Industrial Report

Introduction By means of practical knowledge it’s not possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equaled important in association with the theoretical knowledge.

The 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, skillness 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 cannot 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 Padma Poly cotton knit fabrics 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.

Project Description Padma Poly Cotton Knit Fabrics Ltd. is a state of art composite textile industry specializing in knitting, dyeing, finishing and garments manufacturing. It has been set up at 131 Tejgaon Industrial Area.This is a sizeable industry constructed on 4 acres of land with all modern facilities, equipment having its own power-generating unit. It is in full commercial production from January 1995.

Padma PolyCotton Knit Fabrics Ltd. is a 100% export oriented composite plant for knit fabrics and garments. Padma PolyCotton Knit Fabrics Ltd. is well equipped with most modern & sophisticated European state of the art textile finishing equipment & Japanese made sewing machineries operated by highly skilled 4,500 technicians & managed by a vastly experienced management. PolyCotton’s committed to render best services on timely shipment of garments to the valued customers all over the world.

Padma Poly Cotton Knit Fabrics Ltd. exports different garments like T-shirt, Polo shirt, Trouser, Jacket, Ladies wears, Children wears, Fashion dress etc. to the famous buyers like Tom Tailor, De facto, OBS, IC Company and so on.

Through active management of garments production, merchandising and marketing activities a lot of foreign currency is earned and it is increasing rapidly day after day. It has also managed employment of a lot of peoples.

Padma PolyCotton Knit Fabrics Limited  Year of establishment:Established in the year 1995.  Nature of business:100% Export-oriented composite knit Dyeing factory.  Nature of company:Private Limited Company  Total employees:4500 persons  Turnover :US$ 30 million/year (2007)  Factory and building:300,000 square feet  Building:8 storied dye house and finishing area  Factory location:Padma PolyCotton Knit Fabrics Limited 131 Tejgaon, Industrial Area, Dhaka.

Tel: 88 02 9123928-30, Fax: 88 02 9885389 Email: admin@padmapolycotton.net Website: www.padmapolycotton.net  Name of the contact persons :Khan Mohammad Ameer (Chief Executive Officer) Khalid Hossain Khan (Director Production) Product mix:  Knit fabric: Single Jersey, Heavy Jersey, Pique, Lacoste, Interlock, Rib, Dropneedle, Herringbone, Popcorn, Waffle, Jacquard, Terry, 2/3threadfleece (Brushed/ Unbrushed), Loop Knit Collar & Cuff, Striper Peach and Emarizing Etc with Open Width and Tubular Finish. 100% cotton, 15% viscose + 85% cotton, 10% viscose + 90%cotton, 30% viscose + 70% cotton.  Garments: T-Shirt, Polo Shirt, Sweat-Shirt, Golf Shirt, Cardigan, Jogging Suit, Short/Trouser, Legging Tank Tops, Children Wear, Jogging Suits, Fashion Dress and Children Wear Etc. Awards:  BGMEA Gold Medal-2007(For Outstanding performance on corporate with social Responsibility & knit export)  Bangladesh Business Person-2007,Organized by DHL & The Daily Star.  PVH Gold Medal – 2007 ,For in time shipmen of qualify goods.

ď ś CSR Award – 2008 ,By Standard Chartered bank & Financial Express & so many from nation & international bodies.

Annual Production Capacity: Serial.

No.

Name of Unit

Production per Hour

Production per Production day per month

Production per year

1 2 3 4 5 6 7 8

Knitting Dyeing Finishing Cutting Printing Embroidery Sewing Garments washing

500 kg 300 kg 625 kg 140pcs 300pcs 70pcs 150-200pcs 10pcs

8-10 tons 6-8 tons 10-15 tons 3200pcs 6000pcs 1680pcs 3600pcs 240pcs

3600 tons 3360 tons 3600 tons 11.5 lack 9.6 lack 6.04 lack 12 lack 86000pcs

300 tons 280 tons 300 tons 96000pcs 80000pcs 50,400pcs 100000pcs 7200pcs

Main buyers: Name

Country

Name

Country

S. Oliver

Germany

New look

UK

Tom tailor

Germany

C&A

Germany

IC company

Netherland

LIDL

Germany

Umbro

France

Zagora

Germany

Espirit

Germany

Grey Stone

Germany

Erima

Germany

Landroof

Denmark

Factory Location:

Different section of Padma poly cotton knit fabrics Ltd.

Manpower management Organogram of Administration:

Organogram of Production:

Organo gram of Finance:

Organo gram of Maintenence:

Management System: • • • •

Intercom telephone, Fax, Written letters & Oral.

Shift Change:  Shift of twelve hours for upper level working persons. Shift changes after a week on Saturday.  For workers eight hours shift.

Responsibilities of production officer: From getting an order of upper level all responsibilities are on the production officers. They work with a troop of operators, helpers, fitters etc. to finish the production in due time. In the meantime production officers bear all hazards, problems. They have to explain to the manager for any type of production hamper. So, all production activities and its success depend on the production officers.

Job description:  Senior Production officer: In a garments factory a senior production officer plays a great role in production and man power management who are production related. Here we enlist the duties of senior production officer: 1) Follow up garments production, 2) Regular observation garments floor, 3) Prepare garments order status regularly, 4) Maintain the quality of the product, 5) To help the senior production officer & co-operate with others for fulfilling the required destination.

 Production officer: Production officer is the right hand of senior production officer and he is directly related with production manpower and informs senior production officer time to time. Here are his listed duties:1) Follow up overall garments production, 2) Decide every m/c utilization during production, 3) Recruit new labor, 4) To inform the authority on the overall garments prod. and make it financial profitable, 5) Regular m/c maintenance, 6) Maintain sub-contract orders, 7) Help garments manager & also guide the junior officers of the section, etc.

Remarks: Production runs with the help of mechanical fitters. For any kind of mechanical fault of any machine they fix and work under technical in-charge. Production officers’ takes account of daily production by running after the two supervisors and workers so on.

Knitting section In Padma PolyCotton knit fabrics ltd. produce various type knit fabric. This factory has two knit fabric production floor. This floor are well decorated with various type high class circular knitting machine .This factory is equipped with over 50 circular knitting m/c & 25 flat knitting machines with a production .

Knitting is the interlocking of one or more yarns through a series of loops. The length wise columns of stitches, corresponding to the warp in woven cloth, are called Wales; the cross wise rows of stitches, corresponding to the filling in woven cloth, are called Courses, Filling knits (Weft Knits) are those fabrics in which the courses are composed of a single strand of yarn, while warp knits are those in which the Wales are composed of single strand of yarn. Gauge corresponds to the yarn in a woven fabric, and is defined as the number of needles of yarns in half inches of cloth. The higher the gauge, the more compact and finer is the cloth.

Raw materials for knitting Types of raw material:  Yarn  Lycra: CREORA, S.Korea.

Source of yarn for knitting: Name of the spinning Mills Arif Knit spinning Ltd The Delta spinning Square yarn Ltd Bengol NFK Textile NRG spinning mill Prime Textile RSWM Ltd AA Kader synthetics Shirin spinning Ltd Hyosung Vietnam Malek spinning Sunny International Aman Cotton Fabrics Ltd

Location Gazipur Kashimpur, Gazipur Kashimpur, Gazipur Gazipur Gazipur Pagla,Narayangong India Narangong Shreepur, Gazipur South Korea Valuka, Mymensingh Thermax spinning ltd

Different yarn and count for knitting: Serial Number 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19

Yarn Count 30/CB 30/CD 30/PC 30/G/M 30/E/M 30/CVC 26/CB 26/PC 26/CVC 24/CD 24/PC 24/G/M 24/CVC 20/CB 20/CD 20/E/M 34/PC 34/CD 34/CVC

Serial Number 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Yarn Count 32/CD 32/CVC 28/CD 28/CVC 22/CVC 20/D lycra 40/D lycra 70/D lycra 44/D lycra 24/RTN 24/RTW 60/CB 40/CB 22/CB 24/E/M 40/D lycra 34/CVC 20/D lycra

Knitting section is divided into three section: 1.Flat knitting section 2.Circular knitting section.

3.Fabric inspection section.

1.Flat knitting section Generally collar and cuff of knitted garments is produced in this section there are flat knitting machines of the same type. There specifications of the machines are given below: M/C Brand M/C No.of M/C Dia Gauge Total Production Capacity Origin machine Needle

Matsuya

Japan

19

54

14

740X2

IN COLLAR 450 Pcs

IN CUFF

Flying Tiger

Taiwan

6

54

14

740X2

450 Pcs

1200Pcs

Shema Siki

Japan

7

54

14

740X2

450 Pcs

1200Pcs

SAEHWA Loom

koria

1

Use for

Twill

Tep

1200Pcs

Collar: Size: L: 45-47xW:09-10cmxT:3/4 /5 ply, 35-45 pcs /Kg (Depends on count, ply and tension of knitting.

Cuff: L:37-39xW:3.8-4.0cmxT:2/3/4 ply, 60-70 pcs /Kg (Depends on count, ply and tension of knitting.

2.Circular knitting section There are two types of machines available in PPC.These are single jersey and double jersey.

Circular Knitting Machine : Single Jersey, Double Jersey Single Jersey : 35 Double Jersey : 20

(Old Floor) Sl No.

M/c Dia, brand & Gauge, Country feeder (inch)

Yarn count

Grey GS M

Finished GSM

Stitch length

Yarn Fabric tension type

Buyer

Feeder & Needle

1

ORIZIO, Italy

36×24

32 CD

160

180

2.42

5

Double Lacost

Intersto p

76, 2700T

2

ORIZIO, Italy

30×24

30 CD

120

140

2.65

5

Single jersey

OBS

90, 2256T

3

Mayer & 30×20, Cie, Germany

30 CD

160

200

1.75

6

2×1 Rib

Defecto

60, 1860T

4

ORIZIO, Italy

30×24

26 CD

140

160

2.75

5

Single jersey

Multilin e

90, 2256T

5

ORIZIO, Italy

30×24

26 CD

160

190

2.50

5

Single lacost

DRÉS

90, 2256 T

6

ORIZIO, Italy

30×18

26 CB

180

200

2.55

5

1×1Rib

Cherry field

60, 1680T

7

ORIZIO, Italy

30×18

36 CD

145

160

2.52

6

1×1Rib

Mavi

60, 1680T

8

ORIZIO, Italy

30×20

18 CB

250

280

3.00

5

Heavy jersey

OBS

90, 1860T

9

ORIZIO, Italy

30×20

28CD (75% poly+ 16% CVC)

250

280

B-4.5, BS2.85, L-1.6

5

Fleece

Cherryf ield

90, 1860T

10

ORIZIO, Italy

30×24

26 CD

160

190

2.50

5

Single lacost

DRÉS

90, 2256T

11

ORIZIO, Italy

28×24

30 CD

120

140

2.75

5

S/J(stri pe)

OBS

96, 2112 T

12

JIAHAO, China

34×24

30 D+G M 10%

120

140

2.75

7

S/j

Global tex

72, 2544T

13

JIAHAO, China

32×24

30CD +20D

180

200

3.00

6, 1.5

Lycra S/J

TCM

96, 2400T

14

FALMAC , Singapore

27×24

30 CD

120

140

2.65

5

S/J

OBS

80, 2040 T

15

TERROT, Germany

34×24

26 CD

160

180

2.50

5

Single lacost

Mirajte x

72, 2544T

16

TERROT, Germany

28×20

26 CB

160

180

2.60

5

Double Lacost

Norther n

56, 1752T

17

ORIZIO, Italy

36×18

26 CD

220

255

2.55

6

1×1Rib

Navy

72, 2016T

18

Mayer & 30×18 Cie, Germany

30 CB

180

200

1.8

6

2×1Rib

Defecto

60, 1680T

19

TERROT, Germany

34×18

30 CD

180

200

1.75

6

2×1 Rib

Defecto

70, 1908T

20

TERROT

30×18

30 D/Y+ 40 D

120

160

2.75

5

1×1 L/rib

Global tex

60, 1680T

21

TERROT

36×18

30 CD

180

200

1.80

5

2×1 Rib

Defecto

72, 2016T

22

Mayer & 30×20 Cie, Germany

28 CD(7 5 poly+ 16% CVC)

250

280

4.5-B, 2.85BS 1.60-L

6

Fleece

Cherry field

90, 1860T

(New Floor) Sl No.

M/c brand Dia & Yarn & Gaug count Country e (inch)

Grey GSM

Finish ed GSM

Stitch length

Yarn tensio n

Fabri c type

Buyer

Feeder & needle

1

PAILUNG, Taiwan

34×24

26 CB

140

160

2.80

6

S/J

S.Olive r

102, 2544T

2

PAILUNG, Taiwan

36×24

26 CB

145

160

2.75

6

S/j

S.OIive r

108, 2712T

3

PAILUNG, Taiwan

36×24

28CB

140

160

2.75

6

S/J

ICCO MP

108, 2712T

4

PAILUNG, Taiwan

42×24

26 CB

140

160

2.75

6

S/j

S.Olive r

126, 3168T

5

PAILUNG, Taiwan

40×18

26CB

190

230

2.60

5

1×1

Multili ne

80, 2268T

6

JIAHAO, China

28×24

30 CD+20 170 D lycra

200

3.00

5, (L)1.5

L/S/J (FF)

TCM

84, 2112T

7

JIAHAO, China

34×24

32 CD+20 180 D lycra

200

3.00

5, (L)1.5

L/S/J (FF)

DRÉS

102, 2556T

8

JIAHAO, China

38×18

34 CD

160

180

1.70

5

2×2 Rib

Global tex

76, 2136 T

9

JIAHAO, China

36×24

32 CD+20D Lycra

160

180

3.00

5, (L)1.5

L/S/J

DRÉS

108, 2712 T

10

JIAHAO, China

30×24

31 CD+20 160 D

180

2.75

5, (L)1.0

L/S/J (FF)

Multili ne

90, 2256T

11

LISKY, Taiwan

32×20

38 CD

250

280

4.50,2.

85,1.6 0

6

Fleece

Cherry field

102,

12

LISKY, Taiwan

32×20

28 CD

250

280

4.50-B 2.85BS L-1.60

6

Fleece

Cherry Field

102, 2556 T

Maintenance of knitting Machine:  For fabric production, keep yarn tension always medium.  Check the needle & needle hook for good production.  If Jung fall on the needle then lubricant use for removing Jung.  If sinker break down then change the sinker.  Setting of the feeder accurately.  Wheel setting accurately and when jamming by dust fibre then clean it.

       

Setting cam design accurately.

Feed the breakage yarn carefully for remove needle breakage.

For decrease the reduction of decay of cam, sinker, and needle use lubricants.

When pulley decay by friction then Change it.

The belts which are use for movement of wheel sometime tear then it is repair.

The motor bearing sometime damage then repair it.

Feeding yarn pipe jamming by dirt & dust, sometime it clean by air pressure.

Always check the parts of the m/c carefully to reduce problem which occur during running m/c.

3.Fabric inspection section There is one machine in cloth inspection section. Specification of this machine is given below: Name & Type Country Model No Manufacturing date Speed Description of knitting process:

Garment Machine (Cloth Inspection Machine ) China YX-2400 A 2005 32 m/min

In every mill, there maintains a sequences in production processing. It is also followed in this mill where we were in industrial attachment. The process sequences are in list below:  Firstly, knitting manager gets a production shit from the merchandiser as accordance as consumer requirements then he informs or orders production officer about it.  Production officer informs technical in charge and knows about machine in which the production will be running.  Technical in charge calls for leader of mechanical fitter troops, they two take decision about machine for production considering machine condition, production capacity, maintenance complexity, etc.  Production officer with experienced mechanical fitter adjusts required stitch length and grey GSM for required final GSM.  Supervisor checks daily production regularity and make operator conscious about finishing tin due time.  Operators operate machine in high attention as if there were no faults in the fabrics. If he thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty.

Mechanical fitter then fixes it if he can or he informs technical in charge. Then he comes in spot.  After required production and final inspection in 4-point system, they sent in dyeing section.

Production parameter: 1. Machine Diameter; 2. Machine rpm (revolution per minute); 3. No. of feeds or feeders in use; 4. Machine Gauge; 5. Count of yarn; 6. Required time (M/C running time); 7. Machine running efficiency.

Relation between knitting parameter: 1. Stitch length increase with the increase of GSM. 2. If stitch length increase then fabric width increase and WPI decrease.

3. If machine gauge increase then fabric width decrease.

4. If yarn count increase (courser) then fabric width increase.

5. If shrinkage increases then fabric width decrease but GSM and WPI increase.

6. for finer gauge, finer count yarn should use.

7. Grey GSM should be less than finish GSM.

Production calculatuion of knitting fabric: A. Production/shift in kg at 100% efficiency =

RPM ×No. of Feeder ×No. of Needle ×SL( mm) 3527.80 ×Yarn count

B. Production/shift in meter Course / min .

Course / cm RPM × No. of Feeder × 60 ×12 × Efficiency = Course / cm ×100 =

C. Fabric width in meter:

Total no. of wales Wales / cm × 100 Total no. of Needles used in knitting = Wales / cm × 100 =

Methods of increasing production By the following methods the production of knitted fabric can be increased –

1. By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased.

But it has to make sure that excess tension is not imposed on yarn because of this high speed.

2. By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time.

3. By using machine of higher gauge: The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased.

4. By imposing automation in the m/c: a) Quick starting & stopping for efficient driving system. b) Automatic m/c lubrication system for smoother operation. c) Photo electric fabric fault detector.

5. By imposing other developments:  Using creel-feeding system.  Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage.  Using yarn feed control device.

Effect of stitch length on color depth: If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted then. Similarly in case of light shade loop length should be relatively smaller.

Faults and their causes in knitting: Hole mark: Causes:  Buckling of the needle latch  Buckling the sinker  Higher G.S.M

Star mark: Causes:

 Buckling of the needle latch.  Yarn tension variation during production.  Low G.S.M. Oil spot/Grease spot: Causes:  Excess oil/Grease use.  Jamming of needle & sinker.

Patta: Causes:  Yarn comes from different lot.  Faulty cam use in the m/c.

Needle mark: Causes:  Faulty needle use in the m/c.

Sinker mark: Causes:  Faulty sinker use in the m/c Fabric Shrinkage: Causes:  Yarn twist.  Knitting tension.  Fabric G.S.M.

Twist G.S.M. Shrinkage

End products of circuler knitting machine: Single Jersey M/C: a) b) c) d) e) f) g)

S/J Plain Single lacoste Double lacoste Single pique Double pique Mini jacquard Terry

Interlock M/C: a) b) c) d) e)

Interlock pique Eyelet fabric Mash fabric Honeycomb fabric Face/Back rib

Rib M/C: a) 1X1 Rib fabric b) 2X2 Rib fabric c) Separation fabric d) Honeycomb Different Fabric GSM and their yarn count: 1. S/J without Lycra -

Shrinkage

Fabric G.S.M 110 – 120 120 – 130 130 – 140 140 – 150 150 – 160 170 – 210

Yarn Count 40 S – 36 S 36 S - 32 S 32 S – 28 S 28 S 26 S 24 S

2.Rib without Lycra Fabric G.S.M 180 – 190 190 – 200 200 – 215 215 – 230 230 - 250 250 - 300

Yarn Count 36 S - 32 S 30 S 28 S 26 S 24 S 24 S

3.Interlock without Lycra Fabric G.S.M 200 - 220 220 - 230 230 - 250 250 - 300

Yarn Count 34 S 32 S 30 S 26 S

4.Lacoste without Lycra Fabric G.S.M 180 - 190 190 - 210 210 - 230 230 – 250

Yarn Count 30 S 28 S 26 S 26 S

Fabric G.S.M 230 - 240 240 - 250 250 - 280 280 - 300

Yarn Count 32 S 30 S 26 S 24 S

Fabric G.S.M 180 - 190 190 - 210 210 - 220 220 – 240 240 - 250

Yarn Count 34 S 32 S 30 S 28 S 26 S

40D Lycra Rib -

40D Lycra S/J –

Different parts of knitting machine:  Creel: Creel is used to place the cone.  Feeder: Feeder is used to feed the yarn.  Tensioning device: Tensioning device is used to give proper tension to the yarn.

     

VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length.

Guide: Guide is used to guide the yarn.

Sensor: Sensor is used to seen & the machine stops when any problem occurs.

Spreader: Spreader is used to spread the knitted fabric before take up roller.

Take up roller: Take up roller is used to take up the fabric Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger.

Circular Knitting m/c

Flat knitting machine

Some points are neede to maintain high quality of fabric:  Brought good quality yarn.  Machines are oiled and greased accordingly.  G.S.M, Stitch length, Tensions are controlled accurately.  Machines are cleaned every shift and servicing is done after a month.  Grey Fabrics are checked by 4 point grading system.

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

Object of batching: To receive the grey fabric roll from knitting section or other source.

Turn the grey fabric if require.

To prepare the batch of fabric for dyeing To send the grey fabric to the dyeing floor with batch card.

To keep records for every previous dyeing.

Proper batching criteria: To use maximum capacity of existing dyeing m/c.

To minimize the washing time or preparation time & m/c stoppage time.

To keep the no. of batch as less as possible for same shade.

To use a particular m/c for dyeing same shade.

Factors considered during batching: Order sheet (Received from buyer) Dyeing shade (color or white, light or dark) M/C capacity M/C available Type of fabrics(100% cotton, PE, PC, CVC) Emergency Batch management: Primarily batching is done by dyeing manager taking the above criteria under consideration.

Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency.

M/C s in batch section: Machine Brand Name Name Air turning CABER

No. of M/c

Model No

Origin

01

T1506

Italy

m/c Back Sewing BENEKS m/c

01

B107253

Turkey

Batching Calculation:  For assortate color & assortate dye: For 500 kg batch in one m/c: Fabric quantity for m/c = (m/c capacity ÷ Total quantity) × Fabric order quantity Fabric Dia (inch)

Fabric order quantity(kg)

Fabric quantity for m/c(kg)

37" 40"

500 300

90 53

50"

800

143

42"

1200

214

Total =2800 kg

500 kg

 If fabric GSM 200 and above then take 80% fabric for dyeing. If 500 kg batch with 200 GSM, then 500 × 80% = 400 kg for machine.  If fabric less than 160 GSM then take 60 % fabric for dyeing machine. Then 500 × 60% =300 kg for dyeing.  For dyeing fabric 14 % fabric get extra in batching calculation.  Load collar (+5%), twill tap (+20%) in dyeing m/c with fabric.

Batching Precautions:  The Weight of fabric roll should be taking perfectly.  The measuring instrument should be check carefully.  If different counts of fabric mix, then the fabric roll are reject, so very careful for before dyeing.  Done the batching calculation accurately.  Maintain the batching schedule carefully & check it every moment.  All finishing process like heat setting done accurately.

Dyeing Section Dyeing lab Lab Dip Development means the sample which is dyed according to buyer’s requirements (similar shade and so on).Depending on lab dip development sample dyeing and bulk production dyeing planning done.

Objective of Lab Dip The main objectives in lab dip are as follows.  To calculate the recipe for sample dyeing.  To compare dyed sample with swatch by light Box or Spectroflash.  To calculate revise recipe for sample dyeing.  Finally approved Lab Dip(Grade: A B C) Dyeing lab instrument & their function: • Rubbing tester : Brand & manufacturer GUVEN CELIK, England.

•

function This m/c used for rubbing test of fabric at wet & dry situation, its mechanism 10 revolutions per 10 second.

Perspiration test m/c:

Brand & manufacturer

function

James. Heal. Co. ltd. England

•

Two methods are used for perspiration; they are Acid media (for man) & Alkali media (for women).

Chemical for perspiration test:

Acid media: (for man)

Alkali media:(for women)

Alhistrydine mono hydrochloride -0.5gm/l Disodium hydrogen ortho phosphat -2.2 gm/l NaCl -5gm/l

Alhistrydine -0.5gm/l Sodium di -2.5gm/l NaCl

mono hydrogen

hydrochloride ortho

phosphate

Working process:        •

Pilling & Snagging tester: Brand & manufacturer

function

James. Heal. Co. ltd. –ORBITOR, England

Measure the fabric sample hairiness

•

•

•

Standard fabric - (10×4) cm [fabric weight vary with fabric standard sample] Liquor ratio -1:50 Fabric wet by chemical and immersed for 30 min.

Then sample take in m/c with multi fiber.

Temperature- 37±1 ˚C Time -4 hours Then multi fiber compare with grey scale.

Pilling assessment viewer:

Brand & manufacturer

function

VERIVIDE, England

Microscopic view of pilling

Sample dryer: Brand & manufacturer

function

Copower, Taiwan

Lab sample dyeing,temp-140˚C For normal fabric-240 sec=4 min For heavy fabric-300 sec=5 min

Machines are use for stock solution make: 1. AUTOLAB, SPS, Solution, Taiwan 2. DATACOLOR, AUTOLAB, SPS Mixer Station

-5gm/l

3. DATACOLOR, AUTOLAB TFTM , Laboratory Dispenser , JAPAN. Working process of stock solution: Firstly bottle numbering for stock solution, then give input of dyes amount in computer, take dyes in bottle with water. Hot and cold water mix with dyes by 4 nozzle where 3 nozzle for cold water and 1 nozzle for hot water. Press confirm button for taking half amount of water in bottle. Then computer indicate the mixer point number where placed the bottle. Six mixing point are include in mixer station. Each bottle has size 850 cc. In mixer station mixer time need 1 min for mixed dye with water. Return the bottle in solution m/c for other half water. Then computer indicate accuracy of amount of dyes stock solution.

Then take bottle in gravimetric LAB Dispenser where 10 lines for bottle placed and every line has 8 bottles in the dispenser. These lines use for reserve the stock solution bottle. Automatic pipetting is done by computer program when the stock solutions are need.

Colour measurement of standard SAMPLE: Color measurement is mainly done for the purpose of shade matching as perfectly as possible. Shade matching of the produced sample with the standard one is compulsory. Color measurement can be done by two methods – Color Measur ement

Manual Method

Instrumental Method

In manual method, the std. sample’s color is measured by comparing it with previously produced samples of different tri-chromatic color combination. The sample with which the color of the std. matched, that sample’s color recipe is being taken for shade matching .This method’s accuracy completely depends on the vision of the person related to it but person must be needed gather experience about color matching.

The instrumental method is more reliable if it is operated accurately to do the work of color measurement. “Spectrophotometer” interfaced with a PC is used for shade matching .This instrument works with the principle of reflectance measurement of light at different wave length.

When the standard sample is being subjected under spectrophotometer, then the instrument suggest a recipe with required tri-chromatic colors within the tolerance limit of color difference.

In this way, color measurement of the standard sample is carried out for the purpose of shade matching.

For 100% cotton fabric (all in one method):  Fabric weight measured by electric balance.  Calculate the recipe.  Keep the fabric in the pot.

 Then required amount of dyes, water, salt, soda and other chemicals are taken to the pot by pipeting.  Start the program for dyeing. The dyeing time and temperature depend on types of dyes being used.

Program – 1: For light shade Fixed temp. = 600c Time = 60 min.

Program – 2: For dark shade Fixed temp. = 800c Time = 60 min.  After finished the dyeing time then cold wash two times.  Acid wash for neutralization.  Then soaping by required soap solution for 10 min. at 950c.  Cold wash then drying the lab dip and compare with the standard.

For Polyester/cotton blend fabric (all in one method):  Fabric weight measured by electric balance.  Calculate the recipe for polyester part.  Keep the fabric in the pot.  Then required amount of dyes, water, dispersing agent, acetic acid and sodium acetate are taken to the pot by pipetting.  Start the program for dyeing. The dyeing time and temperature are carried out for 30 min. at 1300c.  After finished the dyeing time then cold wash two times.  Then reduction clearing by hydrose, caustic & detergent for 20 min at 70 0c.  Cold wash then drying and match with the standard sample.

Again,  Calculate the recipe for cotton part.  Keep the fabric in the pot.  Then required amount of dyes, water, salt, soda and other chemicals are taken to the pot by pipetting .  Start the program for dyeing. The dyeing time and temperature depends on what types of dyes are being used.  Then soaping by required soap solution for 10 min. at 950c.  Cold wash then drying the lab dip and compare with the standard sample.

Program –01: Fixed temp. = 600c Time = 60 min.

Program – 02 : Fixed temp. = 800c Time = 60 min.

Stock solution PREPARATION: Shade % 0.0001-0.009 0.10-0.99 1-1.99 2-3.99 4 TO MORE

Stock solution % 0.1 0.5 1 2 4

For production: Shade % salt soda water 1 0.0001-0.01 7 5 1:8 2 0.01-0.08 10 6 3 0.08-0.15 12 7 4 0.15-0.8 15 8 5 0.8-1.5 18 9 1:7 6 1.5-2 20 10 7 2-2.5 30 13 8 2.5-3 40 15 9 3-3.5 50 16 10 3.5-4 60 18 11 4-4.5 70 20 1:6 12 4.5 and over 80 20 Dyeing production The dyeing house is equipped with the latest fully computerized control state of the art dyeing machinery from THEIS Germany, DILMENLER Turkey, BRAZOLLI Italy. A complete range of atmospheric type and high temperature version dyeing machines allow the dyeing house to handle 35 tons per day of 100 percent cotton, blended CVS, CVC, cotton/viscose, cotton/lycra, cotton/modal, polyester fabrics, etc.

Dying m/c specification: (Old floor) SL No.

M/C brand Country name

Temp(ËšC)

Liquor Ratio

Noz zle

Production/ Function

Turkey

M/C capacity(k g) 100

1.

Dilmenler

95-100

1:8

1

Sample dyeing

2.

Thies

Germany

320

98

1:8

4

3.

Thies

Germany

320

98

1:8

4

All types of fabric dyeing Without fleece

4.

Thies

Germany

150

98

1:8

2

Without fleece

5.

Thies

Germany

320

High

pressure

m/c

stop

6.

Dilmenler

Turkey

1500

135

1:6

12

7.

Thies

Germany

500

100-110

1:8

6

8.

Thies

Germany

320

100-110

1:8

4

All type open fabric dyeing Without polyester & fleece fabric No polyester & no fleece

9.

Dilmenler

Turkey

150

130

1:8

2

10.

11.

12.

13.

Dilmenler Dilmenler Dilmenler Dilmenler

Turkey Turkey Turkey Turkey

650 60 150 550

130 95-98 110 95

1:8 1:7 1:8 1:8

8 1 2 3

Only cotton fabric dyeing All cotton Sample dyeing Sample dyeing Cotton dyeing

(New floor) SL No.

M/C brand Country name

M/C capacity(k g)

Temp(˚C)

Liquor Ratio

Nozzle

Production/ Function

1.

MCS

Italy

1500

130

1:6

6

All type fabric

2.

Then

German y

700

145

1:5

3

3.

Brazzolli

Italy

800

145

1:6

4

4.

Brazzolli

Italy

1200

145

1:6

6

5.

Beneks

Italy

1200

130

1:4

8

180 GSM fabric dyeing light shade

6.

Kgunghum

Korean

800

100

1:4

6

Only fabric

7.

A.K.

Korean

1200

110

1:4

6

No dye

8.

TEKST

Turkey

600

110

1:6

4

white polyester

The raw materials used for production are• •

Grey Fabric Dyes and Chemical

Dye & chemical Used in Padma PolyCotton: Sl.

Chemicals Name

1

Salt

2

Soda Ash

3

Basic Chemical

Custic

4

H2O2

5

Hydrose

6

Blecing powder

7 8

Albatex FFC Rucofin SIQ

Company name New Master/Noor Inter New Master/Noor Inter New Master/Noor Inter New Master/Noor Inter New Master/Noor Inter New Master/Noor Inter Swiss Color Rudolf/Chemi

TK/Kg

TK/Kg

$/E

20.50

17.00

$0.29

35.50

37.00

$0.51

50.00

60.00

$0.71

19.00

95.00

$1.36

88.00

75.00

$1.26

90.00

$1.29

392.00 247.00

$5.60 $3.35

World Ltd 9 10 11

Perrostol IMA 500 Faran Ice Amonium Sulphide

12

Forming Agen

13 14

Cibatex AB-45 Formic Acid

15 16

Acetic Acid Ruco Neutraliser(acid) Ruco Acid Abs Oxalic Acid

17 18 19 20

Matacid AS(acid) Wetting Agent

21 22 23 24 25 26 27 28 29 30 31

Fixing Alkali Rustol ASA(FFC) Common Salt

Anticreasin g

Invatex-AC Invadine DA Felosan NOF

Sequesterin g

Ecalnol RO Ecalnol nfw Albkogent LD Cibafluid C Rucolin JES Matlube –ca

32 33

Ecallube –ECB Biavin-109

34 35

Invatex CS Matquest US Stabilizer

36

Verlan NBO

37 38 39 40 41

Dekoster SQ Ecalquest DCF Ecalrate N-100 Clarite-CBB Roco Stab-OKM

42 43

Peroxide Killer

Ecalzyme HK-200 Rucorit wez

New Master/Noor Inter New Master/Noor Inter Swiss Color New Master/Noor Inter RCI Limited

New Master/Noor Inter2.00 Matex 1.00Bangladesh Chin5.60a Gold View Swiss Color New Master/Noor Inter Swiss Color R.H Corporation ECC ECC S.Amin Swiss Color Chemi World Matex Bangladesh ECC R.H.Corporatio n Swiss Color Matex Bangladesh Chemi world Ltd S.Amin ECC ECC Swiss Colours Chemi World Ltd ECC Rudolf/Chemi

330.00 171.00 45.00

$4.71 $2.44 $0.64

60.00

$0.86

147.00 100.00

$2.10 $1.43

60.00 60.00

98.00

80.00 94.00 124.00

$1.33 $1.57 140.00

70.00 392.00 8.25

$1.40 $0.86

$2.00 $1.00

7.40

$5.60 $0.11

400.00 245.00 210.00

$5.71 $3.50 $2.35

161.00 175.00 175.00 84.00 56.00 70.00

2.30 $2.50 $2.50 $1.20 $0.80 $1.00

68.00 245.00

$0.98 2.70

108.00 147.00

$1.55 $42.10

94.00

$47.00

130.00 122.00 84.00 113.00 122.00

$1.86 $1.75 $1.20 $1.63 $0.93

84.00 113.85

$4.80 $1.10

World Ltd 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

Invatex PC Febrilase HDL-350 Enzime

Leveling

Soaping agent

62 63 64 65 66 67 Fixing 68 69 70 71 72 73 74 75 76 77 78 79 80

Silicon

Cationic Softener

81 82 83 84 85 Buffer 86

Biozyme ECR Bio polish SA-500 Cellzyme 90L Matlevel DBS-80 Dekoven LVR Albatex DBC Lyoprint RG Invadine DIF Seta V/N- SF(BL) Setavin-CO Univadine TOP Sun Salt RM 400N Cotoblane SEL Matwash DSP Serisop CA Chemtech SAR

Cytrax Chemicals S.Amin MR Int Matex Bangladesh Swiss color Swiss Color

Swiss Color Fakir Dyes Matex Bangladesh

China Gold Resource Eriopon OLS Swiss Color Dekosoap SA S.Amin Silvaton FLN Swiss Color Sinogal N-Cone Dysin Rocogal NZA Rudolf/Chemi World Ltd Neofix R-250 ECC (FRD) Cibafix ECO Rudolf/Chemi World Ltd Hydrocol Sun Rucofin S/Q Swiss color Ultratex UM New Silicon AMZ Ultraifil HMS Chemi World Ltd Ecalsil SL (silicon) Chem Tech Rocofin HHS Swiss Colours Ecalsil SL(Silicon) Swiss colours Spamine CWS Chem Tech Softner GWS Siltouch HPSN Feran ICE (Polyester) Chemsoft MLSP Exilic 800CWS Sapamine FPG Chem soft MAKP Amonium Sulphide New Master/Noor Inter Formic Acid New

65.00 336.00

$5.60 392.00

77.00 550.00 550.00 105.00

$7.86 $7.86 $1.50

150.00 143.00 400.00 385.00 350.00 150.00 230.00 240.00 129.00 175.00

$2.14 $2.05 $5.71 $5.50 $5.00 $2.14 $43.29 $3.43 $E-1.90 $1.85

189.00

$2.50 $2.70

175.00 175.00 185.00 318.00 150.00

185.50

$2.65 $2.64 $4.54 $2.14 $4.00

280.00

$3.26

228.00

$4.16

291.00

247.00

$3.53 $5.71 $5.00 $2.86 $2.31

400.00 350.00 200.00 162.00 303.00 140.00 210.00

$4.33 $2.00 $3.00 $4.21 $3.57 $3.57 $2.45

295.00 250.00 250.00 147.00 600.00 131.00

171.50 230.00

$8.57 $1.87 $3.29 $0.64 $1.43 $2.1013.4

87 88 89 Brightener 90 91 92 93 94 95

Brightener

96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114

Master/Noor Inter Albatex AB-45 Swiss Color Syno White BNH Imperial Dye Chemicals Syno White BYB Imperial Dye Cone Chemicals Siba White Legend Dye Chemicals Uvitex BHV Swiss colours Uvitex BBT Swiss colours Uvitex ERH Swiss colours Uvitex EBH Swiss colours Chemtech White China golod 4BK View Uvitex BH-T Swiss colours Cibofix Pas Swiss colours Sun White 4BK Imperial Dye Chemicals GSS Cytech Ecalprove ECC FR( Finishing) Ecalpres SCD ECC Near Card OPBD Swiss Colours Chemtech ALF China gold view Chemtech HD-600 China gold resource Softafine-1101 Legend Dye Chemicals Ruco BAC AGP Multifunctional China gold Squaring View Sarabid MIP Dekoven Lvr Polyester Softner Syno White 4BK Neucrystal BGS Matclean AFD Dekolube SL

Dyes Stock Report (REACTIVE DYES): Sl. Dyes Name Company Name 1 Cibacron Yellow FN2R 2 Cibacron Yellow (H2G) 3 Cibacron Red FN-3G 4 5 6 7

Ciba

Cibacron Red FNR Cibacron T/HGN Cibacron Blue FNR Cibacron Yellow Taha/Swiss F4G

3 147.00 45.00

$5.80 $5.58

100.00

$5.71

147.00

390.00

$8.57

940.00 406.00 380.00 400.00 600.00

$5.71 $5.00 $3.45 $4.29 $5.71

400.00 350.00 241.00

$5.43 $23.57 $5.71

300.00 400.00

$1.39 $2.14

380.00 1650.00 400.00

$2.46 $0.94 $1.30

97.00

$4.29

150.00 22000.00 77.00

$314.29 $1.10

165.00 150.00 250.00 380.00 145.00 238.00 105.00 1.50

$1.65 2.14 $3.57 $5.58 $2.07 $3.40

Tk/kg 1158.50

Tk/kg 1183.00

$/E $16.90

1700.00

$24.29

1900.00

$27.14

1600.00 1100.00 1820.00 1500.00

1025.50 1844.50 1396.00

$14.65 $15.71 $26.35 $19.95

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Novacron

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Sumitomo

Cibacron Navy WBT Colours Cibacron Navy H2G Cibacron Br. Blue FNG Ciba Black WHK Cibacron Red HB/WB Cibacron Yellow HR/WR Cibacron Blue FGFN Ciba Orange FR Cibacron Red HD Cibacron Navy FNB Cibacron Br.Yellow H-4GN Ciba dark Blue WR Novacron Red FN3GL Novacron Red FN2BL Novacron Red C48 Novacron Deep Red S-B Novacron Br. Blue HGR Nova yellow S-3R Nova Ruby S-3R Nova Ruby S-3B Nova Yellow NC Nova Brown NC Sarkel Colours Nova Grey NC Nova Olive NC Nova Cron Yellow NP Nova Lemon S3G Nova Red S2B Nova Ocean-SR Sumifix Sup. Scariet 2GF Sumifix Sup. T/Blue G Sumifix Sup. Blue EXE Sumifix Sup. Red Fokir Dyes EXF Sumifix Sup. Yellow EXF Sumifix Br. Blue R Sumifix Br. Yellow 4GL Sumifix HF Yellow 3R

312.00 1300.00 3136.00

$18.57 $44.80

700.00 1000.00

$10.00 $14.00

1600.00

$22.00

2000.00 1200.00 1600.00 1500.00 1800.00

$28.57 $28.00 $17.00 $22.00 $21.00

1365.00 1365.00

1435.00

$25.00 $20.00

1600.00

$19.50

7446.00 5500.00

$22.00

494.00

$78.00

700.00 700.00 2618.00 2876.00 3162.00 3345.00 1960.00 1015.00

$7.06 $10.00 $10.00 $37.00 $41.00 $45.00 $47.79 $28.00

1015.00

$14.50 $32.00 $28.40 $12.64

2415.00 885.00

2240.00

1141.00

$16.30

710.50

$10.15

595.00

$8.50

1337.00

$19.10

763.00 749.00

$10.90 $10.70

770.00

$11.00

44 45 46 47 48 49 50 51 52 53 54

Taifix

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

Taicron

71 72 73 74 75 76 77 78 79

Drimarine

Sumifix HF Red G Sumifix HF Red 28 Sumifix HF Blue 2R Sumifix sup. Marine exf Sumifix Sup. Yellow 3RF Sumifix Sup. Bri Red 3BF Sumifix Br. Yellow 3GF Sumifix Sup. Blue BRF Sumifix Sup. Red GF Tarifix Red SF 3BT Tarifix Black SF BSDT Tarifix Br. Blue RTSPC Tarifix Navy Blue BRNT Tarifix Sup Tur/BGT Tarifix SUP Black Imperial Dyes VSBT Terasil G/Yellow W3R Terasil Red W4BS Terasil Red WWBFS Terasil Blue Wrbs Terasil Blue BGE-01 Terasil Yellow 4G Terasil Red R Terasil Blue WBLS Terasil Navy WRS Terasil Black WNS Terasil Red WFS Trasil Royal Blue WEL Terasil Yellow W6GS Terasil Orang 5RL Terasil Red 5BN Taicron Yellow HWT Taicron Black HW-T Taicron Deep Red XF-T Taicron Navy Blue HW-T Taicron Blue SE-2BT Taicron Br. Blue SE

900.00 1680.00 800.00 869.00

2700.00

$12.86 $38.57 $11.43 $12.41

700.00

$10.00

700.00

$10.00

1523.00

$21.76

2000.00

$28.57

470.00 470.00

$6.71 $6.71 $19.10

1337.00

$7.57

530.00

$6.00

420.00

$3.90

273.00

$13.80

966.00

$14.50

1015.00 2678.00 2310.00 1288.00 644.00 1375.00 2184.00 1295.00 1103.00 2678.00 3060.00

$38.26 $33.00 $18.40 $9.20 $19.64 $31.20 $18.50 $15.76 $38.26 $43.71 $17.14

1200.00

$18.57

1300.00 1400.00 588.00

$20.00 $8.40 $6.90

483.00 1043.00

$14.90 $9.21

645.00

$12.50

875.00 850.00

$12.14 $20.71

80 81 82 83

Livafix

84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117

Remazol

GLT Drimarine Navy HFGN Drimarine Red K4BL Drimarine Red CL5B Drimarine Yellow Imperial Dyes CL2R Drimarine rubine CL3BL Drimarine Red K8B Drimarine Blue CLBR Drimarine Blue HFRL Drimarine Red HF3GL Livafix Br. Red EBA Livafix Yellow CA Livafix Red CA Livafix Blue CA Sarkle Colours Livafix Fast Red CA Livafix Amber CA Livafix rubinc CA Livafix Br. Yellow CA Livafix scarlet CA Livafix Br. Red EBA Remazol Red RGB Remazol Yellow RR Remazol Blue RR Remazol Green 6B Remazol D/Black Gwf Remazol Bri Blue RSPL Remazol Ultra Sarkle Colours carmine rGB Remazol Red RR Remazol T/Blue G Remazol Bri Blue BB Remazol Navy-RGB Remazol Br. Yellow 3GL Remazol Deep Red RGB Remazol Red RGB Remazol G. Yellow RGB Remazol Orange RR Remazol Yellow RR Remazol Red F3B Polafix Black B

1450.00

$27.86

1950.00 675.00 700.00

$9.64 $10.00 $19.29

1350.00

$42.86

3000.00 1900.00

$27.14 $40.00

2690.00

2800.00

$25.71

1800.00

$42.00

2940.00 880.00 1249.00 1548.00 1407.00 1544.00 1541.00 2100.00

$12.57 $17.84 $22.11 $20.10 $22.06 $22.01 $30.00 $31.43

2200.00 2940.00 348.00 654.00 795.00 2793.00 341.00

$42.00 $4.97 $9.34 $11.36 $39.90 $4.87 $16.39

1147.00

$10.00

700.00

$9.04

633.00 373.00 1175.00 387.00 598.00

$5.33 $16.79 $5.53 $8.54 $6.14

430.00

$4.97

348.00 348.00

$4.97 $13.66

956.00 654.00 2600.00 575.00

$9.35 $37.14 $4.50 $4.50

315.00

118 119 120 121 122

Polafix

123 124 125 126 127 128 129 130 131 132 133

Corazol

134 135 136 137 138 139 140 141 142 143 144 145

Everzol

Papilion

146 147 148 149 150 151 152 153 154

Start fix

Polafix Red 3BS Polafix Yellow 3RS Polafix Black Grn Polafix Navy blue BS Polafix Br. Blue M.R Enterprise RSPL Polozol Black B Polozol Blue R/HC Polafix Orange 3r Polafix l/Yellow 4 GLS Polafix Orange 2NR Polafix Black G Polafix T.blue g Protofix black B Corazol Red ME4BP

315.00 294.00 371.00 483.00 1032.00

Corafix Black BP Corazol deep Red RFT Corazol Yellow RFT Corazol T/Blue G Corazol Red RFT Corazol g-Yellow MERP EV Yellow LX EV Blue LX EV Red LX EV Red LFB Papilon Red FE5B Papilon Green FFB Papilon Red FFG Papilon Yellow F10 GTN Reacter star fix Red ED3B Reacter star fixYellow ED Reacter star fix Red ED Reacter star fix black ED Reacter star fix Navy ED Reacter star fix Black EDHG Reacter star fix Yellow 4 GL Reacter star fix Navy Blue BF Reacter star fix Yellow 3R FN

Chami Way Enterprise

800.00 1500.00

$4.30 $5.30 $6.90 $14.75 $4.50

315.00 1000.00 504.00 476.00

$14.29 $7.20 $6.80 $7.20

504.00 371.00 406.00 575.00 450.00 300.00 530.00

$5.30 $5.80 $8.21 $6.43 $4.29 $7.57 $6.43 $7.00

450.00 490.00 480.00 700.00

$6.86 $10.00 $10.29 $19.29

720.00 1350.00 Ever shine 1090.00 enterprise 1640.00 2346.00 1540.00 Legeud dyes 2400.00 Chemicals 2850.00

Nafisa enterprise

315.00 301.00

$15.57 $23.43 $33.51 $22.00 $34.29 $40.71

560.00

$8.00

553.00

$7.90

616.00

$8.80

350.00

$5.00

546.00

$7.80

420.00

$6.00

455.00

$6.50

455.00

$6.50

301.00

$4.30

155 156 157 158 159

Reactive

160 Dionix 161 162 163

Dysel

164 165 166 167 168 169 170 171 172 173 174 Disperse dye:

Reacter star fix red 3B FN Reactive Star Fix T. Blue g Reactive yellow 3RXF Reactive Red HSB Reactive orange 2RXF Dionix Yellow Brown XF Sparkle Colours Dionix D/Red SF Dionix Blue ER Dysel G. Yellow MERL Dysel Red ME6BL Synolon Br. Blue VRN Bezaktive Blue V-RN Amron Red HR2d Starfix Red ED 3B Starfix Yellow ED Starfix navy ED Starfix black ED-HG Starfix T. Blue G Starfix Blur RSPL Starfix Yellow 4GL

301.00

$4.30

385.00

$5.50

375.00

$5.36

925.00 575.00

$13.21 $8.21

1200.00

$17.14

2300.00 1100.00 400.00

$32.86 $15.71 $5.71

450.00 4125.00

$6.43 $58.93

1600.00 800.00

$22.86 $11.43 $7.15 $7.05 $7.05 $5.90 $5.30 $17.00 $6.10

500.00 493.00 493.00 413.00 371.00 1190.00 427.00

Dyes

Imperial Chemical company

Taifix

UK

Terasil Huntsman

Switzerland

Naka

Japan

Recipe at different stages in dyeing cotton fabric: PRETREATMENT Ingredient Quantity Wetting agent (Sun Mori CK-1) 0.5 g/l Anti creasing agent (Texport D – 600) 1.3 g/l Sequestering agent (Sirrix-SQ) 0.5 g/l Caustic 3 g/l Stabilizer (Neorate PH-100 ) 1 g/l Hydrogen per oxide (H2O2) 3.5 g/l Peroxide killer(Crocks-N) 1 g/l NEUTRALIZATION Acetic acid 1 g/l ENZYME TREATMENT Acetic acid 0.3 g/l Bio –polish EC 1 g/l DYEING Acetic acid for leveling agent 0.3 g/l Levelling agent(Neocrystal EDX/200B) 1 g/l Anti creasing agent (Texport D – 600) 1.5 g/l

Dyes name Taifix Red SF 3BT Taifix Yellow SF 3RT Taifix Black SF BSDT Taifix Black SF BT Taifix Br. Blue RTSPC Everzol Black B Everzol Black GR Everzol Red 3BS Everzol Yellow 3RS Terasil G/Yellow W3R Terasil Red W4BS Terasil Red WW-BFS Terasil Blue WRBS Terasil Blue BGE-01 Terasil Yellow 4G Terasil Yellow W4G Terasil Red R Terasil Blue WBLS Terasil Navy WRS Terasil Black WNS Terasil Red WRS Terasil Red WFS Terasil Orange 5RL Terasil Yellow W5SL Terasil Red FBN Protofix Red 3BS Protofix Yellow 3RS Nakalon Blue 2 RLS Nakalon Yellow 4GN

Dyes Salt Soda AFTER TREAMENT Fixing agent (Neofix ECO/Cibafix FRD) Soaping agent(Lipotol PS-60) Acetic acid SOFTENING Acetic acid Softener( Perrostol CWS)

40% owf 15% owf 0.5 g/l 0.8 g/l 1 g/l 0.2 g/l 1 g/l

Machine wash recipe: Recipe for machine wash Ingredient Detergent (Solax) Caustic Hydrous

Amount 0.5 gm/L 1 gm/L 2 gm/L

Different parameters in DYEING: A. pH During peroxide bleaching & scouring During enzyme treatment Before addition of leveling agent Before addition of color softener(Perrustol IMA-500) Before addition of white softener(Perrustol VNO-500) Softener at stenter & de-watering Silicon softener Reactive dyeing Disperse dyeing B. Temperature For cotton scouring For cotton cold wash For cotton hot wash For cotton acid wash For cotton dyeing

9-11 4.5-5 6-6.5 6-6.5 4.5-5 5.5-6 5.5-6 10.5-12 4.5-5.5

95-110˚C 40-50˚C 70-80˚C 60-70˚C 80˚C ( For hot brand)/60˚C(For cold brand)

C. Time For scouring and bleaching For reactive dyeing For disperse dyeing

60-90 mins 60-90 mins 60-90 mins Recipe for white 100% Cotton S/J, 160/180 GSM, S/J Lycra, H/J, Fleece Chemical/Auxiliaries (160 GSM) g/l (180 GSM) g/l Temp. Oc Demineralizing Felosen NOF 0.3 0.3 80 Invatex CS 0.5 0.5

Time in minute 20

Albafluid C Post bleaching Felosen NOF Invatex CS Ecalrate N100/clarite CBB Abafluid C Custic Peroxide Cooling at 85 dgC Brightener Hot Wash} Neucrystal BGS Acetic acid Enzyme(Process) Fabrilase HDL Acetic acid Softener Sapamine FPG/Chemsoft MAKP

0.3-0.5

0.3-0.5

[0.3g/l used for Rib/Pk/Int/F/L]

0.5 0.5 0.6

0.5 0.5 0.6

105/98

1.0 3.0 8/10

1.0-1.5 3.0 8/10

[1.5g/l used for S/J,H/J & S/J-Ly]

30/50

95 80

20 10

0.4 0.3

55

10

As per buyer standard 0.3 0.3

55

50

1/1.5

45

20

0.4 1.0

1/1.5

Note: 180GSM Fabric/Ly-Fabric must be used demineralization process.

Chemical/Auxiliaries Demineralizing Felosen NOF Invatex CS Albafluid C Post Bleaching Felosen NOF Ecalrate N-100/Clarite CBB Albafluid C Caustic Peroxide Hot Wash P.Killer Ecalzyme HK-200 Acetic acid Enzyme (Process) Fabrilase HDL Acedic acid Dyeing (Auxilaries) Albatex DBC Albafluid C

Navy, Red, Black and Dark Shade 100% Cotton (160 GSM) g/l (180 GSM) g/l Temp. Oc

Time in minute

Nill Nill Nill

0.3 0.5 0.3

80

20

0.5 0.5

0.5 0.5

105/98

45/60

1.0 3.0 3.5

1.0-1.5 3.0 3.5

[1.5g/l used for S/J,H/J & S/J-Ly]

80

10

0.2 1.0

80 55

10 10

As per buyer standard 0.3 0.3

55

50

0.2 1.0

1.0 0.5-1.0

1.0 0.5-1.0

[0.5g/l used for Rib/Pk/Int/F/L]

Acedic acid After /Treatment Acetic acid Soap Dekosoap SA/NZA Fixing Neofix R-250/ECO Softener Acetic acid Sapamine CWS/Chemsoft MLSP

0.1

0.1

1.0

1.0

1.00

1.0

90

0.5/1.00

0.5/1.0

[1g/l used for black color]

0.3 1/1.5

0.3 1/1.5

45

10

20

Note: 180GSM Fabric/Ly-Fabric must be used demineralization process.

Lt Shade/ Tricomatic(khaki, Brown, Olive) 100% Cotton Chemical/Auxiliaries Demineralizing Felosen NOF Invatex CS Albafluid C Post Bleaching Felosen NOF Invatex CS Ecalrate N100/Clarite CBB Albafluid C Custic Peroxide Hot wash P. Killer Ecalzyme HK-200 Acetic acid Enzyme (Process) Fabrilase HDL Acedic acid Dyeing (Auxilaries) Albatex DBC Albafluid C Acedic acid After /Treatment Acetic acid

(160 GSM) g/l

(180 GSM) g/l

Temp. Oc

Time in minute

0.3 0.5 0.3-0.5

0.3 0.5 0.3-0.5

80

20

0.5 0.5 0.5

0.5 0.5 0.5

105/98

1.0 3.0 3.5

1.0-1.5 3.0 3.5

[1.5g/l used for S/J,H/J & S/J-Ly]

[0.3g/l used for rib/Pk/Int/F/L] 45/60

80

10

0.2 1.0

80 55

10 10

As per buyer standard 0.3 0.3

55

50

0.2 1.0

1.0 0.5-1.0 0.1

1.0 0.5-1.0 0.1

0.6/1.0

0.6/1.0

[0.5g/l used for Rib/Pk/Int/F/L]

Soap Dekosoap SA/NZA Fixing Neofix R-250/ECO Softener Acetic acid Sapamine CWS/chemsoft MLSP

0.5/1.0

0.5/1.0

90

10

0.5

0.5

[No need used for Lt-Shade]

0.3 1/1.5

0.3 1/1.5

45

20

Note: 180GSM Fabric/Ly-fabric Must be used demineralization process.

Turquise Color 100% Cotton Chemical/Auxiliaries Demineralizing Felosen NOF Invatex CS Albafluid C Post Bleaching Felosen NOF Invatex CS Ecalrate N100/Clarite CBB

(160 GSM) g/l

(180 GSM) g/l

Temp. Oc

Time in minute

0.3 0.5 0.3-0.5

0.3 0.5 0.3-0.5

80

20

0.5 0.5 0.5

0.5 0.5 0.5

105/98

Albafluid C Custic Peroxide Hot wash P. Killer Ecalzyme HK-200 Acetic acid Enzyme (Process) Fabrilase HDL Acedic acid Dyeing (Auxilaries) Albatex DBC Albafluid C Albatex DBC After Treatment Acetic acid Soap Albatex DBC Eriopon OLS

1.0 3.0 3.5

1.0-1.5 3.0 3.5

[1.5g/l used for S/J,H/J & S/J-Ly]

[0.3g/l used for rib/Pk/Int/F/L] 45/60

80

10

0.2 1.0

80 55

10 10

As per buyer standard 0.3 0.3

55

50

90

10

0.2 1.0

1.0 0.5 0.25

1.0 0.5 0.25

1.0

1.0

0.5 0.75

0.5 0.75

Fixing Neofix R-250/ECO Softener Acetic acid Sapamine CWS/chemsoft MLSP

0.5

0.5

40

10

0.3 1/1.5

0.3 1/1.5

45

20

Note: 180GSM Fabric/Ly-fabric Must be used demineralization process.

COTTON DYEING STEPS WITH CURVE: Required amount of water was taken into the machine The fabric was loaded and run for 5-10 minutes in normal temperature CK-2,D-600/C,SQ-12UD and PH-100(Scouring Chemicals) were added at a time for 5 minutes Caustic was added at normal temperature for 5 minutes Temperature increased at 60 0 C Hydrogen per Oxide(H 2O2)was added for 5 minutes Temperature increased at 95 0C and continues for 1 hrs Sample check Cold wash at 40 0C for 5-10 minutes Hot wash at 95 0C for 5-10 minutes Required amount of water was loaded Croak-N was added Acetic acid was added Temperature increased at 80 0C for 15-20 minutes Cold wash at 40 0C and drain Water filled and Acetic acid was added P H check at 4.5 Temperature increased at 55 0C Enzyme (Bio-EC) was added and run for 1hrs at 55 0C

Shade check Cold wash at 40 0C and drain Water filled/Required amount of water was taken Temperature increased at 95-99 0C for 5-10 minutes Cold wash at 40 0C and drain Acetic acid was added P H check at 4.5 EDX/200B and C/D-600 were added at a time Salt dosing Color dosing for 30 min Run for 10 min Soda dosing for 40 min Run for 7 min Temperature increase at 60 0C for 5 min Run for 10 min Shade check (OK) Rinsing Water was filled at required amount PS-60 was added Temperature increase at 80 0 C for 10 min Hot wash at 900 C for 20 min and shade check in this time (OK) Rinsing Water was filled at required amount Acetic acid was added for neutralization for 10 min Shade check (ok) ECO/FRD was added for 10 min Rinsing

Water was filled at required amount P H check at 6.5 (C.W.S) softener was added Final shades check and run for 20 min Temp.( OC )

Unload the dyed fabric

Time of addition for Scouring & Bleaching Chemicals: 0 = Fabric load 10 = CK-2, C, SQ, PH-100(Scouring auxiliaries)

Dyeing Curve: 20 = Caustic Soda (NaOH) Fig: Scouring & Bleaching

30 = Hydrogen Peroxide (H2O2)

Temp.( OC )

170 = Croak – N, Acetic Acid

Time of addition for Enzyme & Chemicals: 0

= Water filled Scouring Bleaching

100 100

Hot wash

&

10 = Acetic acid added

90 90 80

25 = Enzyme (BIO-EC) added

H2O2 Killer

70 80 60 50 4070

60

0 Min.

20

40

60

80

100

120

140

160

180

200

160

180

200

50

40

0

20

40

60

80

100

120

140

220

Figure: Enzyme Treatment Curve DYEING PROCEDURE OF POLYESTER FABRICS WITH CURVE: Required amount of water filled Fabric was loaded and run for 10 min.

Drain Required amount of water filled CK-2 and oxalic acid was added for 5 min.

Run for 20 min. at 800 C Rinse for 15 min.

Drain Required amount of water filled Formic acid added for PH- controlled Check PH at 4.5 Leveling agent (DIF) added for 10 min.

Temperature increase at 600 C Color/Dyes added for 15 min.

Run for 10 min.

0

Temperature increase at 130 C for 30 min.

Run for 30 min.

0

Cooling at 80 C Shade check

Reduction Cleaning

Caustic Dosing (600C X 6 min) Raising Temp at 1300C Hydrose injection (Run time (10 min x 800C)) Normal wash Drain

Rinsing for 15 min.

Drain Required amount of water filled Hot wash at 800 C Shade check Rinsing for 15 min.

Temp.( OC )

Unloading

Time of addition Dyeing Chemicals: 0 = Fabric load 10 = CK-2,Oxalic acid added 60 = Formic acid added 65 = leveling agent added

80 = Dyes Dosing

Dyeing

130 120 110 10 090

Hot wash

80 70 60 50 Figure: Dyeing Curve of Polyester

40

Process of Polyeste/Cotton(p/C) Fabric dyeing: ďƒ˜ At first the Polyester Part dyeing same as Polyester Dyeing 0 20 40 60 80 100 120 140 ďƒ˜ Then the Cotton Part dyeing same as Cotton Dyeing.

Min.

160

180

200

220

WHITENING RECIPE & SEQUENCE FOR GREY MÉLANGE: Ingredient Amount CK-2(detergent) 0.5 g/l SQ 1.0 g/l D-600

0.8 g/l

PH-100

0.8 g/l

Caustic soda

3 g/l

Per oxide

3 g/l

Ciba white(Brightening agent)

0.1 g/l

WORKING SEQUENCE: Water load Fabric load Run 5’ at normal temperature Drain Water load CK-2+SQ,D-600,PH-100 are added at normal temperature Run 5 minute Caustic dosing10’ at 40 0C Steam rise to 700C Peroxide(600C x10’ dosing) Temperature 950C Run time 40’ at 950C Ciba white dosing 20’ Run 10’ Sample check Unload PROCESS SEQUENCE OF TOPPING: Required amount of water filled Fabric was loaded and run for 10 min.

Drain Required amount of water filled Acetic acid was added for 5 min.

Temperature increased at 600 C Run for 20 min.

Rinsing for 10 min.

Drain Require amount of water filled CK-1 was added Temperature increased at 950 C Run for 30 min.

Ringing for 20 min.

Leveling agent (DIF) added for 10 min.

Salt dosing Color dosing for 30 min Run for 10 min Soda dosing Run for 1 hrs Temperature increase at 600C for 5 min Run for 10 min Shade check (OK) Rinsing for 20 min.

Drain Acetic acid was added for neutralization for 10 min Shade check (ok) Hot wash at 700C Rinsing for 10 min.

Fixing agent (ECO/FRD) was added for 10 min

Rinsing for 10 min.

Water was filled at required amount PH check at 5.5 C.W.S softener was added Final shade check and run for 20 min Unloading the dyed fabric

PROCESS SEQUENCE OF STRIPPING: Required amount of water was taken into the machine The fabric was loaded and run for 5-10 minutes in normal temperature CK-2 and C were added at a time for 5 minutes Caustic was dosing at normal temperature for 5 minutes Run for 10 min.

Temperature increased at 1100C and continue for 40 min.

Cooling at 800C Hydrose inject for 5 min.

Temperature increased at 1100C for 10 min.

Run for 30 min.

Cooling at 800C Sample check Rinsing for 15 min.

Hot wash Cold Wash Unload the Fabric PROCESS SEQUENCE OF REMOVAL SOFTENER SPOT: Required amount of water filled Fabric was loaded and run for 10 min.

Drain Required amount of water filled Acetic acid was added for 5 min.

2UD added for 5 min.

Run for 10 min. at 700 C Rinse for 15 min.

Drain Required amount of water filled Acetic acid added for PH- controlled Check PH at 4.5 HDL-350(enzyme) added Run for 1 hrs Shade check Rinsing for 10 min.

Anti-crease (C) was added for 5 min.

Leveling agent (200B) added for 5 min.

Run for 20 min at 800 C Rinsing for 10 min.

Acetic acid added for PH- controlled Check PH at 6.5 FK-7 (Softening agent) injected Run for 10 min. at 500 C Unload the Fabric COMMON FAULTS AND THEIR REMEDIES IN KNIT DYEING 1. Crack, rope & crease marks: Causes:  Poor opening of the fabric rope  Shock cooling of synthetic material  Incorrect process procedure  Higher fabric speed Remedies:  Pre-Heat setting

 Lower rate rising and cooling the temperature  Reducing the m/c load  Higher liquor ratio  Running at a slightly higher nozzle pressure 2. Fabric distortion and increase in width: Causes:  Too high material speed  Low liquor ratio Remedies:  By decreasing both nozzle pressure & winch speed

3. Pilling: Causes:  Too high mechanical stress on the surface of the fabric  Excess speed during processing  Excess foam formation in the dye bath Remedies:  By using of a suitable chemical lubricant  By using antifoaming agent  By turn reversing the Fabric before dyeing 4. Running problem: A. Ballooning: Causes:  Seam joining with too densely sewn Remedies:  By cutting a vertical slit of 10-15 cm in length for escaping the air.

B. Intensive foaming: Causes:  Pumping a mixture of air and water Remedies:  By using antifoaming agent 5. Uneven dyeing: Causes:  Uneven pretreatment (uneven scouring, bleaching & mercerizing)  Uneven heat-setting in case of synthetic fibres  Quick addition of dyes and chemicals  Lack of control of dyeing m/c Remedies:  By ensuring even pretreatment  By ensuring even heat-setting in case of synthetic fibres  By slow addition of dyes and chemicals  Proper controlling of dyeing m/c 6. Shade variation (Batch to batch):  Batch to batch shade variation is common in exhaust dyeing which is not completely avoidable. Even though, to ensure a consistent batch to batch production of shade the following matters should be controlled carefully Use standard dyes and chemicals

    

Maintain the same liquor ratio Follow the standard pretreatment procedure Maintain the same dyeing cycle Identical dyeing procedure should be followed for the same depth of the shade Make sure that the operators add the right bulk chemicals at the same time and temperature in the process.  The Ph, hardness and sodium carbonate content of supply water should check daily.

7. Dye spot: Causes:  Improper mixing of dyestuff in the solution, in right amount of water, at the temperature.

Remedies:  We should pass the dissolved dyestuff through a fine stainless steel mesh strainer when adding it to the chemical tank, so that the large un-dissolved particles are removed.

8. Patchy dyeing: Causes:  Uneven heat in the machine.  Improper impregnation of dye liquor due to the low wetting property of the fabric.  Dye migration during intermediate dyeing.

Remedies:  By proper pretreatment.  By adding extra wetting agent.  Heat should be same throughout the dye liquor.

9. Specky dyeing: Causes:  Excessive foam in the dye bath.  Fall of water droplets on fabric surface before or after dyeing.  In sufficient after treatment.

Remedies:  By using antifoaming agent.  Sufficient after treatment.  By using a good wetting agent in the dye bath.

10. Roll to roll variation or Meter to Meter variation: Causes:  Poor migration property of dyes.  Improper dyes solubility.  Hardness of water.  Faulty m/c speed, etc Remedies:  Use standard dyes and chemicals.  Proper m/c speed.  Use of soft water 11. Crease mark: Causes:  Poor opening of the fabric rope  Shock cooling of synthetic material  If pump pressure & reel speed is not equal  Due to high speed m/c running Remedies:  Maintaining proper reel sped & pumps speed.  Lower rate rising and cooling the temperature  Reducing the m/c load  Higher liquor ratio

12. Dye spot: Causes:  Improper Dissolving of dye particle in bath.  Improper Dissolving of caustic soda particle in bath.

Remedies:  By proper dissolving of dyes & chemicals  By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the large un-dissolved particles are removed 13. Softener Mark: Causes:  Improper mixing of the Softener.  Improper running time of the fabric during application of softener.  Entanglement of the fabric during application of softener Remedies:  Maintaining proper reel sped & pump speed.  Proper Mixing of the softener before addition.  Prevent the entanglement of the fabric during application of softener Finishing section In textile manufacturing, finishing refers to any process performed on yarn or fabric after weaving or knitting to improve the look, performance, or "hand" (feel) of the finished textile or clothing. It is one of the basic operations in the final processing of materials (fabrics and knits), as a result of which they gain several valuable characteristics, which include increased durability, water repellency, and resistance to shrinkage, wrinkles, mildew, and fire.

In order to impart the required functional properties to the fiber or fabric, it is customary to subject the material to different types of physical and chemical treatments. For example, wash and wear finish for a cotton fabric is necessary to make it crease-free or wrinkle-free. In a similar way, mercerizing, flame retardant, water repellent, waterproof, anti-static and peach finishing achieve various fabric properties desired by consumers.

•

The techniques of finishing depend on the following:

a. Nature of the fabric, i.e. chemical composition, state, weave, etc. This determines the appearance, i.e. transparences, luster, fullness, weight, whiteness, etc. b. The physical properties of the fabric, i.e. feel, softness, stiffness, tensile strength, elongation, shrinkage property, insulation etc. c. The end-use of the material i.e. non-shrinking, non-creasing, stiffening etc. d. Receptivity of the fabric to various finishing operations, i.e. water-proofing, flameproofing, rot-proofing etc. e. Susceptibility to chemical modifications.

Classification of Finishing Textile finishes are classified into several ways. The most common classifications are: 1. Aesthetic finishes: that modifies the appearance and or handle/drape of fabrics. i.e.

Calendaring, mercerization etc.

2. Functional finishes: that improves the performance properties of fabric. i.e. crease resistance finishes, water repellent finishes etc.

Textile finishes are also categorized as: 1. Mechanical finishes (Dry finishes): to involve in specific physical treatment to a fabric surface in order to change the fabric appearance. i.e. compacting, raising.

2. Chemical finishes (Wet finishes): usually applied to fabric by padding followed by curing after drying. i.e. starches, gum etc.

Finishes can also be classified by their degree of performance as follows: 1. Permanent finishes: it involves a chemical change in fiber structure & do not change throughout the life of a fabric.

2. Durable finishes: these types of finishes usually last throughout the life of the fabric, but effectiveness reduces after each cleaning & near the end of normal use life of the article, the finish is nearly removed.

3. Semi-durable finishes: usually last several launderings or dry cleanings.

Temporary finishes: these types of finishes are removed or dismissed after first time laundering or dry-cleaning of the articles.

Machine deascription of finshing section: Seria l

Machine

Machine No.

Brand name

Manufacturer

Experiment

1.

Dewatering machine

01

WEISS

Germany

Dia, shrinkage

2.

Dewatering machine

02

BIANCO, CORINO

Italy

Pressure mark

3.

Round hydro

01

DILMENLER

Turkey

GSM

4.

Slitting machine

01

BIANCO (tube)

Italy

Dia & GSM

5.

Tensionless slitting m/c

01

BIANCO(open)

Italy

GSM

6.

Dryer machine

03

RUCK,KRANZ, Germany, Italy DILMENLER,

GSM, Shade change

7.

Stenter machine

02

BRUCKNER, KRANZ

GSM, Shrinkage, width control

Germany

8.

Open compactor 02 m/c

FERRARO, FEBCON

Italy, USA

Shrinkage control, spirality control, width change

9.

Tube compactor 02 m/c

FERRARO, FEBCON

Italy, USA

Shrinkage control, spirality control, width change

10.

Weft straightener 02 m/c

BIANCO ,MEHLO

Italy ,England

Remove bowing effect

11.

Raising Brushing m/c

PRATO

Italy

Brushing effect of fabric back side

12.

Sueding machine

SANTA BRUSH

Italy

Carbon finishing

& 01

01

LAYOUT OF FINISHING SECTION

Open

Finishing

Compactor

Table Lift

Tube Compactor

Open Compactor

Dryer

Stenter

Dryer

Supervisors Office Slitting

Hydro Hydro

De-watering

Lab Dip & Testing Room

Finishing is given to fabric in 2 forms 1. Open form 2. Tube form

Hydro Hydro

De-watering

E

DE-WATERING M/C Objectives of de-watering m/c:  Remove excess water  Application of softner  To control GSM  To control the crease mark of the fabric Operational parameter  Speed: As much as possible (40-60 m/min). Higher the GSM lower the speed.  Over feed: As required. Higher the GSM higher the over feed.  Padder pressure: 3-7 bar as required. Higher the GSM lower the padder pressure.  Width: Fabric width is adjusted as per required width.  To control width Machine no: 01 Machine name : De-watering-1 Brand name : Weiss Origin : Western Germany Pressure : 50 psi Speed : (60-70) m/min Machine no: 02

Machine name

: De-watering-2

Brand name

: Bianco

Origin

: Italy

Hydro Extractor

Figure: Dewatering machine

Hydro Extractor: ď ś To extract excess water.

Working Process: Moving baskets are round and made of steel. There are a lot of holes on the down side of these baskets. Through the holes water can be drained out. It is located at the centre of the machine.

Machine name: 03

Machine name Brand name Origin Machine no:04 Capacity Extraction % Time

: Hydro Extractor : Dilmenler : Turkey : 125kg : 80 : 5-10 mins

Figure:Hydro Extractor

SLITTING MACHINE Objectives: ď ś To open tube fabric according to specific needle mark.

Machine no: 05

Machine name : Slitting Brand name : Bianco Working Speed : 80-85 m/min

Manufactur year : 2003 Origin : Italy .

Figure :Slitting machine Dryer Function:  To dry the fabric.  To control the overfeed system.  To control the vibration which increase the G.S.M .

Drying temperature setting Fabric color

Temperature (˚C)

White color fabric Dark shade fabric Grey mélange Turquoise Fleece Interlock fabric

100-130 160-165 170 120-130 200 150

Machine no: 06 Machine name Brand Origin Speed Temperature range No of chamber No of blower Production capacity applied for No of rotamatic burner

Dryer Ruckh Germany 4-30 m /min 100-180 C 3 6 Open and tube fabric 2

Machine no: 07 Machine name

Dryer

Brand Origin

Dilmenler Turkey

Speed range Temperature

4-30 m/min 110-220 C

Used utilities

Electricity, Gas ,Compressed air

No of motor Caapcity

8 8 ton per day

Chamber Applied for

3 Open and tube

No of rotamatic burner

3

Figure:Drye Compactor Function:  to control shrinkage  to control width  to control GSM  to smooth fabric Machine no :08(open Compactor) Brand name Model no.

Manufacturing country Speed range Temperature Used utilities Production capacity Maximum width Minimum width Applied for

Ferraro Comptex/Fv200 Italy 13-22 m/min 110-140C Electricity,Compress air,Steam 4 ton/day 86” 36” Open width

Machine no:09 (Tube Compactor) Brand name

Ferraro

Model no.

Manufacturing country Speed range

Comptex/Fv200 Italy 16-35 m/min

Temperature

110-145C

Used utilities

Electricity,Compress air,Steam

Production capacity

8 ton/day

Maximum width Minimum width

52” 16”

Applied for

Tube width

Figure: Compactor m/c Stenter Function of stenter: apply chemicals and softeners to dart set the T/C fabric  drying of fabric  to control width  curing of fabric  apply pigment dyeing  to control GSM  to control shrinkage  to decrease spirality  to decrease bowing effect  surface coating for Teflon finish  apply soil release chemical finish 

Brand Name Serial no Origin Year of manufacture Speed range Temperature range Used utilities Production capacities No. of chamber Maximum fabris width Minimum fabric witdth Steam pressure Air pressure Applied for No. of ratamatic burner Extra Attachment M/C parts

Bruckner 72276-0463 Germany 1995 15-30 m/min 50-250C Electricity, Gas, Compress air, Steam 8 ton /day 3 102” 30” 2 bar 10 bar Open tube fabric 6 Mahlo weft straightener Burner,Nozzle, Exhaust air fan, Over feed roller, Suction fan, Chain arrangement

Figure : Stenter Machine Raising MAchine Function:  Surface raising of tubular knitted fabrics and open width knitted fabrics  To provide greater warmth to the wearer  To make the cloth more compact  To make the fabric softer in hand or smoother in feel  To increase durability 

Brand name

Xetma

Origin

Germany

Speed range

20-30 m/min

Used utility

Electricity

no. of cylinder/drum

1

No. of pin roller

24(pile-18,Counter pile-6)

cylinder rpm

100

Tension

3 kg

Pin type

Both pile and counter pile

Figure:Raising MAchine FINISHED FABRIC INSPECTION 1. The following defects are found in the final inspection.

2. Uneven shade 3. Oil spot 4. Neps 5. Crease mark 6. Machine Stoppage mark 7. Listing 8. Line mark 9. Pick missing 10. Double yarn 11. Dead cotton 12. Bowing 13. Fly yarn contaminatio Printing section: MACHINERIES IN PRINTING SECTION:  Semi automatic flat bed printing machine : 03 pcs  Dryer: 02 pcs  No. of Flat bed Table:05 pcs

MACHINE DESCRIPTION OF PRINTING SECTION: Sl. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19

20

Name of M/C MHM Printing M/C MHM Flock Washing MHM Dryer(gas) Heat Press M/C Heat Press M/C Exposing become light Box Exposing wash for light Box Exposing film closet Cabinet Exposing Inspection Cabinet Label Printing M/C Label Washing M/C Label Dryer M/C Flock M/C Flock M/C Dryer M/C Color Mixing Dryer M/C Auto creage M&R Printing M/C (8 color) M&R Printing M/C (6 color)

Name Brand Tesoma

of Origin Australia

Capacity 600 pcs/hrs

Number of M/C 1 Set

Tesoma

Australia

1 Set

Tesoma

Australia

1 Set

Metalnox

4 Set

Wagen

Germany

1 Set

Acosgral

Portugal

1 Set

Acosgral

Portugal

1 Set

Acosgral

Portugal

1 Set

Acosgral

Portugal

1 Set

Shanghai

China

Shanghai

China

1 Set

Shanghai

China

1 Set

Thailand

2 Set 2 Set 1 Set 1 Set

Thailand

1 Set

Thailand

4 Set

Germany Local Local H.S.Z Kiddzigrino H.S.Z Kiddzigrino H.S.Z Kiddzigrino M&R

M&R

5000 pcs/hrs

1 Set

Poland

500 pcs/hrs

1 Set

Poland

500 pcs/hrs

1 Set

21 22 23

Spray Gun M/C Printing Table Printing Table

Germany H.S.Z Kiddzigrino Local

2 Set Thailand Bangladesh

1000 pcs/hrs 1600 pcs/hrs

2 Set 4 Set

CHEMICAL USED  Thickener(PG):It is a main compound for making a paste.  Binder: Hold color on to the fabric surface.  Fixar: Cross linking chemical (when drying at high temperature about 150 ºC)  Printing section  Pigment :It is a coloring substance.

DIFFERENT TYPE OF PRINTING: 1. Pigment printing 2. Rubber printing 3. Crack printing 4. Discharge printing 5. Plastic sol/ High-density printing 6. Flocking printing 7. Foil printing 8. Glitter printing 9. Emboss / Pub printing PRINTING PROCESS SEQUENCE:  Pigment printing Recipe: Thickener------2% Binder--------8% Fixer----------2% Water---------90% Sequence: Table preparation Fabric plaited on the table Pigment printing paste apply with the help of screen Curing at 160ºc(belt speed 6.50 m/min) Delivery  Rubber printing Recipe: Rubber----------------60% Clear------------------38% Fix---------------------2% Sequence: Table preparation Fabric plaited on the table Rubber printing paste apply with the help of screen Hanging the fabric for 30 min Curing at 150ºc (belt speed 5 m/min) Delivery

 Crack printing Recipe : Rubber-----------------98% Fixer-------------------2% And crack paste / clear Sequence: Table preparation Fabric plaited on the table Crack paste/clear apply with the help of screen Dry in air temp or hand dryer m/c (slight) Printing paste apply with the help of screen Curing at 190ºc (belt speed 2 m/min) Delivery  Flock printing recipe : Flock paste-----------------90% Fixer(Nylon)---------------10% And, Flock powder (Synthetic or cotton) Sequence: Table preparation Fabric plaited on the table Apply flock paste with the help of screen Flock powder apply with the help of flock gun Manually dry by hanging for 30min Curing at 180ºc (belt speed 3 m/min) Brushing Delivery

 Foil Printing Foil paper solid color which is made by buyer requirement.

Recipe : Foil paste----------------90% Fixer---------------------10% Sequence: Fabric preparation Fabric plaited on the table Foil gun /Foil paste apply by screen

Dry slightly in air temp / Hand dryer Apply foil paper on the fabric Heat apply by heat press m/c(150ºc for 5sec) Cooling for 4 sec Foil paper removed by hand Delivery Emboss / Pub Printing Recipe: Rubber paste------------49% Pub / Emboss-----------49% Fixer----------------------2% Sequence: Table preparation Fabric plaited on the table Apply printing paste by screen(3times) Hanging for 15min Curing at 170ºc (belt speed 3m/min) Delivery Discharge Printing Recipe: Discharge rubber paste------------90% Discharge/ RNS powder-----------49% Sequence: Table preparation Fabric plaited on the table Apply printing paste with the help of screen Curing at 190ºc (belt speed 3m/min) Delivery  Plastic sol/ high-density printing Recipe: High-density paste------------100% Sequence: Table preparation Fabric plaited on the table High-density paste apply by screen Curing at 160ºc (belt speed 3m/min) Delivery

Glitter printing Recipe: Rubber paste------------ 70% Fixer--------------------- 2% Glitter------------------- 28% Sequence: Table preparation Fabric plaited on the table Glitter paste apply by screen Hanging for 15min for dry Curing at 160º c (belt speed 3m/min) Delivery Faults in printing  Fatting: If the pigment printed fabric is fatted (on printed portion) after washing. Then this fabric is rejected. So it is major fault for printing.  Cracking: If the rubber printed fabric is braking (on printing portion) after elastration.

Figure:Printing section Embroidery section DESCRIPTION OF M/C IN EMBROIDERY SECTION: Sl. No. Description of M/C Origin 01 SWF 15 head,9 needle Korea with sequin device 02 SWF 20 head,9 needle Korea with sequin device 03 SWF 12 head with 9 Korea needle sequin device Process Sequence of Embroidery:  At first designed the buyer design by CAD software  The design software install into the machine  The fabric clamped by the clamp board  Then run the machine until finished the design  Then the fabric collect for delivery

Figure: Embroidery machine

No. of Machine 2 Set 3 Set 1 Set

Quality section QUALITY ASSURANCE SYSTEM: The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing.

Objects of quality Control: 1.

2.

3.

4.

5.

6.

Research.

Selection of raw materials.

Process control.

Process development.

Product testing.

Specification test.

QUALITY ASSURANCE AT DIFFERENT STAGE: Padma Polycotton knit Fabrics Ltd. assures the quality of the products of dyeing section in the following three steps: 1. In laboratory 2. In dyeing section & 3. In finishing section Procedures are described below: In laboratory: 1. Swatch card from buyer according to their requirement 2. recipe prediction for sample dyeing 3. sample dyeing until matching with swatch card 4. Fastness & other tests of the fabric or yarn are done here.

In dyeing section: 1. According to the buyer’s sample, sample dyeing is done in sample dyeing machine in dyeing shed & again matched with the approved sample.

2. If result is OK, then bulk production.

3. During dyeing, samples are taken until accurate shade matching. The interval may be 3040 minutes.

4. After dyeing sample is collected after softening matching is done.

5. Last of all, sample is collected after fixation & matched.

6. Then allowed the fabrics to be finished.

In finishing section: 1 By using a series of finishing machines correct width, softness & appearance are maintained according to requirements.

Then sampling is done for several times to test GSM, Shrinkage & fastness properties.

Finally fabric is inspected & prepared for delivery.

Quality Policy Padma polyCotton knit Fabrics Ltd. Follows the quality standard: ISO-9001:2000.

LIST OF EQUIPMENTS: In the quality assurance Department the followings equipments are used    

KERN Electronics Balance Iron Ahiba Nuance lab. Dip Dyeing Machine Rota Wash Crock Meter

 Spectro Photometer with software (Data Color)  PH meter DIFFERENT QUALITY TESTS METHOD: Different types of fastness tests of the dyed fabric are done in quality control department of the Padma Polycotton knit Fabrics Ltd. Different types of method (Standard or buyer’s recommended) are followed for different types of tests.

There are two types of tests are done in Quality Assurance department. They are1. physical Tests 2. Chemical Test.

Physical Tests:    

GSM Test Shrinkage test Spirality test Pilling resistance

Chemical Tests:  Fastness to washing.  Fastness to rubbing Fabric Inspection: The inspection of fabric is a procedure by which the defects of fabric are identified and fabric is classified according to degree or intensity of defects. The fabric inspection is done for both grey and finished fabric. The inspection and grading of fabric quality is one of the important functions of Quality Control in the grey or finished state, the grading of fabric is a difficult task, taking two primary considerations: as the frequency of effects and the seriousness of defects.The grading has two primary functions: First, to classify the fabrics according to standard qualities based on the end-use and costumer demands and second, to supply information as to the qualities actually being produced.

Grey Fabric Inspection: 1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from the cloth or batch roller and they are carried to inspection section by the helpers.

2) Almost four inspection workers are for every shift to check the fabric rolls. For any kind of fault they are checked thoroughly. Skilled inspectors find them and indicate them by the scissors in some cases.

3) Quality is specified on the basis of 4-points system. Here is the point distribution for different kinds fault in this system:Four (4) - Point system for knitting fault inspection: Knitting fault

Point

Slub

1

Any hole

4

Needle/Sinker line

4

Needle breakage(upto 10)

4

Press off

4

Thick, Thin, Dirt, Oil spot, Contamination up to 3" in length

1

Thick, Thin, Dirt, Oil spot, Contamination up to 6" in length

2

Thick, Thin, Dirt, Oil spot, Contamination up to 9" in length

3

Thick, Thin, Dirt, Oil spot, Contamination above 9" in length

4

Quality (points per 100 square meter) = (Total point X GSM)/(Roll weightX10) Quality Classification: 1

2

3

<20

20 â&#x20AC;&#x201C; 30

>30

OK

Ask

Reject

Finished Fabric Inspection: 4 point numbering system is followed for finished fabric inspection.

Grading procedure a) All open defects or major defects counted with 4 points per defect. b) Surface defects over 9 inch length counted with 4 points per defect. c) Surface defects 6 to 9 inches length counted with 3 points per defect. d) Surface defects 3 to 6 inches length counted with 2 points per defect. e) Surface defects up to 3 inches length counted with one point per defect. f) Running defects, such as tucks, needle lines, Barrie mark, crack marks, are judgment defects There is a formula to evaluate the defects of fabric at 4 points system; (Total pointx36x100)/(fabric length x fabric width) The finished Knitted fabric can be classified into three levels of quality, each one have a number of points for defects as follows.

The First quality level

The Second quality level

The Third quality level

40 points per 100 Linear Yards.

(40 â&#x20AC;&#x201C; 80) points per 100 Linear Yards.

80 points or more per 100 Linear Yards.

If the fabric falls into 1st quality level then it is almost ok. If the fabric falls into 2 nd quality level then it is sometimes acceptable. But in case of 3rd quality level fabric, the fabric is rejected.

Defects found in the final inspection.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Uneven shade Oil spot Neps Crease mark Machine Stoppage mark Listing Line mark Pick missing Double yarn Dead cotton Bowing Fly yarn contamination Running shade Color spot Tear Damage Softener spot Dirty spot Pressure mark

FIG: TEAR

FIG: DAMAGE

FIG: OIL SPOT

FIG:CREASE MARK

FIG: DIRTY SPOT

FIG : YARN CONTAMINATION

FIG: DEAD YARN

FIG: SOFTENER SOT

FIG: COLOR SPOT

FIG: COLOR SHADE

Rejection points for collar & cuff: No.

Faults

Response

1.

Wrong ply

Reject

2.

Hole

Reject

3.

Needle line

Reject

4.

Slubs

Reject

5.

Wrong design

Reject

6.

Fly & contamination

Acceptable for color but not for white

7.

First round problem

Reject

8.

Uneven tension

Discuss with manager

9.

Missing yarn

Reject

10.

Crease line

Reject

11.

Rust line

Reject

12.

Oil stripe

Reject

13.

Thick-thin

Reject

14.

Wrong tube

Reject

General Instructions for the final inspection: a. All pieces will be graded on the base of 40 points per 100 linear yards Mapping will be done on each piece to insure proper grading. Do not count more than 4 points per one yard. b. All defects must be recorded and marked in final inspection and an accurate account of points made to insure proper grading. c. All fabric must meet specifications. d. At the end of each piece of fabric, the inspector will add up total points and decide whether the piece can be shipped as first quality or not, reworked, placed in lower quality, or cut and upgraded for shipment. Fifteen yards or more can be shipped as first quality. e. The quality control supervisor must approve the grading of all quality levels and check the lower quality. f. Major or unsightly defects in the first and last yard of a roll or piece will be cut. All defects of one yard length or more will be cut out of the piece. Defects within the first 2 inches or the last 2 inches of a piece will not be cut out or counted in the grading. g. Open defects on the back of fabric such as drops, runs and hanging picks are to be included in the grading of fabric. h. Pieces can be connected together, once each piece must be the same shade. i. All defects such as runs that extend more than a yard in length will be cut out. j. Fabric up to 70 inches will be allowed a bow of not more than 1 inch and a Bias of not more than 2 inches. k. Defects within one inch of the fabric edge will not be counted except on tubular fabrics. All defects will be counted in tubular goods.

COLOR FASTNESS TO WASH TEST PROCEDURE: COLOR FASTNESS: The â&#x20AC;&#x153;color fastnessâ&#x20AC;? of a colored textile is defined as its resistance to these changes when subjected to particulars of conditions. It follows that color fastness must be specified in terms of these changes and expressed in terms to the magnitude.

Required materials : 1. Sample size 40 x 100 mm 2. multifiber at 40 x 100 mm 3. ECE detergent (WOB)-4g/L 4. Sodium Perborate (Na2BO3.H2O2-1g/L)-1g/L 5. Distilled water 6. Normal cold water 7. Steel balls Required instrument: 1. Rota wash 2. Scissor 3. Stitch machine Procedure: 1. Cut sample & multifiber at 40 x 100 mm 2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the sample. For marks & Spencer, the solution is taken by the following formula: (Sample fabric + Multifibre weight) x 50 ml 3. the sample is kept in 600C for 30 minutes in Rota Wash Machine 4. Rinse the sample twice with cold water.

5. Dry at 600C by hanging or by Flat iron pression but temperature should bot be more than 1500C. Report: Dry the specimen and the change of shade & degree of staining is measured by Grey Scale & Staining Scale.

COLOR FASTNESS TO RUBBING (DRY & WET) TEST: Sample:  Dyed fabric -15 cm x 5 cm  White Test Cloth -5 cm x 5 cm Procedure:  White test cloth is put on to the grating and stag by steel wire.  The sample is run twenty times manually for ten seconds. And the rubbing fastness of the sample cloth and degree of staining is accessed.  For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked and squeeze. The wet rubbing cloth is placed on to the grating and stag with stainless steel wire and run ten times manually then assesses the attaining on to the rubbing cloth and the rubbing fastness of the sample cloth is accessed.

Report:  Change of shade of the sample is measured with grey scale and degree of staining of the white test cloth is measured by Staining Scale.  There are also some tests are done in the lab. And the process is described belowMEASURING DIMENSIONAL STABILITY (SHRINKAGE & SPIRALITY): Sample:  Two piece of 50 cm x 50 cm fabric is taken for test.

Procedure :  Conditioning : Put the sample in the table for 4 hours for conditioning before starting test.  Cut the sample 50 x 50 cm & benchmark should be 35 x 35 cm. Stitch the sample (3 sides) by over lock sewing machine.  Put sample in washing machine and run according to buyer’s choice.  Drying: All Buyers’ requirement is tumble Dry except ECHO SCOURING is flat dr Shrinkage test calculation:

Before wash – After Wash

Shrinkage % =

Before wash Spirality test calculation: S= (S1+ S2)/2 Spirality = (S+S X L)/100.

Suppose, S1= The right side distance of the specimen from the stitch line wash.

S2= The left side distance of the specimen from the stitch line after wash.

L= length before wash.

Remarks:

Padma Poycotton knit Fabrics Ltd. Always about the quality of the product. The quality of the product is always approved by the buyer. They follow the quality standard: ISO â&#x20AC;&#x201C; 9001:2000.

Padma Polycotton knit Fabrics Ltd is well equipped for checking the quality of the product. They sent the quality report to batch. We think as Padma Polycotton knit Fabrics Lts strictly meet up the quality level thatâ&#x20AC;&#x2122;s why they are the only one direct manufacture of Marks & Spencer garments.

Picture-27: Specto photometer

Picture-28:Crock Meter

Picture-29:Washing machine

Garments Section MACHINE DESCRIPTION: Sl. No

Name of Machine

Brand

Quantity

01

Automatic Tubular M/C

Gerber

2 Sets

02

1 Needle Lock Stitch

Juki

122 Sets

03

1 Needle Lock Stitch

Typical

80 Sets

04

1 Needle Lock Stitch

Brother

33 Sets

05

Over Lock 6 Thread

Pegasus

20 Sets

06

Over Lock 4 Thread

Pegasus

130 Sets

07

Over Lock 3 Thread

Pegasus

1 Sets

08

Over Lock 5 Thread

Juki

7 Sets

09

Over Lock 4 Thread

Juki

12 Sets

10

Over Lock 4 Thread

Typical

30 Sets

11

Flat Lock

Pegasus

70 Sets

12

Flat Lock

Juki

6 Sets

13

Flat Lock

Typical

18 Sets

14

Zig Zag

Juki

2 Sets

15

Zig Zag

Yeamata

2 Sets

16

Back Top

Pegasus

6 Sets

17

Picoting

Kansai

2 Sets

18

Scabiling

“

1 Sets

19

Somking 33 N

“

2 Sets

20

Rib Cutting

Idea Ltd

3 Sets

21

Rib Cutting

Pegasus

3 Sets

22

4 Thread Over Lock

Kansai

12 Sets

23

Flat Lock

“

12 Sets

24

Thread Reconing M/C

Hashima

3 Sets

25

Snap Button

Ngishing

2 Sets

26

Button Holl

Juki

3 Sets

27

Button Stitch

Juki

2 Sets

28

Button Holl

Brother

1 Set

29

Button Stitch

“

1 Set

30

P.M.D Kansai

Kansai

2 Sets

31

Thread Cutter M/C

Grand

20 Sets

32

Thread Suction

1 Set

Remarks

33

4. Needle Feed of the ARM

34

4. Needle Feed of the Yeanato ARM

Sl. No

Name of Machine

Pegasus

2 Sets 3 Sets

Brand

Quantity

1

Rib Cutting

Hasima

1 Set

2

1 Needle Vertical

Juki

6 Sets

3

Back Top

Kansai

2 Sets

4

Cutting Machine 10”

K.M

4 Sets

5

Cutting Machine 8”

K.M

2 Sets

6

Cutting Machine 8”

Eastman

3 Sets

7

Bar Tack

Juki

3 Sets

8

Over lock

Pegasus

23 Sets

9

Button Stitch

Brother

1 Set

10

Feed of the arm

Brother

1 Set

11

Plain Machine

Brother

42 Sets

SEQUENCE OF GARMENT PRODUCTION: SEWING SEQUENCE OF JACKET: Contrast joint with the pocket by pressing.

Pocket rolling Number matching with body & Pocket Pocket joint Zig Zag top sin over Pocket Numbering & gathering back & front pants

Solder joint Top sin on the solder joint line Collar make Chain stitching on collar marking line Collar Joint Collar over locked in joining line Numbering sleeve and body part Sleeve joins with body Zigzag top sin on Arm hole Zipper piping Side sewing /body sewing by over lock Zig Zag topsin (side sewing line) Bottom hem tuck sewing Tuck bottom hem with body parts Arm hole tuck Botton hem top sin Zig zag Cuff making Cuff joint Cuff top sin Zig Zag

Zipper joint with body part Collar tape part joint with zipper side Collar taping part join with body part Zipper top sin Collar top sin Label joint with body part Quality Table (Arm hole point, sleeve hem, Bottom hem, Top sin, side seam, Thread cutting. Spot etc are inspected) SEWING SEQUENCE OF T-SHIRT: Number matching front 2 back pant (back on pant on upper side) Solder stitching (By over lock m/c) Neck rib truck (By plain m/c) Neck rib sewing by plain m/c Neck rib joins with body pant Neck top sin Solder to solder back tip Size label sewing Solder to solder back top sin Sleeve marking ad number matching with body parts.

Sleeve tuck with body part (Sleeve mark point & solder mark point) Sleeve joint with the body part Side sewing and care label joint Bottom hem tuck (at the end side) Bottom hem sewing Arm bottom hem joint Inspection TROUSER SEWING SEQUENCE: Number matching back & front pant Back rise & Front rise joint Pocket facing joint with pocket part by over lock m/c Pocket part sewing by over lock m/c Pocket tracing joint by plain m/c Top stitch pocket with pocket facing To sin Zigzag (pocket Rolling) Pocket marking by catalog & scissor Number matching pocket & body part Pocket tuck (2 end side of the pocket)

Pocket joint with the body part Pocket top sin (Zig Zag) Back & front matching (number) Side sewing of the trouser Side top sin (Zig Zag ) In side sewing by over lock Elastic tuck for waist belt Eye lot at middle point of the belt Rib tuck sewing for belt Elastic cutting at size wise Elastic + Rib (belt) tuck Belt surfacing Belt & body tuck Belt & body joint Label joint Top sin belt joining point Bottom hem sewing Dosting cutting & fildeng Dosting tuck

Supporting tuck on bottom hem & belt top sin Pocket Eye lot snap button M/C Inspection POLO- SHIRT SEWING SEQUENCE: Lining joint with collar part by heat pressing Collar marking for open stitch Collar inside open stitch Collar marking Collar Âź top sin Collar cutting Band Rolling Band joint with Collar Band top sin 1/6 Placket lining Placket marking Placket Rolling Placket joint Placket top sin 1/6 Placket Pattern top sin

Placket pattern top sin 1/6 Box Sewing Pocket Rolling Pocket iron Pocket marking Pocket joint with body Yoke joint with back part Yoke Âź top sin Back & front part matching number Solder joint Solder top sin Collar marking Collar & body number matching Collar joint with body part Collar top sin in jointing point Sleeve marking Sleeve over locked Sleeve Rolling

Sleeve pair matching Sleeve & body matching Sleeve body tuck Sleeve joint with body part Sleeve marking for batch Sleeve batch joint (left & right side) Body marking for batch Batch joint with body part Label make Label Iron Main label joint in back side Sleeve opening tuck Body hem sewing Care label sewing Side joint Band tuck Band tape joint Band top sin Sleeve chap tuck

Inspection

Fig:Garment line

Picture-21: Pattern making

Picture-23: Button stitching m/c

Picture-22: production line

Picture-24: Button hole m/c

Picture-26: CAD marker printer m/c

Utility section UTILITY SERVICES Here the following utility services are available Water  Electricity  Steam  Gas  Compress air Water Water PUMPS: Centrifugal Pump for water supply to Dyeing & Others Section 1 20 H. P Pedrollo Pump each pump, 1000L/min 4 Units 4,000.00L/min 2 10 H.P Pedrollo Pump flow rate, 600 L/Min 1 Unit 600.00L/min 3 5.5 H.P Pedrollo – Pump flow rate, 50 L/Min 1 Unit 350.00L/min 4 Spare Pump Motor Pedrollo 20 H.P1 Unit and 5.5 H.P 1 Unit 1, 00L/min 5 Jhonson Pump (30 H.P) 2 Unit 100 m3/hr 6 KSB Pump (30 H.P) 1 Unit 100 m3/hr 7 Submerssible Pump KSB 46 Kw 150 m3/hr Natural water quality: Water for a textile plant may come from various sources. These include surface water from rivers and lakes, and subterranean water from wells. In PPC they collect water from Under ground.

Natural and pretreated water may contain a variety of chemical species that can influence textile wet processing in general, and dyeing in particular.

The various salts present in water depend on the geological formations through which the water has flowed. These salts are mainly the carbonates (CO 32- ), hydrogen carbonates or bi-carbonates ( HCO3- ), Sulphates ( SO42- ) and chlorides ( Cl- ) of calcium ( Ca2+), magnesium (Mg2+) .

Although calcium and magnesium carbonates in limestone are relatively insoluble in water. So in this reasons, water hardness can be divided into two ways1) Temporary hardness : Ca(HCO3)2 , Mg(HCO3)2 , Fe(HCO3)2 .

2) Permanent hardness : CaCl2 , CaSO4 , Ca (NO3)2 , MgCl2 , MgSO4 , Mg(NO 3)2 .

This water hardness causes some serious consequences in a textile dyeing and finishing industries and these are  Precipitation of soaps.  Redeposit ion of dirt and insoluble soaps on the fabric being washed ,  this can cause yellowing and lead to uneven dyeing and poor handle.  Precipitation of some dyes as calcium and magnesium salts.  Scale formation on equipment and in boilers and pipelines.  Reduction of the activity of the enzymes used in washing.  Incompatibility with chemicals in finishing recipes and so on.

Hardness expressed by parts per million (ppm) of CaCO 3 which is standard hardness scale and it is also called American hardness. The hardness of raw water is 100 ppm or more. To use it in dyeing and in boiler this water must need to soft & foreign materials needs to remove.

STANDERD WATER QUALITY FOR DYE HOUSE: Parameter Permissible concentration Color Color less Smell No bad smell Water Hardness <5 ppm PH value 7-8 (Neutral) Dissolve solid < 1 ppm Inorganic salt < 500 ppm Iron(Fe) < 0.1 ppm

Manganese(Mn) < 0.01 ppm Copper (Cu) <0.005 ppm Nitrate(NO3) < 50 ppm Nitrate(NO2) < 5 ppm WATER SOFTENING: There is an ion exchange method by which hardness of water is removed.

The flow chart of water treatment plant is given below Carbon Stone Filter

Resin

Filter

Hard Hard Water Water Store Store Tank Tank

Filter

Delei Very Pump

Soft Water Store Tank

Fig: Water treatment plan ELECTRICITY: Sl. Machine description no

Origin

No. Machine

1 2 3 4

USA France Spain Bngladesh

1 No. 1 No. 1. No 1 No

Caterpillar Gas Generator Warsila gas Generator Prime Power Generation Sub â&#x20AC;&#x201C; Station, Power Board(PDB) PRIME POWER GENERATOR:

Origin Model Standby Voltage Prime Voltage Phase Weight

Development

: : : : : : :

GUASCOR Spain FGLD 480 380 V, 795 KvA 636 Kw, 1208 KvA 3 1845 kg

: : : : : :

Singapore KOMATSU EGS 630-3 30112 440 Kw, 550 KvA 440 Kw, 500 KvA

DISEL GENERATOR

Origin Brand Name Model SL No. Standby voltage Prime Voltage

Of Capacity 1145 KW 952 KW 636 KW 1000KVA

Frequency Phase Weight

: : :

50 Hz 3 3800 kg

Figure : Generator Steam Sl. No 1 2 3 4

Brand name of boiler

Origin

Standard Kessel Cleaver Brooks Cleaver Brooks Hurst

Germany USA USA USA

No. Machine 1 1 1 1

Of Capacity 12 Ton 3 Ton 10 ton/hr 470Kg/Hr

BOILER: Brand Name Origin Model SL No. Standby voltage Max. Pressure

: : : : : :

KOMATSU Singapore EGS 630-3 30112 440 Kw, 550 KvA 200 PSI

Figure : boiler AIR COMPRESSOR Description of Machine 1 Kaeser Screw compressor, Model AS44, 30 KW, 4 M3/Min each Origin â&#x20AC;&#x201C; Germany 2 AIR PLUS. Screw Compressor. (LG Com.) Gms-37-52, Made in Korea

No. Of Machine 2 Units

Capasity 8.00 M3/Min

1 Unit

50.10 M3/Min

3 4 5

Ingersoll-Rand, Air Discharge - 8 M 3/Min, 1 Unit Model No. 55R, ML-50, 57.5 KW Kaeser Screw Compressor, Origin – Germany 1 Unit Model – CSD 102 Sl no. 9_5700_06_E Atlas Copco ROTARY SCREW Compressor, 2 unit GA 37-10, 10 BAR, India

8.00 M3/Min 8.00 M3/Min 75 Hp/55 Kw

Air Dryer: 1

2 3 4 5

KAESER Air Dryer Machine, Model TE121, 5KW Years of Manufacture, 1998, Made in Germany JUCAI Air Dryer Machine, Model No. 100A Ingersoll-Rand Air Dryer, Model TMS 80.30 KW Ingersoll-Rand Air Dryer, Model TMS 30.20 KW Kaeser Air Dryer, Origin – Germany Mode TE – 141 Act 80 T, Italy

1 Unit

13.00M3/Min

1 Unit 1 Unit

13.00M3/Min 6.00 M3/Min

1 Unit

3.00 M3/Min

1 Unit

13.00M3/Min

2 unit

9000 L/min

Figure:Compressor GAS PPCes natural gas from Titas Gas Transmission Company. Gas is used as the fuel of Boiler, Generator and also used for heating dryer, Stenter and compactor m/cs etc.

Maintenence section: Defination: Machine, Buildings and other facilities are subjected to deterioration due to their use and exposure to environmental condition process of deterioration, if unchecked, culminates in rendering these service facilities unserviceable and brings them to a standstill. In Industry, therefore has no choice ut to attend them from time to time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so.

OBJECTIVES OF MAINTENANCE:  To keep the factory plants, equipments, machine tools in an optimum working condition.

Fig: Generator

 To ensure specified accuracy to product and time schedule of delivery to customer.  To keep me downtime of machines to me minimum must to have control over me production program.  To keep the production cycle within the stipulated range.  To modify the machine tools to meet the need for production.

Types of Maintenance Maintenance

Preventive Maintenance Break down maintenance

Electrical Maintenance

Electrical Maintenance

Mechanical Maintenance

Mechanical Maintenance

(Production)

e Preventive maintenance: Preventive maintenance is a predetermined routine actively to ensure on time inspection/ checking of facilities to uncover conditions that may lead to production break downs or harmful description.

Break down maintenance: In this case, repairs are made after the equipment is out of order and it cannot perform its normal functions.

Routine Maintenance: Maintenance of different machines is prepared by expert engineer of maintenance department.

Normally in case of dyeing machine maintenance after 30 days complete checking of different important parts are done.

MANPOWER SET-UP FOR MAINTENANCE:

A Shift

8 AM

8 PM

B Shift

8 PM

8 AM

General Shift

9 AM

6 PM

Maintenance Manager-01

Mechanical

Electrical

Mechanical In charge- 02

Electrical foreman-04

Diploma (Mechanical)- 02

Diploma (Electrical) â&#x20AC;&#x201C; 02

Welder and fitter â&#x20AC;&#x201C; 01

Electrician -02

Fitter - 01

MAINTENANCE PRODCEDUCRE: Normally preventive maintenance should be done. During maintenance procedure following points should be checked.

Check List of Different Parts: Maintenance: Mechanical Machine: Dyeing machine Sl No Items need to be checked & Serviced 01

Crease the M/C bearing.

02

Complete cleaning of machine.

03

Cleaning of drain valves, replace seals if required.

04

Check air supply filters, regulators auto drain seals

05

Clean filters element and blow out.

06

Greasing of unloading roller bearing.

07

Checking of oil level and bolts of unloading roller gearbox.

08

Checking of unloading roller coupling and packing.

09

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

10

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

11

Check the function of heat and cool modulation valves

12

Check all door seals

Maintenance: Electrical Machine: Dyeing machine Sl No Items need to be checked & Serviced 01 Check & clean fluff and dirt at dirt at all motor fan covers.

02 03

Check all motorâ&#x20AC;&#x2122;s terminals Check main panels (by using compressed air)

04 05

Check panel cooling fan & clean its filter Clean main pump inverter and its cooling fan.

06 07 08

Check all circuit breaker, magnetic conductors and relays.

Check current setting of all circuit breaker & motor over load.

Visual checking of all power & control cables.

09 10

Check all pressure switches.

Check calibration of main vessel & all addition tank.

11 12

Check all pneumatic solenoids Check calibration of heating / cooling modulation value

13 14

Check setting of tangle sensor.

Check setting & operation of lid safely switches

15 16

Check all emergency switches Check all indication lamps

17

Check all on/off switches

18

Check all signal isolators

MAINTENANCE TOOLS & EQUIPMENTS: 1. Combination tools / spanner Function : Tightening & looseng of nuts & bolts.

2. Socket ratchet set Function : Tightening of nuts & bolts 3. Slide Range Function : Tightening & loosening of nuts & bolts 4. Monkey pliers Function : Tightening & loosening of nuts & bolts 5. Pipe threat cutting tools Function : To cut the threat in pipe.

6. Bearing puller Function : To assist the opening of bearing from shaft.

7. Pipe range Function : Tightening & loosening of pipe joint 8. Pipe cutting tools Function : for pipe cutting.

9. Hole punch Function : Punching the hole.

10. Divider

Function : For circle making on metal & wood.

11. Easy opener Function : To open the broken head bolt.

12. External threat die Function : For external threat cutting.

3. Heavy scissor Function : Cutting of gasket & steel sheet 14. Pipe threat cutting tools Function: To cut the threat in pipe.

15. Drill machine and drill bit.

Function : for drilling.

16. Grease gun Function : For greasing of moving parts of M/C. 17. Grinding M/C Function : For grinding & cutting of mild steel.

18. Welding M/C Function : For welding & cutting.

19. Spirit leveler Function : For perfect leveling.

20. File Function : For smoothing the surface.

21. Harmmer Function : For scaling & Right angling.

22. Circlip tools Function : Circlip opening & closing.

23. Hacksaw blade Function: For metal cutting.

24. Handsaw (wood) Function: For wood cutting.

25. Grinding stone Function: For smooth finishing.

26. Grinding paste Function: For easy cutting of metal.

REMARKS: Maintenance of M/C’s are very essential to prolong the M/C life and good maintenance is important consideration. It is necessary to check that all routine maintenance is being done regularly and properly otherwise efficiency of each department will be reduced.

Effluent Treatment plant Major sources of liquid discharge are:  Scouring chemical.  Bleaching chemical .

 Washing chemical  Dyeing chemical

Characteristics of waste water of PPC assumed as follows:  pH = 9-11.5  BOD = 300 mg/L  COD=200 mg/L Process sequence: Process: Biological.

Capacity: 1500 m3 / day.

Final treated Quality of PPC discharge is:  PH = 7-8

 Suspended solid (SS) = 200 mg/L  Color = dark

   

BOD = 30 mg/ L COD = 160 mg / L Suspended solid = 30 mg/L Color = color less.

Department of Environment, Government of Bangladesh required:  PH = 6-9  BOD = 50 mg/L  COD= 200 mg/L  Suspended solid = 150 mg/L SCREENING  Color = Light brownish.

(Removal of suspended solid)

HOMOGINIOUS TANK (Uniform mixing of solids by air).

neutralization PH drop to 7-8 by H2SO4

DISTRIBUTION TANK

(Anti foamer NaOCl

is used )

OXIDATION TANK

(Air is pushed for oxidation)

CLARIFIRE TANK

(Here removed suspended solution and correction the water color)

SLUDGE RETURN TANK

THICKENER TANK (Polyelectrolyte is used)

FILTER PRESS

Inventory INVENTORY CONTROL: Store is the place where every type of raw materials, spares finished goods are kept in proper system. Inventory control means the accurate calculation and data of every type of raw materials spares and finished goods in time to time. store inventory control are necessary, because –

Ferrous

    

sulphate

To know about the required amount of raw material.

To know about the job no – which would be processed?

To be continued the production process.

To fine out the profit or loss of a company.

Stock and stock value for consumption measuring.

FREQUENCY OF INVENTORY UPDATE:  Daily  Monthly  Annual SCOPE OF INVENTORY CONTROL          

Dyes store.

Raw material.

Other chemicals.

Grey fabrics.

Spare parts.

General store.

Capital equipments.

Accessories.

Stationary.

Maintenance parts.

INVENTORY SYSTEM FOR RAW MATERIAL: In Padma Poly Cotton knit Fabrics Ltd. There are different inventory systems for different raw materials.

GREY FABRIC STORE: All the grey fabrics are stored in the fabric store near the batch section. Different types of fabric are listed in the sheet according to fabric types, quantity and consumer’s requirement.

DYES AND CHEMICALS: There is different store for dyes and chemicals. Varies types of dyes and chemicals are stored here according to dyes and chemicals companies. Different types of dyes and chemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are also included. Every day the sheet is updated and a copy of this sheet is supplied to the dyeing manager, dye house and lab section.

SPARES:

In Padma poly cotton knit Fabrics Ltd. required amount of spears of different machines are stored in the mechanical store room. All the spears are listed in a sheet which is controlled by the mechanical & maintenance personnel. Spares are arranged in the store room according to there size, quantity & requirements. There are shelfâ&#x20AC;&#x2122;s in the store room to keep the small spare parts.

FINISHED GOODS: Padma poly cotton knit Fabrics Ltd. Supplies its finished dyed fabrics to its garments section.

So, dyed finished fabrics are stored for short time in the finishing section. All the delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter, buyerâ&#x20AC;&#x2122;s name, color & considering other technical parameters.

REMARKS: Padma poly cotton knit Fabrics Ltd. has individual stores for raw materials, finished goods etc.

There is not enough space to store the finished goods. It requires increasing the store area. In Padma poly cotton knit Fabrics Ltd. the store for inventory control is satisfactory. Sometime, they fluctuate form ideal process otherwise they are ok.

Cost Analysis FACTORS OF COSTING OF A PRODUCT: 1. Entertainment 2. Printing & stationary 3. Miscellaneous expenses 4. Night allowance 5. Mobile bill 6. Conveyance allowance 7. Medical expenses 8. Electric expenses 9. Paper & periodicals 10. Repair & maintenance 11. Mesh fabrics 12. Thread purchase 13. Testing materials 14. Car repair 15. Bonus 16. Salary allowance & wages 17. O.T. & food allowance 18. Telephone bill

19. Gas gen. expenses 20. Factory rent 21. Depreciation 22. Gas bill 23. Poly 24. Water treatment plant.

Price of the product: Generally price of the product is determined by the required profit adding to the total expense. So, Price of products = (Direct expense + Indirect expenses + Factory overhead) + Required profit.

Price range of different products: T-shirt= $1.25-$4.5 /Pcs Polo shirt= $2.50-$6.50 /pcs Kids wear= $1.25-$2.15 /pcs

Price list of different types of yarn: Cotton: Yarn Count

Combed Yarn

Carded Yarn

Yarn Count

Rotor Yarn(O/E)

40/1

5.00 $/Kg

3.75 $/Kg

20/1

2.45$/Kg

36/1

5.00 $/Kg

3.7 $/Kg

16/1

2.50$/Kg

34/1

4.10 $/Kg

3.65 $/Kg

14/1

2.55$/Kg

32/1

4.00 $/Kg

3.55 $/Kg

12/1

2.70$/Kg

30/1

3.80 $/Kg

3.40 $/Kg

10/1

2.75$/Kg

28/1

3.80 $/kg

3.40 $/Kg

26/1

3.75 $/Kg

3.35 $/Kg

24/1

3.75 $/Kg

3.35 $/Kg

22/1

3.70 $/Kg

3.30 $/Kg

20/1

3.70$/Kg

3.30$/Kg

07/1

3.00$/Kg

Knitting charge of different knit items: Fabric name

Charge per kg (tk)

Single jersey

8-9

Single jersey with lycra

30-35

Single lacoste PK

16

Double lacoste PK

16

Single PK

16

Double PK

16

Rib

12-17

Rib with lycra

30

Interlock

18-22

Fleece

22-25

Dyeing charge of different fabrics: Name of fabric process

Charge per kg (Tk)

White with enzyme

45

White without enzyme

35

Avg. color with enzyme

85

Avg. color without enzyme (Light & Medium)

75

Deep shed with enzyme (Black)

120

Deep shed without enzyme (Black)

95

Only wash (tubular)

25

Only wash (open)

45

Double dyeing (Face & Back)

115

Finishing charge of different fabrics: Name of fabric process

Charge per kg (Tk)

Slitting only

5

Stenter only

25

Compacting only

15

Stenter + Compacting

35

Stenter + Compacting + wash

50

Tube compacting

10

Costing of the product: Let, price of yarn is $ 3.00/kg Process loss of yarn for knitting (10%) = $0.30 Knitting fabric cost= $3.30 Cost of dyes & chemicals= $2.50 Process loss for dyeing (12%) = $0.30 Dyed fabric cost= $6.10 Packing cost= $0.05 Production cost of fabric= $6.15 Fabric price (with 25% margin) = $7.79 Fabric consumption/doz. =

Garment specification: Body length= 78 cm Sleeve length= 33 cm Chest length= 62 cm GSM= 210 Fabric consumption/doz. =

= 3.469 kg

Fabric consumption/doz (with 10% wastage) = 3.816 kg Body fabric cost/doz = $(7.79 × 3.816) = $29.73 Cost of collar & cuff/doz= $4.00 Cost of trims= $2.25 Cost of trims (with 5% process loss) = $2.36 Production cost of garment/doz= $36.09 Garment price/doz (with 25% profit) = $45.12 Remarks: Costing is very important for a productive factory. Without proper costing all production curriculums will go vain. Because a factory cannot reach to its goal without achieving good profit and good profit is not possible without skillful costing. In Padna Poly Cotton Knit Fabrics Ltd. there are some skillful personnel to do this job.

Marketing Activities CONSUMER OF PRODUCTS: PPC is a 100% export oriented industry. All the goods produced in this industry are exported into various foreign countries. Name f the main buyers are given below: Name of the buyer 1. S. Oliver 17. Sprider 32. Triglobe 2. Tom tailor 18. Esprit 33. Brice 3. IC Company 19. P.P. Tex 34. Shobi Fashion 4. Ed Ward Wang 20. Gastrock 35. Max. 5. Umbro 21. Texco 36. Etam 6. New Look 22. Maxim 37. Zagora 7. TMS 23. OBS 38. Air Sohution 8. Algodon 24. Multiline 39. Vood Bridge.

9. Q. Solution 25. MB Fashion 40. Lion Star 11. Maskos 26. DR & S 41. Evrozon 12. Walmant 27. Katag 42. Sumi Tomo 13. Up-2-Date 28. Collince 43. Ginkana 14. Grenvilly.

29. Cream Soda.

44.Target 15. Asmara 30. Octagon 16. Erima 31. Kiabi Importing countries: There are some countries which are importing gods from The PPC. The name of the countries are given below –  Spain  Denmark  Germany  Europe Union  Denmark  United State of America  Europe Marketing Strategy: Marketing strategy is a very important factors to sale the products to the buyer. If the marketing strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing the dealings with the buyer is a very important factor.

Padma Poly Cotton knit Fabrics Ltd. mainly senior marketing officers, merchandiser & higher officials deal with the buyer. There are some fixed buyers of the industry. The buyers give their

orders continuously all over the year. The marketing officers & the merchandisers communicate with the buying houses to collect the orders.

By both side understanding the rate & the order quantity are fixed.

DUTIES & RESPONSIBILITIES OF MARKETING OFFICER: Dealing with the buyer & convince the buyer is the main duty of marketing officer. A marketing officer also has some other duties. The main duties & responsibilities of a marketing office are given bellow – To prepare cost sheet by dealing with the buyer.

To take different steps by discussing with the high officials & merchandisers.

To maintain a regular & good relationship between commercial officer & merchandisers.

To maintain a communication with the buyers and buying houses.

Communicate with better criteria of the products.

REMARKS: Padma Poly Cotton knit Fabrics Ltd. has marketing & merchandising team. They always communicate with the buyers Padma Poly Cotton knit Fabrics Ltd. has some fixed buyers. The marketing section also looks the quality & quantity buyers.

Compliance Definition: Compliance means conformity of certain standard. PPC maintain a moderate working condition for their employees. Though it is well established project, there is some lacking of proper compliance issues.

List of compliance issues: Here is the list of compliance in which some points are maintained fully and some are partially.

• Compensation for holiday • Sexual harassment policy • Leave with wages • Child labor abolition policy • Health register • Anti-discrimination policy • Time care • Zero abusement policy • Accident register • Working hour policy • Workman register • Hiring /recruitment policy • Equal remuneration • Environment policy • National festival holiday • Security policy • Overtime register • Buyers code of conduct • Labor welfare • Health and safety committee • Weekly holiday fund • Canteen Health: • Drinking water at least 4.5 L/day/employee • Cup availability • Drinking water supply • Water cooler ,heater available in canteen • Drinking water signs in Bangla and English locate min. 20 feet away from work place • Drinking water vassal clean at once in a week • Water reserve at least once a week • Water center in charge person with cleanliness • Suggestion box register Toilet: • Separate toilet for women and men • A seat with proper privacy and lock facility • Urinal accommodation • Effective water sewage system • Soap toilet • Water tap • Dust bins • Toilet white washed one in every four month

• Daily cleaning log sheet • No-smoking signs • Ladies /gents toilet signs both in bangle and English • Deposal of wastes and effluent FIRE: • Sufficient fire extinguisher and active • Access area without hindrance • Fire signs in both languages • Fire certified personal photo • Emergency exit SAFETY GUARD: • Rubber mats & ironers • First aid box one • Ironers wearing sleepers • First trained employees • Motor/needle guard • Eye guard • Nurse • Doctor • Medicine • Medicine issuing register • Welfare office Conclusion Padma Poly cotton knit Fabrics Ltd. is a well-planned versatile project. The administrations, management, chain of command – all are well organized. They are devoted to satisfy the customer by their activities. However, some of the point we want to mention for the good of Padma Poly cotton knit Fabrics Ltd. LASTLY: What special in this report is that the information, data & description very much subjective & practical. So, one can easily have an idea about the whole dyeing unit of Padma Poly Cotton knit Fabrics Ltd. at a single look on it.The newcomer can use this report for further detailed study or can know Padma Poly Cotton knit Fabrics Ltd. without much work. But what should be remembered the chemical, some process steps may be modified within the pined this papers goes the reader.