washed about 800c for 10 minutes. Then rinse wash is done. Take water at required level Raise the temp at 600c & circulate the fabric. Add sequestering agent, anti creasing agent, fixing agent & leveling agent. pH remain at 6.6 Circulate the fabric for 3-5 min at constant temp. Glauber salt is added. Then color is added by linear dosing for 25 minutes and run for 20 minutes. Then soda is added by curve dosing for 45inutes then run for 30 minutes. Then shade check at 600c. Drain. Take water at required level the take acetic acid and run for 10 minutes and drain. It is called neutralization. Then drain. Take water at required level and add soaping agent, anti creasing agent. Then raise temperature at 850c and run for 10 minutes. Decrease the temperature at 600c and then drain and rinse the fabric. Unload the fabric.
Curve:
For Bleaching: 1000c × 30 min 700c × 10 min E 600c × 10 min 500c × 10min D 600c Cooling + Drain C A BHere,A= Water + FabricB= ChemicalC= Caustic SodaD= Hydrogen per OxideE= Sodium thiosulphate (Killer)
For acid Wash: 600c × 10 min
Water Acetic acid Drain
For Dying:
600c 20 min run 30 min run
A B C pH Check D E Shade Check Drain
Here,A= WaterB= ChemicalsC= SaltD= Color Dosing (25 min)E= Soda Ash Dosing (45 min)pH = 6.6
For Sopping: 500c × 10 min
Water Acetic acid Drain 850c × 10 min
500c × 10 min
Water Sopping Chemical Drain
450c 10 min
Water Rinse Complete Sample Drain
Dark Shade:
Batch weight: 360 Kg
Recipe name: RN7161, PMS Single jersey, US Polo.
Chemical Name g/l KgChimistone Nilf 1.000000 2.880000Phenolas Crease-10 1.000000 2.880000Chemical 540 1.000000 2.880000Chimistab FG 0.400000 1.152000Caustic Soda 1.800000 5.184000Hydrogen per oxide 2.010000 5.789000Sodium Thiosulphate 1.020000 2.938000Acetic acid 0.700000 2.016000Acetic acid (enzyme) 0.262500 756.0000gPhenolas CLN.20 1.507500 4.342000Phenozyme 1000 0.500000% 1.800000Glaubers Salt 60 172.8000SQA6 00000000 6.000000Phenolas Crease-10 1.000000 2.880000Phenolas LVA Plus 1.500000 4.320000Chimis SQA 1.005000 2.894000Reactive Turquiose Blue G 5.20000% 18.720000Solazol Blue SPBB 0.20000% 720.0000gReactive BR. Blue R-SP 0.100000% 360.0000gLVA 0000000 3.000000SQA6 0000000 4.000000Soda Ash 10.00000 28.80000Acetic acid 0.525656 1.514000Chimisperse RK 0.750000 2.160000Phenolas Crease-10 0.500000 1.440000Chemical LVA 0.500000 1.440000Phenolas FAX-33 1.000000 2.88000
Process steps and procedure:
Fabric is loaded in the machine. 3760 liter water is added in the dye bath. As liquor ratio is 1:8. Temperature is raised at 600c & fabric is circulated for (3-5) minutes. Add sequestering agent, anti creasing agent, detergent & stabilizer. Add Caustic Soda at linear dosing for about 10 minutes. After 5 minutes add H2O2 at curve dosing for about 40 minutes at temperature 700c & run the m/c for 5 min. Raise temperature at 1000c. Maintaining pH at 10.6 Fabric is circulated for 30 minutes at 1000c. Add Sodium thiosulphate (peroxide killer) dosing for 10 minutes & run for 10 minutes. Decrease temperature at 600c and then drain. Take water and add acetic acid and raise temperature at 600c and run for 10 minutes then drain. Again take water and add acetic acid to maintain pH 4.5 Then enzyme and enzyme catalyst is added and fabric is circulated for about 60 minutes. Then bath is drained off and fabric is washed about 800c for 10 minutes. Then rinse wash is done. Take water at required level Raise the temp at 600c & circulate the fabric. Add sequestering agent, anti creasing agent, fixing agent & leveling agent. Maintaining pH at 6.6 Circulate the fabric for 3-5 min at constant temp. Glauber salt is added. Then color is added by linear dosing for 25 minutes and run for 20 minutes. Then soda is added by curve dosing for 45inutes then run for 30 minutes. Then shade check at 600c. Drain. Take water at required level the take acetic acid and run for 10 minutes and drain. It is called neutralization. Then drain. Take water at required level and add soaping agent, anti creasing agent. Then raise temperature at 850c and run for 10 minutes. Decrease the temperature at 600c and then drain and rinse the fabric. Unload the fabric.
Curve:
For Bleaching:
1000c × 30 min 700c × 10 min E 600c × 10 min 500c × 10min D 600c Cooling + Drain C A B
Here,A= Water + FabricB= ChemicalC= Caustic SodaD= Hydrogen per OxideE= Sodium thiosulphate (Killer)
For acid Wash: 600c × 10 min
Water Acetic acid Drain
For Enzyme Wash: 800c × 10 min
600c × 60 min hot wash
A B pH Check C 600c Cooling + Drain Here,A= WaterB= Acetic acidC= Enzyme WashpH = 4.5
For Dying:
600c 20 min run 30 min run
A B C pH Check D E Shade Check Drain
Here,A= WaterB= ChemicalC= SaltD= Color Dosing (25 min)E= Soda Ash Dosing (45 min)pH = 6.6
For Sopping: 500c × 10 min
Water Acetic acid Drain 850c × 10 min
500c × 10 min
Water Sopping Chemical Drain
450c 10 min
Water Rinse Complete Sample Drain
Bleaching One Bath:Batch weight: 400 Kg
Chemical Name g/l KgChimistone Nilf 1.000000 3.200000Phenolas Crease-10 1.000000 3.200000Chemical 540 1.000000 3.200000Chimistab FG 0.400000 1.280000Caustic Soda 1.800000 5.750000Hydrogen per oxide 2.010000 6.432000Sodium Thiosulphate 1.020000 3.264000Acetic acid 0.700000 2.240000Acetic acid (enzyme) 0.262500 840.0000gPhenolas CLN.20 1.507500 4.824000Phenozyme 1000 0.500000% 2.000000
Procedure and steps:
Fabric is loaded in the machine. 3200 liter water is added in the dye bath. As liquor ratio is 1:8. Temperature is raised at 600c & fabric is circulated for (3-5) minutes. Add sequestering agent, anti creasing agent, detergent & stabilizer. Add Caustic Soda at linear dosing for about 10 minutes. After 5 minutes add H2O2 at curve dosing for about 40 minutes at temperature 700c & run the m/c for 5 min. Raise temperature at 1000c. Maintaining pH at 10.6 Fabric is circulated for 30 minutes at 1000c. Add Sodium thiosulphate (peroxide killer) dosing for 10 minutes & run for 10 minutes. Decrease temperature at 600c and then drain. Take water and add acetic acid and raise temperature at 600c and run for 10 minutes then drain. Again take water and add acetic acid to maintain pH 4.5 Then enzyme and enzyme catalyst is added and fabric is circulated for about 60 minutes. Then bath is drained off and fabric is washed about 800c for 10 minutes. Then rinse wash is done. Fabric is unloaded.
Curve:For Bleaching:
1000c × 30 min 700c × 10 min E 600c × 10 min 500c × 10min D 600c Cooling + Drain C A BHere,A= Water + FabricB= ChemicalC= Caustic SodaD= Hydrogen per OxideE= Sodium thiosulphate (Killer)
For acid Wash: 600c × 10 min
Water Acetic acid Drain
For Enzyme Wash: 800c × 10 min
600c × 60 min hot wash
A B pH Check C 600c Cooling + Drain
Here,A= WaterB= Acetic acidC= Enzyme WashpH = 4.5
Topping Process:
Batch weight: 125kg
Chemical Name g/l KgGlaubers Salt 40 25.0000Phenolas Crease-10 1.000000 1.000000Phenolas LVA plus 1.500000 1.500000Chimisperse FA 1.005000 1.005000Solazol Yellow 3RS 0.092000% 25.0000gSolazol Blue SPBB 1.180000% 1.239000Reactive Yellow 4GL 1.520000% 80.00000gLVA plus 500.0000 00000000Soda Ash 10 7.000000Acetic acid 0.788484 788.484gChimisperse RK 0.5000000 500.0000gPhenolas Crease-10 0.500000 500.000gChemical 540 0.500000 500.000gPhenolas FAX-33 1.000000 1.000000
Process and steps:
Fabric is loaded in the machine. Take required amount of water (1000 kg). And circulate the fabric at 500c temperature for 10 minutes Add anti creasing agent, leveling agent, fixing agent to the bath and run for 10 minutes at 500c temperature. pH remains 6.6 Add color to the dye bath by linear dosing for 20 minutes and then run for 10 minutes. Add salt by linear dosing for 10 minutes and run for 16 minutes. Then add soda ash by curve dosing for 30 minutes and raise temperature at 600c and run for 30 minutes. Then shade was checked and run for more 30 minutes. pH maintained 11. Again shade check. Rinse wash. Drain. Take water at required level the take acetic acid and run for 10 minutes and drain. It is called neutralization. Then drain. Take water at required level and add soaping agent, anti creasing agent. Then raise temperature at 850c and run for 10 minutes. Decrease the temperature at 600c and then drain and rinse the fabric. Unload the fabric.
Curve:For Dying:
600c × 30 min
500c 10 min 10 min 4 min 16 min D Drain
A B pH Check C
Here,A= Fabric + WaterB= ChemicalC= Color Dosing (20 min)D= Salt Dosing (10 min)E= Soda Ash Dosing (30 min)pH = 6.6
Stripping: Batch weight: 570kg
Chemical Name g/l KgAcetic acid —— 5.000000Chimistone Nilf —— 4.000000Phenolas Crease-10 1.000000 4.560000Chemical 540 2.000000 2.120000Caustic Soda 2.000000 15.00000Hydrosulphite 7.000000 40.00000Chimistone Nilf 0.669933 3.055000Phenolas Crease-10 1.000000 4.560000Chemical 540 1.000000 4.560000Chimistab FG 0.400000 1.824000Soda Ash 3.000000 13.68000Hydrogen per oxide 2.010000 9.166000Acetic acid 0.787500 3.591000Catalase BF 0.150000 684.0000g
Process and steps:
Fabric is loaded in the machine. 3700 liter water was added. Then add acetic acid at 600c temperature and run for 10 minutes and drained. Add water again and also add detergent, anti creasing agent, sequestering agent and run for 10 minutes at 500c temperature. Raise the temperature at 600c and add caustic soda and run for 10 minutes. Raise the temperature at 900c and Hydro sulphite was added and run for 30 minutes. Then temperature was raised at 1350c for 30 minutes. Then temperature at 600c. Shade is checked and then drained. Again 4000 liter water was taken. Detergent, anti creasing agent, sequestering agent, and stabilizer was added and run for 10 minutes at 500c temperature. Raise temperature at 600c and add soda ash by linear dosing and run for 10 minutes. Then bleaching agent hydrogen peroxide was added and run for 45 minutes. Then temperature is raised up to 950c and run for 30 minutes. Then temperature is decreased at 600c and drained. Water was taken again and acetic acid was taken and run for 10 minutes at 500c temperature. Then a Catalase BF is added and run for 10 minutes Temperature was raised at 600c. After running 10 minutes bath was drained. Fabric was unloaded.
Curve:
For acid Wash: 600c × 10 min
Water Acetic acid Drain
For Stripping:
1350c × 30 min
900c × 30 min D 600c × 10 min 600c Cooling + Drain 500c × 10min C A B
Here,A= Water + FabricB= ChemicalC= Caustic SodaD= HydrosulphiteFor Bleaching: 950c × 30 min 600c ×45 min 600c Cooling + Drain B C A
Here,A= Water + FabricB= Soda ash (Dosing 10 min)C= Hydrogen peroxide
For stripping wash: 600c × 10 min
500c × 10 min
Water Acetic acid Catalase BF Drain
Process Flow Chart of P/C Blend Fabric (65/35):
Batch weight: 565 kgRecipe name: RN 1324-18 Navy CH, TC, Back PiqueRequired amount of water: 4520 liter
Chemical Name g/l KgChimistone Nilf 1.000000 4.520000Phenolas Crease-10 1.000000 4.520000Chemical 540 1.000000 4.520000Caustic soda 2.200000 9.944000Acetic acid 1.051300 4.751424Geilev-YDL 1.008990 4.560634Phenolas Crease-10 1.000000 4.520000Chimisperse FA 0.670000 3.028400Phenolas P-96 0.504900 2.282148Eulysin 0.230000 1.039600Dianix navy CCR 0.23000% 1.299500Dianix Black CCR 0.55000% 3.107500Boron Red W4BS 0.01430% 0.080795Acetic acid 1.051300 4.751876Caustic soda 2.002000 9.049040Hydrose 3.090000 13.96680Chimisperse RK 0.500000 2.260000Glauber salt 60.00000 271.2000Phenolas Crease-10 1.000000 4.520000Phenolas LVA plus 1.500000 6.780000Chimistab FA 1.005000 4.542600Solazol yellow K-HW 0.290000% 1.638500Solazol red K-HW 0.400000% 2.260000Reactive black B 2.300000% 12.99500Soda ash 5.000000 22.60000Caustic 0.700000 3.164000Acetic acid 0.788000 3.561760Chimisperse RK 0.750000 3.390000Phenolas Crease-10 0.500000 2.260000Chemical 540 0.500000 2.260000Phenolas fax-33 1.000000 4.520000
Sequence of polyester part and cotton part dyeing:
Water is taken in the dye bath. And then fabric is loaded in the machine. Wetting agent, anti creasing agent, sequestering agent are added to the dye bath. And circulate the fabric for 5 minutes. Then caustic soda is added at 600c and raises the temperature at 1000c and circulates the fabric for about 30 minutes. Then the bath is drained with rinsing wash. Then acetic acid is added and temperature raised at 600c and run for 10 minutes for neutralization. Then drain the bath. Water is taken in the dye bath at the required level. Dispersing agent, anti creasing agent, fixing agent, leveling agent, and buffer solutions are added to the dye bath and circulate the fabric for 5 minutes at 600c. Then acetic acid is added to the dye bath. After running 5 minutes pH is checked of the dye bath. pH is maintained at 4.5. Then polyester dyes are added to the dye bath at linear dosing and fabric is circulated for 10 minutes at 600c temperature. Then temperature is raised at 1300c and fabric is circulated for 45 minutes. Then temperature is decreased at 600c. Then shade is checked. Then bath is drained off. Then again required amount of water caustic soda and hydrose are added to the dye bath. And circulate the fabric for 10 minutes raising temperature at 800c. Then drained. It is called reduction cleaning. Then the bath is drained again. Take water at required level. Raise the temp at 600c & circulate the fabric. Add sequestering agent, anti creasing agent, fixing agent & leveling agent. pH remain at 6.6 Circulate the fabric for 3-5 min at constant temp. Glauber salt is added. Then color is added by linear dosing for 25 minutes and run for 20 minutes. Then soda ash & caustic are added by curve dosing for 45inutes. pH remains 11 and run for 30 minutes. Then shade check at 600c. Bath is drained. Take water at required level the take acetic acid and run for 10 minutes and drain. It is called neutralization. Then drain. Take water at required level and add soaping agent, anti creasing agent, sequestering agent, fixing agent. Then raise temperature at 850c and run for 10 min