Industrial Attachment Intramex Group

view with charts and images
Industrial Attachment Intramex Group

Introduction

Textile and garments sector is the biggest and fastest growing sector in Bangladesh. It is also the highest foreign currency earning sector in Bangladesh. Among this sector, Knit garment is growing very rapidly due to smaller investment requirement, greater backward linkage facility & higher profit than woven garments. That’s why export knit garments is increasing steadily for last few years and up to now. Industrial training is very much important for textile education. I have gathered a lot of information’s from this Industrial training which will help me to lead my future life and as well as the greater development in textile fields. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at INTRAMEX GROUP, which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing.

General information about the companyName of the company: INTRAMEX GROUP

Factory:INTRAMEX Group Laxmipura, Jaidebpur,

Gazipur.BangladeshEmail: info@intramex group.com

Different Sections

INTRAMEX Knit-Dyeing Composite Unit: a) knitting Section:KnittingInspectionb) Dyeing section:Batch sectionDye houseDyeing lab.Quality controlFinishingc) Garments section:MerchandisingSampleCutting SectionSewing SectionFinishing Section

d) Maintenance section:ElectricalMechanical

e) Store Section

f) Administration Sectiong) Security Section

h) Marketing Section

i) Production Planning & Controlj) Human Resource & Development Section

INTRAMEX GROUP INFORMATION:

Nature of company : 100% Export Oriented Knit composite Factory.

Certification : FARE TRADE As a textile conglomerate having, 40320 spindle spinning. Given by, FLOCERT GmbH of Germany in 2007.

Qualify Certification: ISO 9002 Marks & Spencer NANOTEX TUV DuPont Teflon Puma DOTS by Cu (Control union) OE by CU (Control Union)

BGMEA from compliance Award-2009 Capacity: Garments – 3.2 million pcs/Month Embroidery – 8000 pcs/day Printing – 30000 pcs/day Knit Fabric – 600 tons/month Dye Fabric – 30 metric tons/.day Washing – 12000 pcs dyeing & 40000 pcs Wash/day Cotton yarn –8142 metric ton ring spoon & 2124 metric Ton rotor spoon cotton yarn/year Woven RMG – 24000 pcs/day Hanger – 50000 pcs/day (Average) Poly –PE-2.5 tons/day 7 pp-1500 kg/day Buyer:

Name of The Buyer CountryMarks & Spencer U.KS.Oliver GermanyLi fung JapanGap U.S.APuma GermanyEsprit GermanyG-Star NetherlandPVH U.S.ACelio FranceAbercrombie& Fitch U.S.AGerry Weber Germany

Unit History, Location, Manpower & Item of Product

Unit Location Manpower Finished GoodsINTRAMEX Garments 1996 Laxmipura, Jaidebpur,Gazipur.Bangladesh 5500 Readymade Garments ( knit) + Embroidery)INTRAMEX Fabrics 2002 Laxmipura, Jaidebpur,Gazipur.Bangladesh 1200 Knit Fabric ( Dyeing, finishing & washing)INTRAMEX Spinning 2005 Laxmipura, Jaidebpur,Gazipur.Bangladesh 1100 Cotton YarnInterfab Shirt Mfg. Ltd 1998 Laxmipura, Jaidebpur,Gazipur.Bangladesh 2400 Readymade Garments (Woven)Gothic Design Ltd. 2007 Laxmipura, Jaidebpur,Gazipur.Bangladesh 400 Printing of fabricFashion Plastic & Packaging Ltd.2003 Laxmipura, Jaidebpur,Gazipur.Bangladesh 100 Poly, Hanger & Button Poly,Hanger & Button

RAW MATERIAL Raw materialRaw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric.

Types of raw material: 1. Yarn 2. Fabric 3. Dye stuff 4. Chemical and auxiliaries

Name and source:

Yarn: The raw material (cotton yarn) used in Knitting are the product of INTRAMEX Spinning Ltd. They produce carded and also combed yarn according to their buyer requirement. The yarn count range vary for carded yarn from (34/1) to (7/1) Ne. The yarn count range vary for combed yarn from (40/1) to (20/1) Ne.

Mellange:Mellange is produced by blending different amount of top dyed fibre with grey fibre. Different types of mellange used in knitting are: Mellange

White/Ecru mellange Grey mellange Anthra mellange(Dyed fibre 0.2-2%) (Dyed fiber 2-15%) (Dyed fibre 15-30%)

Sources of mellange: PatartoliPrimeShohag purThermax

Sources of polyester:

Kader Synthetic.China.Count: 75den, 100den, 150den.Sources of Lycra:

* Brand : Texlon Country : Korea.

*Brand : Acelen Country: China

*Brand : Creora Country: Japan

*Brand : Lioli (In INTRAMEX used mostly) Country: China

Count: 20 den, 40 den, 70 den.

Price list of different types of yarn:

Cotton:

Yarn Count Combed Yarn Carded Yarn40/1 3.65 $/Kg 2.65-2.7 $/Kg34/1 3.00 $/Kg 2.5-2.6 $/Kg32/1 2.90 $/Kg 2.30 $/Kg30/1 2.70 $/Kg 2.30 $/Kg28/1 2.70 $/Kg 2.25 $/Kg26/1 2.65 $/kg 2.25 $/Kg24/1 2.60 $/Kg 2.25 $/Kg22/1 2.55 $/Kg 2.20 $/Kg20/1 2.50 $/Kg 2.15-2.2 $/Kg

Polyester Yarn: Kader Synthetic – 2.40 $/Kg China – 1.60 $/KgLycra Yarn: 20 den – 12.70 $/Kg 40 den – 8.40 $/Kg 70 den – 7.50 $/Kg

Knitting section

Lay Out Of Knitting Section:

Lay Out Of Grey Store Section:

Organogram of Knitting Section:

DGM / AGM

Manager /Asst. Manager (Production & Plan) (02) Manager (Technical) Asst. Manager (01) Sr. Executive (Production, Plan & Sample) (02) Sr. Feeder/Feeder (07) Executive / Jr. Executive (Prod. & Sample) (05)

Asst. Feeder (04) Sr. Supervisor/Supervisor (06) Sample Supervisor (02) Needle Man (03) Sr. Operator/Operator (135) Sample Asst. (05) Servicing Man (06)

Asst. Operator (33) Servicing Helper (06)

Production Helper (21)

Manager / Asst. Manager (Store)(01)

Sr. Executive / Executive (02)

Jr. Executive (Yarn) (02) Jr. Executive (Grey Fabric) (03)

Store Asst. (Yarn) (03) Store Asst. (Grey Fabric) (07)

Loader (Yarn) (26) Batch Helper/Loader (35)

MANPOWER OF KNITTING SECTION:Section No. of PersonOffice staff 35 Q.C 30Grey Store 35Collar 15Operators 107Helper 27Total 249

Recommended points of buyer:When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows-Diameter of the fabricDesign of the fabricGSM of the fabricTotal wt. of the fabricYarn countTypes of yarnColor of the fabricFinishing of fabric.Handling & fastness property

Machine List of Knitting Section in INTRAMEX GROUP :

Machine name Machine QuantityCircular Knitting(Single jersey) m/c 51 Circular Knitting(Rib) m/c 21 Engineering Stripe m/c 08 V-bed Knitting m/c 25 Grey Fabric Inspection m/c 03

All m/c specification of knitting section:

M/C NO: 01 M/C NO: 02 Machine type: Rib Machine type: Singly jerseyBrand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: Pl-X2B/CE Model: Pl-X2B/CECam Box: 80 Cam Box: 80 Cylinder dia: 38 Cylinder dia: 36Gauge: 18 Gauge: 24Needles: 2124 Needles: 2714Safety rpm: 28 Safety rpm: 25Production: 150kg/shift Production: 150kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 03 M/C NO: 04 Machine type: Rib Machine type: RibBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXL-3.2S Model: VXL-3.2S Cam Box: 72 Cam Box: 72 Cylinder dia: 36 Cylinder dia: 36Gauge: 18 Gauge: 18Needles: 2035 Needles: 2035Safety rpm: 25 Safety rpm: 26Production: 150kg/shift Production: 150kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 05 M/C NO: 06 Machine type: Rib Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXL-3.2S Model: VXL-3.2S Cam Box: 72 Cam Box: 90 Cylinder dia: 36 Cylinder dia: 30Gauge: 18 Gauge: 24Needles: 2036 Needles: 2035Production: 150kg/shift Production: 150kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 07 M/C NO: 08 Machine type: single Jersey Machine type: Single JerseyBrand name: Fukuhara Brand Name: Pai lungOrigin Country: Japan Origin Country: TaiwanModel: Model: Pl-X2B/CECam Box: 72 Cam Box: 84 Cylinder dia: 30 Cylinder dia: 28Gauge: 24 Gauge: 24Needles: 2222 Needles: 2111Production: 85kg/shift Production: 150kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 09 M/C NO: 10 Machine type: Single Jersey Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXC-3S Model: VXC-329 Cam Box: 90 Cam Box: 90 Cylinder dia: 30 Cylinder dia: 30Gauge: 24 Gauge: 24Needles: 2222 Needles: 2222Production:100 kg/shift Production:105kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 11 M/C NO: 12 Machine type: Single Jersey Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXC-3S Model: VXC-329 Cam Box: 78 Cam Box: 90 Cylinder dia: 26 Cylinder dia: 30Gauge: 24 Gauge: 24Needles: 2222 Needles: 2222Production: 80 kg/shift Production: 105kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006 M/C NO: 13 M/C NO: 14 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-XS3D/A/CE Model: PL- XS3D/A/CECam Box: 78 Cam Box: 78 Cylinder dia: 26 Cylinder dia: 26Gauge: 24 Gauge: 24Needles: 1944 Needles: 1944Safety rpm: 34 Safety rpm: 40Production:150kg/shift Production:100kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 15 M/C NO: 16 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-XS3DB-V1/A/CE Model: PL- XS3D/A/CECam Box: 74 Cam Box: 77 Cylinder dia: 25 Cylinder dia: 36Gauge: 24 Gauge: 24Needles: 1872 Needles: 2772Safety rpm: 28 Safety rpm: 25Production: 150kg/shift Production: 100kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 17 M/C NO: 18 Machine type: Singly jersey Machine type: Rib Brand name: Terrot Brand Name: Terrot Origin Country: Germany Origin Country: Germany Cam Box: 82 Cam Box: 82 Cylinder dia: 20 Cylinder dia: 22

M/C NO: 19 M/C NO: 20 Machine type: Singly jersey Machine type: Rib Brand name: Terrot Brand Name: TerrotOrigin Country: Germany Origin Country: Germany Cam Box: 82 Cam Box: 82 Cylinder dia: 34 Cylinder dia: 22Gauge: 18 Gauge: 24

M/C NO: 21 M/C NO: 22 Machine type: Rib Machine type: Singly jersey Brand name: Terrot Brand Name: Pai lungOrigin Country: Germany Origin Country: Taiwan Cam Box: 82 Models: PL- XS3D/A/CECylinder dia: 26 Cam Box: 82 Gauge: 18 Cylinder dia: 22Safety rpm: 25 Gauge: 24Production: 100kg/shift Needles: 2772Date of Manufacturing: 2006 Safety rpm: 25 Production: 100kg/shift Date of Manufacturing: 2007M/C NO: 23 M/C NO: 24 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-XS3D/A/CE Model: PL- XS3D/A/CECam Box: 84 Cam Box: 80 Cylinder dia: 24 Cylinder dia: 40Gauge: 24 Gauge: 18Needles: 2112 Needles: 2356Safety rpm: 37 Safety rpm: 28Production: 120kg/shift Production: 150kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 25 M/C NO: 26 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-XS3D/A/CE Model: PL- XS3D/A/CECam Box: 72 Cam Box: 74 Cylinder dia: 36 Cylinder dia: 25Gauge: 24 Gauge: 24Needles: 2712 Needles: 1872Safety rpm: 25 Safety rpm: 28Date of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 27 M/C NO: 28 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-XS3DB-V1/A/CE Model: PL- XR/A/CECam Box: 90 Cam Box: 90 Cylinder dia: 30 Cylinder dia: 30Gauge: 20 Gauge: 24Needles: 1872 Needles: 2256Safety rpm: 30 Safety rpm: 28Production: 120kg/shift Production: 100kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 29 M/C NO: 30 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-X-2B/A/CD Model: PL- XRA/CECam Box: 72 Cam Box: 76 Cylinder dia: 36 Cylinder dia: 38Gauge: 22 Gauge: 18Needles: 2484 Needles: 2160Safety rpm: 28 Safety rpm: 37Production: 150kg/shift Production: 105kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 31 M/C NO: 32 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai lungOrigin Country: Taiwan Origin Country: TaiwanModel: PL-X2B/CE Model: PL- XRA/CECam Box: 76 Cam Box: 76 Cylinder dia: 38 Cylinder dia: 38Gauge: 18 Gauge: 18Needles: 2124 Needles: 2124Safety rpm: 30 Safety rpm: 30Production: 120kg/shift Production: 105kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 33 M/C NO: 34 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Mayer & CieOrigin Country: Taiwan Origin Country: GermanyModel: PL-XRA/CE Model: Relanit 3.2Cam Box: 96 Cam Box: 76 Cylinder dia: 38 Cylinder dia: 30Gauge: 18 Gauge: 28Needles: 2124 Needles: 2640Safety rpm: 37 Safety rpm: 30Production: 120kg/shift Production: 105kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 35 M/C NO: 36 Machine type: Singly jersey Machine type: Singly jersey Brand name: Mayer & Cie Brand Name: Pai LungOrigin Country: Germany Origin Country: Taiwan Model: Relanit 3.2 Model: PL-XRA/CECam Box: 96 Cam Box: 80 Cylinder dia: 30 Cylinder dia: 40Gauge: 28 Gauge: 18Needles: 2640 Needles: 2256Safety rpm: 30 Safety rpm: 30Production: 150kg/shift Production: 120 kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 37 M/C NO: 38 Machine type: Rib Machine type: Rib Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XRA/CE Model: PL-XR2B/CECam Box: 80 Cam Box: 84 Cylinder dia: 40 Cylinder dia: 42Gauge: 18 Gauge: 18Needles: 2256 Needles: 2376Safety rpm: 28 Safety rpm: 30Production: 130kg/shift Production: 120 kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2007

M/C NO: 39 M/C NO: 40 Machine type: Rib Machine type: Rib Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-X2B/CE Model: PL-XRA/CECam Box: 84 Cam Box: 72 Cylinder dia: 36 Cylinder dia: 36Gauge: 18 Gauge: 16Needles: 2376 Needles: 1800Safety rpm: 28 Safety rpm: 28Production: 130kg/shift Production: 130 kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 41 M/C NO: 42 Machine type: Rib Machine type: Rib Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XBA/CE Model: PL-XRA/CECam Box: 74 Cam Box: 74 Cylinder dia: 25 Cylinder dia: 25Gauge: 24 Gauge: 24Needles: 1872 Needles: 1872Safety rpm: 28 Safety rpm: 28Production: 140kg/shift Production: 130 kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 43 M/C NO: 44 Machine type: Singly jersey Machine type: Singly jersey Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XS3B/CE Model: PL-XS3B/CECam Box: 78 Cam Box: 78 Cylinder dia: 26 Cylinder dia: 26Gauge: 24 Gauge: 24Needles: 1941 Needles: 1941Safety rpm: 28 Safety rpm: 28Production: 130kg/shift Production: 130 kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 45 M/C NO: 46 Machine type: Single Jersey Machine type: Single JerseyBrand name: Fukuhara Brand Name: Pai LungOrigin Country: Japan Origin Country: TaiwanModel: VXC-25 Model: PL-X-2D/CECam Box: 90 Cam Box: 40 Cylinder dia: 30 Cylinder dia: 36Gauge: 24 Gauge: 24Needles: 1941 Needles: 2712Production: 100 kg/shift Production: 105kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2007

M/C NO: 47 M/C NO: 48 Machine type: Rib Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXC-22 Model: VXC-3.29 Cam Box: 90 Cam Box: 90 Cylinder dia: 30 Cylinder dia: 30Gauge: 24 Gauge: 24Needles: 2222 Needles: 2222Production: 100 kg/shift Production: 105kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 49 M/C NO: 50 Machine type: Auto striper (S/J) Machine type: Auto striper (S/J) Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XCS/6 Model: PL-XCS/6Feeder: 42F x 6C Feeder: 42F x 6C Cylinder dia: 30 Cylinder dia: 30Gauge: 24 Gauge: 24Needles: 2956 Needles: 2256Safety rpm: 28 Safety rpm: 28Production: 130kg/shift Production: 130 kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 51 M/C NO: 52 Machine type: Auto striper (S/J) Machine type: Auto striper (S/J) Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XCS/6 Model: PL-XCS/6Feeder : 54 Feeder: 54 Cylinder dia: 36 Cylinder dia: 30Gauge: 18 Gauge: 24Needles: 2040 Needles: 2040Safety rpm: 16 Safety rpm: 16Production: 130kg/shift Production: 130 kg/shiftDate of Manufacturing: 2006 Date of Manufacturing: 2006

M/C NO: 53 M/C NO: 54 Machine type: Auto Striper (S/J) Machine type: Auto Striper (S/J) Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XSCS-6 Model: PL-XSCS/6Feeder: 54 Feeder: 42F x 6C Cylinder dia: 30 Cylinder dia: 30Gauge: 24 Gauge: 24Needles: 2256 Needles: 2256Safety rpm: 22 Safety rpm: 16Production: 150 kg/shift Production: 130 kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 55 M/C NO: 56 Machine type: Auto Striper (S/J) Machine type: Auto Striper (S/J) Brand name: Pai Lung Brand Name: Pai LungOrigin Country: Taiwan Origin Country: Taiwan Model: PL-XSCS-6 Model: PL-XSCS/6Feeder: 52F x 6C Feeder: 42F x 6C Cylinder dia: 36 Cylinder dia: 36Gauge: 24 Gauge: 24Needles: 2712 Needles: 2712Safety rpm: 19 Safety rpm: 19Production: 150 kg/shift Production: 130 kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 57 M/C NO:58 Machine type: Single Jersey Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXL-3.2S Model: VXL-3.2S Cam Box: 86 Cam Box: 84 Cylinder dia: 36 Cylinder dia: 26Gauge: 18 Gauge: 24Needles: 3096 Needles: 2016Production: 120 kg/shift Production: 105kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 59 M/C NO: 60 Machine type: Single Jersey Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXL-3.2S Model: VXL-3.2S Cam Box: 86 Cam Box: 84 Cylinder dia: 26 Cylinder dia: 26Gauge: 26 Gauge: 24Needles: 3096 Needles: 2016Production: 120 kg/shift Production: 100 kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 61 M/C NO: 62 Machine type: Rib Machine type: Single JerseyBrand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXL-3.2S Model: VXL-3.2S Cam Box: 96 Cam Box: 96 Cylinder dia: 30 Cylinder dia: 30Gauge: 24 Gauge: 24Needles: 3096 Needles: 2016Production: 120 kg/shift Production: 105kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 63 M/C NO: 64 Machine type: Single Jersey Machine type: Rib Brand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXC-DF3D Model: VXC-DF3DCam Box: 90 Cam Box: 60 Cylinder dia: 30 Cylinder dia: 30Gauge: 20 Gauge: 24Needles: 2700 Needles: 1800Production: 120 kg/shift Production: 100kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 65 M/C NO: 66 Machine type: Single Jersey Machine type: Rib Brand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXC-39 Model: VXC-29Cam Box: 84 Cam Box: 106 Cylinder dia: 28 Cylinder dia: 32Gauge: 24 Gauge: 24Needles: 2352 Needles: 3392Production: 120 kg/shift Production: 150kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 67 M/C NO: 68 Machine type: Single Jersey Machine type: Rib Brand name: Fukuhara Brand Name: FukuharaOrigin Country: Japan Origin Country: JapanModel: VXC-3.29 Model: VXC-3.29Cam Box: 106 Cam Box: 96 Cylinder dia: 32 Cylinder dia: 36Gauge: 24 Gauge: 24Needles: 3392 Needles: 2304Production: 150 kg/shift Production: 150kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 69 M/C NO:70 Machine type: Top Knit Machine type: Top KnitBrand name: Keumnong Brand Name: KeumnongOrigin Country: Korea Origin Country: KoreaModel: KM-30F Model: KM-30FCam Box: 90 Cam Box: 90 Cylinder dia: 30 Cylinder dia: 30Gauge: 20 Gauge: 20Needles: 1800 Needles: 1800Production: 100 kg/shift Production: 100kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

M/C NO: 71 M/C NO:72 Machine type: Top Knit Machine type: Top KnitBrand name: Keumnong Brand Name: KeumnongOrigin Country: Korea Origin Country: KoreaModel: KM-30F Model: KM-30FCam Box: 90 Cam Box: 90 Cylinder dia: 30 Cylinder dia: 30Gauge: 20 Gauge: 20Needles: 1800 Needles: 1800Production: 100 kg/shift Production: 100kg/shiftDate of Manufacturing: 2007 Date of Manufacturing: 2007

Specification of Flat Bed Machine (1-25):

M/CNO.(01-15) M/C NO. (16-25)

M/c type: Rib (collar) M/c type: Rib (collar)Brand name: Matsuya Brand name: Strickmaschinen GMBHOrigin: Japan Origin: GermanyModel: M-100 Needle: 2040Bed Length: 102 inch Gauge: 16 Head: 2 Date of manufacturing: 2002Feeder: 6 Type: Fully Automatic Flat Knitting Machine Manufacturing no: 8103 Gauge: 14 Date of manufacturing: 2004

Fig: Flat Bed Machine

Product of v-bed knitting m/c

1. Collar 2. Plain collar 3. Tipping collar4. Raising collar5. Folding collar 6. Peacot collar

1. Cuff 2. Waist Band/ Hem

Others Machines in Knitting Section:

Fig: Inspection M/C

Knitting Flow chart:

Collect the approved sample and parameter?Analyze the work order and select yarn?Arrange yarn source and yarn in house in store?Set the cam design?Collect yarn from yarn store?Cone set the creel and yarn pass through the positive to the guide tension?Set the GSM/stitch (it control by VDQ pulley)?Inspect the fabric after making approximately half match?If ok, then continue the m/c be run?If not ok, then identify the problem and solve?Roll cut after making 20-25kg?Roll making (Dia, GSM, Gauge Order no. Color, Buyer etc)?Roll send to the inspection section?After inspection roll grading according to the quality?Then it sends to the grey fabric store?Fabric delivery from the store according dyeing batch card

Knitting:

The process in which fabrics are produced by set of connected loops from a series of yarns is called knitting.Warp knittingWeft knittingWhen fabric is produced by this method in weft direction then it’s called weft knitting & warp direction then it’s called warp knitting.

Loop formation of Knitting

Picture of knitting M/Cs:

Pilung Fukuhara Auto Stripe

Single Jersey Circular Knitting m/c:

Fig: Knitting m/c

DIFFERENT PARTS OF KNITTING MACHINE: Start/Stop/Inch buttons: This set of buttons is used to start/stop/slow running of machineRatchet lever: This lever permit the hand movement of the machine.Auto stop motion: Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicator lamps are on individual stop p motions & on the main control panel. While the yarn is broken we can find the location which is broken as well as to repair, meanwhile the motor can brake and stop operation at once to keep the security of the machine.Side creel: For each feed, there are two cones of yarn on the creel. Creel is used to place the coneTensioning device: The yarn goes to the feeder of the machine from the creel through different tensioning devices. These devices are used to maintain the proper tension ofthe yarn.Feeder: Feeder is used to feed the yarn.VDQ pulley: This is one of the important parts of the machine. VDQ pulley is used to control the GSM by controlling the stitch length. If the value of the VDQ pulley is increased, then the loop length of the fabric will be less and the GSM of the fabric will be high. Vice versa for make low GSM fabric.Guide: Guide is used to guide the yarn.Sensor: Sensor is used to seen & the machine stops when any problem occurs.Spreader: Spreader is used to spread the knitted fabric before take up roller.Auto counter: Two shift revolution with display counter with predetermined stop, to settle freely the weight or yardage of fabric. Variable speed drive with machine break: Transistor inverter provided for free controlled, the process of V.S. motor-drive from slow operation to normal operation is quite & fast break to prevent damages in case of needles or yarn breakage.Fabric take up system: With variable speed control by a belt drive set can be adjusted the speed for different course of fabric-constant and uniform fabric tension.Rethom: These devise are used in Electrical Auto Striper Knitting machine.Take up roller: Take up roller is used to take up the fabric.Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger

Typical Parameter at knitting section:Yarn count GsmStitch length

Points should be considered for GSM changing:VDQ (Variable Dia. Quality Control) pulley diameter.Yarn count.Machine gauge.Cam positionTake up motion

Factors that should be considered for changing of fabric design:Cam arrangement changing.Needle butt setting & needle dropping.Using of different colors in selected feeder.Using of jacquard mechanism.Size of the loop shape

YARN TYPES:

100% COTTON YARN SOURCE:INTRAMEX Spinning Ltd.INTRAMEX Spinning an export oriented 40320 spindle ring & 1280 spindle rotor spinning industry equipped with all brand new state of the art European machines. It was established in the year 2004.MELANGE YARN SOURCE:Prime Spinning Ltd. 04. Shohagpur Spinning Ltd. Phartoli Spinning Ltd. 05. ChinaThermax Spinning Ltd. 06. India

PC / CVC YARN SOURCE:Arif Spinning Ltd. 03. Square Spinning Ltd.Akij Spinning Ltd.

Type of Machines

Single Jersey = 35Fleece = 10Double Jersey =19Auto Stripper (S/J) = 06Auto Stripper (Rib) = 02Flat Bed Knitting M/C = 25Fabric Inspection M/C = 03Grand Total = 100

Buyers: Buyers Logo: S. OliverG STARPUMAMarks & SpencerESPIRITPVH

Products of Circular Knitting Machine:

Single Jersey M/C:a) Plain jerseyb) Lycra jerseyc) Single Lacosted) Double Lacostee) Single Piquef) Double Pique g) Fleece (Three threads) h) Terry Fleece (Two thread)

Double M/C:1×1 rib1 1 lycra ribYarn dyed rib2 1 rib2 2 rib2 2 lycra ribInterlock

Type of Collar:TippingSolid collarRaising collarFolding collarCuffEmboss

Faults, Causes & their Remedies in Knitting:

Hole Mark: Causes:Holes are the results of yarn breakage or yarn cracks.During loop formation the yarn breaks in the rejoin of the needle hook.If the yarn count is not correct on regarding structure, gauge, course and density.Badly knot or splicing.Yarn feeder badly set. Remedies:Yarn strength must be sufficient to withstand the stretch as well as uniform.Use proper count of yarn.Correctly set of yarn feeder.Knot should be given properly.Needle Mark: Causes:When a needle breaks down then needle mark comes along the fabrics.If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies:Needle should be straight as well as from broken latch.Sinker Mark: Causes:When sinker corrodes due to abrasion then some times cannot hold a new loop as a result sinker mark comes.If sinker head bend then sinker mark comes. Remedies:Sinker should be changedStar : Causes:Yarn tension variation during production.Buckling of the needle latch.Low G.S.M fabric production. Remedies:Maintain same Yarn tension during production.Use good conditioned needles.Drop Stitches: Causes:Defective needle.If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.Take-down mechanism too loose.Insufficient yarn tension.Badly set yarn feeder. Remedies:Needle should be straight & well.Proper feeding of yarn during loop formation.Correct take up of the fabric & correct fabric tension.Yarn tension should be properly.Oil stain:Causes:When oil lick through the needle trick then it pass on the fabrics and make a line.Remedies:Ensure that oil does not pass on the fabrics.Well maintenance as well as proper oiling.07. Rust stain: Causes:If any rust on the machine parts. Remedies:If any rust on the machine parts then clean it.Proper maintenance as well as proper oiling.Pin hole : Causes:Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:Change the needleGrease stain: Causes:Improper greasing Excess greasing Remedies:Proper greasing as well as proper maintenance.10. Fly dust: Causes:In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies:Blowing air for cleaning and different parts after a certain period of time.By cleaning the floor continuously.By using ducting system for cleaning too much lint in the floor.Over all ensure that lint does not attach to the fabric.11. Yarn contamination: Causes:If yarn contains foreign fiber then it remains in the fabric even after finishing,If lot, count mixing occurs. Remedies:By avoiding lot, count mixing.Fault less spinning. 12. Yarn Faults:Neps.Slubs.Yarn count variations.Thick/Thin place in yarn.

Quality Assurance of knitting Section

Yarn Test after Receiving Yarn

Sample Fabric Preparation before Bulk Production

Online Quality Control

Offline Quality Control

Fabric Inspection using 4 point system

Measurement of Fabric Faults:

Four Point System: Defect Length Assigned Point 0-3” 1 point 3.1-6” 2 point 6.1-9” 3 point >9.1” 4 pointCalculation:Avg. Points/100 yds = total points /total inspected yds * 100

Maintenance:

During servicing or maintenance the following things are cheeked- NeedleSinkerCam BoxCylinderOilBelt Type of Maintenance:

Breakdown Maintenance Scheduled Maintenance

This is basically the servicing of the machine. This is done becauseTo maintain the quality of the fabricTo reduce the fabric faultRemoval of the lint from the machineCleaning the different parts of the machine

Production Calculation:

Production / shift in Kg at 100% efficiency:

Production / shift in Meter : Fabric Width in Meter:

Efficiency : Actual production Calculated production 100 Sample of various Type of Knitted fabric:

Fabric Type Sample Single jersey Lycra Single jersey Single Lacost Double Lacost Fleece

(1*1) Rib (2*2) Rib Lycra Rib Stripe Single jersey

Remarks & conclusion:Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good so that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements.

BATCH SECTION

Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.

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 capacityM/C availableType of fabrics(100% cotton, PE, PC, CVC)EmergencyTo send the grey fabric to the dyeing floor with batch card.To keep records for every previous dyeing.

Proper batching criteria:

To use maximum capacity of existing dyeing m/c.To minimize the washing time or preparation time & m/c stoppage time.To keep the no. of batch as less as possible for same shade.To use a particular m/c for dyeing same shade.

Batch management:

Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency.

Machines in batch section

M/c quantity: 02

M/c Specification:

Machine Name : Air turning m/cM/c No : 01Brand Name : TaidaOrigin : ChinaM/c Speed : 300-500m/minModel : DF 200Max up clothing : 150 kgCompany : Shandong Taida Dyeing & Finishing Machinery Co.Ltd

Machine Name : Air turning m/cM/c No : 02Brand Name : TaidaOrigin : ChinaM/c Speed : 300-500m/minModel : DF 200Max up clothing : 150 kgCompany : Shandong Taida Dyeing & Finishing Machiner

LABORATORY

Laboratory MACHINEries with its specification:

1. Tearing Strength Tester:No. of m/c-01Brand Name: ElmatearOrigin : U.K

2. Button Strength Tester:No. of m/c-03Brand Name : TitanOrigin : U.KMax.Pressure: 10 barCapacity : 3000N

3. Bursting Strength Tester:No. of m/c-01Brand Name: TruBurstOrigin : U.K

4. Pilling Resistant Tester:No. of m/c-04Brand Name: ImpulseOrigin : U.K

5. Sprectra Flash:No. of m/c-01Brand Name: Data ColorOrigin : U.S.A

6. Test Name : Colorfastness to Washing, Dry cleaning.Name of the m/c: Rota WashOrigin : U.KNo. of m/c : 02Test Method : ISO105-C06, ISO105-D02

7. Test Name : Dimensional Stability, Spirality, and Appearance after washing.Name of the m/c : Eltrolux wascator.Origin : U.KNo. of m/c : 01Test Method : ISO 6330, ISO 26330

8. Test Name : Shrinkage Test.Name of the m/c: Eltrolux Origin : U.KNo. of m/c : 01Test Method :

9. Test Name : Color Fastness to Wash Test.Name of the m/c: Gyro washOrigin : U.KNo. of m/c : 02Test Method : ISO 105-C06

10. Lab Dip m/c:No. of m/c: 02M/C NO- 01Brand name: Ahiba Nuance Lab Dip Dyeing m/cOrigin : U.S.A

M/C NO- 02Brad name: Ahiba Nuance Lab Dip Dyeing m/cOrigin : U.S.AColor Matching Cabinet (Light box):

No. of Light Box: 02Light Box no: 01Brand : Spectralight-111Origin : U.S.ALight Source:Day Light (D-65)Cool WhiteHorizonUVTL-84A (F11-10 degree) Light Box no: 02Brand : VerivideOrigin : U.KLight Source:Day Light (D-65)UVTL-84A (F11-10 degree)

Lab Working Procedure: Sample in (Fabrics)

Check & note the Lot no, Style no, Item no& Collar

Sample Preparation

Run the test

Physical test Wet lab

Color Fastness to wash Bursting strength Pilling Color Fastness to washing Crocking

Evaluate the sample Pre-production Sample Final sample

Report Making Test Test

Prepared the report prepared the report Pass Fail

Deliver Refinish Pass Fail Pass Fail

Need to test again Go for the final Refinish

Need to test again Dimensional stability. Prepare the sample

Wash the sample according to buyer method.

Tumble dry

Keep the sample flat in the conditioned temperature at least four hours before, after measurement.

Measure the sample

Prepared the report

Pass Fail Ready to delivery Refinish

Need to test again Quality Management System The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. Objects of quality control:

Research. Selection of raw materials.Process control.Process development.Product testing.Specification test

Quality management system in INTRAMEX :

Online Quality control:

There are two types of online quality control. These are as follows: -Raw material control:Raw material control means control the quality of raw materials (e.g.- Quality of Grey fabric, Dyes, Chemicals and Auxiliary)Process control:Process control means the selection of right process and controlling of some parameters. Such as PH, Water hardness, water volume, Temperature, Reel Speed, Pump pressure, etc.

Online Tests:Dyed fabric.Shade check.Wash fastness.Water fastness.Crocking fastness.

Laboratory:Laboratory is the heart of dyeing Industry. An efficient laboratory can increase the efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before bulk production a sample is sent to buyer for approval. Laboratory supplies the recipe to the floor. Purpose of Laboratory:Get color approval from buyer.Recipe supply to the floor.Shade correction.Minimize the deviation between bulk and laboratory. Laboratory line:Standard sample: At first recipe % of standard sample is measured by CCM (computer color matching) system.Laboratory Trial:Then by taking those recipe laboratory officers produce laboratory trial and match with standard according to buyer requirement.Approved Sample:Then sample swatch, which is matched with the standard, is send to buyer for approval.

Off-Line Tests:Off-Line tests for finished fabrics are divided into two groups. These are as follows:Physical testsChemical tests

Physical Tests:GSM of Fabric.Abrasion resistance / Pilling.Dimensional stability test.Spirality test.Color fastness to rubbing test (Dry / wet).Bursting strength test (For Knitted fabric).Tensile Strength test (For Woven fabric).

Chemical Tests:Color Fastness to washing.Color Fastness to light.Color Fastness to heat.Color Fastness to actual launderingColor Fastness to Chlorinated water.Color Fastness to water spotting.Color Fastness to perspiration.Color Fastness to Seawater.Flammability test.Fibre analysis.PH test.Spray test (water repellency).Phenolic yellowing. Quality standard:Here in the factory they are following ISO standards for their testing purpose. But testing standard depends on buyer requirements.

SOME TEST PROCEDURE

Color fastness to rubbing (wet & dry):Procedure:At first take a sample of size (14 × 5) cm at Wales & Course wise. Put the crocking cloth on to the finger & stag by finger clip & run 10 times in 10 seconds manually & assess the crocking cloth with gray scale.

Place the crocking cloth on the water, it will sucked some water and then squeeze the crocking cloth. Then place the wet rubbing cloth on to the finger and stag with finger clip and run 10 times in 10 seconds manually. Then assess the crocking cloth by gray scale for wet rubbing. Wet and dry rubbing are checked according to buyer’s requirement.

Color fastness to washing. (ISO/05-CO6):

Procedure: Size of specimen: Cut sample & multifibre at (10 × 2) cm then stitch.Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in distilled water & cooled at 20°C & measured PH (where necessary).Run the program in the following way: -Test no. Temp°C Liq.volume ml Time min.Steel balls Adjust pH C2S 60°C 50 30 25 10.5±1 Rinse the sample twice with cold water.Dry at 60°C by hanging or by flat iron pressing but temperature should not less more than 150°C.

Pilling test:

Procedure: Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using template. Then sewn the fabric so that it can be firmly fit in the tube a moulded polyurethane tube. Then four tubes are placed in a box & start 60±2 rev/min for 5 hrs or according to buyer requirement. Here mainly used 3hrs (1100 cycle). Then assess the pilling by putting tested specimen on the viewing cabinet & compare with standard photographs.

Shrinkage & Spirality test:

Buyer’s requirements:Template size: 50cm & 35cm, 25.5cm &18cm (use after quick wash). Shrinkage: length wise— 5% Width wise—-5% Spirality: Left ——– 5% Right ——– 5%Procedure:At first take two ply of fabric & put the template (50cm) on to the fabric. The template has 8 holes. Both length & width wise the template holes can measure 35cm at 3 places. Then we mark the 8 holes by permanent marker & also at the edges of the template.Then sewn the fabric & it is given to the washing m/c for run at 60°C for 60minutes with water. After that dry the sample & then measure the fabric Spin speed — 500rpm Drum speed–500rpm

Calculation

Shrinkage Test:

Lengthwise: After wash – Before wash = ———————————-×100 Before wash Width wise: After wash – Before wash = ———————————-×100 Before washSpirality test: = × 100 %

Color fastness to water (ISO 105 EO1& EO2):

Sample size: Cut the specimen & multi-fiber at 10×2cm & sewn together.Solution: Wet in distilled water at room temperature & it will suck water.Place it in acrylic resin plates & put the weight on to the plates.Keep it in oven & keep the temperature at 37± 2°C for 4hrs.Open the specimen & dry it in the air hot exceeding 60°C.Assess the staining & shade change with gray scale. Color fastness to perspiration Alkaline & Acid solution (Method: ISO 105 E04):1) Procedure: Cut the specimen & multifibre at 10×2cm & sewn together.2) Prepare solution:Alkaline Solution:0.5g/l of 1-histadine mono hydrochloride monohydrate5g/l of sodium chlorideThis solution is brought to pH -8 with 0.1 mole/l caustic solution. Acid solution:0.5 g/l of 1-histadine monohydrochloride monohydrate5g/l of sodium chloride.2.2 g/l of sodium dihydrogen orthophosphate dehydrate.This solution is brought to pH-5.5 with 0.1 mole/l caustic solution.3) M: L = 1: 504) Wet the specimen in flat dish containing acid & alkaline solution & keep for 30min. Then take the specimen & squeeze the excess solution by two glass rods.5) Put the specimen in to the acrylic resin plates & put wt. on the plates.6) Keep it in the woven at 37°C ± 2°C for 4hrs. 7) Open the specimen 6 multi fibre & dry separately in the air temperature not exceeding 60°C.8) Access the staining & shade change with grey scale.

6.17 PH Test:

Procedure:Take 2gm sample fabrics and cut into small pieces. Then put it conical flax with 100cc water (M: L -1:50). Then shake it 15 min, then place it in a shaker m/c for 1 hour. Then check PH by PH meter.

GSM TEST:

Procedure: GSM is the most important factor. There is a GSM cutter. The sample cut by the GSM cutter is weighted in the electronic balance. The reading (in gm) from the balance is multiplied by 100 to get the value of GSM.

RESPOSIBILITY OF OFF-LINE quality control: To check the following things:Inspection of fabric in the inspection M/C under 4-point system.Yarn count and lot no.Buyer.Design.Stitch length of grey fabric.Shade of grey fabric within one order.

RESPOSIBILITY OF ON LINE quality control: To check the following things:M/C Dia/GaugeBuyerDesignGrey fabric GSN & Stitch LengthYarn count & Lot noYarn whether approved or not by Q.C. DepartmentFinished dia & grey dia.Fabric quality checking under 4-point system.Responsibility of IN CHARGE of quality control:Making report.Supervise the grey Q.C.Check machine is running according to program or not Check program can meet the requirement. Which is mentioned in the order sheet or not.Check yarn is approved by Q.C. or not.

Maintain resister khata.Make daily batch re-process job card. Remarks & conclusion:Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good so that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements.

DYE

A colorant that becomes molecularly dispersed at some point during application to a substrate and also exhibits some degree of performance.

DYEING

The application of color producing agents to fibre, yarn, or fabric or part usually fibrous or flim, in order to impart a degree of color permanence demanded by the projected end use, usually by immersing in a bath of dye.

Lay out of dyeing floor:

Organogram of Dyeing:

Machines of fabric dyeing floor:

Turning machine: 02 BulkTotal bulk dyeing m/c: 15Total sample dyeing m/c: 7Fong’s machine:Bulk m/c: 10Sample m/c: 06Thies machine:Bulk m/c: 05Sample m/c: 1

Specification of different machines: Bulk dyeing section:

Dyeing Machine. 01(Fongs):

Type Jet Dyeing MachineManufacturer name FONG’SCountry ChinaModel No. ECO-38-2TYear of manufacturing 2003Temp. Range 00-980CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KG

Dyeing Machine.02(Thies):

Type Jet Dyeing MachineManufacturer name THIESCountry GermanyModel No. D-48653 COESFELDYear of manufacturing 2004Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo Of Nozzle 04

Dyeing Machine. Thies-03:

Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653 COESFELDYear of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4

Dyeing Machine. THIES-04:

Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. ECOSOFT PLUSYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1Dyeing Machine. THIES-05:

Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41350Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KGNo. of Nozzle 2

Dyeing Machine. THIES-06:

Type HTHP Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41354Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4

Dyeing Machine. FONGS-07:

Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 200 KGNo. of Nozzle 1Permissible Working Pressure 380 KpaTest Pressure 585 Kpa

Dyeing Machine. FONGS-08:Type Jet Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1Permissible Working Pressure 380 KPATest Pressure 585 Kpa

Dyeing Machine. FONGS-09:

Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-3TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 750 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 585 Kpa

Dyeing Machine. FONGS-10:Type High Speed jumbo Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 8Production Capacity 1120 KGNo. of Nozzle 4Permissible Working Pressure 350 KpaTest Pressure 520 KPa

Dyeing Machine. FONGS-11:

Type HSJ Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 8Production Capacity 840 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 520 Kpa

Dyeing Machine.FONGS-12:

Type HSJ Dyeing MachineManufacturer name FONGSCountry ChinaModel No. HSJ-SR-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 3Production Capacity 560 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 520 KPaDyeing Machine.FONGS-13:

Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 6TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 1680KGNo. of Nozzle 6

Dyeing Machine.FONGS-14:

Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 840 KGNo. of Nozzle 3

Dyeing Machine.FONGS-15:

Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 1120 KGNo. of Nozzle 4

Sample Dyeing Machine.FONGS-01:

Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 25KGNo. of Nozzle 1

Sample Dyeing Machine.THIES-02:

Type Sample Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653-COESFELDYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Inhalt Capacity 523 LitreNo. of Nozzle 1

Sample Dyeing Machine.FONGS-03:

Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 30KGNo. of Nozzle 1

Sample Dyeing Machine.FONGS-04:

Type ALL FIT-120 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 120 KGNo. of Nozzle 1Sample Dyeing Machine.FONGS-05:

Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2006Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 30 KGNo. of Nozzle 1

Sample Dyeing Machine.FONGS-06:

Type ALL FIT-60 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 60 KGNo. of Nozzle 1

Sample Dyeing Machine.FONGS-07:

Type ALL FIT-60 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 60 KGNo. of Nozzle 1 Dyeing Floor Area:

Total length of dyeing floor: 412 feetTotal width of dyeing floor: 34 feetArea of the dyeing floor: 412×34 = 14008 square feet.

Production capacity:

Sample Production: Sample dyeing machine = 07 pcsTotal machine capacity of sample m/c = 355 kgTotal production capacity of sample m/c = 275 kg

Bulk Production

Dyeing machine = 15 pcsTotal machine capacity = 11,710 kg /shift =35,130 kg/ dayTotal effective capacity* = 9,953 kg / shift = 29,859 kg/day* With 85 % machine loading For 100 % cotton fabric dyeing total capacity (2.5 batch/day) =24,883.75 kg/dayFor CVC dyeing total capacity (1.5 batch /day) = 14,929.5 kg / day

FEATURES OF FONG’S ATMOSPHERIC M/C:The M/C is designed for the pre-treatment, dyeing and after-treatment under atmospheric condition.Nozzle is sized for smooth passing through by the fabric and extensive exchange with the dyeing liquid. Two standard nozzle sizes with sufficiently large diameters are available.Circulation pump is sized for heavy fabricProduction capacity:500kgsMax temperature:98?C Max pressure:1atm

Features of high temperature machine (Thies M/C):

The M/C is designed for the pre-treatment, dyeing and after-treatment which can Provide temperature up to 140?c nozzle lead get interlock after temperature exceed 80?C Loading per nozzle 250kgDesign pressure:350-550kpaDesign Temp :140?CHydraulic Test Pressure:585Kpa Manufacturer: Germany(Thies),Taiwan (Fong’s)No of nozzles:1-8Features of fong’s (hsj) machine:

Variable Loading (VL) storage chamber design gives extra capacity to carry loading up to 280 kg per tube. Heat Exchanger of extreme efficiency gives the largest heating rate with minimum heat loss to the environment.Multi Saving Rinsing System (MSR)Shortens the dye cycle and reduces the water consumption. Advanced Intelligent Rinsing System (MIR) controls the rinsing water consumption and shortens the rinsing process.Highly optimized machine structure reaches the lowest possible liquor ratio of 1:4.5 to run the machine.Dissolution pumps for proper circulation of liquor.Safety valve test: 350kpa.Maximum fabric speed: 400 m/min. Maximum working temperature: 140°C.Design pressure: 350kpa.Hydraulic test pressure: 510kpa.

Unique features of thies & fong’s m/c:Thies machine: Fong’s machine:CCR Function MIRWinch dia can be controlled MSROne addition tank Dissolution PumpNozzle pressure is 0.5-0.6 bar Two Addition TankVl chamber setting is not possible in thies ecosoft plus.* Filter & Heat Exchanger Is In Same Shell TubeSeparate filter & heat exchanger Variable Chamber Setting Is PresentHeat exchanger is at vertical position Nozzle Pressure Is 8-8.50psi Heat Exchanger Position Is HorizontalComparison between Fong‘s and Thies dyeing machine:Fong‘s ThiesHave heat-exchanger for preparation tank. Such facilities are not present.Liquor pass through the filter & heat-exchanger Filter and heat-exchanger are separate.Have dissolution pump for mixing chemical in1:4 ratio. Not present.Horizontal heat-exchanger. Vertical heat-exchanger.Two additional tanks. One additional tank.Variable loading chamber. Not present.Loading per nozzle 280 kg (HSJ). Loading per nozzle 250 kgWinch speed can be above 450 m/min. Up to 350 m/min.

Technology of dyeing machine:

INTRAMEX dyeing unit used special types of dyeing machine. In these machine, the Jet and Winch technology is combined i.e. during dyeing, dye liquor circulate through the machine like jet dyeing machine also the fabric is circulated through the winch as like winch dyeing machine. This combination is made for better dyeing of the fabric.Main parts of dyeing machine:The main parts of the dyeing machine are Main tankReserve tank/PT tankAdditional/Mixing tankMain pumpHeat exchangerFilter

The description of the main parts of the machine is as follows –Main tank:Main tank is the largest part of the dyeing machine. This is the main dye bath which contains the dye liquor & the fabric. The size of the tank depends on the capacity of the machine. Liquor & fabric circulates in the main tank during dyeing process. There may have different number of nozzle connected to main tank according to the machine capacity. Each nozzle may handle 300-900m of fabric.

Main tank

Reserve/ PTtank:This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for heating the water in the main tank which results in the reduction of total dyeing time.

Fig: Reserve/PTtankAdditional/Mixing tank:This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for hea