Overview of BEXTEX LIMITED

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Company Profile

Company
name   :   BEXTEX LIMITED

Corporate
headquarter :   House
no. 17, Road no.02

  Dhanmondi R/A, Dhaka-1205, Bangladesh

Operational
headquarter :   BEL Tower

House
no.19, road no.01

Dhanmondi
R/A, Dhaka-1205, Bangladesh

Factory :   Sarabo, Kashimpur, Gazipur

Date
of incorporation  :   08 March
1994

Commercial
production :   1995

Listing
status :   Public  listed company

Stock
Exchange listing :   Dhaka & Chittagong

Productivity   :   Beximco Textile Division

·
Bextex
Limited

Yarn
Unit-1&2

Woven
Fabric Unit

Knit
Fabric Unit

Denim
Fabric Unit

·
Beximco
Apparels Ltd

·
Beximco
Fashions Ltd

·
International
Knitwear & Apparels Ltd

·
International
Knitwear & Apparels Ltd (Unit-2)

·
International
Knitwear & Apparels Ltd (Unit-3)

·
Esses
Fashions Ltd

·
Freshtex
Bangladesh (Pvt.)Ltd

·
Design
Studio

·
Yellow
By Beximco

Company
Space :  900 Acre

Production
Capacity :   100000 meter (Woven)  

Phone  :  8618220-7, 8611891-5, 9677701-5

Web site   :   www.bextex.net

Sequence of
operation:


Weaving

Grey
fabric inspection









Singeing


Scouring/Bleaching












Mercerizing






















Calendaring

Emerizing





Sanforizing


Stentering


Dyeing



































Final
Inspection

Delivery
to garments industry











Packing







Preparation Section

Singing and Desizing

Definition:

Singing:

Singing is a process for removing
hairy/projectile fiber from the fabric surface.

 Desizing:

Desizing is a process for
removing sizing material from the fabric by chemical treatment.

Cold Bleach:

It is a process to remove dirt,
dust, husk, leaf from the fabric and transfer it into permanent white by
chemical treatment in cold condition.

Process Requirement:

Equipment Used: OSTHOFF singing and Desizing
machine.

Key Accessories: Fork lifter, wooden plate, sewing
machine, A-frame or batchers etc. are the key accessories for singing for white
cotton fabric and special yarn dyed fabric (PC-015)

In addition to the aforesaid tools mixing
tank, reserve tank, pH meter polythine paper, rotation station, hand gloves,
eye protecting glass, clip/finger clip etc are some additional tools/
accessories used for the following fabric process-

Ø 
For
all cotton color fabric.

*
For
all cotton color peace finish fabric.

*
Singing
and Desizing for yarn dyed fabric and PC / CVC fabric.

*
Singing
and cold bleach for PC / CVC fabric.

*
Only
Desizing for PC / CVC / yarn dyed peach finish fabric.

*
Singing
and cold bleach for Bull-Twill (Heavy fabric).

Material and Chemical
used: Steam,
compressed air, water, natural gas, Desizing agent, wetting agent, sequestering
agent and dearating.

Singing, Desizing
and Cold Bleach recipe:

Fabric Name

Chemical/material
used

Composition

1. All cotton color fabric

2. All cotton color peach finish
fabric (for only desizing)

3. Yarn dyed and PC / CVC fabric

Desizing
agent

Dearating
agent

Wetting
agent

Sequestering
Agent

Follow
the bulk recipe by fabric type

Natural
gas for burner, steam, compressed air, water

 

N/A

 

4. White cotton   fabric and special yarn
dyed fabric (for only singing).

Natural
gas for burner, compressed air, water

N/A

5. PC /  CVC fabric (for singing and cold bleach)

H2O2

NaOH

Stabilizer

Wetting
agent / Detergent

Sequestering
Agent

Dearating
agent

Follow
the bulk recipe by fabric type

Natural
gas for burner, compressed air, water

N/A

6. PC / CVC yarn dyed peach finish
fabric (only for desizing)

Desizing
agent

Dearating
agent

Wetting
agent

Sequestering
Agent

Follow
the bulk recipe by fabric type

steam,
compressed air, water

N/A

7. Bull-Twill i.e. heavy  fabric (for singing, desizing, cold bleach)

H2O2

NaOH

Stabilizer

Wetting
agent

Sequestering
Agent

Dearating
agent

Desizing
agent

Follow
the bulk recipe by fabric type

Natural
gas for burner, compressed air, water

  N/A

Production
Procedure:

Machine set-up for
production:

Machine set-up for
singing and desizing for all cotton color fabric:

Machine set-up
parameter

Actual parameter
range

Machine set value

M/C-1

Machine set value

M/C-2

Temperature

(70-80)°C

(70-85)°C

(70-85)°C

pH
or Litmus paper

6.5-7

6.5

6.5

Burner
position

1,
2, 3

3rd

Chemical
level

(700-1400)
L

(750-800)
L

(1000-1200)L

Reserve
chemical

(1000-2000)liter

1000L

1000L

Flame
intensity

(1-20)
m.bar

11-13
m.bar

11-15
m.bar

Pressure

(1.3-1.5)
bar

(1.2-2)
bar

(2-2.5)
bar

Fabric
position

Face
or Bake

Face

Face

Burner

1
or 2

2

2

A-frame
position

Set
nicely

Set
nicely

Set
nicely

Machine set-up for
singing desizing for yarn dyed fabric and PC / CVC fabric:

Machine set-up
parameter

Actual parameter
range

Machine set value

M/C-1

Machine set value

M/C-2

Temperature

(65-85)°C

(65-85)°C

(65-85)°C

pH
or Litmus paper

6-7.5

6.5

6.5

Burner
position

1,
2, 3

2nd=PC

3rd=yarn
dyed

Chemical
level

(700-1400)
L

(750-800)
L

(1000-1200)L

Reserve
chemical

(1000-2000)liter

1000
L

1000
L

Flame
intensity

(1-20)
m.bar

(14-16)
m.bar

(11-15)
m.bar

Pressure

(1.5-2)
bar

(1.8-2)
bar

2
bar

Fabric
position

Face
or Bake

Face

Face

Burner

1
or 2

2

2

A-frame
position

Set
nicely

Set
nicely

Set
nicely

Machine set-up for
singing and cold bleach for PC / CVC fabric:

Machine set-up
parameter

Actual parameter
range

Machine set value

M/C-1

Machine set value

M/C-2

Burner
position

1,
2, 3

2nd  position

Chemical
level

(700-1400)
L

(750-800)
L

(1000-1200)L

Reserve
chemical

(1000-2000)liter

1000
L

1000
L

Flame
intensity

(13-16)
m.bar

(13-16)
m.bar

(11-15)
m.bar

Pressure

(1.3-1.5)
bar

(1.8-2)
bar

2
bar

Fabric
position

Face
or Bake

Face

Face

Burner

1
or 2

2

2

A-frame
position

Set
nicely

Set
nicely

Set
nicely

Operation
Procedure:

Type of fabric

Machine speed
(m/min)

Cotton
colored

60-80

Cotton
white

70-80

Yarn
dyed

100-120

P.C/C.V.C

100

Bull-Twill

60

Processing continues until a frame or a
batcher is complete. After completion of the batcher the operator stop the
machine and warps the batcher with polythene paper and set it into the rotation
station for at least 6-8 hours. In case of singing and cold bleach of P.C /
C.V.C fabric the polythene paper warped batcher is set into the rotation
station for 24 hours. But in case of only singing of white cotton fabric and
special yarn dyed (PC-015) fabric the batcher need not to set into the rotation
station. In the rotation station the batcher rotates and the chemicals
distributed equally in the fabric.The quality of the product depends on various
parameters like the machine speed, temperature, pressure, flame intensity,
chemical level burner position and pH value etc. The operator must check the
above parameter carefully during processing to avoid any defect.

Product quality
check:

During production the operator
will check frequently the pH level of the solution by pH meter or litmus paper
check. The operator also check the cosmetic defect like projectile hairy fiber
by paralelly looking at fabric, fabric position, crease on the fabric, fabric
sewing and any other abnormalitic that can be detect by naked eye.

Q.C sample test:

Quality control department follow
the pickup percent test method to verify the quality during the process. This
is done once in a month or after every maintenance. But in case of only singing
of white cotton fabric and yarn dyed fabric (PC-015) fabric it is not need.

Scouring and Bleaching

Process Definition:

Scouring:  Removing
wax and oil by chemical treatment.

Bleaching:  Removing of natural nitrogenous coloring
compound, dirt, dust, broken parts of seed or leaf and whitening of fabric by
chemical treatment.

Washing: Removing
size chemical and spot of fabric and increasing absorbency.

Process Requirement:

Equipment Used:  GOOLER scouring and bleaching machine.

Key Accessories: Mixing tank, reverse tank,
conical flax, pipette, burette, acid, Potassium permanganate, Phenolphthalein,
eye protecting and hand gloves, sewing machine, boume meter, handle for
carrying batch/A frame fork lift.

Production
Procedure:

Operation stuff:  Operator, Executive, Assistant Manager,
In-Charge Preparation.



Fig: Flow diagram
of Bleaching Machine

Machine Set-up: Describe bellow the machine
set-up for scouring and bleaching process-

Machine speed set up

Fabric type

With conveyer

m/min

Without conveyer

m/min

Scour and bleach

Light/white

Light/color

Medium/white

Medium/color

Heavy/white

Heavy/color

70-80

60-70

60-70

60-65

50-55

45

N/A

60

N/A

45-50

N/A

30

Scour only

Light/white

Light/color

Medium/white

Medium/color

Heavy/white

Heavy/color

N/A

60-70

60-70

60-65

50-55

30-35

N/A

90-95

N/A

45-50

N/A

30-35

Bleach for white only

Light/white

Light/color

Medium/white

Medium/color

Heavy/white

Heavy/color

80-90

N/A

70-80

N/A

40-50

N/A

N/A

90-95

N/A

45-50

N/A

30-35

Washing for yarn dyed

Light and medium

N/A

90-100

Washing for solid dyed

Medium

heavy

N/A

N/A

70-90

50

Mercerizing

Definition:

Mercerizing: Mercerizing is a process for
increasing dye absorbency, strength and lusture of the fabric by chemical
treatment.

Process
requirement:

Equipment used: The GOLLER Mercerizing range
machine.

Key accessories: The necessary tools or
accessories used for the mercerizing process are given bellow –Sewing machine,
sewing thread, cylinder, Baum meter, A-frame, handles for carriage, mixing
tank, reserve tank, hand gloves, eye protecting gloves, clip/finger clip etc.

The following fabrics go through
the mercerizing process-

  1. All cotton fabric.
  2. TC / CVC fabric.

Materials / Chemicals
used:

The materials and chemicals used
for the GOLLER mercerizing range machine for all cotton fabric TC or CVC fabric
and Bull-Twill fabric are described bellow-

Chemicals /
Material used

Composition

Sodium
Hydroxide (NaOH)

(28±2)º
Be (Baume´)

267
gm/l (see note)

Mercerizing
Oil (Mercirol QW2F)

3-4
gm/l

Green
acid / Nurta acid (32%)

3-4
% of total water

Wetting
agent

1-1.5
gm/l

Compressed
air

As
required

Steam,
water

As
required

Baume (°Be)

gm NaOH 100% (per
1 L NaOH solution)

20

166.7

24

213.7

28

267.4

30

296.8

38

441.0

40

484.1

Production
Procedure:

Machine Set-up: Describe bellow the machine
set-up for mercerizing process-

Machine set up
parameter

Actual parameter
range

Machine set value

Temperature
of washing chamber

(90-95)°C

90°C

Temperature
of NaOH chamber

(18-45)
°C

(40±5)
°C

Fabric
position

Face
or back

Face

Reserve
chemical caustic

3-8

6.5-7

Reserve
acid ( for all cotton

(6000-8000)
L

(4000-6000)
L

 TC or CVC fabric

(200-300)
kg

200
kg

Pressure
Squeezer of impregnation 1 & 2

(2-4)
bar

(2-3.5)
bar for all cotton TC/CVC

3
bar for Bull-Twill

Tension
(% of fabric)

0-2

2-3
for all cotton & TC fabric

Padder
pressure of washing

(1.5-5)
bar

(2-4)
bar

Compensator
Pressure

(1.5-5)
bar

(2-4)
bar

Dyeing section

Reactive Dyeing

(PDB Process)

Definition:

Solid dyeing with
reactive dyes (Pad Dry Bake or PDB process):

Solid dyeing with reactive dye by
PDB process is a process in which the fixation of dyes is carried out by means
of using relatively high temperature dry air in process of alkali along with
the dyeing liquor after padding and drying operation. Final fixation is carried
out at relatively high temperature in curing thermex (i.e. 150°C-170°C).



Impregnate with
dye and squeezing of surplus liquor



Partial dyeing of
fabric in IR section



Complete drying of
fabric in hot flue

Fixation of dye by means
of relatively very high temperature with dry air

Process
requirement:

   Equipment:  Monforts-Pad-Thermosol Dyeing Range (P-Th 1)
and (P-Th 2)

Key accessories:  A-frames, Jack for A-frame, over lock sewing
machine, normal sewing machine, scissors, mixer, bucket.

  Material / Chemical
used:
 The material and chemical
used for the solid dyeing with reactive dye (PDB process) are describe bellow- Fabric,
reactive dyes, reduction inheritor, antimigrating agent, urea, alkali and
additional chemicals and axillaries for e.g. water softening agent, wetting
agent, antifoaming agent, sequestering agent etc.

 Sample of guide
recipe:


Reactive
dyes – a  gm/l


Reduction
inhibitor – b 
gm/l


Anti
migrating agent – c  gm/l


Urea
–   d  gm/l


Alkali –   e  gm/l

Production
Procedure:

 Machine Set-up:

Describe bellow the
machine setup for the solid dyed PDB process with reactive dyes-

Check List

Set-up Range

Set Value

Level
of dyeing bath

(0-500)
% for P-Th 1

manual
for P-Th 2

As
per requirement

Process
selector knob or switch

Pad
batch/ continues

Continues

Speed
variable knob VTG-1

(0-100)
%  velocity%, meterage%

As
per requirement

Speed
variable knob VTG-2

(0-100)
%  velocity%, meterage%

As
per requirement

IR
section 1:  Speed

(0-100)  m/min%

As
per requirement

Intensity
(in %)

(20-100)
P%

As
per described in parameter sheet

IR
section 2:  Speed

(0-100)  m/min%

As
per described in parameter sheet

Intensity
(in %)

(20-100)
P%

As
per described in parameter sheet

Padder
pressure (center bar)

(0-4)
bar

As
per described in parameter sheet

Speed
m/min

(0-120)
m/min

As
per described in parameter sheet

Temperature
of thermex no-1

(0-250)°C

As
per described in parameter sheet

Temperature
of thermex no-2

(0-250)°C

As
per described in parameter sheet

Temperature
of thermex no-3

(0-250)°C

As
per described in parameter sheet

Blower
fan setting for thermex no-3

Low
/ High

As
per described in parameter sheet

Position
of main damper thermex no-1

(0-6)
division

3/3

Position
of main damper thermex no-2

(0-6)
division

3/3

Position
of main damper thermex no-3

(0-6)
division

6/6

Position
of exhaust damper thermex no-1

(0-6)
division

3/3

Position
of exhaust damper thermex no-2

(0-6)
division

6/6

Position
of exhaust damper thermex no3

(0-6)
division

As
per requirement

Position
of air flow knob of thermex no-1

±8
division

0

Position
of air flow knob of thermex no-2

±8
division

0

Position
of air flow knob of thermex no-3

±8
division

0

Pneumatic
pressure of guiders

(0-10)
bar

Should
be as minimum as possible

Pneumatic
pressure of compensator

(0-6)
bar

Should
be adjusted during running  as per
requirement

Position
of compensator

Load
/ Relive

Should
be adjusted during running  as per
requirement

Gas
pressure for IR section

(0-40)
m/bar

Minimum
30 m/bar

Gas
pressure for burners

(0-250)
m/bar

Minimum
50 m/bar

Position
of p/v gear box for traction device & windows

(0-6)
division

Should
be adjusted during running 

Operation
Procedure:  Trial procedure:
After receiving the dye line and
requisition form the color man is responsible to collect and weight out the
dyes and chemical and to prepare the color as describe in preparation of dyeing
liquor.First of all a 10 meters trial is conducted after adjusting it
confirmation is done. In confirmation normally (50-300) meter of actual fabric
is used to check the shade after trailing effect (change in shade comes during
running). An additional washed tap may also be used along with the actual
fabric in order to get the actual result after trailing.At the completion of a
trial operator is responsible to do the CPS (After treatment) either in pilot
plant or on pad steam dyeing machine, production officer compare the trial
result with the ALD in shade continuity card in data color system by using
particular type of illumination (As per the requirement of customer) based on
the result. Production officer is authorized to make necessaries change in
recipe in order to obtain the lest distribution during bulk production.

Preparation of dyeing
liquor:


Weigh
out accurately the dyes and chemical as per recipe given by production officer.


Pour
urea directly into the stock tank.


Pour
the dye into the stock color tank having some amount of water & water
softening agent (If applicable) slowly and gradually and allowed it to stiffer
for about 5-10 min. for pastel and light shade it is advisable to dissolved
separately in a bucket or beaker before adding in the tank.


Extra
care must be taken in dissolving that the dye having least g/l should be
dissolved first and then in ascending order.


Add
pre dissolved in last before level the liquor.

Operation
procedure for bulk production
:


Thread
up the machine according to the requirement under proper tension by using a tap
fabric.


Set
the parameter according to the parameter chart as per requirement.


Switch
on the exhaust fan, circulation fan or blower and burner of thermex
respectively.


Switch
on the exhaust fan, blower and lognition of IR-section respectively.


Switch
on all section drives through which the fabric is threaded up.


Switch
on the padder pressure.


Switch
on to keep the padding trough in up position.

Product
Quality Checked:

Listing:

  1. Production operator take 20
    cm dyed fabric after first 200 meter and then after every 500 meter.
  2. Mention left side and right
    side properly.
  3. Divided into 5 parts and
    give number 1 to 5 from left to right.

1

2

3

4

5

  1. Stitch as per number wise.

1

3

5

2

4

  1. Production office check if
    their exist any shade variation and take the following corrective measure
    where necessary:

Reactive Dye

(CPB Process)

Definition:

Solid dyeing
with reactive dyes (Cold Pad Batch or CPB process):

Solid dyeing with reactive dye by
CPB process is a batch process in which the fixation of dyes is carried out at
low temperature (i.e. 25-28 °C) in the pressure of highly alkaline medium and
by providing execs time (i.e. more than 8 hours).

In CPB process the most important
future is dyeing liquor and alkali solution which is prepared separately in
separate tank than it is pumped by a dosing pump into the padding through with
a color alkali ratio of 4:1. After padding the fabric is winded on the A-frame
in wet form and on completion of one batch. It is wrapped with the water proof
material in order to prevent evaporation and stored for more than 12 hours.
Finally it is washed in normal way.

For storage batching stationed
may be used where it should rotate at a rate of 5 to 7 revelation per minute.


Impregnate with dye and
alkali squeeze of surplus dyeing liquor



 Store wet

 
Wash off

Process
requirement:

Equipment:  Monforts-Pad-Batch

Key
accessories:

A-frames, Jack for A-frame, over lock sewing machine, normal sewing machine, scissors,
mixer, bucket.

Material / Chemical
used: The material
and chemical used for the solid dyeing with reactive dye (CPB process) are
describe bellow- Fabric, reactive dyes, reduction inheritor, urea, alkali and
additional chemicals and axillaries for e.g. water softening agent, wetting
agent, reduction inheritor (if require) etc.

Sample of guide
recipe:


Reactive
dyes   – a  gm/l


Reduction
inhibitor   – b  gm/l


Urea   –   c  gm/l


Alkali-1   –   d  gm/l


Alkali-2  – e  gm/l

Production
Procedure

Machine
Set-up:
 Describe bellow the machine setup for the
solid dyed CPB process with reactive dyes-

Check List

Set-up Range

Set Value

Level
of dyeing bath

(300-800)
mm  ws

As
per requirement

Process
selector knob/switch

Pad
batch/ continues

Pad
batch

Padder
pressure (center)

(20-50)
daN/cm

(30-35)
daN/cm

Speed
m/min

(0-120)
m/min

?
40 m/min

Operation Procedure: Trial procedure: After receiving the dye line and
requisition form the color man is responsible to collect and weight out the dyes
and chemical and to prepare the color as describe in preparation of dyeing
liquor.

In trial normally (5-10) meter of
actual fabric is used to check the shade before starting production. Trial
result can be checked by drawing sample of (6?×4?) approximately and by giving
it after treatment as follows:

  1. Warping the fabric on a
    glass rod.
  2. Covering it by polythene
    paper to make it air tight.
  3. Witting for 16 min.
  4. Opening the polythene paper
    and hanging it on a beaker having a small quality of water at a temperature
    of (53-60) °C in such a way that it should not touch the surface of water.
  5. Placing the beaker in
    microwave oven for 4 min at a time of not more than 80°C.
  6. Washing or soaping the
    fabric in pilot plant.
  7. Ironing and condition of
    fabric.

Reactive Dye

(PDD Process)

Definition:

Solid dyeing
with reactive dyes (PDD Process):

Solid dyeing with reactive dye by
PDD process is a process in which the fabric is padded and dried with the dying
liquor in the absence of alkali, so the final fixation is carried out somewhat
next process.

Process
detail:
 In pad dry process the fabric(in open with
form) is impregnated with the dyeing liquor in absence of alkali and squeeze by
means of padding mangle to remove the surplus liquor and to level the dyeing
liquor onto the surface of fabric which after passing through the airing zone
is subjected for drying.

Initially fabric is dried by
passing through the IR section in order to remove the maximum amount of
moisture and to raise the temperature of surface of fabric. Complete drying is
carried out in hot flue by means of circulation of hot air.

The chemical pad steam process is
carried for final fixation.



Impregnate with
dye and squeezing of surplus liquor



Partial dyeing of
fabric in IR section

Complete drying of fabric
in hot flue

Process
requirement:

Equipment:  Monforts-Pad-Thermosol Dyeing Range (P-Th 1)
and (P-Th 2)

Key
accessories:
 A-frames, Jack for A-frame, over lock sewing
machine, normal sewing machine, scissors, mixer, bucket.

Material /
Chemical used:
The
material and chemical used for the solid dyeing with reactive dye (PDB process)
are describe bellow-Fabric, reactive dyes, reduction inheritor, antimigrating
agent, urea, alkali and additional chemicals and axillaries for e.g. water
softening agent, wetting agent, antifoaming agent, sequestering agent etc. 

Sample of guide
recipe:


Reactive
dyes   – a  gm/l


Reduction
inhibitor   – b  gm/l


Antimigrating
agent   – c  gm/l

Operation
Procedure:  Trial procedure:
 After receiving the dye line and requisition
form the color man is responsible to collect and weight out the dyes and
chemical and to prepare the color as describe in preparation of dyeing liquor.

 First of all a 10 meters trial is conducted
after adjusting it confirmation is done. In confirmation normally (50-300)
meter of actual fabric is used to check the shade after trialing effect (change
in shade comes during running). An additional washed tap may also be used along
with the actual fabric in order to get the actual result after trailing.

At the completion of a trial
operator is responsible to do the CPS (After treatment) either in pilot plant
or on pad steam dyeing machine, production officer compare the trial result
with the ALD in shade continuity card in data color system by using particular
type of illumination (As per the requirement of customer) based on the result.
Production officer is authorized to make necessaries change in recipe in order
to obtain the lest distribution during bulk production.

Disperse Dyeing

(PDB Process)

Definition: Solid dyeing with
disperse dyes (Pad Dry Bake or PDB process):
 Solid dyeing with disperse dye by PDB process
is a process in which the fixation of dyes is carried out by means of using
relatively high temperature dry air in process of alkali along with the dyeing
liquor after padding and drying operation.

Initially it dried by passing
through the IR section in order to remove the sufficient amount of moisture and
to raise the temperature of surface of fabric. Complete drying is carried out
in hot flue by means of circulation of hot air. Final fixation is carried out at
relatively high temperature in curing thermex (i.e. 150°C-170°C).



Impregnate with
dye and squeezing of surplus liquor



Partial dyeing of
fabric in IR section

Complete drying of
fabric in hot flue





Fixation of dye by means
of relatively very high temperature with dry air

Process
requirement:

 Equipment:
Monforts-Pad-Thermosol Dyeing Range (P-Th 1) and (P-Th 2)

Key
accessories:

A-frames, Jack for A-frame, over lock sewing machine, normal sewing machine,
scissors, mixer, bucket.

Material /
Chemical used:
The
material and chemical used for the solid dyeing with disperse dye (PDB process)
are describe bellow-Fabric, disperse dyes, antimigrating agent, dispersing
agent, leveling agent, water softening agent (if required), acid other
axillaries e.g. wetting agent, antifoaming agent, etc.

Sample of guide
recipe:


Disperse
dyes   – a  gm/l


Dispersing
agent – b  gm/l


Antimigrating
agent – c 
gm/l


Acid   –   d  gm/l

Product
Quality Checked:

Carbonization:

 Carbonization is a process in which one
component of blended fabric (normally cotton part) is dissolved by using a
solvent in order to check the individual property of other component.

In practice a small washes wet
piece of blended is dipped in a solution of sulfuric acid having a
concentration of (80:20) and
temperature ? 15°c is used to dissolve the cotton portion of PC / CVC blended
fabric which is helped in studding the actual shade of polyester portion after
completion of polyester dyeing with disperse dyes or one bath (Disperse /
Reactive) dyeing.

Pigment Dyeing

Definition: Solid dyeing with
pigment dyeing:

Solid dyeing of cotton and blended fabric with pigment is a surface phenomenon
in which the pigment are bond the fiber in the presence of an adhesive known as
binder, usually fixation is carried out by means of using high temperature dry
air after padding and drying operation.

 In dyeing of cotton fabric with pigment the
fabric (in open width form) is impregnated with the dyeing liquor in presence
of binder along with the pigment. This is then squeeze by means of padding
mangles to remove the surplus liquor and to level the dyeing liquor onto the
surface of the fabric, which after passing through the airing zone is subjected
for drying.

Process
requirement:

Equipment: Monforts-Pad-Thermosol Dyeing
Range (P-Th 1) and (P-Th 2)

Key
accessories:

A-frames, Jack for A-frame, Over lock sewing machine, normal sewing machine,
scissors, mixer, bucket.

Material /
Chemical used:
The
material and chemical used for the solid dyeing with pigment are describe
bellow-Fabric, pigment, binder, antimigrating agent, wetting agent, antifoaming
agent etc.

Sample of guide
recipe:


Pigment   – a  gm/l


Binder  – b  gm/l


Antimigrating
agent – c  gm/l


Wetting
agent –   d  gm/l


Anti
Striking agent –  e  gm/l


Antifoaming
agent – f  gm/l

Operation
Procedure: Trial procedure:

After receiving the dye line and requisition form the color man is responsible
to collect and weight out the dyes and chemical and to prepare the color as
describe in preparation of dyeing liquor.

First of all a 10 meters
trial is conducted after adjusting it confirmation is done. In confirmation
normally (50-300) meter of actual fabric is used to check the shade after
trailing effect (change in shade comes during running). An additional washed
tap may also be used along with the actual fabric in order to get the actual
result after trailing.

At the completion of a trial
operator is responsible to do the CPS (After treatment) either in pilot plant
or on pad steam dyeing machine, production officer compare the trial result
with the ALD in shade continuity card in data color system by using particular
type of illumination (As per the requirement of customer) based on the result.
Production officer is authorized to make necessaries change in recipe in order
to obtain the lest distribution during bulk production.

Dyeing Process in Pad-Steam Machine

Key
accessories:

A-frames, Jack for A-frame, over lock sewing machine, normal sewing machine,
scissors, mixer, bucket

Material /
Chemical used:
The
material and chemical used for the solid dyeing with chemical pad-steam process
are describe bellow-Steam, compressed air, gas, detergent reducing agent,
alkali, acid, ionic or non ionic salt, reduction inhibitor etc.

Production
Procedure:

  Machine Set-up: Describe bellow the machine setup for the solid
dyeing with chemical pad steam (CPS process):

Section

Parameters

Value range

Setting value for
each individual process

Washing &
De-finishing

Chemical Pad
Steam

Reduction clear
&Striping

FOULARD

Foulard
Position

UP/
Down

UP

UP

UP

Foulard
Temperature

(0-50)
°C

N/A

As
min as possible

As
min as possible

Foulard
filling position

Open/
Close

Open

Open

Open

Foulard
dosing selector switch

On/off/auto

N/A

Auto

Auto

Foulard
discharge position

Open/
Close

A
P R

Close

Close

STEAMER

Main
steam supply valve

Open/
Close

N/A

Open

Open

Supply
valve for LIPS D1

Open/
Close

N/A

Open

Open

Supply
valve for entry wall D2

Open/
Close

N/A

Open

Open

Supply
valve for roof D3, D4, D5

Open/
Close

N/A

Open

Open

Supply
valve for exit wall D6

Open/
Close

N/A

Open

Open

Supply
valve for steamer sump D8, D9

Open/
Close

N/A

Open

Open

Main
steam valve for direct injection

Open/
Close

N/A

As
per require

As
per require

Steam
valve for direct injection D10, D11, D12, D13, D14

Open/
Close

N/A

As
per require

As
per require

Roof
temperature of steamer

(0-120)
°C

N/A

?
105 °C

?
105 °C

Temperature
of steamer 1

(0-110)
°C

N/A

(100-105)
°C

(100-105)
°C

DX-Fill
position

Open/
Close

N/A

Open

Open

DX-Discharge
position

Open/
Close

N/A

Close

Close

Temperature
of water seal (L)

(0-100)
°C

N/A

As
min as possible

As
min as possible

Temperature
of water seal (R)

(0-100)
°C

N/A

As
min as possible

As
min as possible

Without
steamer selector switch

On/off

On

Off

Off

Pot
position of steamer 1

(0-100)
°C

N/A

As
per require

As
per require

Pot
position of steamer 2

(0-100)
°C

N/A

As
per require

As
per require

Pot
position of water seal

(0-100)
°C

N/A

As
per require

As
per require

WASHING

Showers
for WA (1-8)

Open/
Close

OPN
except WA-4

OPN
except WA-4

OPN
except WA-4

Padder
pressure WA (1-8)

(0-10)
bar

(2-4)
bar

(2-4)
bar

(2-4)
bar

Compensator
pressure WA (1-8)

(0-6)
bar

As
per require

As
per require

As
per require

Compensator
position

Load/relief

As
per require

As
per require

As
per require

Over
flow valve WA (1-8)

Open/
Close

CLS
except WA-5,2

CLS
except WA-5,2

CLS
except WA-5,2

Drain
valve

Open/
Close

Close

Close

Close

Expender
roll WA (3-6)

Auto/manual/off

Auto

Auto

Auto

Torque
motor pot valve WA(1-8)

0-100

As
per require

As
per require

As
per require

Feeding
valve WA (1-8)

Open/
Close

CLS
except WA-4

CLS
except WA-4

CLS
except WA-4

DRYER

Main
steam valve

Open/
Close

Open

Open

Open

Steam
valve for exhaust roof

Open/
Close

Open

Open

Open

Exhaust
fan for dryer 1,2,3

Open/
Close

On

On

On

Cooling
cylinder water supply valve

Open/
Close

On

On

On

Checklist
before production:

Parameters / Item

Value / Checking

Machine
set up

a) Threading of machine should be
as per process requirement.

b) Parameter should be as per
process requirement.

Fabric
availability

According
to program schedule and the rout card having test status ok.

Preparation
of chemical

Checking
of preparation and also the shifting of liquor to the delivery tank.

Tap
fabric

Availability

Operation
procedure:

 Preparation of chemical:

Recipe:

Gluberies salt   250
g/l

Reduction
inhibitor  
5-10 g/l

Caustic soda 6-10
g/l

Soda ash
10-20 g/l

1. Weigh out the chemical as per
recipe given by production officer.

2. Add Gluberies salt in stock tank
gradually having ½ of liquor of total requirement at (40-30) °C under constant
stirring.

3. Add the pre dissolved reduction
inhibitor, caustic flask and soda ash (if required) separately.

4. Make up the level up to desire
amount.

5. Stir well for about 15-20 min
before use.

Preparation
of chemical for R/C & striping process:

Recipe:

  Sodium hydrosulfite
(30-50) g/l

  Caustic flasks   (15-25) g/l

  1. Weigh out the chemical as
    per recipe given by production officer.
  2. Add pre dissolved caustic
    flask in stock tank having at least ½ of water of total requirement at
    room temperature.
  3. Add sodium hydrosulfite
    directly but gradually in stock tank under constant stirring at room
    temperature.
  4. Make up the level up to
    desired amount.

Preparation
of chemical for washing and Definishing:

Recipe:

Chemical

For washing tank

For stock tank

Detergent

(1-3)
g/l

(5-15)
g/l

Soda
ash (if require)

(5-10)
g/l

(25-50)
g/l

  1. Weigh out the chemical as
    per recipe given by production officer.
  2. Detergent and soda ash can
    be dissolved very easily in sufficient amount if water at normal
    temperature because of excellent solubility.

Preparation
of chemical for vat development process:

Recipe:

Sodium hydrosulfite 50 g/l

Caustic flask 25
g/l

Glubers salt   13
g/l

Dispersing agent 3 g/l

  1. Weigh out the chemical as
    per recipe given by production officer.
  2. Add the glubers salt and
    dispersing agent in stock tank gradually having ½ of liquor of total
    requirement under constant stirring.
  3. Add the pieces of ice or use
    chilled water in order to keep the temperature of liquor less than 15 °C.
  4. Add the pre dissolved
    dispersing agent and caustic flask in stock tank separately.
  5. Make up the level up to
    desired amount.
  6. Add sodium hydrosulfite into
    the stock tank just before stirring it into the delivery tank.

For washing section
recipe:

For
washing tank

For
washing tank

For
W/A-2

Hydrogen
peroxide

3 g/l

15  g/l

Acidic
acid

5 g/l

25  g/l

for
W/A-4

Detergent

2 g/l

10  g/l

Soda
ash

5 g/l

25  g/l



























Definition:

Finishing:  

A fabric finishing process is a
process for providing specific quality to the fabric  that is required by the customer .i.e. (soft,
wrinkle free etc ).

 Refinishing and topping:

Refinishing and topping is a
repetitive finishing process to cotton fabric, TC  fabric and yarn dyed fabric. To minimize the
dyeing as per customer swatch and if necessary some pigment dyes are used for
the purpose.

Process
requirement:

Equipment: MONFORTS STENTER MACHINE I & II

Key accessories: Two electronic measuring
balance, two breakers, pH paper (3-12), sewing machine, pinning brush.

Materials and
chemicals used:

  Name of the fabric

Chemicals and materials used (the chemical sequence no is
given in the left of wrinkle free finished fabric)

1) White fabric (soft)

Cotton OBA (optical brightening
agent)

Polyester cotton OBA

Softener

Tinting agent

2) White fabric (wrinkle free and

Easy care)

 l. 
Softener

ll.  cotton OBA

lll.  Polyester cotton OBA

lV. pH adjusted with CH3COOH.

V.  resin depends on fabric weight .i.e 110 g/l
is recognized as light ( 110-300) g/l is medium fabric and 

(330-500) g/l is heavy fabric.

Vl. Wetting agent (when
chemical absorbency is poor)

Vll. Tinting agent.

Vlll. Additives.

lX. Catalyst (20-30)% of resin

3) Colored fabric

(soft)

Softener

Dye fixer (it is used according
to color fastness)

pH adjusted with acetic acid

Anti foam for 100% cotton and
twill fabric

(for deep shade)

4) Colored fabric

(Wrinkle free)

L Softener

ll. Resin

lll. Wetting agent (when
chemical absorbency is poor)

lV. pH adjusted with acetic
acid

V. Dye fixer

Vll. Catalyst 25-30% or resin

5) Yarn dyed (soft)

Softener

Acetic acid for pH adjustment

OBA as per requirement

6) Yarn dyed

 (ultra soft)

Softener

Acetic acid for pH adjustment

OBA as per requirement

7) Yarn dyed (wrinkle free &
easy care)

l. Softener/Catalyst

ll. Additive

lll. Resin

lV. Wetting agent

V. OBA (if required)

Vl. pH adjusted with acetic
acid

Vll. Catalyst 25-33% or resin

8)  Colored fabric

(hard finish & shiny
finish)

Softening agent

Wetting agent

Additive

Resin

Catalyst

Acetic acid

OBA

Production procedure:

Machine setup:

 Described below is the machine set up for the
stenter machine for TC fabric, Twill fabric, 100% cotton fabric, cotton poplin
and other light fabric finishing, re-finishing process for white and colored
fabric.

Checklist

Set-up range

Set
value

Mangle pressure

(2-6) bar

Depends on pick up

Temperature
setting

(60-250)°C

According
to the shade (reference are taken from production register)

Temperature (for re-finishing)

(150-180)°C

According to the shade
(reference are taken from production register

Over feed

(0-18)%

As required

Blower fan setting for solid
dyed fabric

Low and high

High

Blower fan setting for yarn
dyed fabric

Low and high

  High

Exhaust fan setting

Auto /manual

  Manual

Width of machine chain setting

  (70-80)cm

1. Described with (+8)cm in case
of pin

2. Described with (+6)cm in case
of clip

Pleva setting parameter for
TC”g” for cotton “O”

(4.5-5.5) %

  As required

Fabric pneumatic dyed bar
pressure

  (0-2) bar

0.5 bar

Machine pins/clips

  N/A

Pins (for light fabric)

Clips (for heavy fabric)

Burner gas pressure

20 ml (fixed)

20 ml

Machine speed

(7-120) m/min

m/min

light shade   –  
40-100

dark shade   –  
40-100

light/soft finished fabric


40-100

Twill
fabric –   40-70

Wrinkle
free fabric – 20-25

Bianco

Program no (1-10)

Depends on fabric structure

Operation procedure: Operation procedure for white
fabric finishing (Soft)

The pilot plant (fabric) provides
customer approved swatch with recipe of the white fabric to the finishing
department where as preparation department provides the bleached fabric. The
finishing procedure begin with the calculation of solution a amount for a
particular fabric the formula as below

v 
Solution
amount = fabric weight (kg) X fabric length (m) X
pick up % +

Through
content + 3% wastage

   HERE  

Pick
up % = 60% – 70% (for white fabric)

= 50% – 55% (for colored
fabric)

Through
content is 80 L solution required in the through wastage is 3% of solution.

The
trial process fast start with same fabric of 
1 m and required chemical solution. Chemical are measured by using
balance and takes in the bucket separately. Then tinting agent is measure and
taken into a breaker to dilute with hot water. Other chemical are dilute with
hot water on normal water based upon the reference of  the chemical 
literature book of the chemical company.

Mixing
tank is filled up with 50% of water to the required solution level (100L) and
the chemical are poured separately into the tank through a piece of filter
cloth. A sequence is maintained for chemical pouring into the mixing tank for
the wrinkle free finished fabric so the fabric is not damaged by the chemical
solution. Then the solution is measured to ensure the 100 L level by using a
still rolled and water is added if necessary. Chemical are stirred for five minutes
by the fan in the mixing tank and then sets to the upper tank.

The
upper tank sets the solution to the trough machine which has a value at the
level of 80 L the value close automatically. At that specific level and opens
when the solution level goes lower than 80 L.

The
operation fixes the one m of sample fabric on the pins on the endless chain at
the feed side starts the machine to develop it. When the trial fabric is
developed it is usually impacted with the approved sample for the parameters (
softness, hardness, stiffness, shade match etc )  ordered by customer. Then  a piece of fabric ( Max “14 X 14” ) is cut
from the trial fabric to scan the shade in the data color of pilot plant (Lab
). The shade scan is necessary to fixed out any deviation in the fabric and
also to take corrective action to overcome these fault / deviation.

If
the trial fabric matches with the customer approved sample then trial ends and
production department decide to go for bulk production. After every 1000 m. 1 m
sample is sent to the QC for QC tests. If the trial does not match then the
recipe, temperature or the machine speed is adjusted from the reference of
parameter register, and the shade scanning report and the same trial process repeat
until it match with the customer approved sample. For the bulk production
chemical solution is prepared from the formula mentioned above and poured in
the mixing tank of one bath at a time capacity of each bath is 400 L.

BEXTEX
LIMITED

Operation procedure for white fabric finishing (Soft)

The operation procedure of white
fabric (wrinkle free) finishing is same as white fabric soft finishing process.
Except the chemical composition. Some new chemical (Resin, Catalyst, Wetting
Agent, Acetic Acid and Additives) are added here.

Operation procedure for colored fabric finishing (Soft)

Planning department provides the
customer approved swatch and the dyeing department the fabric to the finishing
department then a recipe is prepared base on the reference of the chemical
literature book of the chemical company, program register and data color of
pilot plant (Lab).

The process starts from the
calculation of solution amount and is same as white fabric (soft) finishing
process. The only difference here is the pickup % which is (47-50) % and the
chemical stirring in the mixing tank which is (2-3) minute.

Operation procedure for colored fabric finishing (wrinkle free)

The operation procedure of
colored fabric wrinkle free finishing is same as colored fabric soft finishing
process except the chemical composition. Some new chemical (Resin, Catalyst,
Wetting agent and Acetic Acid) are added here.

Production quality
check:

 In case of TC fabric, 100% cotton and twill
fabric. The operator checks the shade in naked eyes in the stenter machine. If
any deviation is found then he informs the responsible shift officer who take
the necessary action to overcome the problem. If the officer then the
departmental head production is informed and finally he give the decision.
Shade checking is not applicable for the sanforizing process.

Fault check:

The operator check the weaving
faults (.i.e. Double yarn, Warp and Weft missing, yarn contamination etc.) ,
spinning faults ( .i.e. Dye resist mark, Stop mark, Bend mark, Chemical spot,
Dropping mark, Listing, Torn and Hole, Fabric structure etc.).

During process when minor fault
occur within 30 m of fabric ( while running about 300-500 m of fabric) which is
not  resulted from previous process and
also not recorded on the process route card, the necessary actions to be taken
are as follows:

*
Check
the feed side batcher to make sure that thus fault did not occur from previous
process.

*
Stop
the machine to identify whether thus faults are occurring due to machine faults
or the faults are due to the chemical (checks cleanliness of machine parameters
and chemical composition).

Width check: Measure fabric with by using a
measuring tape. Compares with the required finished width that is mentioned in
process route card, in case of wrinkle free yarn dyed width checking is 2cm
less than the normal fabric finish fabric width.

Design the fabric bow
check for yarn dyed fabric:
In the delivery side the operator checks the design and bow, adjust the machine
for checking stripe by straightening the weft of the fabric.

Pin setting check
(for TC and yarn dyed fabric):
Check at the delivery side if the selvedge of fabric is set in pins correctly.

QC sample test: 1m sample fabric is cut from
each batch (which represent the bulk) and sent to the QC lab for test. The
shade continuity card is checked with the sample for the QC sample test. QC
department does the physical test, chemical test and analysis the test and
notes the result in fabric test result for details of QC test. During scanning
of twill fabric data color machine the sample must be set vertically warp wise.
Refer to specification for details of the methods of sample scanning.

FINISIHING PROCESS
IN SANFORIZING MACHINE

Process definition:

Sanforizing: Sanforizing is a mechanical
treatment of fabric (sample given cotton and CVC) in the sanforizing for
shrinkage of soft fabric (sample given cotton and CVC fabric etc) and
transforming the fabric into soft, glossy and smooth fabric for end use.

Process
requirement:

Equipment:  MONFORTS
SANFORIZING MACHINE  

Key accessories:  The necessaries tools/accessories used for the
sanforizing machine are as follows : Sewing machine, measuring tape, white
papers.



Fig: Process flow diagram of
sanforizing machine

Production
procedure:

Operation staff

>  
In
charge finishing

>  
Assistant
manager

>  
Textile
technologist

>  
Production
officer

>  
Finishing
operator

>  
Assistant
finishing operator

>  
Helpers

>  
Learners

Machine set up:

Described below with the machine
set up for cotton and CVC fabric is:

 
Check list

Set up range

  Set value

Steam pressure for damping
roller

(0-5)  bar

2.5 bar

Water pressure for spraying
before damping roller

(0-5)  bar

4.5 bar

Over feed

(0-10) bar

5% as required loose

Rubber belt pressure

(0-18) bar

8-12 bar

Rate of water spraying on
rubber belt

As required

Steam pressure for rubber belt

(0-3) bar

0-2 bar less than two

Rubber belt tension

(0-10) bar

Depends on belt thickness

Air pressure for felt belt

(0-6) bar

4.5 bar

Steam pressure for felt belt

(0-3) bar

2-3 bar

Pressure for winding batcher

(0-10) bar

0-4 bar

Operation procedure:

* After completion of the checklist
before starting the sanforizing process (for the cotton and CVC) the operator
gets approval from the production officer.

* The operator sets the feed side
batcher and check the shrinkage of the fabric by a special type of scale and
the fabric is guided up to the damper. The fabric process through the friction
and heat of the rubber belt region and also through the felt calendar region of
the sanforizing machine.

* The empty batcher is set to the
rare end of the rotation station.

* During the process the operator
stop the machine to check the shrinkage of the fabric at the rare end. If the
shrinkage setting is all right then the bulk production continuous and if there
is any deviation in the shrinkage setting then the setting pressure and roller
pressure are adjusted.

* For wrinkle free fabric the
shrinkage is controlled by resin finishing and then passed through the calendar
region for getting soft, glossy and smooth finishes quality as a final product.

* The quality of the fabric depends
on various parameters discussed in the checklist. The operator must check these
parameters carefully during the process to avoid any defects.





Process
definition:

 Peace finish: Emerizing is a mechanical treatment of fabric in
the emerizing machine for giving the fabric a soft hairy appearance by
protruding the fiber from the fabric surface. Peace finish can be done either
before or after dyeing process in any case before emerizing fabric must be
stretched and stitched.

Process requirement:
Equipment:  THE EMERIZING MACHINE

Material and chemical
used: Emery sticks
and emery paper with different grades are used in this process. Chemical are
not used directly on the emerizing machine.

Machine setup:

Machine set up

Actual parameter range

Machine set value

Emery sticks roller setting

3-5

1-3 for light fabric

5-9 for heavy fabric

Emery sticks setting/roller

One (50-60)

Two -24

One – 60

Two – 24

Exhaust fan setting

Auto/manual

Manual

Roller pressure

0-40

As required

Emery paper gauge

180-240

120 for heavy fabric

180-240 for light fabric

Emery paper change cycle

(30000-45000) m

30000 m for heavy fabric

45000 m for light fabric

Machine speed

One – 25 m/min

Two – 12 m/min

As required

Finishing process in
calendaring machine

Process definition:

Calendaring process: In fabric finishing process,
calendar plays an important roll in achieving effect like smoothing, luster
effects. In this process fabric is passed through a machine in which heavy
roller (bowis) rotate in contact under mechanical or hydraulic pressure.

Four
type of calendaring are done here-

a) Chintz calendar (smoothing effect
with paper roll and steel roll)

b) Ironing (soft, smoothing and
glazing effect with steel roll)

c) Calendaring for smooth surface
(mating effects with cotton)

d) Calendaring (soft and smoothing
effect with cotton roll, paper roll and steel roll)

Process requirement: Equipment: THE RAMISH CALENDERING MACHINE

Key accessories: The necessaries tools/accessories
used for the stenter machine are as follows: Sewing
machine, measuring tape, white papers.

Material and chemical
used: Sometimes
wetting agent (.e.g. mixture of surface active compound) are used as chemical
for the heat setting and stretching process.

Machine setup: Described below is the machine
set up for the stenter machine for TC fabric, Twill fabric, 100% cotton fabric,
cotton poplin and other light fabric finishing, re-finishing process for white
and colored fabric.

Machine set up parameter

Actual parameter range

Steam
pressure for steel bowl

As
required

Pressure
for cotton bowl

(50-100)
K/N

Pressure
for paper bowl

(50-200)
K/N

Temperature

(50-240) °C

Speed

(30-70)_
m/min

Quality Control




Lab





















Pilot plant   Q.C side


 Online  Offline

Pilot 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 BTL are:

1.  Reactive dyeing: 100 % Cotton is dying in alkali
medium (in accordance to existing dyes) and fixation at relatively high
temperature (130 oC-160 oC).

2. Disperse dyeing:
Polyester part dyeing in acid medium. There is different process for blended
fabrics such as PC or CVC.

 Tow
bath process:

Process for dyeing fabric separately using disperse dye for the poly part and
reactive dye for the cotton part.

 One
bath method:

Process for dyeing fabric using a solution that is made by both disperse and
reactive dyes together.

Chemical Quality Verification

Applicable test for chemical
quality verification are as follows:


Concentration
of Hydrochloric acid.


Formic
acid test.


Glubers
salt test.


Concentration
of Acidic acid.


Concentration
of Soda ash.


Concentration
of Oxalic acid.


Concentration
of Caustic soda.


Concentration
of Sulfuric acid.


Concentration
of Hydrogen peroxide.


Wetting
agent test.

Concentration of Hydrochloric acid:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard base
(Sodium Hydroxide).

Reagent

:

Sodium Hydroxide 1(N),
Phenolphthalein indicator

Procedure

:


Take
10ml HCl weight it in gm and then make 1L solution with distilled water in
volumetric flask


Take
2.5 ml of that solution in a conical flask; add 2-3 drops of phenolphthalein
indicator.


Titrate
with 0.1(N) caustic soda.

Burette reading × 0.1×0.369×400

Result=

Sample weight

Performance standard

:

37% or as required

In case of non conformity

:

Rejected

Document / form used

:

Chemical test register (log
book)

Formic acid test:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard base
(Sodium Hydroxide).

Reagent

:

Sodium Hydroxide 1(N),
Phenolphthalein indicator

Procedure

:


4.6
gm formic acid is added in 100ml distil water.


Take
10ml of that solution in a conical flask and 2-3 drop of phenolphthalein
indicator.


Titration
with 1(N) caustic soda

Result = Burette reading × 10

Performance standard

:

80-100 % or as required

In case of non conformity

:

Rejected

Document / form used

:

Chemical test register (log
book)

Gluber Salt / Sodium chloride test:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

 N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

N/A

Reagent

:

N/A

Procedure

:


Take
a beaker dry it and take the weight (example X).


Take
10gm Glubers salt in a 50ml distilled water and make solution.


Filter
the solution.


Take
the solution in a beaker and evaporate it.


Take
the weight of the beaker (example Y).

Result = {(Y-X) ÷ 10} × 10

Performance standard

:

As required

In case of non conformity

:

Rejected

Concentration of Acidic Acid:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

 N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard base
(Sodium Hydroxide).

Reagent

:

1 (N) caustic soda,
Phenolphthalein indicator

Procedure

:


Take
6 gm acidic acid and dissolved it in 100ml distills water.


Take
10 ml of that solution in a beaker and add 2-3 drops of phenolphthalein
indicator.


Titrate
with 1(N) caustic soda.

Result(% of acidic acid) =
Burette reading × 10

Performance standard

:

90-100%

In case of non conformity

:

Rejected

Concentration of soda ash:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard acid
(HCl)

Reagent

:

1 (N) HCl, Methyl orange
indicator

Procedure

:


Take
5.3 gm soda ash and dissolved it in 100 ml distill water.


Take
10 ml of that solution + 10 ml distill water and 2-3 drops of Methyl orange
indicator.


Titrate
with 1(N) HCl.

Result = Burette reading × 10

Performance standard

:

80-100 %

In case of non conformity

:

Rejected

Concentration of Oxalic acid:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

 N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard base
caustic soda

Reagent

:

1 (N) caustic soda,
Phenolphthalein indicator

Procedure

:


Take
6.3 gm oxalic acid and dissolved it in 100ml distilled water.


Take
10 ml of that solution in a beaker and add 2-3 drops of phenolphthalein
indicator.


Titrate
with 1(N) caustic soda.

Result = Burette reading × 10

Performance standard

:

As required

In case of non conformity

:

Rejected

Concentration of Caustic soda:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

 N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard acid
(HCl)

Reagent

:

1 (N) HCl, Phenolphthalein
indicator Ethanol.

Procedure

:


Add
8.3 ml of HCl in 100 ml distill water.


Dissolved
4 gm caustic soda in 100 ml  water


Take
10 ml of that caustic soda solution in a beaker and 2-3 drops of
phenolphthalein indicator.


Titrate
with 1(N) HCl.

Result = Burette reading × 10

Concentration of Hydrogen Peroxide:

Machine / apparatus used

:

Burette, pipette, beaker,
balance

Machine / apparatus
manufactured by

:

N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Titration with standard
permanganate

Reagent

:

Potassium permanganate (KMnO4),
H2SO4 (1:4)

Procedure

:


Weight
sample such that there is no more than 0.06 gm of H2O2 present, dilute with
50 ml of distill water and add 10 ml of (1:4) H2SO4.


Titrate
with 0.1 (N) potassium permanganate (KMnO4) till pink color appearance.

Volume of (KMnO4) (0.1) (0.017) (100)

Result=

   Sample weight

Performance standard

:

45-50 %  or as required

In case of non conformity

:

Rejected

Document / form used

:

Chemical test register (log
book)

Wetting agent test:

Machine / apparatus used

:

1 L beaker

Machine / apparatus
manufactured by

:

N/A

Person responsible

:

Lab assistant

Frequency

:

Every new lot also as and when
required

Method

:

Dipping test and comparing with
running lots performance.

Reagent

:

Wetting agent

Offline Quality assurance test

The entire offline QA test for
finished fabric of Bextex limited can be groped as-


Physical
test


Chemical
test

Physical test:  The applicable QA physical test
for finished fabric is as follows-


Tensile
strength test


Tear
strength test


Abrasion
resistance test


Pilling
resistant test


Crease
resistant test

Tensile strength test:

Machine
used

:

Alphatens
tensile tester & Titan universal strength tester.

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Every
order

Procedure

:

According
to customer’s requirement and / or as specified in the BTL quality stander
specification.

Performance
standard

:

According
to BTL quality stander specification

In
case of non conformity

:

To
increase tensile strength re-mercerized (increase of 5 %to 10%) and re
finish.

Tear strength tester:

Machine
used

:

Tearing
tester 1653.

Machine
manufactured by

:

Person
responsible

:

QA
lab assistant

Frequency

:

Every
order (only for 100% light fabric)

Procedure

:

According
to customer’s requirement and / or as specified in the BTL quality stander
specification.

Performance
standard

:

Both
warp and weft 7000 mN  minimum or 713
gm minimum or as per the customer requirements.

In
case of non conformity

:

To
increase tearing strength re-mercerized and re finish.

Abrasion resistance:

Machine
used

:

Nu-Martindal
abrasion and pilling tester.

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
required.

Procedure

:

BS-5690
ref: Breakdown and according to customer requirement.

Performance
standard

:

Maximum
ends breakage per 20000 revolutions.

In
case of non conformity

:

Re-singing,
Re-washing and Re-finishing.

Pilling resistance:

Machine
used

:

ICI
pilling box & random Pilling tester.

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
required.

Procedure

:

BS
5811, ASTM D3512 and according to customer requirement.

Performance
standard

:

Grade
– 4

Grade
– 3 (for peach fabric)

In
case of non conformity

:

Re-singing
followed by Resin finish.

Crease resistance:

Machine
used

:

Crease
recovery tester.

Machine
manufactured by

:

Shirley,
England

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
buyer requirement

Procedure

:

BS
EN 22313, AATC 66, ISO 2313.

Performance
standard

:

According
to buyer given stander.

In
case of non conformity

:

Resin
finish.

Chemical test:

The following chemical test are
carried out by QA of finished fabric –


Fastness
to perspiration


Fastness
to light


Fastness
to heat


Fastness
to sea water


Fastness
to chloraminated water


Washing
stability


Fabric
pH

Fastness to perspiration:

Machine
used

:

Perspirometer
chemical kit & Carbolite incubator.

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
customer required.

Procedure

:

BS
1006 ref: E 04, AATCC 105, AATCC 15.

Performance
standard

:

BTL
stander

Color
change

Color
staining

Acid
sweet

4
C

3-4S

Alkali
sweet

4
C

3-4S

Fastness to light:

Machine
used

:

Light
fastness tester (Mercury Vapor Lamp).

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
customer required.

Procedure

:

BS
1006  B02.

Performance
standard

:

For
dark shade 4C, for light & Pal shade 3C and according to customer
requirement.

In
case of non conformity

:

Select
dye stuff with better light fastness property

Fastness to heat:

Machine
used

:

Contact
heat test unit

Machine
manufactured by

:

Roaches
Engineer limited

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
required.

Procedure

:

ISO
105 : Poland BS 1006 : X11.

Performance
standard

:

According
to customer requirement.

In
case of non conformity

:

Select
dyestuff with better fastness to heat

Fastness to sea water:

Machine
used

:

Perspirometer
chemical kit & Carbolite incubator.

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
required.

Procedure

:

ISO
105 E02 : 1989.

Performance
standard

:

According
to customer requirement.

In
case of non conformity

:

For
color change 4C and for color staining 4S.

Fastness to chlorominated water:

Machine
used

:

Gyrowash

Machine
manufactured by

:

James
. H . Heals and company, England.

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
required.

Procedure

:

AATC
162

Performance
standard

:

According
to customer requirement.

In
case of non conformity

:

For
color change 3C

Fabric pH:

Machine
used

:

Metller
Toledo

Machine
manufactured by

:

Metller
Toledo AG

Person
responsible

:

QA
lab assistant

Frequency

:

Whenever
required.

Procedure

:

AATCC
81 – 1996

Performance
standard

:

According
to customer requirmment.

In
case of non conformity

:

Re-wash
or Re finish with acid .

Discussion

Bextex Ltd. is the largest and
most versatile business conglomerate in the private sector in Bangladesh.
Bextex Ltd. is committed to the best human workplace practices. Their goal is
to continuously improve their Human resource policies and procedures through
education, training, communication and employees involvement. Right from
inception the policy of the company has been to provide total customer
satisfaction by offering quality woven & knitwear in time. Working on new
concepts in styling & content of the knitwear is a continuous activity in
Bextex Ltd. With an objective to up the quality and the value of merchandise.
To meet the manufacturing to quality and promote delivery, Bextex Ltd. decided
to integrate the manufacturing process in a planned manner. Over the year the
entire process has been integrated by importing sophisticated machinery from
world-renowned manufacturers. For achieving their goal, Bextex Ltd. is textiles
graduates. According to their capacity they have an enriched production team
which is very rare in other factories of Bangladesh. The working environment of
Bextex Ltd. is very cordially & friendly. All of the executives &
employees of Bextex Ltd. are very much cordial & they always appreciate the
learners.

The goal of Bextex Ltd. is to get
high production & to maintain the quality of the product at a minimum cost.
There is no non-woven m/c in Bextex Ltd. But Bextex Ltd. is able to produce all
types of woven structure. There is no person to input the self shade of
different types of lot everyday in the spectrophotometer but for accuracy of
the recipe, it is very important to input the self shade of different lot of
dyes in a regular basis. In dyeing lab Bextex Ltd. is using digital pipetting
system I think their accuracy will increase to a maximum level.

Conclusion

Industrial attachment program
send me to the expected destiny of practical life. The completion of six weeks
industrial attachment at Beximco Textile Ltd., I have got the impression that
the factory is one of the most vital role in woven dyeing project in
Bangladesh. Though it was established many years ago, it has earned very good
reputation for its best performance over any other woven dyeing project.

During my industrial attachment
program I had tried to my best to done my duty. My supervising officer also
satisfied to me & offer co-operation in every steps. It is completely a new
experience in my life, which will be very effective in my service life. During
my training period I realized that practical experience is valuable for service
life.