One Composite Mills Pvt Ltd (Wet Processing Technology)
Introduction
The purpose of this report is to aware the viewer about the technical processes that takes place in a mill. Technical education, practical experience is almost equally necessary in association with the theoretical knowledge. The industrial attachment is the most effective process of achieving the practical experience. It provides us sufficient practical knowledge about production management, productivity, evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory control, purchasing, utilities and Maintenance of machinery and their operation technique etc.
ONE COMPOSITE MILLS LTD. is a well established knit composite industry. The industry stands on industrial area of Gazipur. ONE COMPOSITE MILLS LTD. Is a Group of Companies, ONE SP1NNING,ONE DENIM. ONE GROUP LTD. is going to prove its own standard about product quality in world market as they know that their reputation depends on its quality. ONE GROUP LTD. is a profitable project and contributes the economy of our country.
OBJECTIVE OF INDUSTRIAL ATTACHMENT
Physical infrastructure:
The mill is built in such a way that there is possibility for further expansion of the mill. The structure such as mill, office buildings, record rooms, guardrooms & dining room etc. are made of solid hard concrete & brick . The whole area is surrounded by safety brick wall .The main set up for are built of corrugated iron & iron sheet, transparent hard plastics with enough ventilation & scope for passing light & air.
Management System:
• Intercom telephone
• Fax
• Written letters &
• Oral
Shift Change:
There are three shifts in the industry. So the shifts are changed at every 8 hours.
Shift Change! for worker of Security:
A Shift — 06:00 — 14:00
B Shift — 14:00 — 22:00
C Shift—22:00—06:00
General shift:
09:00— 18:00
Office Time
09:00 — 18:00
Responsibilities of Production Officer:
1. To give dyeing program slip.
2. To match production sample with target shade.
3. To collect production sample for sample matching next production.
4. To observe dyed fabric during finishing running & also after finishing.
S. To identify disputed fabrics & report to P.M/G.M for necessary actions.
6. To discuss with P.M. about overall production if necessary.
7. To sign the store requisition & delivery Chillan in the absence of P.M.
8. Also to execute overall floor works.
9. To maintain loading/unloading khata.
10.Any other assignment given by higher authority.
Job Description of P.O & S.P.O:
Job title: Production officer & Senior Production officer
Report to: Production Manager
Purpose:
To control shift accoTding to the plan made by the production manager
Territory:Dyeing section (major)
Batching and Finishing section (minor) ~~ure and Scope:
Role within the organization:
Responsible for own shift production with good quality and minimum time.
Environment:
Production officer has to work under huge stress. He has to work in acute heat under physical and mental pressure. Also he has to work in acute heat all the year round.
Job Description of Production Officer:
Report To: Sr. production officer
Job Summary:
To plan, execute & follows up the production activities & control the quality production with related activities.
Duties & Responsibilities:
Ø Overall supervision of dyeing, finishing production.
Ø Batch preparation & PH check.
Ø Dyes & chemical requisition issue & check.
Ø Write fabrics loading & loading time from mlc.
Ø Program making, sample checking, color management.
Ø Control the supervisors, operator, asst. operator & helpers of dyeing milk.
Ø And also any other work as & when required by the management.
Job Description of Sr. Production Officer:
Report To: P.M (production)
Job Summary:
To plan, execute & follows up the production activities & control the quality production with related activities.
Duties & Responsibilities:
Ø Overall supervision of dyeing, fmishing production.
Ø Checks the different log books of different areas & report to management.
Ø Checks the sensitive parameters of different machine for smooth dyeing.
Ø Checks out the plan to control the best output from supervisor & workers.
Ø To trained up & motive the subordinates how to improve the quality production.
Ø Maintenance of machine & equipment. Any other works & when required by the management.
Ø Control the supervisors, operator, asst. operator & helpers of dyeing mlc.
REMARKS:
The manpower management system ONE GROUP LTD. is well arranged. Every officers & stuffs are responsible for their duty. But there are only six textile engineers in the industry (2 for dyeing, Finishing). It is sufficient for fluent production. The efficiency of the worker should be increased for more quality production.
Knitting
Knitting section is divided in 1ou.r sections,
1. Inspection section
2. Circular Knitting section
3. Store section
1. Cloth Inspection Section:
In cloth inspection section two machines are available. Specification of those machines is given below.
Type Cloth Inspection Machine
Manufacturer name Uzu fabric Inspection
Country Thailand
Model No. UZ 900.31
2. Circular Knitting Section:
This section contains 13 circular knitting machines. Circular knitting machines are of different types, made by same manufacturer. In this section body fabric for knitted garments is produced. The different specifications of different machines are given one after another.
Knitting Machine
| Machine no: 01Machine type: Single jersey
Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 30”; 24G Extra cylinder: 30”; 20G No of needle: 1860 No of feeder: 90 |
Machine no: 2Machine type: Single jersey
Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 26”; 24G Noofneedle: 1932 No of feeder: 78 |
| Machine no: 03Machine type: Single jersey
Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 26”; 24G No of needle: 1932 No of feeder: 78 |
Machine no: 04Machine type: Single jersey
Brand: Origin: Kobe, Japan Machine dia &Gauge: 30”; 24G Extra cylinder: No of needle: 2268 No of feeder: 90 |
Machine no: 05 Machine no:6
Machine type: Single jersey Machine type: Rib
Brand: Mayer & Cie Brand: Mayer & dc
Origin: Germany Origin: Germany
Machine dia &Gauge: 36”; 24G Machine dia &Gauge:34”; 1 8G
No of needle: 2712 No of needle: 3840
No of feeder: 108
Machine no: 7 Machine no: 8
Machine type: Interlock Machine type: Interlock
Brand: Mayer & Cie Origin: Germany Brand: Mayer & Cie Origin: Germany
Machine dia &Gauge: 30”; 24G Machine dia &Gauge: 30”; 24G
No of needle:4 128 No of needle:4 128
No of feeder: 90 No of feeder: 90
Machine no:9 Machine no: 10
Machine type: Flece Machine type: Fleece
Brand: Mayer & Cie Brand: Mayer & Cie
Origin: Germany / Origin: Germany
Machine dia &Gauge: 30”; 24G Machine dia &Gauge: 30”; 24G
No of needle:4128 No of needle:4 128
No of feeder: 90 No of feeder: 90
Machine no: 11 Machine no: 12
Machine type: Rib Machine type: Auto strip
Brand: Mayer & Cie Brand: Mayer & Cie
Origin: Germany Origin: Germany
Machine dia &Gauge: 34”; 18 G Machine dia &Gauge: 30”; 24G
No of needle:3840 No of needle:2208
No of feeder: 90
No of Machine for Dyeing and Finishing Section:
DYEING SECTION:
Dyeing Machincthies-O1
Type Jet Dyeing Machine
Manufacturer name Thies
Country Germany
Model No. ECO-38-2T
Year of manufacturing 2002
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 10 KG
Dyeing Machine.02
Type Jet Dyeing Machine
Manufacturer name This
Country Germany
Model No. ECO-38-2T
Year of manufacturing 2002
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 10 KG
No. of Nozzle I
Dyeing Machine.03
Type Jet Dyeing Machine
Manufacturer name Thies
Country Germany
Model No. ECO-38-2T
Year of manufacturing 2002
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 30 KG
No. of Nozzle 1
Dyeing Machine. 04
Type Jet Dyeing Machine
Manufacturer name Thies
Country Germany
Year of manufacturing 2000
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 250 KG
No. of Nozzle 1
Dyeing Machine.05
Type Jet Dyeing Machine
Manufacturer name Thies
Country Germany
Year of manufacturing 2000
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 350 KG
No. of Nozzle 2
DYEING SECTION:06
Type Jet Dyeing Machine
Manufacturer name Thies
Country Germany
Model No. ECO-38-2T
Year of manufacturing 2002
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 10 KG
Dyeing Machine. Thies-07
Type Jet Dyeing Machine
Manufacturer name THIES
Country Germany
Year of manufacturing 2002
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 9
Production Capacity 500 KG
No. of Nozzle 2
Dyeing Machine. Thies-08
Type Jet Dyeing Machine
Manufacturer name THIES
Country Germany
Year of manufacturing 2000
Temp. Range 0°-140°C
Used Utilities Water, Steam, Electricity,
Compressed Air
No. of Motor 7
Production Capacity 750 KG.
No. of Nozzle 3
FINISHING SECTION:
Finishing:
Textile finishing, in a restricted sense, is the term used for a series of processes to which all bleached, dyed, printed and certain grey fabrics are subjected before they are put on the market. In fact, finishing includes the final treatment of every kind of fabric made from every kind of fiber.
Objective of finishing:
Ø Improving the appearance — Lecture, whiteness, etc.
Ø Improving the feel, which depends on the handle of the material and its softness, suppleness, fullness, etc.
Ø Wearing qualities, non — soiling, ant crease, antis rink, comfort, etc.
Ø Special properties required for particular uses — water — proofing, flame —proofing, etc..
Ø Covering of the faults in the original cloth.
Ø Increasing the weight of the cloth.
Types of finishing:
1. Chemical finishing:
2. Chemical reaction of auxiliaries with fibers.
3. Application of the handle modifying products I additives.
4. Mechanical finishing:
Ø Mechanical treatment with machines. Finishing effects:
Ø Easy—care
Ø Crease recovery.
Ø Dimensional stability.
Ø Good abrasion resistance.
Ø Improved tear strength.
Ø Good sew ability.
Ø Soft or stiff handle.
Ø Shine or luster
Raw Material for Knitting
The raw material for knitting is the yarn. Different types of yarn of wide range of count are used. In yarn store section we had the chance to know about different yarns of different count used in ONE COMPOSITE MILLS LTD . We also have known different yarn manufacturer/suppliers name for this knitting section i.e. sources of yarn. Both carded and combed yarn is used for knitting.
Generally used yarn and their count:
Cotton 24.s, 26S 28~, 3çjS 32S 34S
Polyester 75D, 100D
Spandex yarn 20D,40D, 70D
Grey Mélange (C_ 24s, 26S
Ecru Mélange (C-85% V-15%) 24S 26s~, 28s
Anthra Mélange (C-65% V-35%) 24S 26S 28S
PC (65%Polyester & 35% cotton) 24S 26S 28S 30S
CVC 24s, 25S 28S .30S
| Count | Tyep | Composition | Price/ Kg |
| 24S | carded | 100% | 140/- |
| 140/- | |||
| 30S | Carded | 100% | 170/- |
| Combed | 180/- | ||
| 40S | Combed | 150/= | |
| 100D | Polyester | ||
| 75 D | Polyester | ||
| 28/ | cbac |
Raw Material for Dyeing
ONE COMPOSITS MILLS LTD. is a knit composite textile industry. In the industry the raw materials used for production are:
1. Grey fabrics
2. Dyes
3. Chemicals.
1. Grey Fabrics:
Following types of gray fabrics are dyed:
Ø Single jersey
Ø Single jersey with lycra
Ø Polo pique
Ø Single lacoste
Ø Fleece
Ø Interlock
Ø Interlock with lycra
Ø Rib
Ø Rib with lycra
Ø 1X1 rib
Ø 2X2 rib
Ø Different types of collar & cuff
2. Chemicals:
List of Chemicals Used In ONE COMPOSTT MILLS Ltd.
Acid
1. Acetic Acid
2. Hydrochloric Acid
Detergent
1. FelosanNOF
Washing Agent
1. CibaponR
Levelling Agent
1. Cibacel DBC
Sequestering Agent
1. Invatex CS
SALT
1. Gluber Salt
2. Common Salt
Whitening Agent
1. UvitexBAM
2. Uvitex BHV
3. Hostalux ETBN (For polyester fabric)
4. BlutonBBV
Softener
1. Alkamine CWS
2. SapamineFPG
3. Sapamine 544
4. Magasoft TET
5. Megasoft FMG (For White Fabric)
Fixing Agent
1. Sandofix BC
Reducing Agent
1. Hydrose
Bleaching Agent
1. H2O2
Enzyme
1. Bioace
2. Tinozyme 44L
Stabilizer
1. Tinoclarite CBB
Anticreasing Agent
1. CibafuidC
PH Controller
1. Acid
2. Neutracid RBT (Non volatile)
3. Soda Ash
4. Caustic
Per-oxide Killer
1. Invatex PC
Source:
Dyeing department of ONE COMPOSITE MILLS LTD. receive grey fabric from knitting department of this company. According to buyer order, store officer receive the grey fabric and he maintains the delivery of finished fabric. Source of the Dyes of ONE COMPOSITE MILLS LTD. are Swiss Color, Dyestar, Bezema, Clariant, Impo color etc.
Annual Requirements,:
To determine annual requirements is very tuff It mainly depends on the buyer order and subcontract order. When the buyer order is large then the consumption is high and vice-versa. The annual requirements of grey fabric depend on the buyer order and the requirements of dyes and chemicals depend on the colour depth.
Remarks:
For smooth running of a factory uninterrupted supply of raw materials is very essential. As far as we saw the raw material control of ONE COMPOSITE MILLS LTD. is good.
Sequence of Operation for Knit Dyeing:
Grey fabric inspection
Batching
Fabric turning
Loading to the mlc
Pre-treatment (Scouring & Bleaching)
Dyeing
Dewatering
Drying
Compacting & Calendaring
Final inspection & packing
Production Parameters:
1) P11
– During H202 bleaching pH 9.2-12
– During reactive dyeing pH 10.5-12.5
– During disperse dyeing pH 4.5-6.0
1) Temperature:
For cotton scouring: 90°-95°C
-For cotton cold wash: 30°-40°C
-For cotton hot wash: 70°-80°C
-For cotton acid wash: 60°-70°C
For cotton dyeing: 80-90°C (For hot brand)
60°C (For cold brand)
Polyester dying: 100°-130°C
2) Time:
For Scouring: 60-90 minutes
– For Disperses dyeing 60-90 minutes.
3) M: L ratio:
– For reactive dyeing M: 1 ratio maintained between 1:6 to 1:10.
Description of Production Process:
Washing for colored fabrics:
• The colored fabrics, to be washed is loaded in the machine
• Required amount of water is taken.
• Felosan NOF (detergents) added & washing continued at 80° C for 20 minutes.
• Cold washing
Scouring tab1eaching:
• Fabric, to be scoured is loaded in the machine
• Required amount of water is loaded
• Washing agent~ detergent is added
• Steam pipes are on & scouring agents
* caustic soda! soda ash) added when the temperature reaches at 70° C
• Then H202 is added.
• Temperature is then raised to 105° C & the process is then carried out for 60-90 minutes depending on the requirements.
• The liquors are then drained.
• Then wash with Felosan NOF (detergent) at 98°C for 5 mm.
• Then cold wash, at 35°-45°C & acid wash, at 60°-70°C is done.
Dyeing:
• After acid wash all liquors are drained out.
o Required amounts of water is taken
• Then leveling agents, anti-creasing agents, dc-foaming agents are added
according to the requirements.
• Steam pipes are on & after 10-15 minutes dyes are added.
• Salts are added and runtime is 15-20 minutes.
• Then soda ash, after another 35minutes.
• Then the temperature is raised slowly up to the mark.
• The process is carried on & samples are taken after every 30-40 minutes to match
with the target shade. It continues until shade matching.
• If the sample is matched, then the liquor is drained out.
• Then cold wash at 35°-45°C.
• Wash with Cibapon R (Washing agent) for 5 minutes.
• Acid wash at 55°C is done.
• Fixing agent is added at 45°C for 15 minutes.
• Then softener is added at 45°C for 15 minutes.
The Quality assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. ONE COMPOSITE MILLS LTD is more about concern about quality. In this factory quality assurance is more preferred than quality control, but both are in advancement.
After collecting fabric rolls from different rn/cs, they are needed to be inspected or assured required quality by the quality inspectors as if there were no big production hampered and no complain from the buyers. Here are the details about it.
Objects of Quality Control:
1.Research.
2.Selection of raw materials.
3.Process control.
4.Process development.
5.Product testing.
6.Specification test
Scope for quality control quality assurance and testing:
1.Testing lab
2.Machine auditing system
3.A good training system
4.Excellent analytical back up
5.Teclmical expertise
Quality Control in Grey Fabric Inspection:
Some Points Are Needed To Maintain For High Quality Fabric:
a) Brought good quality yarn.
b) Machines are oiled and greased accordingly.
c) G.S.M, Stitch length, Tensions are controlled accurately.
d) Machines are cleaned every shift and servicing is done after a month.
e) Grey Fabrics are checked by 4 point grading system.
List of Equipments:
In this factory ONE COMPOSITE MILLS LTD. this is the list of equipments to assure quality:
1) Inspection mlc # 1
2) Inspection mlc #2
3) Scissors
4) Electronic balance
5) GSM cutter
6) Indication sticker
7) Measuring tape
Quality Assurance Procedure:
1)Body & Rib Inspection:
All rolls are kept in front of the inspection rn/c time to time and are inspected over the inspection mlc visually in a pre-set speed against light. For any major or minor faults like thick-thin, barer mark, fall out, contamination, fly, holes, oil lines, needle line, stubs etc are recorded in inspection report to classify the fabric based on the four point system.
2)Collar & Cuff Inspection:
Collar& cuff are inspected visually under the light box, any major or minor faulty collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly counted and recorded.
Quality Standard:
ONE COMPOSITE MILLS Ltd. maintains the ISO: 9002 standard in case of quality. Therefore, the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inspection at ONE COMPOSITE MILLS Ltd.
Four point grading system
Size of defects Penalty
3 inches or less 1 point
Over 3 inch but not over 6 inch 2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point
Following table shows common body and rib faults and response by inspection section at
ONE COMPOSITE MILLS Ltd. :-
Rejection criteria for body & ribs
No. Faults Response
1. Needle mark Major needle line is rejected
2. Stripe Major needle line is rejected
3. Bane mark: Rejected
4. Contamination & fly Approved for color but for white shed I
point is assigned
5. Slubs 1 point
6. Thick thin place Reject
7. Birds eye 1 point
8. Pinholes 1 point
9. Wrong design Reject
10. Mixed yam Discuss with manager
11. Sinker mark Major sinker mark is rejected.
12. Missing yarn Use 4 point
13. Holes Do
14. Oil line/stain Do
15. Chemical Do
16. Dirt stain Do
17. Crease line Do
18. Uneven tension Discuss with manager
Following table shows common collar and cuff fault and response taken by inspection section at ONE COMPOSITE MILLS Ltd.:
Rejection criteria for collar & cuff
No. Faults Response
1. Wrong ply Reject
2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7. Fly & contamination : Acceptable for color but not for white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
15. Wrong tube Reject
Following table shows the acceptance calculation followed by the inspection section at ONE COMPOSIT MILLS Ltd.:Acceptance calculation
Factory: Roll yardage (A)
Total points founds(B)
Formula : Xl 00 points per 100 yard
Classification:
< 40 points = Atype
41-60 = Btype
61-80 = Ctype
Above 8opoin = Reject
Quality Control in Dyeing And Finishing:
ONE COMPOSITE MILLS LTD. assures the quality of the products of dyeing section in the following three steps:
1. In laboratory
2. In Dyeing section &
3. In Finishing Section
Procedures are described below:
In laboratory:
Swatch card from buyer according to their requirement
Recipe prediction for sample dyeing
Sample dyeing until matching with swatch card
Fastness & other tests of the fabric or yarn are done here.
In dyeing section:
According to the buyer’s sample, sample dyeing is done in sample dyeing machine in dyeing shed & again matched with the approved sample.
If result is OK, then bulk production.
During dyeing, samples are taken until accurate shade matching. The interval may be 3 0-40 minutes.
After dyeing sample is collected after softening matching is done.
Last of all, sample is collected after fixation & matched.
Then allowed the fabrics to be finished.
In finishing section:
By using a series of finishing machines correct width, softness & appearance are maintained according to requirements.
Then sampling is done for several times to test GSM, Shrinkage & fastness properties.
Finally fabric is inspected & prepared for delivery.
Quality Standard:
ONE COMPOSITE MILLS LTD. follows the quality standard: ISO-9002:2000.
List of Equipments:
In the Quality Assurance Department the followings equipments are used –
Ø Yarn Grade Tester
Ø 78-i Magnetic Stirrer
Ø KERN Electronic Balance
Ø Spray Rating Tester
Ø Incubator
Ø Iron
Ø Button Tester
Ø Ahiba Nuance Lab. Dip Dyeing Machine
Ø Thermostatic Water Bath
Ø Digital Pipette
Ø Creda Dryer
Ø Rota Wash
Ø Electrolux Washcator
Ø Orbitor Pilling & Snaging Tester
Ø Marks & Spencer Holoscope
Ø Tm Brust
Ø Crock Meter
Ø Push — pull tester
Ø Megasol (Light fastness tester)
Ø Spectro Photometer with software (Data Color)
Ø Thermo hygrograph
Ø a pH meter
Tests
There are two types of tests are done in Quality Assurance Department. They are —
1. Physical Tests
2. Chemical Tests
Physical Tests:
Ø Yam Grade
Ø GSM test
Ø Shrinkage test
Ø Spirality test
Ø Tensile strength
Ø Abrasion resistance
Ø Pilling resistance
Ø Button Strength Testing
Ø Lycra% determination
Ø Crease resistance
Chemical Tests:
• Fastness to washing.
• Fastness to light
• Fastness to actual laundering
• Fastness to sea water
• Fastness to water
• Fastness to perspiration
Fabric Inspection:
The inspection of fabric is a procedure by which the defects of fabric are identified and fabric is classified according to degree or intensity of defects. The fabric inspection is done for both grey and finished fabric.
Grey Fabric Inspection:
Grey fabric inspection is performed according to 4-point system.
Finished Fabric Inspection:
4 point numbering system is followed for finished fabric inspection. Defects found in the final inspection:
1.Uneven shade
2. Oil spot
3.Neps
4.Crease mark
5.Machine Stoppage mark
6.Listing
7.Line mark
8.Pick missing
9.Double yarn
10.Dead cotton
11. Bowing
12.Fly yarn contamination
Procedure of the Different Tests:
Different types of fastness tests of the dyed fabric are done in quality control department of the ONE COMPOSITE MILLS LTD. Different types of method (Standard or buyer’s recommended) are followed for different types of tests. The process of the different tests of fabrics & lab. dip dyeing is described in the following section:
Color Fastness Test Procedure Color Fastness:
The “color fastness” of a colored textile is defined as its resistance to these changes when subjected to particulates of conditions. It follows that color fastness must be specified in terms of these changes and expressed in terms of the magnitude.
1. Color Fastness to Wash Test
Required materials:
1. Sample size 40 x 100 mm
2. Multifiber at 40 x 100 mm
3. ECE detergent (WOB) — 4gIL
4. Sodium Perborate (Na2BO3.H202.3H202-lg/L) – lgfL
5. Distilled water
6. Normal cold water
7. Steel balls
Required instrument:
1. Rota Wash
2. Scissor
3. Stitch machine
Procedure:
1. Cut sample & multifibre at 100 x 400 mm and then stitch.
2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the sample.
For Marks & Spencer, the solution is taken by the following formula: (Sample fabric + Muitifibre weight) x 50 ml
3. The sample is kept in 60°C for 30 minutes in Rota Wash Machine
4. Rinse the sample twice with cold water.
5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not be more than 150°C.
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey Scale & Staining Scale.
2. Color Fastness to Perspiration Test
Test specimen:
• Samplefabric—5Ommx 50nmi
• Multifibre fabric —50 mm x 100 ram
• Cut the multifibre into two piece
• Sandwich the test specimen between two piece of multifibre
Testing Solution:
1. Alkaline Solution:
Histidine monohydro chloride monohydmte (C6H10C1N302.H20)— 5.00 g/L NaC1—5.OOg/L
Disodium hydrogen orthophosphate (Na2HPO4.2H20) — 2.5 g/L pH —8 (Adjust by 0.1 N NaOH)
2. Acidic Solution:
ilistidine monohydro chloride monohydrate (C6H10CIN3O2.1120)— 5.00 g/L
NaC1 – 5.00 gIL
Sodium di-hydrogen orthophosphate (NaH2PO4.2H20) — 2.2 g/L
PH — 5.5 (Adjust by 0.1 N NaOH)
3.Method:
Ø The composite specimen is put in a pen dish (2 specimen of a sample).
Ø Solution (Alkaline & Acidic) is taken in the two pen dish. Here, M:L is taken 1:20.
Ø Bubble is made out from the specimen by tapping.
Ø The specimen is put for 30 minutes.
Ø A glass plate is placed on the composite specimen for 15 minutes at room temperature.
Ø Excess solution is poured off.
Ø Pen dish with composite specimen & glass plate is placed into the incubator at (37±2) °C for 4 hours.
Ø The specimen is dried (Temp _ 60°C)
Ø Report:
Ø Change of shade & degree of staining is measured by the Grey Scale & Staining Scale.
3. Color Fastness to Water Test
Test specimen:
Sample fabric—SO mm x 50mm
• Multifibre fabric —50 mm x 100 mm
• Cut the multifibre into two piece
• Sandwich the test specimen between two piece of multifibre
Testing Solution:
. Water is taken as required
Method:
Ø The composite specimen is put in a peri dish (2 specimen of a sample).
Ø Water is taken in the pen dish as required.
Ø Bubble is made out from the specimen by tapping.
Ø The specimen is put for 30 minutes.
Ø A glass plate is placed on the composite specimen for 15 minutes at room temperature.
Ø Excess solution is poured off.
Ø Pen dish with composite specimen & glass plate is placed into the incubator at (37±2) °C for 4 hours.
Ø The specimen is dried (Temp _ 60°C)
Report:
Change of shade & degree of staining is measured by the Grey Scale & Staining Scale.
5. Color the Fastness to Rubbing (Dry & Wet) Test
Sample:
Ø Dyed fabric—l5cmx5cm
Ø White Test Cloth – 5 cm x 5 cm
Procedure:
Ø White test cloth is put on to the grating and stag by steel wire.
Ø The sample is run twenty times manually for ten ‘seconds. and the rubbing fastness of the sample cloth and degree of staining is accessed.
Ø For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked and squeeze. The wet rubbing cloth is placed on to the grating and stag with stainless steel wire and run ten times manually then assess the staining on to the rubbing cloth and the rubbing fastness of the sample cloth is accessed.
Report:
– Change of shade of the sample is measured with grey scale and degree of staining of the white test cloth is measured by Staining Scale.
There are also some tests are done in the lab. And the process is described below
A. Measuring the Dimensional Stability (Shrinkage & Spiral it)
Sample:
• Two piece of 50 cm x 50 cm fabric is taken for test.
Procedure:
a. Conditioning: Put the sample in table for 4 hrs for conditioning before starting test.
b. Cut the sample 50×50 cm & benchmark should be 35×35 cm. Stitch the sample (3 sides) by over lock sewing machine.
c. Put sample in washing machine and run according to buyer’s choice.
d. Drying: All Buyers’ requirement is tumble Dry except ECHO SCOURING is flat dry.
SHRINKAGE TEST CALCULATION:
Before wash — After wash
Shrinkage%= 1x1oo
Before wash
Spiraled test calculation:
S=(S1-I-S2)12
Spiraled = (S+S x L)/100.
Suppose,
S1 = The right side distance of the specimen from the stitch line after
wash.
S2 = The left side distance of the specimen from the stitch line after
wash.
L = Length before wash
B.pH of a Dyed Fabric Test
Test specimen:
1. 2 gm of dyed fabric is taken.
2. The fabric is cut into pieces of (0.5 cm x 0.5 cm)
Procedure:
1.The sample is taken into conical flax.
2.100 ml distilled water (slightly warm) is taken into the conical flax.
3.The conical flax is put on the Magnetic Stirrer for 30 minutes.
Report:
The P1’ of the conical flax is measured by Digital p” meter.
Lab. Dip Dyeing
1. Sample: Type – 100 % cotton fabric
2. -Weight—Sgm
Procedure:
At first the recipe for the sample is calculated according to the sample weight.
-The fabric is kept in the dyeing chamber.
-Then the dyes, chemicals, salt & required amount of water is taken in that dyeing chamber by digital pipeting on the basis of stock solution.
-Then the beaker is set into the lab. dip. dyeing machine for dyeing.
-The program for dyeing is started for 20 mm at 40°C.
-After 20 mm soda is added by pipeting.
-Then the dyeing program is set for 60 mm at 60°C.
Ø When the dyeing time is finished the sample is taken out from the machine at
Ø 40°C. Then the sample is washed off. At first cold wash & then hot wash is done. After it soaping is done. Then the sample is dried and compared with standard.
Recipe Curve:
Progressive Process For Lab. Dip. Dyeing
Recipe Calculation:
A dyeing recipe for purple color is given below:
Sample Weight —5 gm M : L—l:10
Liquid Required —50 c.c.
Sunfix Yellow S3RD —9.3 c.c. (Shade — 1.86%)
Sunflx Red S3BD — 10.2 c.c. (Shade —4.08%)
Sunflx Yellow S3RD —9.3 c.c. (Shade — 1.86%)
Remazol Blue RR — 6.5 c.c. (Shade — 1.3%)
Salt (80 g/L) — 10 c.c. (40% stock)
Soda (20 g/L) — 2.5 c.c. (40% stock)
Water— 11.5 c.c.
Salt and soda is taken on the basis of the shade%. The salt and soda is used according to the following table:
Shade % Salt g/l Soda g/l
0.001-0.100 20 6
0.101-0.500 24 8
0.501-1.000 30 10
1.001-2.000 40 12
2.00 1-3.000 50 14
3.001-4.000 60 16
Above 4.000 1 80 20
Response of Q.C Officer:
Response to Q.C Faults:
Faults Response
Yarn fault Inform yarn supplier
Knit fault Inform knitting department
Response to Machine Fault:-
Faults Response
Any electrical fault Inform electrical maintenance
Any mechanical fault Inform mechanical maintenance
Remarks:
ONE COMPOSITE MILLS LTD. always aware about the quality of the product. The quality of the product is always approved by the buyer. They follow the quality standard: ISO – 9002:2000. ONE COMPOSIT MILLS LTD. is well equipped for checking the quality of the product. They sent the quality report to the buyer time to time/batch to batch. We think as ONE COMPOSITE MILLS LTD. strictly meet up the quality level that’s why they are the only one direct manufacture of Marks & Spencer garments.
Maintenance:
Machine, buildings and other facilities are subjected to deterioration due to their use and exposure to environmental condition. Process of deterioration, if unchecked, culminates in rendering these service facilities unser: ~able and brings them to a standstill. In Industry, therefore has no choice but to attend them from time to time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so.
Objectives of Maintenance:
Ø To keep the factory plants, equipments, machine tools in an optimum working condition.
Ø To ensure specified accuracy to product and time schedule of delivery to customer.
Ø To keep the downtime of machines to the minimum thus to have control over the production program.
Ø To keep the production cycle within the stipulated range.
Ø To modify themachine tools to meet the need for production
Maintenance of Machinery:
Maintenance
Preventive Maintenance Break Down Maintenance
Electrical Mechanical Electrical Mechanical
Maintenance Maintenance Maintenance Maintenance
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time inspection /checking of facilities to uncover conditions that may lead to production break downs or harmful description.
Break Down Maintenance:
In this case, repairs are made after the equipment is out of order and it cannot perform its normal functions.
Routine Maintenance:
Maintenance of different machines are prepared by expert engineer of maintenance department. Normally in case of dyeing machine maintenance after 30 days complete checking of different important parts are done.
Manpower Set-Up For Maintenance
• AShift 6AM – 2PM
• B Shift 2PM – 10PM
* General Shift 9AM – 6 PM
Maintenance Manager
Mechanical Electrical
Mechanical In charge —02 Electrical foreman
Diploma (Mechanical) — 02 Diploma (Electrical) —02
Welder and fitter — 01 Electrician – 02
Fitter —01
Maintenance Procedure:
Normally preventive maintenance should be done. During maintenance procedure following points should be checked:
Maintenance of knitting machine/flat knitting machine:
Items need to be checked & Serviced
1) Check and tightening all motor terminals.
2) Check and clean pressure sensor and tightening terminals
3) Clean the ventilation fans of panel board and circular fan on top of machine.
4) Check and clean the interfacing and data cables.
5) Check and tightening the proximity switch terminals.
6) Inspection, cleaning and tightening all the terminals in the panel.
7) Check and tightening limit switch, safety door guard and the emergency switch.
8) Functional test of the yarn detector.