Multifbs Ltd and its Mechanism

Multifbs Ltd and its Mechanism 01. INTRODUCTION Industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skill ness about various processing stages.

It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned can not be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility.

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 Multifabs Ltd., 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. So the practical knowledge it’s not possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equal important in association with the theoretical knowledge.

02. PROJECT DESCRIPTION Name of the factory

: Multifabs Ltd.

Types of the factory

: 100% Export oriented Knit composite.

Year of the establishment

: 1992

Total land area: One acre Number of building and floor: Three Buildings Floor space of each section: 3300sf Total number departments: Nine Address of factory: Kashimpur (Noyapara), Konabari, Gazipur, Bangladesh.

Tel: 9297450-52, 9298396 Fax: 880-2-9297188 Head Office:

House # 532 (2nd Floor), Lane # 11 DOHS, Baridhara, Dhaka-1206, Bangladesh Tel: 8861806, 8850008, 8853758, Fax: 880-2-8817496 E-mail: multifab@citech-bd.com; saiful@multi-fabs.com History of the project development: Multifabs Ltd was established in September at 1991 with a vision to build a premium Garments house to rival the finest in South Asia. The company founders imagined a manufacturing company with the ability to deliver impeccable quality and punctual shipment in a framework of a professional, reliable and sincere business atmosphere.

Since then, Multifabs Ltd has strategically taken orders that enhanced and enriched both its employee’s technical skills as well as its level of quality. The company is now a position, in accordance with its founding vision to compete in the area of high fashion and succeed with immaculate consistency.

Multifabs Ltd specializes in the manufacture of high quality men’s Tee shirts/sweaters/polo shirts. The Company’s Brand new machinery includes highly specialized equipment needed in the evolvement of high quality products. The company currently exports its garments to its customers in France, Belgium and The Netherlands.

Multifabs Ltd has a dedicated and professional corporate management Team with over a decade of experience in the field. Its production staff directly recruited from the Top garments houses of the country. The managing director, Heads the company and they form a dynamic team able to address the high demands of such an industry.

Multifabs Ltd specialized in the manufacture of high quality men’s tee shirt/sweaters/polo shirt. We also take order in varied print and fancy embroidery. The company brand new machinery includes highly specialized equipment needed in the productive of high quality products.

Bangladesh is a hotbed of garments manufacturing, now ranking fourth in the list of garments exporting nations. Unfortunately, the country, as a whole, has been unable to break into the arena of high fashion as most of its exports cater to the lower end of the clothing hierarchy.

With this in mind, Multifabs Ltd seeks to become a driving force in an initiative by a selected few companies to change the foreign image of garments industry in Bangladesh by providing first class quality with rock hard commitment. The company wants to present itself as a “Different kind of company in a Different kind of Bangladesh”.

Quality: Comfort, choice, trends, quality all standards which guide Multifabs Ltd in the creation of it’s products.

Design and material are carefully studied to offer you a collection that is always up to date, be it for the basic products or the trendy products.

Multifabs Ltd has a perfect command of these techniques and only offers you the higher quality of these knitted fabrics.

For environment reasons, Multifabs Ltd has chosen to have all the products of its range processed “AZO FREE”. All the dyes used are free from Azo-type pigments, which are known to be harmful to the skin and to the environment. Multifabs use excellent color fastness through the use of “reactive” pigment.

Facility: Child Care Centre, Female Prayer Space, medical centre, wide dining space and all other necessary supporting facilities are provided to ensure a very pleasing working environment for all as well as to enrich the quality of production.

Product Line: T-Shirt •

Men

•

Women

•

Children.

• Polo Shirt: •

Men

•

Women

•

Children

Buyer name: 1) LINDEX 2) STOCK MAN 3) SEPALA 4) STYLE TEX 5) LAHALLA 6) REX & HOLM 7) TEX EBO

Different Departments of Mulifabs knit composite unit: I.

II.

Knitting Section: 1. Knitting 2. Inspection Dyeing section: 1.

2.

3.

4.

5.

Batch section Dye house Dyeing lab.

Quality control Finishing

III. Garments section: 1.

2.

3.

4.

5.

6.

Merchandising Sample Cutting Section Sewing Section Finishing Section Printing section

III.

Maintenance section:

IV.

1. Electrical 2. Mechanical Store Section

V. VI. VII. VIII. IX.

Administration Section Security Section Marketing Section Production Planning & Control Human Resource & Development Section

0 3. Management system Manpower Management: Manpower management is also called as Human resourse management which means employing people, developing their resources, utilizing and maintaining.

The processes involved are: 1. Managing

2. Planning 3. Organizing 4. Directing 5. Controlling 6. Right person for right job.

7. Capacity building 8. Personal co-ordination 9. Divide and rule.

Organogram: Chairman

Director

↓

GM

Factory manager

Maintenance Manager

Knitting Manager

Dyeing Manager

Finishing Manager

Q.C Manager

Ass. Manager

Ass. Manager

Shift Officer

Shift Officer

Shift Officer

Shift Officer

Electrical Incharge

Mechanical Incharge

Administration: In business, administration consists of the performance or management of business operations and thus the making or implementing of major decisions. Administration can be defined as the universal process of organizing people and resources efficiently so as to direct activities toward common goals and objectives.

Administrator can serve as the title of the general manager or company secretary who reports to a corporate board of directors. This title is archaic, but, in many enterprises, this function, together with its associated Finance, Personnel and management information systems services, is what is intended when the term "the administration" is used.

Functions: 1. Planning is deciding in advance what to do, how to do it, when to do it, and who should do it.

It maps the path from where the organization is to where it wants to be. The planning function involves establishing goals and arranging them in logical order. Administrators engage in both short-range and long-range planning.

2. Organizing involves identifying responsibilities to be performed, grouping responsibilities into departments or divisions, and specifying organizational relationships. The purpose is to achieve coordinated effort among all the elements in the organization (Coordinating). Organizing must take into account delegation of authority and responsibility and span of control within supervisory units.

3. Staffing means filling job positions with the right people at the right time. It involves determining staffing needs, writing job descriptions, recruiting and screening people to fill the positions.

4. Directing (Commanding) is leading people in a manner that achieves the goals of the organization. This involves proper allocation of resources and providing an effective support system. Directing requires exceptional interpersonal skills and the ability to motivate people.

One of the crucial issues in directing is to find the correct balance between emphasis on staff needs and emphasis on economic production.

5. Controlling is the function that evaluates quality in all areas and detects potential or actual deviations from the organization's plan. This ensures high-quality performance and satisfactory results while maintaining an orderly and problem-free environment. Controlling includes information management, measurement of performance, and institution of corrective actions.

6. Budgeting, exempted from the list above, incorporates most of the administrative functions, beginning with the implementation of a budget plan through the application of budget controls.

Human resource policy Human resources:

Human resources is a term used to describe the individuals who comprise the workforce of an organization, although it is also applied in labor economics to, for example, business sectors or even whole nations. Human resources is also the name of the function within an organization charged with the overall responsibility for implementing strategies and policies relating to the management of individuals (i.e. the human resources). This function title is often abbreviated to the initials 'HR'.

Human resources is a relatively modern management term, coined in the 1960s.[citation needed] The origins of the function arose in organizations that introduced 'welfare management' practices and also in those that adopted the principles of 'scientific management'. From these terms emerged a largely administrative management activity, co-ordinating a range of worker related processes and becoming known, in time as the 'personnel function'. Human resources progressively became the more usual name for this function, in the first instance in the United States as well as multinational corporations, reflecting the adoption of a more quantitative as well as strategic approach to workforce management, demanded by corporate management and the greater competitiveness for limited and highly skilled workers.

Background: The use of the term 'human resources' by organizations to describe the workforce capacity available to devote to the achievement of its strategies has drawn upon concepts developed in Industrial/Organizational Psychology and System Theory. Human resources has at least two related interpretations depending on context. The original usage derives from political economy and economics, where it was traditionally called labor, one of four factors of production – although this perspective has shifted as a consequence of further ongoing research into more strategic approaches.This first usage is used more in terms of 'human resources development' of the individuals within an organization, although the approach can also be applied beyond the level of the organization to that of industry sectors and nations .

Key functions: Human Resources may set strategies and develop policies, standards, systems, and processes that implement these strategies in a whole range of areas. The following are typical of a wide range of organizations: 1. Recruitment, selection, and on boarding (resourcing) 2. Organizational design and development 3. Business transformation and change management 4. Performance, conduct and behavior management 5. Industrial and employee relations 6. Human resources (workforce) analysis and workforce personnel data management 7. Compensation, rewards, and benefits management 8. Training and development (learning management)

Human resources management trends and influences: In organizations, it is important to determine both current and future organizational requirements for both core employees and the contingent workforce in terms of their skills/technical abilities, competencies, flexibility etc. The analysis requires consideration of the internal and external factors that can have an effect on the resourcing, development, motivation and retention of employees and other workers.

External factors are those largely out-with the control of the organization. These include issues such as economic climate and current and future labor market trends (e.g., skills, education level, government investment into industries etc.). On the other hand, internal influences are broadly controlled by the organization to predict, determine, and monitor—for example—the organizational culture, underpinned by management style, environmental climate, and the approach to ethical and corporate social responsibilities.

Responsibility of production officer: 1. To give dye-line or the program slip according to daily production plan, batch preparation & PH check.

2. To rectify the finished fabric which rejected from quality control department 3. To check daily production report.

4. To study dye & chemicals nature delivery by the manufacture & applied them correctly to the production to get best product 5. Program making, sample checking color measurement.

6. Control the supervisor’s operators & helpers of machines.

7. Overall supervision of dyeing & finishing.

8. Dyes & chemicals requisition issue & check.

9. Execute production activities according to schedules.

10. To work in production line and perform duties on rotating shifts.

11. Monitor and ensure production output meet targets.

Job descriptions of production officer: Job descriptions are essential. Job descriptions are required for recruitment so that you and the applicants can understand the role. Job descriptions are necessary for all people in work. A job description defines a person's role and accountability. Without a job description it is not possible for a person to properly commit to, or be held accountable for, a role. As an employee you may have or be given the opportunity to take responsibility for your job description. This is good. It allows you to clarify expectations with your employer and your boss.

Title: Production officer: Dept: Dyeing Report to: Senior production officer.

Job summary: To plan execute & follow up the production activities & control the quality production with related activities.

Title: Senior production officer: Dept: Dyeing.

Report to: Dyeing manager.

Job summary: 1. To plan execute & follow up the production activities & control the quality production with related activities.

2. Establish and maintain effective working relationships with co-workers, supervisors and the general public.

3. Perform reception duties in and efficient, professional and courteous manner.

4. Maintain regular consistent and professional attendance, punctuality, personal appearance, and adherence to relevant health & safety procedures.

5. Pursue personal development of skills and knowledge necessary for the effective performance of the role.

04. Raw material Raw 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: a.

Yarn

b. Dye stuff c. Chemical and auxiliaries Name and source: Yarn: The raw material for the yarn dying is gray yarn. Generally raw material collect form local or Indian spinning factory. Another raw material is collect form Zarma such as dye material.

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

Sources of mellange: a. b. c. d.

Shohag pur Thermax Patartoli Prime

Sources of polyester: a. Kader Synthetic. b. China.

Sources of Lycra: * Brand

: Roica

Country : Taiwan.

* Brand

: Texlon

Country : Korea.

*Brand

: Acelen

Country: China

Chemicals and their function Hydrogen peroxide: Function: Bleaching Use: It’s help to increase the absorbency of the fibre Soda ash: Function: color fixing.

Use: it’s help to fixed the color.

Acetic acid:

Function: Neutrilization.

Use: 1. To remove the chemical poison.

2. To control the PH of the solution.

Formic Acid: Function: Neutrilization.

Use: To remove the permanent color of the fibre.

Caustic Soda: Function: Scouring.

Use: To remove the dust particales from the fibr.

Hydrose: Function: Stripping Use: 1. To remove the color from the yarn.

2.To wash the machine.

Kappatex –R98: Function: Stripping Use: To remove the color from the yarn.

Albatex –AB-45: Function: Buffering.

Use: control the PH. Uvitex FBF: Function: optical brightener.

Use: Optical brightener.

Invatex PC: Function: Peroxide killer Use: Remove Peroxide.

Glubar salt: Function: Electrolight.

Use: Its help to dye absorbe in the iner side of the yarn.

05. LAYOUT PLAN Over all view of the factory

Layout of Dyeing and Finishing section

Layout of knitting section in Multifabs Ltd.

06. Production Planning & Sequence of operation Production Planning: At its core, production planning represents the beating heart of any manufacturing process. Its purpose is to minimize production time and costs, efficiently organize the use of resources and maximize efficiency in the workplace.

Production planning incorporates a multiplicity of production elements, ranging from the everyday activities of staff to the ability to realize accurate delivery times for the customer. With an effective production planning operation at its nucleus, any form of manufacturing process has the capability to exploit its full potential. Different section of production--A. Laboratory Laboratory is the most important part 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: 0. To shade collection.

1. To minimize the deviation between bulk and laboratory.

2. To get color approval from buyer.

3. To supply recipe of the floor.

Machine specification:

Machine-01: Sample dyeing m/c Name: Starlet Model: DL-600 Made by: Koriya+China RPM:135 Temperature: 140째c Power: 220w Number of pot: 16 Machine-02: Sample dyeing m/c Name: Rota Dyer (Tube m/c) Made by: China Temperature: 135째c RPM:130 Power: 220w Number of pot: 14 Machine-03: Sample dyeing m/c Name: Bangla m/c Temperature: 140째c Number of pot: 14 Power: 220w Machine-04: Dry m/c Name: Daclim starlet Made by: Korie Model: 0F-02GW Voltage: 220 Serial number: M070037 Code number: AAA12255

Temperature: 300째c Machine-05

: Washing m/c

Machine name

:

Indesit

High temperature :

90째c

Cold temperature :

40째c

Model number

WGD836

:

Some equipments used in QC lab of dyeing: 1. Wash cator-71: Color fastness to wash, shrinkage and spirality test.

2. Sample cutter: GSM measurement.

3. Perspirometer: Color fastness to water, sea water, perspiration (Acid, Alkali) 4. Crock meter: Color fastness to rubbing.

5. Color matching cam binate: For visual assessment and rating or grading of color fastness.

6. Grey scale: For visual assisment and rating or grading of color fastness.

7. Ph meter: To measure ph test of solution.

8. Balance: For weight dyes & chemical.

Measurement of strength of dyestuff: Normally, commercial dyestuff are marketed in solid powder or soluble form and consisting not only dye but also other chemical s and auxiliaries eg salt, dispersing agent, solubilizing agent etc.

So the strength of dyestuff must be measured to determine its quality.

Dyestuff can be measured in ways---By color matching: At first sample fabric is dyed with a dyestuff of known strength then the sample is dyed with unknown strength. Match with the previous shade obtained from dyeing by known strength dyestuff. Thus by comparison the strength of unknown dyestuff in determined.

B. KNITTING SECTION Software controlled fabric engineering techniques are employed to set and monitor the fabric dimension in knitting. Multifabs has knitting m/c (Circular and flat bed knit) with various gauge and diameters to produce Jersey, PK, Rib, D/J. ORGANOGRAM OF KNITTING:

MANAGING DIRECTOR ↓ DIRECTOR ↓ GENERAL MANAGER ↓ FACTORY MANAGER ↓ KNITTING MANAGER ↓ FLOOR INCHARGE ↓ SHIFT INCHARGE ↓

SHIFT INCHARGE ↓

FEEDER MAN ↓ OPERATOR ↓ WORKER

FEEDER MAN ↓ OPERATOR ↓ WORKER

KNITTING: Knitting is the process of producing a fabric by forming a series of connected loops from a series of yarn. In this method fabric is produced by intermeshing of loops.

KNITTING TYPES: Warp knitting: each loop in the horizontal direction is made from a different thread and the number of threads used to produce such a fabric is at least equal to the number of loops in a horizontal row.

Weft knitting: a horizontal row of loops can be made using one thread and the thread runs in horizontal direction.

Raw material for knitting: The raw material for knitting is the yarn. Different types of yarn of wide range of count are used.

Different types of yarn used in knitting section that’s are given below: Cotton = 24S, 26s, 30S, 32S, 34S, 40S Polyester =75D, lO0D Spandex yarn =20D, 40D, 70D Grey Mélange (C =24S, 26S Ecru Mélange (C-85% V-15%) =24S, 26S, 28S PC (65%Polyester & 35% cotton) = 24S, 26S, 28S, 30S CVC = 24S, 26S, 28S, 30S Circular Knitting Section: This section contains 72 circular knitting machines. Circular knitting machines are of different types, made by different manufacturer and also have different specifications. In this section body fabric for knitted garments is produced. The different specifications of different machines are given one after another.

Circular Knitting Section Flat Knitting Section: Generally collar, cuff of knitted garments is produced in this section. In this section there are 25 flat knitting machines. all of them are same type and also have same specification. The specification of all machines is given below: Type

Automatic Flat knitting machine Manufacturer name

Precision Fukuhara Works Ltd.

Country

Japan

Model No.

\l-100

Gauge

G14

Automatic Flat Bed m/c

PROCESS FLOW CHART FOR KNITTING

YARN IN PACKAGE FORM

PLACE THE YARN PACKAGE IN THE CREEL

FEEDING THE YARN

SET THE M/C AS PER DESIGN &GSM

KNITTING

WITHDRAW THE ROLLED FABRIC AND WEIGHTING

INSPECTION

NUMBERING Category of Weft or Circular Knitting: 1. Single jersey.

2. Double jersey – I. Rib. II. Interlock.

Single jersey: It requires only one set of needles. The loops are intermesh in only one direction so the appearance of the face and back of the fabric are quite different.

Example: Plain single jersey, Pique, lacoste etc.

Rib: It requires two sets of needles positioned at right angles to each other to form the fabric.

Example: (1×1) Rib,(2×2) Rib etc.

Interlock: Fabric is produced by using both long and short needles. It has a smooth surface on both sides.

Example: Plain Interlock.

Sequence of yarn feeding: Creel ↓ Pipe line ↓ Wheel ↓ Yarn sensor ↓ Yarn guide ↓ Feeder ↓ Needle.

Terms of Knitting: Coarse: Horizontal row of loops produced by adjacent needles in knitting cycle is called the Course of the fabric.

Wales: Vertical column of loops produced by same needle in knitting cycle is called the Wales of the fabric.

Face loop: If the legs of new loop is passes over the old loop is called face loop.

Back loop: If the legs of new loop is passes under the old loop is called face loop

Stitch density: It is expressed as, Course per inch × Wales per inch.

Stitch length: Length of one loop in the course direction express in mm.

Number of needle: Machine diameter × Machine gauge × 3.1416.

Gauge:

Number of needle per inch.

GSM: The weight of one square meter of fabric express in gram is known as GSM. Needle: There are three types of needle1. Bearded needle 2. Compound needle 3. Latch needlea. One butt needle. b. Two butt needle. c. Three butt needle. d. Four butt needle.

The most widely used needle is latch needle.

Cam: Cam is called the specific path of the needles to produce a specific type of fabric.

There are three types of cam used in circular knitting machine 1. Knit Cam. 2. Tuck Cam. 3. Miss Cam. Knit Cam: It moves the needle upward enough to clear the old loop and receive the new yarn.

Tuck Cam: It moves the needle upward not enough to clear.The old loop but receive the new yarn.

Miss cam: It does not moves the needle upward. The needles,neither clears the old loop nor receive the new yarn.

Sinker: It is a thin metal plate with an individual or collective operation approximately at right angles at the hook side between adjacent needles.

Function of sinker: In circular knitting m/c sinker helps to form the loop by holding down the yarn.

Parameters of knitting: There are some parameters of machine, yarn and fabric that determine the production of a particular type of fabric.

Machine parameters: 1. Diameter of m/c: It measures the diameter of the fabric.

2. No. of feeders: It indicates how much yarn feed in the m/c.

3. No. of needles: The fineness of stitch depends on it.

4. M/c speed: Rate of production depends on m/c speed.

5. Efficiency: It means how much the m/c works according to its capacity.

6. Efficiency: It means how much the m/c works according to its capacity.

7. Efficiency: It means how much the m/c works according to its capacity.

Yarn and fabric parameters: 1. Yarn count: The GSM of the fabric or fineness / coarseness of the fabric depend on it.

2. Stitch length: The stitch length of the fabric is inversely proportional to the GSM of the fabric.

Stitch length ↓GSM ↑.

Stitch length ↑GSM ↓.

3. Stitch density: It indicates the no. of coarse and no. of wale per inch of the Fabric.

Selection of knitting machine: The machine is selected on the basis of the design and diameter of the fabric that have to be constructed.

Selection of yarn: The selection of yarn depends on the GSM of the fabric.

According to English cotton count system, low count yarn used to produce high GSM fabric and high count yarn used to produce low GSM fabric.

How to control fabric GSM and stitch length: We know that there is an inverse relationship between stitch length and GSM and these issues are influenced by some factors like type of fabric, yarn count, fabric width, m/c diameter, gauge etc.

First yarn selected before production of any fabric. Then an effective stitch length is select to achieve the required fabric GSM. The stitch length can be changed by changing the direction of vdq pulley How to control fabric width: Fabric width depends on the diameter of the machine and the count of yarn.

Low count of yarn increases the width of the fabric.

High count of yarn decreases the width of the fabric.

Width of fabric can be calculated asNo. of active needles/Wales per inch.

Sequence of knitted fabric production: Yarn selection: First the yarn is selected to get the GSM according to the requirements of the buyer.

Requisition of yarn: Then yarn is supplied from the store or outside on the basis of requisition Machine selection: M/c is selected according to the design and width of the fabric.

Sample making: Sample fabric is produce to check the GSM, stitch length and also to do.

Various physical and chemical tests to make expected type of fabric Make decision: The decision of further process is made by analyzing the characteristics of the sample fabric.

Bulk production: If the sample is approved then everything is arranged for bulk production.

Selection of yarn count: Different type of yarn count is used in different fabric GSM. There are two types of yarn count system1. Direct system.

2. Indirect system.

3.

Direct system: In direct system higher count indicates coarseness of yarn and lower count indicates fineness of yarn.

Example: Tex- No. of grams per 1000 meter.

Denier- No. of grams per 9000 meter

Indirect system: In indirect system higher count indicates fineness of yarn and lower count indicates coarseness of yarn.

Example: English cotton count- No. of 840yd lengths per pound.

Woolen- No. of 256yd lengths/pound.

Conversion: 1 kilogram - 2.2046 pound.

1 Inch- 2.54 Cm. 1 Meter -1.0936 yard.

1 Cm- 0.3937 Inch.

1 Yard- 36 Inch.

Identification of weft kitted fabric: M/C Layout Single Jersey

Fabric Type S/J Stripe

Single Jersey

Pique

Single Jersey

Terry

Rib

Plain Rib

Rib

( 2*1) Rib

Cam setting KKKK KKKK KKTT TTKK T KM M KM MKT KKKK (dial) KKKK KKKK (cylinder) KKKK KKKK (dial) KKKK KKKK KKKK

(cylinder)

Flat Bed Knitting: M/C brand name: MATSUYA FULLY AUTO FLAT M/C. Mainly coarser fabrics like collar, cuff, bottom etc are made in flat bed machine.

Depends on the ply of yarn these products are named as six ply, five ply, three ply etc. Different types of collar can be made by this machine like solid, tripping, ambush etc.

Sequence of flat bed knitting:

Yarn from package ↓ Wheel ↓ Spring ↓ Feeder ↓ Carriage ↓ Needle ↓ Fabric Knitting m/c given below: Description 20 Dia 23 Dia 21 Dia 22 Dia 24 Dia 26 Dia 28 Dia 30 Dia 36 Dia 15 Dia 16 Dia 17 Dia 40 Dia 18 Dia 19 Dia Inspection:

Capacity 1250 1680 2000 2500 255 300 300 300 300 362 510 510 600 740 975

Origin Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan Taiwan

Qty 05 06 08 10 01 01 01 01 01 02 03 03 02 04 05

Brand Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex Unitex

Machine Brand name: Hsing Cheng.

Origin: Taiwan.

Machine diameter: 30inch, 20inch.

Faults of knitted fabric: During the processing of knitting different types of fault may occur. These faults are found during inspection.

Example: Hole: Causes for foreign matter.

Barre: Causes by mixing different shade of yarn.

Yarn contra: Causes by hairy yarn.

Needle broken: Causes for the breakage of needle.

Lycra out: For the absence of lycra on the fabric.

Causes of inspection: After knitting, all types of fabric are inspected to find out any type of fault that will hamper the proper quality of the fabric to the buyer. During inspection four points system is used to make the grade of the fabric depends on the fault. There are some points on each of the faults. The points are calculated in every hundred meters. If the total point for the fault exceeds the predetermined range then fabrics will be hold for further process.

Some point of faults are given below Faults

Points

Hole

04

Yarn contra

01

Lycra out

02 point/inch

Oil spot

01

Star

04

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 corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes.  If sinker head bend then sinker mark comes.

Remedies:  Sinker should be changed.

Star: 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.

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 needle Grease stain: Causes:  Improper greasing  Excess greasing Remedies:  Proper greasing as well as proper maintenance Cloth fall- out: Causes:  Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles.

Remedies:  Make sure all the latches of needle are closed with feeding yarn after a drop stitch.

Barre: A fault in weft knitted fabric appearing as light or dark course wise Stripe.

(width wise)

Causes:    

This fault comes from yarn fault.

If different micro near value of fiber content in yarn.

Different lusture, dye affinity of fiber content in yarn.

During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics.  In draw fame different similar classes sliver is mixed and make one sliver.

Remedies:  We can use this fabric in white color.

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.

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.

Yarn Faults:  Neps.  Slubs.  Yarn count variations.  Thick/Thin place in yarn.  Hairiness.

C. Batch section Batch Preparation:

Batch preparation can be defined as a process where the visually Inspected greige fabric are divided into different batches. It is a part of dyeing process & it is done to feed the dyeing machines for fabric dyeing.

Loading Capacity: In dyeing machines 1600 meters of fabric can be loaded in one nozzle through dyeing machines. Production are calculated by weight normally for fabric with higher GSM & large weight. Maximum load can be done while for fabric with less GSM & width .Minimum loading can be done considering the fabric quality. For the example recommended loading capacity of each machine is shown in the tableMachine No. 01 02 3,4 5

Capacity

Usually loaded

450-600 450-600 450-600 35-75

550 550 550 45

6 7,8 9 10

175-275 450-600 190-240 350-480

200 550 300 450

Nozzle: Each batch is divided into 1-4 stacks, which are termed as nozzle. Generally nozzle weights 125-140 kgs. o Each nozzle is further divided into 1-5 pieces, which are termed as Rolls.

Generally each roll weights about 22-27 kgs.

Operation Staff: 1. Manager 2. Production Officer 3. Supervisor 4. Batch man 5. Helper Machine Set-up: Machine set-up is not applicable for batch preparation process. To start/stop operation, the machine is switched on or off.

Checklist before Operation:

1. Availability of required manpower.

2. Availability of key accessories & other required materials.

3. Availability of power.

4. Check order no. & customers name of the batch/job card.

5.

Check types,quality,quantity,& other specification on the batch/job card.

6. Check fabric & yarn quality & quantity while receiving goods from inspection.

7. Check machine wise production plan to set priority.

Operation Procedure: 1. Check production plan to set the priority 2. Select 7-8 batches/shift to prepare 3. Consult with previous shift stuff to get the required information about the batches 4. Check batch card & job card specification(e.g.-Yarn type,quality,weight etc) for fabric & collars/cuffs respectively 5. Calculate number of batches, nozzles & rolls to be prepared for each order & specify on the batch & job card. One should be very careful while calculating & entering such data on these cards.

6. Start batching operation & check the following information7. Machine no 8. Number of nozzle to be prepared 9. Order no.

10. Customer number 11. GSM 12. Width 13. Lot no.

14. Turning required or not 15. Special instruction(if any) 16. Prepare the body fabric of specified weight. This weight must be accurate & each nozzle of same batch must weight equal to ensure even dyeing.

17. Calculate the number of collar/cuffs & attach the collars& cuffs with the body fabric 18. Write down the weight of each roll on the back of batch card 19. Check hole mark in each roll for identification 20. Turn the roll(if required) 21. Calculate the total weight very carefully & write it down in the specific area of the batch card 22. After completation of one batch, write “OK” as comments at the notes section of batch card & send the batch along with the card to the dyeing section.

Product Quality Check: 1. The number & weight of each nozzle & roll for a particular batch is accurate as mention on the job & batch card 2. Total weight of a single batch is not more than individual machine capacity 3. Number of batch for a particular order is kept as minimum as possible.

4. Following measures are taken to check the quality of product.

5. Yarn lot no. are same for batch both body & rib.

6. Batch no. is not repeated.

7. Special instruction (if any) is followed.

8. Each nozzles are of equal weights.

Remarks: It is very important to make a batch with maintaining a correct length of each nozzle D. DYEING SECTION ORGANOGRAM OF DYEING: MANAGING DIRECTOR ↓ DIRECTOR ↓ GENERAL MANAGER ↓

FACTORY MANAGER ↓ DYEING MANAGER ↓ DYEING MASTER ↓ SHIFT INCHARGE

SHIFT INCHARGE

↓

↓

OPERATOR ↓ WORKER

FLOW CHART FOR DYEING:

BATCHING

SELECT M/C NO.

FABRIC LOADING

SELECT PRODUCTION PROGRAMME

PRETREATMENT

OPERATOR ↓ WORKER

SELECT RECIPE FOR DYEING

RECIPE CONFIRMED BY DM/PO

DYEING

POST TREATMENT

UNLOAD

M/C Specification: M/C NO: 1 Name of m/c: Moon star (HT) Capacity: 450 kg.

Temperature: 135째c Company name: PPM (PASLANMAZ MALZEME VE MAMULLERI) Made by: TURKEY M/C NO: 2 Name of m/c: Long close Capacity: 300 kg Temperature: 170째c Company name: PPM (PASLANMAZ MALZEME VE MAMULLERI) Made by: ENGLAND M/C NO: 3 Name of m/c: Over flow Capacity: 300 kg Company name: PPM (PASLANMAZ MALZEME VE MAMULLERI) Made by: TURKEY M/C NO: 4 Name of m/c: Over flow Capacity: 400 kg Company name: PPM Made by: TURKEY M/C NO: 5 Name of m/c: Over flow Capacity: 500 kg Company name: PPM Made by: TURKEY M/C NO: 6

Name of m/c: Moon star (HT) Capacity: 600 kg Company name: PPM Made by: TURKEY M/C NO: 7 Name of m/c: Over flow (Sample) Capacity: 50 kg Company name: PPM Made by: TURKEY M/C NO: 8 Name of m/c: Fong’s Capacity: 10 kg Temperature: 140°c Design Pressure: 350 Kpa Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 9 Name of m/c: Moon star (HT) Capacity: 100 kg.

Temperature: 95°c Company name: PPM (PASLANMAZ MALZEME VE MAMULLERI) Made by: TURKEY M/C NO: 10 Name of m/c: Moon star (HT) Capacity: 150 kg.

Temperature: 135°c-150°c Company name: PPM (PASLANMAZ MALZEME VE MAMULLERI) Made by: TURKEY

M/C NO: 11 Name of m/c: Fong’s Capacity: 1000 kg Temperature: 140°c Design Pressure: 380 Kpa Safety valve: 380 Kpa Winch speed: 250 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 12 Name of m/c: Fong’s (Sample) Capacity: 60 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 173 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 13 Name of m/c: Fong’s (Sample) Capacity: 30 kg Temperature: 140°c Design Pressure: 400 Kpa Winch speed: 119 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 14 Name of m/c: Fong’s Capacity: 500 kg Temperature: 140°c

Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. LtdMade by: CHINA M/C NO: 15 Name of m/c: Fong’s (Sample) Capacity: 30 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 16 Name of m/c: Fong’s (Sample) Capacity: 30 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 17 Name of m/c: Fong’s Capacity: 1000 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 18 Name of m/c: Fong’s

Capacity: 1500 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 19 Name of m/c: Fong’s Capacity: 500 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA M/C NO: 20 Name of m/c: Fong’s (Sample) Capacity: 700 kg Temperature: 140°c Design Pressure: 350 Kpa Winch speed: 450 M/min Company name: Fong’s National Engineering (SHENZHEN) co. Ltd Made by: CHINA Process Flow Chart for Demineralization Fabric load ↓ Water fill ↓ NOF + A. Acid (Run time10´) ↓ At 60ºC

Drain bath Scouring: To make the fabric more absorbent, the oil, wax and other natural as well as added impurities are removed by boiling with alkali.

Scouring process depends on: -Type of fiber -Twist of yarn -Weave of fabric / less or high density fabric -Growing area of fiber Types of scouring: -Discontinuous process: Rope form fabric -Continuous process: Open width fabric Objects: -To make fabric highly hydrophilic -To remove impurities such as oil, waxes, cotton etc.

-To produce clean mlt and make ready for next process.

Chemicals use in scouring -Alkali (NaOH) -Sequestering agent -Wetting agent -Soda ash (to maintain pH 8-8.5) Bleaching: The natural coloring materials are removed in this process. It is the destruction of natural coloring matter to produce a white fabric.

Object: -To increase absorbency of fabric.

-To produce white finish -To make ready fabric for next process.

Bleaching agent: The chemical used to destroy natural coloring substance from textile material.

The chemicals are of two types 1. Oxidizing agent 2. Reducing agent

Example of oxidizing agent 1. Calcium hypochlorite---- Ca (OCl) ₂ 2. Sodium hypochlorite----- NaOCl 3. Hydrogen peroxide-----H2 O2 4. Sodium chlorite---------NaCl  Example of reducing agent 1. Sodium Hydrosulphite-----NaS2O2 2. Sulphur dioxide-----------SO2 White Fabric Dyeing Flow Chart: Loading gray fabric ↓ Control PH (Using A/Acid) + Detergent ↓ Enzyme Wash (Enzyme 50L, 50ºc, Run time 40min PH 4-4.5) ↓ Cold Wash (5min 28ºc) ↓ Drain Detergent +Sequestering agent + Caustic + H2O2 Stabilizer +OBA (4BK). ↓Sample cutting Over flow with cold wash (5min, normal temp) ↓ Hot wash (80ºc, 5min) ↓ Over flow cold wash ↓Drain Neutralization (A/Acid) ↓Over flow (10 min) Drain ↓

Softener (10 min, 40ºc) ↓ Unload the fabric

Flow Chart for Turquise color: After salt dosing the temperature will raised 60ºc ↓ Dyes dosing (40min) ↓ The run time (20min) ↓ (80ºc, 10min) ↓ Cooling at 60ºc temp ↓ Soda dosing (40min) ↓ After 10 min cut sample ↓ B.D Dyeing Sequence for Dark Shade Loading fabric after pretreatment with Detergent (60ºc) Check ph 4.5-5.5 Leveling agent (60ºc, 10min)

Salt dosing (600 c x 10 min dosing)

Color dosing (600 c x 30 min dosing) Run 20 min

Soda dosing (if high temp 70ºc, dosing 30min)

Sample check

Run time 10 min

Bath drop Enzyme wash As per Buyer requirement Enzyme wash is given.

Water fill + fabric load ↓ Temp. Raised to 55ºC ↓ A. Acid ((Dosing ) ↓PH check (4.5-4.7) Enzyme (Dosing for 10 min) ↓Run 60 min at 55ºC Sample cut ↓ Hot 80°c (Steam) ↓ Cold wash ↓ Drain ↓ Sequestering agent at 90ºC ↓ Run 10 min Water drain

Cotton part dyeing After Pretreatment

Leveling agent dosing (60ºc, 10min)

Salt dosing (15min x 60˚C) Run time 20 min Color dosing (30 min x 60˚C) Run time 20 min Soda dosing (50 min x 60˚C) Run time 10 min Check ph

Sample cutting ↓ Normal hot wash (B/D)

Drain

Using wash chemical hot wash (90ºc, 10 min) ↓ Over flow 10min ↓ Drain ↓ Water fill (A/Acid) ↓ Fixing agent ↓

Softener ↓ Unload FLOW CHART FOR POLYESTER After loading use detergent ↓ Hot wash (90ºc, 10 min) ↓ Leveling agent ↓ Color dosing (80ºc, 25 min) ↓ Raised temp(135ºc, depth color 60min, light color 40 min) ↓ Cooling 80ºc ↓ Cut sample for carborising and matching sade FLOW CHART FOR STRIPPING After loading fabric add 0.5% detergent ↓ Caustic (80ºC) ↓ Hydrose (10min, 95ºc) ↓ Run time (20-30min, 95ºc) ↓ Drain Hot wash (90ºc) ↓ B.D

DYEING PARAMETER CONTROL CHART -

Water level before fabric loading(Lit) Loading Time(min) Water level after fabric loading(after running 05 min) Dosing time of caustic Run time Dosing time of per-oxide Total time need to raise temp of 105ÂşC Gradiant (Degree/min) Total run time(min) Total time need to cooling at 80c Gradiant (Degree/min) Total MIR /Rinsing time to 50c Total run time after acid dosing Check PH Total runtime after peroxide killer dosing Check residual per-oxide (ppm)

-

-

-

-

-

-

-

Remarks: A state of the art laboratory facility dyeing of various fabrics with respect to color fastness and dimension stability according to customer requirement.

Multifabs use 100% Eco friendly Dyes and chemicals and their Biological E.T.P (Effluent Treatment Plant) which treats the effluent water. Multifabs is a Oekotex Certified Company.

E. Finishing The ‘term' finishing in it’s widest sense has been held to cover all the processes which fabrics undergo after leaving the loom or knitting machine, from this stand print, finishing would include bleaching and dyeing, which indeed are sometime regarded as wet finishing processes.

What is finishing: 1. A kind of treatment to impart some special qualities to textile goods.

2. A simple definition of finishing is the sequence of operations, other than scouring bleaching and colouring, to which fabrics are subjected after leaving the loom or knitting machine. The simple processes of damping smoothing ,stretching and ironing or pressing as carried out in the home to make articles of clothing heat fresh attractive and presentable, have their counterpart in the treatment of long length of fabric which present a rough and crumpled appearance aster bleaching or coloring.

3. From these humble finishing processes many elaborate treatment have been developed to render textile material more attractive either by improving their appearance or by imparting some property normally possessed.

Object of finishing: Finishing is done to improve following things:1. To improve the attractiveness.

2. To improve appearance.

3. To improve properties.

4. To improve quality To improve of dyed and printed fabric.

5. To reduce crimp.

6. To reduce wrinkle.

7. To reduce shrinkage.

8. To reduce loss of strength.

9. To improve lusture.

10. To improve handle.

11. To improve service ability Flow chart of finishing section: Finishing Section

Open fabric

Tube fabric

Slitting machine

Dewatering machine

Stentering

Drying Machine

Compacting machine

Tube compacting machine

Final inspection

Final inspection

Slitting Machine specification: Inspection Slitting m/c01:

Brand name- Corino (SH) Country- Italy

Year of manufacturing-2008

Slitting m/c- 02: Brand name- Bianco (SH) Country- Italy Year of manufacturing-2008 Velocity maximum-90m/min Slitting: Slitting is a process that is applied for cutting the tubular fabric through the intended break Wales line on lengthwise direction prior to stenter processing.

Machine parts: 1.

2.

3.

4.

5.

Sensor: Sense for cutting through break Wales line.

Ring: To help cutting.

Guide Roller: To guide the fabric to plaiting.

Plaiting: To plait the fabric.

Rotary blade: To cut the fabric through break Wales line.

Slitting Machine Operational parameter: a. Set the padder pressure as required (3-7bar) b. Set the speed as much as possible (30-80m/min).

Function of the Machine: 1. Delivered fabric in crease free state.

2. Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer.

3. Used to remove excess water after pretreatment and dyeing.

4. To slit the tube fabric by the knife for opening of the fabric and ready for stentering.

5. It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism.

Dewatering Machine specification: Machine no

: 01

Machine name

: Dewatering

Brand name

: Heliot

Country

: France

Padder pressure

: 1-1.5 bar

Pressure capacity

: 4 bar

Machine no

: 02

Machine name

: Dewatering

Brand name

: Heliot

Country

: France

Padder pressure

: 1-1.5bar

Pressure Capacity

: 4 bar

Function: 1.

2.

3.

4.

5.

6.

Apply over feed to give some compaction.

Open the fabric from the rope form.

Width wise stretch the fabric.

Plait the fabric.

Reduce water content Apply chemicals.

Dewatering Machine Dryer Machine specification: Dryer no -1 Brand name- Heliot Origin- France Chamber-3 Year of construction – 2005 Dryer no- 2 Brand name-Santex AG Origin – Switzerland Type-SANTASHINK Chamber -5 Year of construction- 2007

Dryer Function:.

1. To control the vibration which increase the G.S.M. 2. To dry the fabric.

3. To control the overfeed system Stenter machine Machine specification: Stenter m/c no - 01 Brand name - Sun-Super Country of origin -South Korea Manufacturing date-: 2006 Width Range -2700 Maximum Speed - 100m/min Chamber – 8 Important parts of stenter -Burner (12) - Exhaust air fan (16) -Over feed roller.

- Suction fan (12)

-Nozzle Stenter machine Function of stenter m/c: 1. Drying 2. Loop control.

3. Moisture control.

4. Spirility control.

5. Shrinkage control.

6. Heat setting.

7. Width control Finishing chemical application.

Compactor machine Machine specification of compactor: Tube Compactor m/c: Machine name – Tube compactor Brand name – Heliot Country - France Manufacturing Year – 2005

Tube Compactor machine

Open Compactor: Machine name – Open compactor Brand name – FERRARO Country – Italy Manufacturing Year – 2005

Open Compactor machine Function: a. To control shrinkage. b. To control width. c. To control GSM. d. To smooth fabric. e. Heat seating of fabric for lycra.

Important parts: a. Over feed roller. b. Expander. c. Blanket(2) Dyeing faults analysis: Uneven dyeing: Causes: 1. Improper color dosing.

2. Using dyes of high fixation property.

3. Lack of control on dyeing m/c 4. Uneven pretreatment (uneven scouring & bleaching).

5. Uneven heat-setting in case of synthetic fibers.

Remedies: 1. By ensuring even heat-setting in case of synthetic fibers.

2. Proper controlling of dyeing m/c 3. By ensuring even pretreatment.

4. Proper dosing of dyes and chemicals.

Batch to Batch Shade variation: Causes:

1. Improper dosing time of dyes & chemicals.

2. Batch to batch weight variation of dyes and chemicals.

3. Improper reel speed, pump speed, liquor ratio.

4. Improper pretreatment.

5. Fluctuation of Temperature.

6. Dyes lot variation.

Remedies: 1. Maintain the same liquor ratio.

2. Maintain the same dyeing cycle.

3. Use standard dyes and chemicals.

4. The pH, hardness and sodium carbonate content of supply water should check daily.

5. Follow the standard pretreatment procedure.

6. Identical dyeing procedure should be followed for the same depth of the Shade. .

Patchy dyeing effect: Causes: 1. Dye migration during intermediate dyeing.

2. Faulty injection of alkali.

3. Uneven heat in the machine, etc 4. Due to improper salt addition.

5. Due to hardness of water.

6. Entanglement of fabric.

7. Improper addition of color.

Remedies: 1. To proper dosing of dyes and chemicals.

2. Heat should be same throughout the dye liquor.

3. To proper salt addition.

4. By ensuring proper pretreatment.

Roll to Roll variation or Meter to Meter variation: Causes: 1. Poor migration property of dyes.

2. Hardness of water.

3. Hardness of water.

4. Improper dyes & chemical solubility.

5. Faulty m/c speed, etc Remedies: 1. To proper m/c speed.

2. Use of soft water.

3. Using standard dyes and chemicals.

Crease mark: Causes: 1. If pump pressure & reel speed is not equal 2. Due to high speed m/c running.

3. Poor opening of the fabric rope 4. Shock cooling of synthetic material Remedies: 1. Reducing the m/c load.

2. Higher liquor ratio.

3. maintaining proper reel sped & pump speed.

4. Lower rate rising and cooling the temperature

Dye spot: Causes: 1. Improper dissolving of dye particle in bath.

2. Improper dissolving of caustic soda particle in bath.

Remedies:

1. By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the large un-dissolved particles are removed.

2. To proper dissolving of dyes & chemicals.

Wrinkle mark: Causes: 1. High temperature entanglement of the fabric.

2. Poor opening of the fabric rope.

3. Shock cooling of synthetic material.

Remedies: 1. Maintaining proper reel sped & pump speed.

2. Lower rate rising and cooling the temperature 3. Higher liquor ratio Softener Mark: Causes: 1. Entanglement of the fabric during application of softener.

2. Improper mixing of the Softener.

3. Improper running time of the fabric during application of softener.

Remedies: 1. Prevent the entanglement of the fabric during application of softener.

2. Maintaining proper reel sped & pump speed.

3. Proper Mixing of the softener before addition.

Remarks: Finishing is the very important part for end product.

07. Quality assurance system Quality control: Quality control is a wide subject and covers all those factors which help to ensure that the product, produced is of the desired quality.

Object scope of quality assurance: 1. Judicious selection of raw material.

2. Important in process quality control at all strategic points in processing.

3. Accurate evaluation of the end product for conforming to laid standards.

4. Planned research and development programme.

5. Development of auxiliaries product for in house consumption.

There are two types of quality control system in Multi-fabs Ltd. 1. On-line and 2. Off-line quality control.

On-line quality control: This type of quality control is performed in process stage i,e without stopping the production process. During the production running time, the machine automically tests the variation and takes immediate step to rectify the variation. Sensor is used to measure and rectify the variation. Checking and rectification of variation faults in processing stage is known as 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 refers to in process . Quality control and is aimed to maintain consistently uniform quality of the material in process a . various stages of its manufacture or process.

Online Tests: 1. Water fastness.

2. Wash fastness 3. Dyed fabric.

4. Shade check.

Off-Line Tests: Off-Line tests for finished fabrics are divided into two groups. These are as follows: 1. Physical tests 2. Chemical tests Physical Tests: 1.

2.

3.

4.

5.

6.

Abrasion resistance / Pilling.

Spirality test.

Color fastness to rubbing test (Dry / Wet).

Bursting strength test .

GSM of Fabric.

Dimensional stability test.

Chemical Tests: 1.

2.

3.

4.

5.

6.

7.

Color Fastness to washing.

Color Fastness to light.

Color Fastness to water spotting.

Color Fastness to perspiration.

Color Fastness to heat.

Fibre analysis.

PH test.

Responsibility of quality control manager: 1. Production control is one of the main responsibility.

2. To produce standard product.(Buyer required product) 3. To organize all arrangement of testing , linear programming, operational management.

4. Cost control.

5. To detect shift to shift product variation.

6. To take urgent step at a specific fielda. Low productivity of a particular machine or group of machine. b. Wastage study. c. Utilization percentage of machine. d. Comparative study of different machine.

Responsibility of quality control in Finishing : 1. Maintain the resister of all batches.

2. Check the shade of Body to Rib, Body to Collar & Cuff.

3. After unloading from dyeing cut small piece, check shade with std/approved lab dip/production sample & previous production batch (if any).

4. Then instruction to finishing for finish by mentioning specific temperature in dryer.

5. After finish again cut sample & check same way like before at dry state.

6. Keep the record of every lot after dry & after finished state.

7. If any batch is not OK at any stage then make the re-process card for dyeing.

8. If any batch is closer to standard but not exactly pass with standard, then make trial for that batch in finishing to make it OK.

Quality Assurance Procedure 1) Body & Rib Inspection: All rolls are kept in front of the inspection m/c time to time and are inspected over the inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, stubs etc are recorded in inspection report to classify the fabric based on the four point system.

2) Collar cuff Inspection: Collar& cuff are inspected visually under the tight box, any major or minor faulty collar/cuff like having wrong ply, hole, needle line, stubs, wrong design, first round problem etc

properly counted and recorded.

3) Quality Standard: Multifabs Ltd. maintains the ISO: 9002 standard in case of quality. Therefore the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inspection at MultifabLtd. Four point grading system Size of defects

Penalty

3 inches or less

1 point

Over 3 inch but not over 6 inch

2 points

Over 6 inch but not over 9 inch

3 points

Over 9 inch

4 points

Following table shows common body and rib faults and response by inspection section at Multifabs Ltd. Acceptance Calculation Factory: Roll yardage (A) Total points founds(B) Formula : X100 =points per 100 yard 40 points =A type 41-60 =B type 61-80 =C type Above 8Opoin = Reject Remarks: They have a well-equipped Testing laboratory called Textile Testing Services limited for all kinds of Textile Testing. The laboratory of Multifabs Ltd .is approved by world renowned buyer Marks & Spenser and also Lindex. . Now they are just testing their internal tests but they are trying to develop their laboratory.

So that external author can send their textile material for testing by suitable testing fees.

08. Maintenance Maintenance: Machine building and others services facilities are subject to deterioration due to their use and exposure to environmental conditions. There is no choice without attention time to time to repair and recondition. So their life can be extent economically and physically possible to do so, is called maintenance.

Objective of maintenance:

1. To keep t he factory plant equipment machine tools etc in optimum working condition.

2. To ensure specified accuracy to products and time schedule of delivery to customer.

3. To minimize down time of the machine and to keep the production cycle within stipulated range.

4. To modify the machines to meet extra requirements of product quality and quality.

5. To reduce maintenance cost as far as possible to reduce overhead cost.

6. To prolong the useful life of the factory plant and machinaries.

Advantage of maintenance: 1. Reduction of production downtime.

2. Lesser overtime to pay for maintenance .

3. Lesser no of stand by equipments are required.

4. Less expenditure on repairs.

5. Due to planned spare parts replacement, lesser no of spares need to remain in store all the time .

6. Greater safety to employees because of reduce breakdown.

Four types of maintenance are performed in Multi-fabs Lt. : 1. Capital replacement 2. Provision of stand by capacity 3. Breakdown maintenance 4. Schedule maintenance 1. Capital replacement : Capital replacement is undertaken, if analysis reveals that the retention time of equipment no more remain an economical proposition.

Replacement may have to be affected when-

a. Cost of maintaining in the required condition is higher than invest new one. b. Changes in quality and quality of the product obsolete the original old machine.

2. Provision of stand by capacity: Provision of stand by capacity is often provided for items of equipments that we are critical to production. It is sometimes economical maintenance practice.

Example: To keep gearbox, pump, motor etc.

3. Breakdown maintenance: Breakdown maintenance practice allows a machine or any other facility to run without much more routine attention. This practice hampered the production plan.

Such cases it is impossible to measure workload , distribution of manpower , spare parts availability in stock. It is one kind of symbol of maintenance deficiency.

4. Schedule maintenance: It provides for inspection, overhand, lubrication and servicing of certain m/c at predetermined date. This types of maintenance is practices to a certain extent even in those companies where breakdown maintenance is otherwise a rule.

Advantages: a. Predetermined of work is better for manpower distribution. b. To performing better skill manpower and materials can be kept available.

Maintenance Procedures for Blowers and Pumps: 1. Clean the equipment thoroughly before carrying out any maintenance work.

2. Remove the coupling or belt, as the case may be.

3. Remove the base bolts.

4. Shift the equipment to the maintenance area. (if required).

5. Disassemble the equipment for finding the probable causes of break down.

6. Check the bearing condition and replace it, if necessary.

7. Replace the lubricant.

8. Shift in back to the original position.

9. Fix the base bolts.

10. Align the equipment.

11. Tighten the base bolts.

12. Re-check alignment. Inform the operator and enter it in the daily logbook and history sheet.

Maintenance Procedures for Mechanical: 1. After any maintenance job, check the alignment of the equipment.

2. In case of any leakage, immediately inform the Supervisor In-charge.

3. Enter it in the logbook.

4. Enter in the daily logbook any abnormality you observe in any equipment.

5. Always use the correct type of lubricant.

6. Check the oil level every week for blowers.

7. Replace the oil every 15 days for blowers.

8. Use the proper type of tools for all repair or maintenance operations.

Maintenance for Dyeing machine: 1. Check the function of heat and cool modulating valves.

2. Check all door seals.

3. Check the oil level of pump bearing and refill if required.

4. Checking of unloading roller coupling and packing.

5. Checking & cleaning (if required) of main vessel level indicator.

6. Greasing of unloading roller bearing.

7. Checking of oil level and bolts of unloading roller gearbox., 8. Clean filters element and blow out.

9. Clean the m/c bearing.

10. Complete cleaning of machine.

11. Cleaning of drain valves, replace seals if required.

12. Check air supply filters, regulators auto drain seals.

Maintenance Procedures for Electrical: 1. Follow the lock, tag; try procedure during maintenance operations of any electrical equipment.

2. If the pump trips on overload more than 2 time, inform the concerned Electrical Supervisor.

3. Use double tested lamp to check the presence of supply of power.

4. Keep the area around the electrical panel clean and dry.

5. Use the proper kind of tools for any kind of repair or maintenance operations.

6. Check for the presence of cable route markets once in a week.

7. Report any abnormality to the concerned In- charge or Supervisor.

Maintenance Procedures for General: 1. Maintain a gap of at least two feet from the Raw effluent collection tank. (EQT) and Aerobic digester (AD).

2. Before climbing the Sequencing batch reactors, check that the shoelaces are tight and also the helmet and belts are fastened, to prevent any accidental falls.

3. Be alert while standing on the Bio reactor (Sequencing Batch Reactor).

4. Climb the ladder or Steps slowly.

5. Close

the

concrete

slabs

of

tanks

after

each

operation.

Daily maintenance: 1. Clean them 2. Check internal and external equipment.

3. Clean machine filter if necessary.

Weekly maintenance: 1. Check oil level of gear box.

2. Check operating and alam.

3. Check all bearing seal gasket, nut bolts etc.

Monthly maintenance: 1. Check pressure release value.

2. Check main reel speed , self emerging gasket.

3. Check main pump bearing belt.

4. Inspect main vessel corrosion.

Yearly maintenance:

1. Check all guards water nozzle.

2. Electrical sensor.

Remarks: longtime.

Maintenance of m/c’s are very essential for good production and machine

09. Utility Services Water treatment plant: To remove hardness of the water that means to remove Calcium and magnesium salt from water is called water treatment plant.

Considerable amount of hardness (I, e, bicarbonates, carbonates and other soluble salts of Ca⁺⁺ and Ma²⁺) is also present in deep tube-well water. Use of hard water, I, e, underground water, in boiler is not recommendable. This is because due to thermal decomposition, bicarbonates are converted into insoluble carbonates and severe scale formation takes place in the boiler unless these are removed. The high silica content in underground water also contributes to the formation of hard scales in boiler -CO₂ formed by decomposition of bicarbonate salts also results in production of acid condensate leading to corrosion of the boiler. Hard water consists of salts of Ca, Mg, Fe but Ca and Mg are chiefly responsible for it.

So, To produce high quality product must remove hardness from the water.

Hardness of water two types: Temporary hardness: Calcium and Magnesium carbonates are virtually insoluble in water.

Carbon dioxide which is always present in natural waters will convert Ca or Mg carbonates into soluble bicarbonates: CaCO₃ + CO₂ + H₂O→ Ca(HCO₃)₂ When water is boiled the bicarbonates decompose with liberation of Carbon dioxide and ppt of the insoluble carbonates which are re-formedCa(HCO₃)₂→CaCO₃+CO₂+H₂O Hardness caused by bicarbonates is called temporary because it disappears on boiling.

Permanent hardness: Calcium and magnesium chlorides or sulphates are soluble in water both in the presence or absence of CO₂. Expulsion of dissolved CO₂ makes no difference.

They are not, therefore, precipitated when the water is boiled. Therefore, hardness due to these salts is called permanent.

Measure of hardness: Any hardness can be expressed in terms of calcium carbonate. For, example, if the hardness is due to MgCl2 and is 4 ppm, then we can express this in terms of CaCO₃ as – Hardness₌ 4(wt of CaCO₃) /wt of MgCl₂ For industrial usage the following hardness scale is consideredSoft water ₌ <60 ppm Medium

₌ 60-120 ppm

Hard ₌ 120-180ppm Very hard₌ >180ppm Effect of hard water in industries:

The use of hard water in a textile dyeing or finishing mill can have some serious consequences. These includes1. Precipitation of soap 2. Re-decomposition of dirt and insoluble soaps on the fabric being washed- these can lead to yellowing and caused unlevel dyeing poor handle.

3. Precipitation of some dyes as calcium or magnesium salts.

4. Reduction of the activity of the enzymes used in desizing.

5. Decreased solubility of sizing agents.

6. Coagulation of some types of print pastes.

Properties desirable in water for textile uses: Quality/Substances Turbidity Suspended solid Color PH Hardness Iron Total solid

Acceptable limits in mg/l Less than 5 Less than 5 Less than 10 units (Hazen) 7-9 Less than 70 as CaCOâ&#x201A;&#x192; Less than 0.3 (0.01) Less than 500

Water treatment process: There are two deep tubeweel by the two side of the treatment plant. There are also two submersible pumps in the deep tubeweel one is 100 ft deep and another is 140 ft deep. The submersible pump transfer raw water in the water tank by creates force. The formation of oxidation of the water by showering with the help of another two pimps in the water tank.

Iron content removes by the oxidation.

Two circular transfer raw water in the (vessel no-1) Multigrade filter unit. The large size plastic, iron that means solid content are removed in the multigrade filter unit. The water is transferred to the (vessel No-2) Activated carbon filter unit. In the (vessel No-2) Activated carbon unit to remove chlorine that means bad smell. The water then transfer in to the (vessel No-3) softener unit from the activated carbon unit at the presence of cationic resin (Zeolite) is reacted with water to remove the hardness of water.

The water is transferred in to the reserve tank from the softener unit. The soft water is supplied from the reserve tank by the 7 Boosting pump in the different section of the factory.

The back wash & regeneration process: The back wash process to clean the vessel no-1,2 & 3. The back wash process should be done after 8-12hrs. After 40-48 hrs later the regeneration process should be done. It should be done after back wash process. After back wash the common salt dissolved with water in to the STT (salt saturated tank) the solution of common salt is ringing the resin by the injector.

The use of 18% salt in the total solution. (Suppose, 5000 lit of solution the amount of salt 600kg). The resin is activated by the salt rising. Here used cationic resin (NaHSO 3). If the PH of the water increase or decrease it should be control by the dosing chemical (Sodium Hypochlorite) from the chemical tank.

Generator: Two set To produce electricity power.

Capacity: 1145 kwt.

Origin: USA. Wiring: 16 cylinders.

Brand name: CATER PILLER, USA. Boiler: The equipment used for producing steam from water is called steam generator or boiler.

The boiler used for producing steam in GKL is Cochran boiler which is a fire tube type boiler. This produced steam is supplied by the steam line in different section. Simple vertical boiler of fire tube type is mainly used in small plant requiring small quantity of steam and where floor area is limited.

Use of Boiler: 1.

2.

3.

4.

Power generation (steam engine / turbine).

Processing in industries (dyeing & finishing mill, sugar mill, paper mill etc. ).

Heating purposes (houses, offices, hospitals etc in cold countries).

Hot water supply.

Capacity: 5 and 12 Ton per hour, Also 1.5 Ton per hour Origin: Germany and India Wiring: Fire tube, stream pressure 6 bar.

Brand name: Omrical.

Compressor: Three set To produce Air and use to open any types of water valve.

Capacity: 10.5 cubic meters per hour.

Origin: Germany.

Wiring: 6-8 bar.

Brand name: Bogi.

Generator: To produce electricity power.

Capacity: 1145 kwt.

Origin: USA. Wiring: 16 cylinders.

Brand name: CATER PILLER, USA. Remarks: Multifabs provide best quality product, for that reason they treat water carefully.

9.Store & inventory control Inventory : Inventory is defined as any resources of enterprise to indicate materials raw materials , finished, semifinishid, spares and other stock materials in order to meet an expected demand distribution.

Advantage of inventory control: 1. Improvement of customers relation. a. A maintenance of a better balance among the qualities of finished items on hand. b. Better geographic development of field warehouse inventories.

2. Improvement of labor and community relation.

3. Increase effectiveness of key personnel.

4. Reduction of manufacturing cost. a. By better utilization of labor, supervision and facilities through elimination of idle time cause by raw material shortage. b. By making possible more economical manufacturing runs in place of small lots. c. By minimizing machine downtime due to unavailability of critical spare parts. d. By minimizing inventory losses that results from decline in the market value. e. Reduction in inventory, inventory carrying cost and obsolescence. f. Better utilization of available material by facilitating interdepartment transfer.

Scope of inventory control : 1. Raw materials a. Dyes store b. Others chemicals store c. Grey fabrics 2. Finishing fabric 3. spare parts

4. General store 5. Capital equipment 6. Accessories 7. Stationary 8. Maintenance parts.

Inventory system for raw materials: 1.

2.

3.

4.

Goods are arranged according to OK or rejected group.

Department gives store requisition to warehouse.

As per requisition materials supplied & this record is noted down.

Material Receiving & Inspection Report is prepared. Received quantity is mentioned & noted down.

5. Submitted to QC department. Some are OK & few rejected.

6. Raw materials partially received from production planning & directly from head office.

Grey fabric inventory control.

1.

2.

3.

4.

5.

After knitting production Grey inspection Warehouse Batch preparation Dye house

Finished fabric inventory control 1. Finishing section 2. After final inspection 3. Warehouse.

Dyes and chemical store control: 1. It reduces time to complete one operation and more products from one stage to another.

2. To run manufacturing operation economically.

3. To take care uncertainty in demand from customers and uncertainity in procuring materials in time.

4. To reduce clerical cost and to take advantage of discounts transportation etc.

Remarks: Effective inventory control can save considerable amount executive time that otherwise would be spent on expediting critical raw material correcting repeated production , interruptions and straightening out serious back other problems with important customers.

11. Marchandising and marketing activities

Merchandising: Merchandising is the methods, practices, and operations used to promote and sustain certain categories of commercial activity. In the broadest sense, merchandising is any practice which contributes to the sale of products to a retail consumer. At a retail in-store level, merchandising refers to the variety of products available for sale and the display of those products in such a way that it stimulates interest and entices customers to make a purchase. Visual display merchandising means maximizing merchandise sales using product design, selection, packaging, pricing, and display that stimulates consumers to spend more.

This includes disciplines in pricing and discounting, physical presentation of products and displays, and the decisions about which products should be presented to which customers at what time.

This annual cycle of merchandising differs between countries and even within them, particularly relating to cultural customs like holidays, and seasonal issues like climate and local sporting and recreation.

Marketing policy: Every business owner should develop a written guideline that sets forth the business's marketing strategy. This document is used to judge the appropriateness of each action that the business takes. If a company has to take an action that is off-strategy, it may indicate a temporary emergency action prompted by competition or other factors beyond normal management control. Or it may indicate the need to change or revise the company's marketing strategy.

Multifabs Ltd. provides specific goals and can include: 1. A description of the key target buyer/end user.

2. Competitive market segments the company will compete in.

3. Distribution channels.

4. The unique positioning of the company and its products versus the competition.

5. The reasons why it is unique or compelling to buyers.

6. Price strategy versus competition.

7. Marketing spending strategy with advertising and promotion.

8. Possible research and development.

9. Market research expenditure strategies.

An overall Multifabs Ltd . marketing strategy should also: 1. Define the business.

2. Position the business as a leader, challenger, follower, or niche player in the category.

3. Define the brand or business personality or image that is desired in the minds of buyers and end users.

4. Define life cycle influences, if applicable.

Use the following checklist to help create Multifabs Ltd . marketing strategy.

1. Marketing strategy checklist.

2. Define what your company is

3. Identify the products or services that your company provides.

4. Identify your target buyers/end users.

5. Establish the marketing category (e.g., fast food purveyor, high-end audio equipment sales, etc.).

6. Determine whether your company will be a market category leader, follower, challenger, or niche player .

7. Describe the unique characteristics of your products or services that distinguish them from the competition.

8. Define whether your pricing will be above, below, or at parity with your competitors and establish whether you will lead, follow, or ignore changes in competitors' pricing.

9. Identify the distribution channels through which your products/services will be made available to the target market/end users 10. Describe how advertising and promotions will convey the unique characteristics of your products or services.

11. Describe any research and development activities or market research plans that are unique to your business.

12. Describe the image or personality of your company and its products or services.

Strategy statement tests: If the statements in your strategy are measurable and actionable and work to differentiate your company and products apart from the competition, congratulations!

If they are not measurable and actionable and do not differentiate your company from the competition, revise them until they are.

Marketing policyPlanning of End product: Marketing strategy planning of end product is the driving force behind building up your sales and profits. If you can clearly define what you can offer to your customers and why they need your product or service, you'll have a much easier time putting together a successful marketing campaign.

Given the follow Marketing strategy planning to use Multifabs Ltd.----Developing Your Marketing Assets: So what exactly do you offer your prospects and customers? Do you give them the same worn out brochures and sales spiel? If so, then it's time for a radical change. In this article, I will show how you can maximize profits by matching your marketing assets to each of your buyer stages.

Developing Key Performance Indicators: Key Performance Indicators are simple business metrics that allow you to monitor the health and profitability of your business over time. The main challenge in developing any KPI is to identify the actual metrics that will help grow profits. You can measure until the cows come home, but if your KPI's don't allow for practical changes that actually increase business results, you're wasting valuable time. This article will show you how to get started the right way!

The Marketing SWOT Analysis: The traditional marketing SWOT analysis as taught in marketing courses can be overly academic and not very practical for the small business owner. This article discusses a way to make your SWOT analysis easier to develop and put into action.

The Integral Marketing System: Integral Marketing is a system that allows you to build customer programs in four critical areas; Tools & Technology, Content & Delivery, Customers & Image and Growth & Loyalty. This system will allow you to increase your response rates, attract new clients, and most important, increase your business profits.

The Marketing Strategy Outline: Effective marketing strategy planning doesn't have to be a complex chess game. This article outlines five simple strategies for helping you put together an effective marketing outline.

Building a Referral Marketing Strategy: A good referral marketing strategy is absolutely essential in growing your small business. This article deals with letting your customers find more customers for you. Once you get a good referral program up and running, it will essentially run itself.

Marketing To Your Customer Types: If you're like most small businesses, you are marketing to all your customer types in the same exact way. This article will show you how to market to your customer types based on where they are in the buying process. Doing this will greatly increase your response rates and, most importantly, your business profits!

Creating a Powerful Marketing Communication Strategy: A powerful marketing communication strategy should serve to make your business stand out from the crowd. This article discusses several strategies to develop your own compelling core marketing communications piece.

Creating Your Value Proposition: You won't be successful selling if you first can't define the value your products and services bring to customers. This article will help you create a company Value Proposition upon which the entire foundation of your marketing program can rest.

Finding a Market Niche: Finding a Market Niche Identifying niche markets within your overall market is the key to understanding how your business can deliver the greatest value to all customers and prospects. This article discusses how to uncover profitable groups of customers with similar business needs.

Three Marketing Promotion Strategy Tips: Your marketing promotions don't stand a chance if you can't match your message to the buyer and create trust. This article gives three tips to help your promotions and your business reach new levels.

The Buyer Persona: Do you have the same marketing message for all your customers? If so, you aren't taking advantage of the power of Buyer Personas. This article will show you how to align your message with the needs of your various customers.

Writing a Mission Statement: This tip discusses the importance of writing a mission statement for your small business and gives a simple two-step process for writing your own.

Free Marketing Plan Template: Here is a free downloadable marketing plan template that has been specifically designed for the small business owner.This template will help to organize your thoughts as you create your corporate goals, buyer personas, competitive analysis and promotional action plan.

Remarks: A good working Multifabs Ltd. marketing strategy should not be changed every year. It should not be revised until company objectives (financial, marketing, and overall company goals) have been achieved or the competitive situation has changed significantly, e.g., a new competitor comes into the category or significantly different or new products emerge from existing competitor.

12. Social and Environment information Effluent treatment plant: Textile effluents: Presently garments industries have become the backbone of the economy of Bangladesh. To support those garments industries hundreds of full-scale textile industries have emerged in the past few years and a lot more are going to be setup within a short time.

These textile dyeing industries are contributing in the development if Bangladesh. But at the same time they are coursing some serious water pollution. It is a matter great concern to understand and adopt adequate treatment technologies for the remediation of this problem Design information: ETP Feed Effluent Flow rate: 1200-1400m続/day (24 hours operation).

CONTROLLING PARAMETER: Discharge standard for textile liquid waste according to the National Effluent Quality Standard (NEQS) guided by DoE (Department of Environment) of Bangladesh.

Parameters TSS BOD Total soluble solids pH Total chromium(Cr) Sulfide Phenol

Limits 100mg/L 150mg/L 2100mg/L 6.5-9 2mg/L 2mg/L 5mg/L

The following combined effluent quality is considered for designing the wastewater Treatment plant.

Biochemical Oxygen Demand (BOD), mg/l : 400 Chemical Oxygen Demand (COD), mg/l

: 1200

Total Suspended Solids (TTS), mg/l

: 100

Total Hardness, mg/l as CaCO₃

: 300

Total Dissolved Solids (TDS), mg/l

: 5000

Silica, mg/l

: 10

Ph

: 9.5

TREATED WATER QUALITY: Biological Oxygen Demand (BOD), mg/l : <30 Chemical Oxygen Demand (COD), mg/l

: <150

Total suspended Solid (TSS), mg/l

: <30

Ph

: 6.5-8.5

The above quality will be achieved on a continuous basis.

TREATMENT SCHEME: Raw wastewater ↓ Manual Bar Screen ↓ Equalization Tank ↓ Chemical coagulation ( Lime, FeSO₄ and Poly Electrolyte) ↓ Primary Inclined Plate Clarifier

Primary Sludge

↓ Sequencing Batch Reactor ↓ Disposal of Treated water

Excess Sludge

Aerobic Digester tank

↓ Filter Press

Superratant

Sludge Disposal TYPES: Physiochemical followed by Biological.

Physiochemical followed by Biological is more effective plant. This method includes primary, secondary and tertiary methods.

Primary method: primary treatment includes removal of a portion of the suspended solid from the waste water.

1.Manual Bar Screen: Firstly liquid waste is passed through the screening unit to separate the coarser particle.

No of units

: 1

Design flow

: 100m³/hr

No of screens

:1

Dimension

: 900 X1200 mm

2.Equalization tank: In this unit hot liquid waste is kept to cool.

No of units: 1 Tank Volume: 600m³ Tank Dimension: 11.90M x 5.02 x 3.00M SWD +1.5M FB CHEMICAL TREATMENT UNIT: Objective: The raw effluent is pumped to the chemical coagulation unit for effective coagulation. It is then taken by gravity to the primary inclined plate clarifier for solid liquid separation.

Chemical treatment unit: SL. NO 1

Quantity

2

1 No.

3

1 No.

4

1 No.

1 No.

Description Bulk lime solution preparation tank Tank size: 1.80m(w)x1.80m(L)X 1.50m(SWD)+0.3m Free Board MOC: RCC Lime solution Dosing Tank Tank Size: 1.40m(w)x1.40m(L)x1.50m(SWD)+0.3m Free Board MOC: RCC FeSO₄ Solution Dosing Tank Tank Size: 1.40m(w)x1.40m(L)x1.50m(SWD)+0.3m Free Board MOC: RCC FeSO₄ Solution Dosing Tank Tank Size: 1.40m(w)x1.40m(L)x1.50m(SWD)+0.3m Free Board MOC: RCC

5

1 No.

Polymer Solution Dosing Tank Tank Size: 1.0m(w)x1.0m(L)x1.50m(SWD)+0.3m Free Board MOC: RCC

1. Primary clarifier: The objective of primary clarification unit is to remove the color and Suspended solids present in the effluent by addition of lime, FeSO ₄, and Poly electrolyte. So that sludge is separated through coagulation and flocculation. Sludge is passed to sludge processing unit. pH can be controlled by adding concentrated hydrochloric acid in between coagulation and flocculation processes.

2. Aeration unit: After sludge separation in primary clarifier the liquid waste is passed to aeration unit for biological treatments.

In aeration unit organic waste is introduced into a reactor where the bacterial culture carries out the conversion of organic matter to CO₂, H₂O and other products as typical reaction shown below.

Organic matter +O₂ + Nutrients → CO₂ + H₂O + Other end products.

It should noted that urea, diammonium phosphate (DAP) and phosphoric acid are generally used as nutrients in aeration tank.

3. Sludge processing unit: After biological treatment the sludge is passed to sludge processing unit. Special care should be given for sludge management. The sludge can be filled into the three layer polythene bags and can be used for low land filling purpose.

Sludge holding Tank:

Objective: The main object of the sludge holding tank is to hold the digested sludge that can be ultimately fed to the mechanical dewatering system I, e. to filter press for dewatering sludge that can be disposed off.

Tank Details: Quantity : 1No Capacity : 3000 liters.

MOC

: HDPE

Operation : The sludge holding tank is operated on a fill and batch mode.

Filter press: The main purpose of the filter press is to collect the sludge from Aerobic digestor and to separate the liquid and solid sludge.

Filter Press Details: No of Units

: 1No

Plate dimensions: 1000mmX1000mm No of plates

: 45

The filter press works on the principal of pressure filters, which is to pump the sludge holding tank to filter press.

Filter Press Feed Pump: The main purpose of the filter press feed pump the sludge from sludge holding tank to filter press.

Pump Details: Quantity

: Two No

Model

: 666170-3EB-C.1.5

Operation: The digested sludge in sludge holding tank is pump to the filter press by filter press feed pump for sludge dewatering.

Secondary method: It means the removal of the bio-degradable organic matters and suspended solid in presence of nutrients.

4. Secondary clarifier: After biological treatment the liquid waste is passed to the secondary clarifier. In secondary clarifier the upper layer of the liquid waste remains stationary. The waste is passed from the lower level of the secondary clarifier so that remaining dissolve solids are separated as sludge.

5. Disinfection unit: The treated liquid waste passed to this unit and treated with sodium hypochlorite to kill remaining microorganism in liquid waste. After then effluent is discharged to the water bodies.

Remarks: The country is our, the industries are our, the responsibilities are also our. So we should be controlled pollution for our living. If we donâ&#x20AC;&#x2122;t care of pollution by textiles then we canâ&#x20AC;&#x2122;t stay here after fifty years. We should save our environment from the pollution contributed by textiles. So ETP is mandatory .If these number of dyeing industries emit effluent without treatment into the rivers or narrow way beside the cultivatable lands then river water will be polluted as well as the fertility of land will be decreased respectively. The rivers Shitalakkha, Burigonga and Turag are highly polluted by textile liquid wastes. So we have to stop

pollution immediately &every textile mills should be controlled every parameters of effluent of textile processing.

Conclusion From this industrial attachment we got the details idea about the factory environment, production process, total management, store & inventory process, maintenance, utility etc.

Multifabs Ltd. are well equipped and the working environment is excellent. The relation between top management to bottom level is so nice. The factory runs by a number of efficient Textile Engineers, Skilled technical & Non-technical persons. All the Textile Engineers, technical & Non-technical persons are very sincere, co-operative and helpful.