UNIVERSITY OF

DHAKA
COLLEGE OF TEXTILE TECHNOLOGY
REPORT ON
INDUSTRIAL ATTACHMENT
From 1st October to 30thNovember
BEXIMCO KNITING LIMITED
SARABO, KASHIMPUR, GAZIPUR.
SUPERVISING TEACHER
MD. MONIRUL ISLAM
WET PROCESSING TECHNOLOGY
COLLEGE OF TEXTILE TECHNOLOGY
TEJGAON, DHAKA.
PREPARED BY
Md.Masudur Rahman
Md.Abdullah-Al-Masum
Md. Shahidul Islam
Anup Kumar Dey

ROLL NO.
01
04
06
22

SESSION
2003-2004
2003-2004
2003-2004
2003-2004

ACKNOWLEDGEMENT
Industrial Attachment Course is an academic function of the College of Textile
Technology. Like all other years our teacher Md Monirul Islam, Head of the
Department of Wet Processing Technology Department, gave us an opportunity
to choose preferable mills for Industrial Attachment Course. We, the four
students of 27th batch chose BEXIMCO Knitting Ltd. Joyfully with the
supervision of our teacher Md. Monirul Islam.
During the attachment with BEXIMCO Knitting Limited we worked in all the
departments related with the Wet Processing Section. We not only gave priority
to the Wet Processing but also worked sincerely in theKnitting Section,Utilities,
Maintenance and Effluent Treatment Plant. Beside these, we learned about
Quality Control Section and Finished Fabric Inspection Section, warehouse &
Store & Inventory ,finishing&specially dyeing.
We owe a particular debt of gratitude to Md.MonowarulIslam
Liton,Manager,Dyehouse,BKL.He gave away some of his valuable time
regularly in helping us to achieve our intended goal.We also express our
gratitude to all the executives of BKL knitting, batching,store&inventory
control.
Of course, we wish to pay our special thanks to the persons guided us,inspired
us&cared us during these days-Mr. Mir Azharul Islam,Senior G.M.& Head of
Manufacture,Jameer Qureshi,DGM,BKL.
Lastly we express our gratitude to our supervising teacher,the name that should
be mentioned first, Md.Monirul Islam,Head of the Dept.Wet Processing
Technology,College of Textile Technology for his valuable direction &
supervision.
However, we have prepared our Industrial Attachment report overcoming all the
difficulties & also the shortage of time. Here we would like to present the
report.
Date:08-12-2005
Dhaka

Md.Masudur Rahman
Md.Abdullah Al Masum
Md. Shahidul Islam
Anup Kumar Dey.

CHAPTER - 01
PROJECT DESCRIPTION

Name

: BEXIMCO KNITTING LIMITED (dyeing section)

 Type
: KNIT DYEING.
Year of estab. :1996
Location
: Beximco industrial park,
Chokroborty,
(5 km north from DEPZ).

DEPZ
From Savar
Bypile mourh

Chokroborty
DEPZ

Ashulia

Beximco
Industrial
Park

BKL

West
North

Location of BKL
(not to scale)

Address
:
Corporate Headquarter:
17, Dhanmondi,R/A,
Road no. 2,Dhaka-1205

Operational Headquarter& Factory

Beximco Knitting Limited,
Beximco industrial park,
Sarabo, Kashimpur, Gazipur.

Sponsors

: World Bank, Marubeni.

HISTORY OF BEXIMCO GROUP:

1965.1975 Beximco is born.
1965 New Dacca Industries Ltd

1973 Beximco UK branch.

1976-1989: Beximco diversifies
1978 Beximco foods Ltd.
1979 Beximco pharmaceuticals ltd.
1982 Shinepukur Jute Spinners Ltd.
1985 Beximco apparels Ltd.
1987 Recognised as export house for contribution to countrys export.
1990-1995: Beximco expands
1990 Padma Textile Mills Ltd.(plant -1)
1992 Beximco Synthetics Ltd.
1996-1999: Beximco preparing for the new millennium.
1996 Beximco Textiles Ltd (Phase 1).
Beximco Knitting Ltd.
Beximco Denims Ltd .
1997 Padma Textiles Mills Ltd (Plant -2).
1998 Beximco Textiles Mills Ltd (Phase 2).
Beximco Fashions Ltd .

 Physical
Infrastructure
storied )

: - Single storied building (only dye warehouse is double

- Concrete structure (about 30 ft high)

Different dept

: A) Production oriented department

- Production Planning and control
-Knitting
- Batch preparation
-Dyeing
-Finishing
- Lab& Quality assurance
- Dye warehouse
- Maintenance
- Utilty
- Finished warehouse
B) Supporting department
- personnel administration
- procurement
- marketing
- IT
- HRD
- finance & accounting.

Remark:
-

Available data on physical infrastructure was not available.

Production per day ranges from 8-12 tons.

CHAPTER - 02

MANPOWER MANAGEMENT

Organogram of manpower:

Chief executive officer(CEO)

Head of manufacturing

Chief operating officer

DGM

Maintenance Manager

(Production)

Knitting Manager

Dyeing Manager

Finishing Manager

Q.C Manager

Asst. Manager

Deputy Manager

Shift officer

Shift officer

Shift officer

Shift officer

Electrical incharge

Mechanical Incharge

Shift change :
Per shift is 8hrs
1st shift

: 6:00 A.M. 2:00 P.M.

2nd shift
3rd shift
General shift

: 2:00 P.M. 10:00 P.M.

: 10:00 P.M. 6:00 A.M.
: 8:00 AM - 4:00 PM

Responsibility of a production officer:

Overall supervision of dyeing, finishing production .

Batch preparation & pH check .
Dyes & chemical requisition issue & check .
Write Fabrics loading &loading time from m/c .
Program
making , sample checking ,colour
measurement.
Control the supervisior , operator ,asst. operator and
helper of dyeing m/c.
And also any other work as & when required by the
management.

Job description:
Title :
Production Officer
Dept/Section : Dyeing
Report to
: Sr .Production Officer
Job summary : To plan ,execute & follows up the
production activities & control
the quality production with related
activities .
Title :
Sr. Production Officer
Dept/Section : Dyeing
Report to
: Asst manager (production )
Job summary : To plan ,execute & follow up the
production activities & control
the quality production with related
activities .

CHAPTER- 03

MACHINE DESCRIPTION

Introduction:
BKL is an integrated computerized company. It has total 18 dyeing machines among of
them 10 machines are fully computerized. The machines are centrally controlled by
Beacon Controller.

Specification :
Dyeing machineries:
Machine No.

1, 2, 3, 7, 8

Machine Name

Eco-soft

Company Name :

Thies, Germany

No. of Nozzle

Capacity

500-600 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

Machine Name

Mini-soft

Company Name :

Thies, Germany

No. of Nozzle

Capacity

75 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

Machine Name

Eco-soft

Company Name :

Thies, Germany

No. of Nozzle

Capacity

350 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

Machine Name

Luft-roto

Company Name :

Thies, Germany

No. of Nozzle

Capacity

200-350 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

10

Machine Name

Luft-roto

Company Name :

Thies, Germany

No. of Nozzle

Capacity

500-550 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

11

Machine Name

Local

Company Name :

Beximco, Bangladesh

Capacity

70 kg.

Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

12

Machine Name

Local

Company Name :

Beximco, Bangladesh

Capacity

10-20 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

200-250 m/min.

Machine No.

13

Machine Name

Local

Company Name :

Beximco, Bangladesh

Capacity

5-10 kg.

Diff. Pressure

500-600 m.bar.

Rope speed

100-150m/min.

Machine No.

14

Machine Name

Local

Company Name :

Beximco, Bangladesh

Capacity

120-150 kg.

No. of Nozzle

Diff. Pressure

500-600 m.bar.

Rope speed

150-280 m/min.

Machine No.

15

Company Name :

Thies, Germany

Capacity

150-200 kg.

No. of Nozzle

Diff. Pressure

500-600 m.bar.

Rope speed

150-280 m/min.

Machine No.

16, 17

Company Name :

Thies, Germany

Capacity

350-450 kg.

No. of Nozzle

Machine No.

18

Machine Name

Local

Company Name :

Beximco, Bangladesh

Capacity

8-15 kg.

Diff. Pressure

500-600 m.bar.

DESCRIPTION OF FINISHING M/C :

HYDRO EXTRACTOR M/C:
Manufacturer :

Nazar corporation (Pakistan)

Extraction % :
65% Maximum.
Speed
:
1400 rpm.
Extraction Time : 5-7 min.
Function :
To remove water from fabric by centrifugal extraction.
.

DEWATERING M/C :
Manufacturer : CALATOR BORAS (SWEDEN)

Function :
1.
2.
3.

Reduce water content.

Apply chemicals.
Open the fabric from the rope form.

Controlling Parameters :
Padder pressure
Pick up %
GSM
Speed at m/c
Stretch

:
:
:
:
:

4-7 bar
85%
20-35%
8.5 m/min-60 m/min
8 to 12% minimum than the
requirement of customers.

.Chemical application :
Softener :
To soften the fabric.
Recipe :
Baso soft (Fatty acid condensation)
Acetice acid
PH

DRYER :
Drying :

:
:
:

4 g/L
0.25 g/L
7.5

Drying is defined as a process where the liquid portion of the solution is

evaporated from the fabric.

Curing :
Curing can be defined as a process following addition of a finish to
textile fabrics in which materials are heated for a short time in elevated
temperature to effect a chemical reaction.

Controlling parameters :
GSM
: 15-35%
Shrinkage : 12-15%

EQUIPMENT USED :
Following equipment are used for relax drying process :

a)

Ruckh relax dryer (Germany) :

*
*

b)

Gas burner heated.

4 chamber, 1 burner/ 2 chamber.

Santex Relax Dryer (USA) :

*
*

Steam heated.
2 Chamber.

MACHINE SETUP :
a)

M/C set up for Ruckh relax dryer :

M/C parameter

Set-up value

Temperature setting

1000c- 1200c for white shade

1200c-1300c for light shade
1300c-1400c for Dark shade
1500c-1700c for curing
Auto
Auto
3-35 m/min. Depends on quality of fabric.
0-40% depends on fabric construction.
45-114 cm : Depends on the required width

Blower fan setting

Exhaust fan setting
M/C Speed
Over feed
Width of expreader setting

Burner Gas pressure

b)

of fabric.
10-15 m bar.

M/C set up for Santex Relax Dryer :

M/C parameter

Set-up value

Temperature

1000c- 1100c for white shade

1100c-1200c for light shade
1200c-1300c for Dark shade

Blower fan setting

Exhaust fan setting
M/C Speed
Over feed

Push button switch on

Push button switch on
1-12 m/min. Depends on quality of fabric.
0-45% depends on fabric construction.

Checking parameters :
1. Shade Check
2. Width check
3. Weight check
4. Compaction check
5. Fault check :

Operator checks a)
Knitting faults
b)

Spinning faults

c)
Dyeing faults
d)
Other faults
6. Bow and Slant check for Ruckh Relax Dryer only.

SLITTER M/C :
Slitting :

Slitting is a process that is applied for cutting the tubular fabric through
the intended break wales line on lengthwise direction prior to stenter
processing.

Equipment used :
Airtex Slitter Machine (Sweden)
Speed : 20-25 m/min.

M/C parts :
a)
c)
e)

Rotary blade
Guide Roller
Sensor

b)
d)

Ring
Plaiting

Checking parameters :
1)
2)

Cutting line check

Bow & slant check
3) Fault check :
Operator checks a)
Knitting faults
b)

Spinning faults

c)
d)

Dyeing faults
Other faults

STENTER M/C :
Equipment used:
Krantz Stenter Machine (Germany)
No of chamber
:
7
No of Burner
:
14
No of Padding through :
2
No of exhaust fan
:
7
Type
:
Pin stenter.

Function :
1.
2.

Apply chemicals.
To dart set the T/C fabric.

3.
4.
5.
6.
7.
8.

Drying of fabric.
To control width.
Curing of fabric.
Apply pigment dyeing.
To control GSM.
To control shrinkage.

Machine Setup :
M/C parameters
Padder pressure
Temperature setting
Blower fan setting
Exhaust fan setting
Width of m/c chain setting
Over feed
Burner gas pressure
Machine speed
Light wt (100-140 GSM)
Medium wt (150-180 GSM)
Heavy wt (190-250)
Checking parameters :

Set up value
2 to 8 bar
90- 1800 c
lower to high
Manual
110 cm up to 260 cm
0-60%
30-50 m/ bar
6 to 60 m/ min
20-30 m/min
14-18 m/min
10-15 m/min

1. Shade Check
2. Width check
3. Weight check
4. Compaction check
5. Fault check :Operator checks -

a)

Knitting faults

b)

Spinning faults

c)
d)

Dyeing faults
Other faults

TUBULAR COMPACTOR :
Equipment used :

Ruckh Tubular Compactor m/c.

Function :
1.
2.
3.
4.

To control shrinkage.
To control width.
To control GSM.
To smooth fabric.

M/C set up :
M/C parameters
Steam pressure
Air pressure
Temperature
Cooling fan
Motor
Width control
Speed setting

Set up value
4-6 bars
5 bar
90-1000c
Auto

Checking parameters :
1. Shade Check
2. Width check
3. Weight check
4. Compaction check
5. Fault check :Operator checks -

6)

a)

Knitting faults

b)

Spinning faults

c)
d)

Dyeing faults
Other faults

Edge line checking

Open compactor:
Manufacturer : Feraro (Italy)

Function :

48 to 114 cm
5- 35 m/min

1.
2.
3.
4.

To control shrinkage.
To control width.
To control GSM.
To smooth the fabric.

M/C set up :
M/C parameters

Set up value

Stema pressure

4-6 bars

Air pressure

5 bar

Temperature

700-1000c

Width

36-100

Speed

5-25 m/min.

Checking parameters :
1. Shade Check
2. Width check
3. Weight check
4. Compaction check
5. Fault check :Operator checks -

a)

Knitting faults

b)

Spinning faults

c)
d)

Dyeing faults
Other faults

SOFTENING M/C :
Softening m/c is used as a part of finishing process to soften only the
collar & cuffs to get required hand fell based on the requirements.

Equipment used :
Softening Machine (locally made).

Beacon Controlling System:

In BKL Beacon Controller 2800 is used. It contains programs of pretreatment, washing,
rinsing, unloading, dyeing. It shows graphs for every program.

Where,

Yellow line = Indicates theoritical required temperature.

Red line = Indicates practical temperature.
Blue line = Indicates theoritical chemical dosing to vessel from tank.
Pink line = Indicates practical chemical dosing to vessel from tank.
Green line = Liquor level in vessel.
In BKL from m/c no. 1-10 is controlled by this Beacon Controller.
Advantages :
1. One officer can control 10 m/cs at a time.
2. Production is high.
3. Show programs with graphs.

Dye Kitchen:
Dyeing m/c no. 1-10 require 4 tanks. Tanks no. 1, 2, 3 are present
in dye kitchen and tank no. 4 is present with dye vessel. In dye kitchen operator
measures dye & soda according to requirement. Then operator dissolves dye
with water in tank no. 1. According to program dye passes to tank no. 4 and
then to dye vessel. After required time operator dissolves soda with water in
tank no.1 which pass to tank no. 4 and to dye vessel.

CHAPTER - 04
RAW MATERIALS

INTRODUCTION:
Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in case of continuous production & for high quality fabric.

Types of raw material

The basic raw materials used are:
fabric
dyestuffs

chemicals & auxiliaries.

Names & source

Fabric:
Different types of fabric treated in BKL dyeing section are namely
- Single Jersey
- Single jersey with lycra attachment
- Polo pique
- Back pique
- Rib Fabric
- Lycra fleece
- Jacquard
- Cross -rib
Dyestuffs:
Dye

Brand name

Bezactive
Ciba
Dychufix
Kemafix
Levafix
Procion
Jackazol
Kemazol
Remazol
Solazol
Solacion
Terasil
Disperse dye Dianix
Dispersol
Boron
Chemicals:
Brand name
Novolube Jet
Bluton BVB1
Cibacel DBC
Cibafix ECO
Cibafluid C
SandocleanPCLF
Permacol FA
Novostone CR
Cotton white T

Type
Anti creasing agent
Violet tone brightener
Sequestering agent
Fixing agent
Anticreasing agent
Detergent
Stabilizer
Enzyme
Redder tone brightener

Origin/source
Bezema , Switzerland
Ciba , Switzerland
Hubei Hwalle dyestuff Ind.co.
Jaychem,India
Dystar , Germany
Dystar, germany
India
Jaychem,India
Dyestar , Germany
Solarfine , Taiwan
Solarfine , Taiwan
Ciba , Switzerland
Dystar, germany
Dystar, germany
Zenith chemicals,Taiwan

Source
Techna,Italy
CHT,Germany
Ciba,India.
Ciba ,Switz.
Ciba ,Switz.
Clarient,Germany
Techna,Italy
Techna,Italy
CHT,Germany

Cyclanon E
Cyclanon ECO
Jinlev RLF349
Eulysin S
Felosan NOF
Uvitex EBF
Jinlev CL-225
Oxalic caid
Palegal FA-8
Respumit BU
Permacol SQ
Na thiosulphate
Uniperol O
Uvitex EVF
Uvitex 2B
Mollan129
Acetic acid
Reduction HCS
Mollan130
Bluton 2B

Fixing agent
Reduction cleaning agent
Dispersing agent
pH buffer in PET dyeing
Detergent
Whitening agent
Levelling agent for reactive dye
Iron remover
Levelling agent for disperse dye
Antifoaming agent
Sequestering agent
Peroxide killer
Washing agent for PET dyeing
PET brightener
Yellow tone brightener
Soapinging agent
pH controller
Reduction cleaning agent
Sequestering agent
Whitening agent

BASF,Germany
BASF,Germany
Geigy,Taiwan
BASF,Germany
CHT,Germany
Ciba ,Switz.
Geigy,Taiwan
BASF,Germany
BASF,Germany
Techna,Italy
BASF,Germany
Ciba, Switz.
Ciba ,Switz.
Rota,dystar
Geigy,Taiwan
Rota,dystar
Ciba,India

Remark
-

The list is for the time of our industrial attachment. It varies according
to the availability of the material & their price.
The price has not been supplied to us due to their secrecy act.
The annual requirement was not available & is a record of the
procurement department.

CHAPTER -05

PRODUCTION PLANNING &

SEQUENCE OF OPERATION

SEQUENCE OF OPERATION :
Kniting
Grey inspection
Batch preparation

Pretreatment

White Processing

Polyester dyeing

Cotton dyeing

Hydroextracting
Dewatering
Drying

compacting
Final Inspection

Finished Store

Delivery to Garment industry

Introduction and Basic Procedure of Planning and Control :

A planned work brings success. Without planning nothing is completed
within the required time. So planning has its own importance which is
intolerable. "Planing" gives a scheduled task and 'control' completes it
successfully. But production planning and control is not an easy task. So
BEXIMCO has a self-sufficient and high-performance department called
"Production Planning & Control". Its Basic working procedure is as follows
1.
2.

Taking orders from marketing division.

Analyzing the orders.

3.
4.
5.

Planning for knitting the fabric.

Planning for dyeing the fabric.
Planning for finishing the fabric.

It is only a basic procedure. It may change according to the type of order.

Sometimes, order is places only for finishing the material or only for dyeing the
white goods. Then some steps are omitted for planning procedure.

1.

Taking orders from marketing division:

BEXIMCO marking division supplies Fabric Orders to the BKL Planning

and control division by a special format.

2.

Analyzing the orders :

This section analyze the orders according to buyers, Order Quantity, type
of orders (i.e. type of fabric, color to be dyed etc.), delivery date etc. Then it
selects which M/C. to use, no of M/C. to use, time required for production etc.
This section plans for required quantity of fabric to be knitted (Order quantity +
6% of Order Quantity), knitting balance, fabric need to be dyed. Dyeing
balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery
balance.

3.

Planning for knitting :

This section plans for knitting production. It selects machine for knit the
fabric for specific type of fabric, type of yarn used, required GSM, width etc. It
also gives delivery data for knitted fabric. It also places orders for buying of
yarn from spinning mills by a specific schedule.
4.

Planning for dyeing the fabric:

Production planning for dyeing is called 'Batch Plan'. According to the

batch no. And color, width, style and construction the batch plan is made. For
easy understand this section gives some 'T.' cards. 'T' cards are serialized
according to the priority of delivery. The batches and 'T' cards also serialized as

to dye light shade at first and lastly the dark shades, since faulty shades can be
converted to dark color later.
5.

Planning for finishing the fabric:

Finishing schedule is same us the dyeing. After dyeing the material goes
to the finishing section with the batch plan. Finished data is written to the batch
card and is informed to the planning section.
However, this section always enforces to all the departments to finish all
the works within the delivery time given by the buyers. This section delivers
materials by truck, micro, air etc to the customer within the meantime. Thus it
plays a very important role in the success of the company.

Knitting Process
The BEXIMCO Knitting Limited is a self-sufficient modern company. Its
knitting section is divided into two sections
1. Flat knitting section &
2. Circular knitting section.

1.Flat Knitting Section:

Flat Knitting section consists of Flat Knitting Machines. Its main
production is Collar and Cuff. Different types of designed collar & cuff is
produced here with relation to the body of the garments.

Equipment used:
1.1

Production Equipment
The following equipment are used for production:

Name

Fabric
type

Manu.

Model Gauge

Length

No. of
m/c.

STOLL

semi-

Germany

--------

14

84 inch

jacquard
MATSUYA

Plain

Japan

M-100

14

100 cm

26

MATSUYA

Plain

Japan

M-70

14

70 cm

22

KAUO

Semi-

Taiwan

KH-

14

54 inch

17

HENG

jacquard

MATSUYA

Semi-

14

64 inch

313
Japan

jacquard
Total machines = 69

Note:

Collar & cuff prepared is mainly rib fabric.

Note:

Tipping is also used in the collar & cuff. Tipping is stripe design
mainly knitted by Polyester yarn.

2. Circular Knitting Section:

Circular Knitting section consists of Circular Knitting Machines. Different
types of body fabric are produced in this section.

Equipment used:
2.1

Production Equipment

BEXIMCO Knitting Limited (BKL) is capable to knit Weft Knitted

fabrics only. Following types of machines are available with BEXIMCO
Knitting Ltd. for Circular Knitting.
Gauge
18

Model
No.
1995

20

1995

24

1995

28

1995

Origin
CAMBER,
UK
CAMBER,
UK
CAMBER,
UK
CAMBER,

No. of
Cylinder
05

Existing Setup
0

10

08

14

14

26

06

16 (RIB)

1995

18 (RIB)

1995

20 (RIB)

1995

UK
CAMBER,
UK
CAMBER,
UK
CAMBER,
UK

Total

01

01

01

01

01

58

Note : There are 7 (Seven) machines with lycra facilities.

Knitting Faults:

Barre or stripe

Miss stitch/ drop stitch

Press off
Needle mark

Sinker mark
Crease mark/Edge mark

Excessive slubs
Broken needle

Spirility
Pin hole

Tight course

Missing Yarn,etc.

Oil stain
Holes

Greige Body & Rib inspection

To detect and identify the knitting fault in fabric by visual assessment on
Inspection m/c.
Collar & cuff inspection:
Collar & cuff inspection is a process of identifying quality fault in knitted
collar & cuff from flat knit m/c.
Equipment used :
a)

Inspection m/c (Calator Sweden)

b)

Inspection Table.

M/C Set up (Inspection m/c):

M/C set up

Parameter range

Set value

Roller speed

0-40 m/min

25-30 m/min

light

Not applicable

Artificial day light

Length measuring Not applicable

unit

Attached
m/c.

Following faults are detected :

Faults:
H= Hole

OS= Oil stain

DS= Drop stitch.

WD=Wrong Design

NL = Needle line.

S = Stripe

TT = Thick & Thin yarn.

S = Slubs

SM = Sinker Mark.

WP=Wrong Ply,etc.

FOUR POINT SYSTEM :

Size of defect

Penalty

3 inches or less

1 points

over 3 but not over 6

2 points

Over 6 but nor over 9

3 points

Over 9 inches

4 points

Acceptance calculation :
Total point per 100 square yards
=

Actual points counted

Actual Roll length

36
Actual width

100

with

= Points/100 square yards.

Classification of Inspection Fabric :

< 40 points

=A

41-60 points

=B

61-80 points

=C

80 above

= Reject.

Acceptance:
Generally any piece of fabric with 40 points or less faults per
100sq. yard is allowed to pass however for a roll, the average value should
not exceed 18point per 100sq.yard.More than 40points faults per 100sq yard
is recorded as REJECT.

Batch Preparation
Process sequence of Batch preparation receive batch card from Grey In-charge

Make the priority as per dyeing plan

Take one specific Batch card.

Read the Batch Card for own understanding

Check the availability of fabric

Take required quantity of body fabric from ware-house.

Make required no. of Rope maintaining equal length.

Take collar/cuff as per size, keep the total weight.

Distribute the collar /cuff or Rib in each rope equally unsure equal length

Stitch the fabric

Write down the weight against roll no. in the back side of the Batch Card.

Write the total weight in Batch Card.

Put signature & date.

Fill up the production report form.

M/c for Batch preparation :
Two types of m/c.s
a)Turning m/c

b)Plaiting m/c.

SINGEING :
Singeing is the process of burning of the fibre hairs projecting through the fabric
surface. In a gas-singeing machine this burning is carried out by passing fabric against
hot flames under specified conditions.
Objects :

To obtain a uniform & smooth fabric surface by removing hairiness.

To ensure uniform optical reflectance throughout the fabric surface in

subsequent fabric wet process.

Equipment-used :

Machine : Sando Gas Singing m/c.

Manufactures : Sando Iron Works, Japan.
Required Parameters :
a)

Steam :Steam is supplied to the steam box of the machine.

b)

Compressed air :The standard air supply pressure requirement is 4 kg/cm2.

c)

Water : The standard water supply pressure requirement is 1-1.2 kg/cm 2.

d)

Natural gas :The standard gas supply pressure requirement is 3 kg/cm2.

M/C Setup :
Setup parameters

Range

Set value

Speed(m/min)

0-120

55-60 for cotton.

70 for PC/CVC.

Potentiometer Setting
(rpm)

0-150

80-90 for cotton fabric

60-70 for CVC/PC.

Burner in use

1 or 2

Burner operation mode.

Auto/Manual

Auto

Flame height (cm)

1-8

6 for white & light shade

fabric.
6.5 for medium & dark
shade fabric

Flame angle with the

direction of fabric.

450 to 900

450 for blends

900 for cotton

Flame intensity

Low/normal/
high

Low not used

Medium for white &
light shade
High for medium &
dark shade fabric

Singeing Fault :
a)Singeing line :

Due to ununiform joint of bricks by cement, there become gaps

between flame and thus singeing line is formed.
b)Uneven singeing :

One to uneven flame height uneven singeing is occurred.

MERCERIZING PROCESS :
Mercerizing:

Mercerizing is a physio-chemical process in which cotton fabric is

treated with concentrated solution of caustic alkali & subsequently stretched
& washed under specified conditions.
Objects :

To increase lusture of fabric.

To increase the strength of fabric.

To improve dimensional stability.

To increase dye absorbency.

Equipment used :Dornier Mercerizing m/c (Germany).

Required parameters :

Parameters

Value

Squeeze pressure

1.5-2 bar (by compressed air)

Temperature of washing

800-900c

PH after mercerizing

7-7.5

Caustic solution temperature

In mixing tank : 80-900c

In caustic stroage tank : 70-800c

In chiller : 140c
In Mercerizing bath : 160-200c
1st sigar diameter

Set with fabric dia +3

2nd sigar diameter

Set with fabric dia +5

Caustic strength

280 Be

Function of m/c parts :

Sigar :

1.

To stretch the tubular knit fabric.

2.

To prevent shrinkage.

3.

To retain dimensional stability of fabric.

4. To wash off mercerizing chemicals from the fabric by spraying

water on it.

Padder Pressure :

To squeeze and drive the fabric to a little extent otherwise there is a

risk of forming edge line at two sides of fabric.

Water valves :

Supply water to washing tank.

Steam values :

Steam value supply steam to washing chamber.

Mercerizing process faults :

PH variation
Crease
Water drop mark
Spot
Problem from sigar
Holes
Distortion of dimensional stability

PRE-TREATMENT
SCOURING :
Objects:

To remove fats, wax, impurities from fabric.

To increase absorbency of fabric.

To remove natural nitrogenous coloring materials, dirt, dust, husk, broken

seed, protein, leaf etc. by oxidizing on chemical treatment.

To obtain pure & permanent white color.

:

Single Stage Scouring-Bleaching:

Process steps :

Take water in bath at required level.

Load fabric.

Circulate fabric & raise temp. at 60oc

Add Anti-creasing agent, Detergent, sequestering agent, stabilizer.

Add Caustic soda

Circulate fabric.

Add H2O2.

Continue circulation fabric 25 min. at 100oc

Decrease temp. at 800c

Rinse & Drain.

Add Detergent & H2O2 killer and raise temp 80oc

Continue circulation for 10 at 60oc

Rinse & Drain.

Hot wash for T/C TTC :

To remove waxes, fats.

Increase absorbency for T/C & TTC for dark shades.

Curve:
900c

15

60 c
1

Recipe :
1.
2.

Anti-creasing Agent
Detergent

: 1 g/L
: 1.5 g/L

Steps :

Take water in bath at required level.

Load fabric.

Circulate fabric & raise temp. at 60oc

Add Anti-creasing agent, Detergent.

Circulate fabric and raise temp.

Enzyme Treatment :
If dead fibre or hairiness present in fabric then enzyme treatment is done.
Function :
It attacks surface cellulose fibre and removes it from surface.

Precaution :
Excess enzyme is harmful for cellulose fabric.
Application of enzyme is done by two ways :
a)
Pretreatment Enzyme treatment Dyeing
b)
Pretreatment Dyeing Enzyme treatment
Enzyme treatment carve :
750c
2+3
0

55 c

10

30
1
Drain 3

Recipe :
1.
2.
3.

Acetic Acid
Novostone CR
Novolube JET

:
:
:

0.1g/L (pH 4.5-5)

0.5~1 %
0.3~0.5 g/L

Steps :

Take water bath at required level.

Load fabric.

Circulate fabric and raise temp. at 55oc

Add acetic acid , Novostone CR& Novolube JET

Drain.
Hot fill for 10 min. at 75oc Novolube JET.

Rinse & Drain.

Drain

REACTIVE DYEING :
Properties :
1.
2.
3.
4.
5.
6.

Anionic in nature.
Soluble in water.
Form strong covalent bond
Better wet & light fastness.
Have better substantivity.
Dyeing is carried out at alkaline condition.

Influencing factors :
1.
2.
3.
4.
5.

PH
Temperature.
Conc. of electrolyte.
Time.
Liquor ratio.

Amount of salt, soda, caustic for Cibacron dye at 60oC:

Shade %
<0.25
026-0.5
0.51-1
1.01-2
2.01-3
Above 3

G. salt g/L
10
20
30
40
50
60

Soda g/L
5
5
7.5
10
5
5

Caustic Soda g/L

0.3
0.7

1.REACTIVE DYEING FOR SENSITIVESHADE AT 60oC

Dyeing steps :

Take water required level.

Load fabric
Raise temp. at 60oc

Add anti-creasing agent, sequestering agent.

Add color by injecting for 30 min & circulate fabric

Injection of G. salt & circulate fabric.

Add soda ash by injecting 40 min.

Rinse & Drain

Wash at 60oc by circulating fabric for 10 min.

Hot fill & circulate fabric for 10 at 90oc with soap.

Wash at 50c by circulating fabric for 7 min.

Rinse & Drain

Unload fabric.

Dyeing curve:

REACTIVE DYEING FOR DARK SHADE AT 60oC:

Process steps :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Take water required level.

Load fabric.
Raise temp. at 60oc & circulate fabric
Add anti-creasing agent, sequestering agent.
Add G. salt.
Circulate fabric for 5 min.
Continue circulate color inject for 30 min.
Circulate fabric & Add soda ash & caustic soda for 60 min.
Rinse & Drain.
Hot fill & circulate fabric for 10 min & Drain.
Add acetic acid & raise temp 600c for 10 min.
Hot fill & circulate fabric for 15 with soap.
Rinse & Drain.
Hot fill & circulate fabric for 10 min & Drain.
Hot fill & circulate fabric for 10 min.
Rinse & Drain.
Unload fabric.

Dyeing curve:

HOT BRAND REACTIVE DYEING :

DYEING AT 92oC :
Required Salt, Soda ash :
Shade %

70

10

0.51-1.2%

80

15

1.21-2%

90

15

above 2%

90

20

5 10

60 c

Soda ash g/L

up to 0.5%

Dyeing curve :

Glauber salt
g/L

920c 60
20
5

Shade
check
Rinse
0

80 c

600c
10

Recipe :
1.
2.
3.
4.

5.
6.
7.

600c

Rinse

Anti-creasing agent (Ciba fluid C) : 0.5 g/L

Sequestering agent (Ciba cel DBC ) : 1.5 g/L
Glauber salt : 90 g/L
Procion Flavine HEXL : 0.0942 %
Procion Yellow HEXL : 1.633 %
Procion Sapphire HEXL : 2.061 %
Soda ash
: 20 g/L
Acetic acid : 0.75 g/L
Soap (Albatex S ) : 1 g/L

Rin
se

10

Process steps :

Take water at required level.

Load fabric.
Raise temp at 60oc & circulate fabric

Add anti-creasing , sequest agent & Glauber salt.&check ph.

Circulation fabric for 5 at 60oc.

Color inject for 25 min.

Continue fabric and raise temp. at 92oc and continue 20 min.

Continue circulation & add soda ash for 60 min.

Decrease temp at 80oc.

Check shade.
Rinse & Drain.

Hot fill & raise temp at 80oc & continue circulation for 10 min. &
Drain.
Cold fill & raise temp at 60oc add acetic acid and continue 10 min.

Raise & Drain.

Hot fill & raise temp at 90oc Add soda & continue for 10 min.

Rinse & Drain.

Cold fill & raise temp at 60oc for continue circulation for 10 min.

Rinse & Drain.

Unload fabric.

POLYESTER DYEING :
Disperse dye :
Disperse dye is one kind of organic colouring substances which is free of
ionizing group, less soluble in water & used on hydrophobic Textile material .

Properties of Disperse dye :

1.
2.
3.
4.

Non ionic in nature.

Insoluble in water.
Wet & light fastness are good.
They are used in acidic condition.

Influencing factors for dyeing :

a)

PH of bath (4.5~5.5)

b)
c)
d)

Temp. of bath.
Concentration of dispersing agent.
Time of dyeing cycle.

Dyeing curve :
1300c
30
Rinse
4 600c
1 2
600c

Recipe :
1.
2.
3.
4.

5.
6.
6.

500
c

Rinse
600c
Rinse
600c

Shade check

780c

800c
10

Rinse

5+6

800c Rinse
7

400c

400c

Acid Buffer (Eulusin FAS) : 1.8 g/L

Rinse
Dispersing agent
(Jinlev RLF349) : 1.8 g/L
600c
Antcreasing agent (Ciba fluid C) : 0.5 g/L
Dianix Red
: 0.106 %
Rinse
600c : 0.07%
Dianix Yellow
Dianix Black : 0.78 %
ReductionRinse
clearing (Reduction HCS) : 1-3 g/L
600c
Acetic Acid:1g/l.
DetergentRinse
(Albatex S) : 0.5 g/L
600c
Rinse
600c
Rinse
0

Rinse

Rinse
600c
Rinse
600c
Rinse
600c
Process steps for Polyester
part :

Take water
at required level.
Rinse
Load fabric.
600c
Raise temp. at 40oc & circulate fabric
Add AcidRinse
Buffer, Dispersing agent, Anticreasing agent
Raise temp60at0c50oc
Continue circulation of fabric & inject color.
Rinse
Raise temp.
to
90oc by 1.5oc/ min. Then raise temp at 130oc, 1oc/
0
60 c
min. and continue
30 min.
Decrease temp. at 90oc,, 0.750c/min. Thus decrease temp. at 78oc,
Rinse
1oc/min.
600c
Rinse & Drain.
Mixed fill,Rinse
add reduction clearing agent.
0 80oc and continue 15 min. & Drain
Rinse temp.
60at
c
Cold fill & raise temp at 80oc & rinse & Drain.
Cold fill, Rinse
add detergent & raise temp. at 80oc & continue 10 min.
600c
Rinse & Drain.

Rinse
600c
Stripping is carried out to remove uneven of shade or to reduce dark
Rinse
shade. In BKL Stripping
is done for 100% cotton, T/C, CVC & TTC.
600c

STRIPPING :

I.

FULL STRIPPING
RinseFOR 100% COTTON:
600c

.
Curve:

Rinse
600c
80C

50C

3
1

Rinse
600c
Rinse
600c
Rinse
600c

100Cx60min
CR
80C

60CX15
80CX10

600c
Rinse
600c
Rinse
600c
Recipe :
1.
2.
3.
4.
5.
6.
7.

Rinse
Anticreasing
600cagent : 1 g/L
sequestering agent-1g/l
Caustic soda
: 5 g/L
Rinse
Hydrose : 60
5 g/L
0
c
Stabilizer : 0.5 g/L
Caustic :Rinse
2 g/L
H2O2 : 2 g/L
600c
Acetic acid : 0.5 g/L

Process steps :

Take water at required level.

Load fabric.
Raise temp. at 50oc & circulate fabric.
Add Anti-creasing agent, caustic & Hydrose.
Circulate fabric & raise temp at 1000c & continue 60min.
Decrease temp at 800c & rinse for 10 min. & Drain
Hot fill & raise temp at 600c, & continue for 15 min. & Drain
Polyester striping

Process curve :

500c

Rinse

1
Recipe :
1.
2.
3.

1350c
30
Rinse
3c/min 600c
5

Cold rinse
Check shade

900c

10

30

70 c
Rinse

Rinse
600c

600c
10

Rinse
600c

Rinse
600c

600c
6

5
Rinse
Anti-creasing agent
600c
sequestering agent:
Caustic soda
:
Rinse
Hydrose
:
600c

:1 g/L
1g/l
5 g/L
5 g/L

600c
Rinse
600c
4.
5.
6.

Carrier DTE
:
Rinse
Acetic Acid
:0
60
Bleaching agent : c

3g/L
1 g/l
2 g/L

Rinse
Process steps :
600c

Take water in bath.

Raise temp. at 40oRinse

c & circulate fabric.
0

Add Anti-creasing60
agent,seq
agent, caustic soda, Hydrose, Carrier.
c

Continue 5 min.
0

Raise temp. at 135Rinse

c & continue 30 min.
0
c

Cool rinse & check60shade.

Drain.
Rinse

Hot fill & raise temp

at 700c
0
60 c

Drain

Cold fill & add Bleaching

agent.
Rinse

Raise temp. at 900c.

600c

Rinse & Drain.

Rinse
600c
Rinse
600c

Whitening :

Rinse
Whitening Is A Chemical
treatment, fabric white at a desried level by
0
bleaching & OBA treatment. 60 c
Factors Influencing Whitening:Rinse
600c
H
1.
P
2.
Temp.
Rinse
3.
Time
600c
0

100
c
Whitening Process for 100%
cotton
:
Rinse
30
600c
Rinse
Process curve :
0
60
c
Rinse
600c 800c
Rinse
0
6
4
5
60
c
Rinse
600c
1

600c
Rinse
0
60
c
Rinse
0

10

800c

Rinse

10
600c
8

10

0
60
c
Rinse
600c
Rinse
0
60
c
Rinse

600c
Rinse
0
60
c
Rinse
600c
Rinse
0
60
c
Rinse
Recipe :
1.
2.
3.
4.
5.
6.
7.
8.

600c
Rinse
0
60
c
Rinse
Detergent (Sando clean
600c PCLF) : 0.7 g/L
Rinse
Anticreasing agent
(Novolube JET) : 0.4 g/L
0
60
cFA) : 0.7 g/L
Rinse
Stabilizer (Permacol
0
60g/L
c
Caustic soda : 2.25
Rinse
050% :6.5 g/L
Hydrogenperoxide
60
c
Rinse
Bluton 2B : 0.8% 0
60 c
Rinse
Bluton BVB1:.06%
0
60
c
Glauber salt : 5 g/L
Rinse
0
Acetic acid : 0.860
g/L
c
Rinse
0
60
c
Rinse

Process steps :

Rinse
600c

Rinse level.
Take water at required
600c
Load fabric.
Raise temp. at 600c & circulate fabric.
Rinse
Add Detergent, Anti-creasing
agent stabilizer.
600c
Add caustic & circulate fabric.
Continue circulation
Rinse& add Hydrogenperoxide
0
Add Uvitex 2b &60circulate
fabric.
c
Add Glauber salt & continue 5 min.
0
Rinse
Raise temp. at 100
c & continue 60 min.
0 0
Decrease temp. at6080c c.
Rinse for 10 min. & Drain.
Rinseat 800c and continue 10 min. & Drain.
Hot fill & raise temp
600c
Drain.
Rinse
600c
Rinse
0

Rinse
600c
Rinse
0
c acetic acid & raise temp at 600c & continue
Mixed water fill,60
add
10 min.
Rinse & Drain. Rinse
600c

T/C whitening process :

Rinse
6000c
110 c
30
Rinse
Rinse
6000c
60 c

Process curve :

60 c
1

3 6

Rinse
600c

900c

Rinse
Rinse
6000c
60 c

Rinse
Rinse
700c 0
60 c

Rinse
Rinse
6000c
60 c

Rinse
Rinse
600c 0
60 c

Recipe :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

800c
10
10

600c
10

Rinse
Rinse
Rinse
6000c
Detergent
: Rinse
5 g/L
600c 0
60 c
60
c g/L
Anti-creasing agent
:
0.1
Rinse
Stabilizer
:
0.5 g/L
Rinse
Rinse
6000c
0 Rinse
Sequestering agents
: c 01 g/L
60
60 c
60 c
Caustic soda Rinse
:
1.5 g/L
Rinse
Rinse
Hydrogenperoxide
: Rinse
1.5 g/L
600050%
c
600c 0
60
c
Blankophor ER-T330% : 60 0.066
c
%
Rinse
Uvitex 2B
:
0.363 %
Rinse Rinse
Glauber salt
: 0cRinse
5 g/L
60
600c
600c
Acetic acid
:
0.5 g/L
Rinse Rinse
Process steps :
Rinse
600c 0
600c
60 c

Take water at required level.

Rinse Rinse

Load fabric.
Rinse
0
600c 0
60
0 c
60fabric
c

Raise temp. at 60 c & circulate

Add detergent, anti-creasing

agent, stabilizer, sequestering agent.
Rinse Rinse
0 Rinse
0
60 c 0
60 c
60 c
Rinse
600c

Rinse
Rinse
600c 0
60 c

Rinse
600c

Rinse
Rinse
600c 0
60 c

Rinse Rinse
Rinse
600c 0
600c
60 c
Continue circulation of fabric & add caustic soda.
Rinse& add Hydrogen peroxide.
Rinseof fabric
Continue circulation
Rinse
0
600c 0
60 c
c
Add PES brightener & cotton60
brightener.
Continue circulation
Rinse& add Glauber salt.
Rinseof fabric
Rinse
0
600c 0 30 min.
600cc& continue
Raise temp. at 110
60 c
0
Decrease temp. slow at 90
c.
Rinse Rinse
0
0 Rinse
Decrease temp. quickly
c. 0
600c at6080c60
c
Rinse for 10 min. & Drain.
Rinse at Rinse
Hot fill & raise temp.
8000cRinse
& continue.
0
60 c 0
60 c
60 c
Drain.
Mixed fill & addRinse
Acetic Rinse
acidRinse
and raise temp. at 600c & continue 10
600c 0
600c
min.
60 c
Rinse & Drain.
Rinse Rinse
Rinse
600c 0
600c
60 c

Dyeing faults:

Rinse
600c

Rinse
Rinse
600c 0
60 c

Dyeing faults are given

Rinse :
Rinseas below
Rinse
600c 0
1.Patchy effect :
600c
60 c
Reasons :

Rinse Rinse
Rinse
0
1.
Entanglement of 60
fabric.
600c 0
c
60 c
2.
Faulty injection of alkali.
3.
Faulty color addition.
Rinse Rinse
Rinse
4.
Due to hardness 60
of 0water.
600c 0
c
60 c
5.
Due to impure salt addition.
Rinse Rinse
Rinse
Remedies :
600c 0
600c
60 c
By partial or full stripping of dyed fabric.
Rinse Rinse
Rinse
0
2.Roll to Roll variation / 60
Meter
to0cMeter
variation :
60
c
600c

Reasons :
1.

Yarn lot mix

Rinse
600c

Rinse
Rinse
600c 0
60 c

Rinse
600c

Rinse
Rinse
600c 0
60 c

Rinse

Rinse
Rinse

60 c
Rinse
600c

Rinse
Rinse
600c 0
60 c

Rinse
faulty heat setting 0
60 c
Hardness of water.
Faulty m/c speed.
Rinse
600c
3.Dye-stain :

Rinse
Rinse
600c 0
60 c

2.
3.
4.

Rinse
Rinse
600c 0
60 c

Reasons :

Rinse Rinse
0 Rinse
c 0
1.
Undissolved dye particle 60
in bath.
60 c
2.
Undissolved caustic particle in bath.
Rinse
Rinse
Remedies :
600c
By patrial or full sripping
Rinse
4.Crease mark :

Reasons :
1.
2.

If pump pressure & reel speed is not equal.

Due to high speed m/c running .

4.Rub mark:
Reason :
1.
2.
3.

Due to reel cranking .

Due to sharp point of nozzle.
Due to sharp delivery roller.

5.Nozzle to Nozzle variation :

Reason :
Pump pressure & reel speed is not equal.

FINISHING
INTRODUCTION

After dyeing, knit fabric is required to finish. During dyeing all knit
fabric are dyed in tubular form. According to buyers requirement knit fabric
are finished in Open form or tubular form.

For Tubular form following m/c are required :

Hydro-extractor

De-watering

Dryer

Tubular
Compactor

For open form following m/c are required :

Hydro-extractor

De-watering

Dryer

Slitter

Stenter

Open compactor
For collar & cuff finishing following m/c are required :
Hydro-extractor

Softening Machine

Dryer

Chemicals used :
TC collars & cuffs:
1.
Softener (cationic & nonionic)
2.
Additive
3.
Stiffener
4.
Acetic Acid to adjust pH
100% cotton fabric (soft):
1. Softener
2. Additive
3. Acetic acid to adjust PH
100% cotton collar & cuffs (cross-linking):
1. Softener (cationic /nonionic)
2. Additive
3. Resin
4. Catalyst.
5. Acetic acid to maintain PH

CVC collar & cuffs:

1.
Softener (cationic & nonionic)
2.
Additive
3.
Stiffener
4.
Acetice acid to maintain PH
CVC collar cuffs (soft) :

1.
2.
3.

Softener
Additive
Acetic acid to maintain PH

Water Repellent collar & cuffs :

1.
Hydrophobic agent.
2.
Softener
3.
Additive
4.
Acetic acid to adjust the PH

M/C set up :
M/C parameters
Padder pressure
M/C speed

Set up value
2-7 bar
As standard speed set by
manufacturer.

Final inspection
Inspection refers to an investigation process of accepting or rejecting
the final finished fabric from the bulk. It is an observation process of
finding. Out each and every visible fault in the fabric.
Responsibilities :
1.
2.
3.
4.

100 Fabric Inspection

Joint Inspection with buyer.
Problem rectification.
Fabric transfer to store.

Equipment used :

a)
b)

Nazer Inspection m/c, Pakistan.

Verivide Day Light box.

Following faults are detected & identified in final inspection for body :
a)

Penalty points legend :

H= Hole
OS = Oil stain
CS= Chemical stain.
W= Water spots.
Fy= Fly yarn.
YC = Yarn contamination.
WX= White speaks.
IS = Insect spots.
R= Rub mark.
DS= Dye stain.
D= Dirt stain.
Rs= Rust stain.

b)

Faulty appearance :
US = Uneven shade.
N = Neps
CR = Crease Mark
P = Patches.
HR= Hairy
MS= Machine stoppage.
N= Needle line.
BR= Barre mark.
CM= Crumple mark.
DC= Dead cotton.
BW= Bowing.

Beside these, role to role and meter to meter variation is checked.

Four Points system :
Size of defect

Penalty

3 inches on less

1 point

over 3, but not over 6

2 point

Over 6, but not over 9

3 point

Over 9 inches

4 point

ACCEPTANCE CALCULATION :
Total point per 100 square yards
=

Actual points counted

Actual Roll length

36
Actual width

= Points/100 square yards.

Classification of Inspection Fabric :

100

< 40 points = A
41-60 points = B
61-80 points = C
80 above
= Reject.
Collar & cuff inspection :After dyeing & finishing operation measure collar & cuff size
and width and compare with buyer requirements.
Following faults also detect and identify :

Faults

Decision

1.

Rub mark

Reject

2.

Cutting

Reject

3.

Hole

Reject

4.

Crumple

Reprocess

5.

Tipping bleed

Reprocess

6.

Uneven shade

Reprocess

7.

Neps

Enzyme wash

8.

Oil spot

Reject

9.

Role to role variation

Reprocess

10.

Yarn contamination

Reject

11.

Barre mark

Reject

Some definition of yarn faults :

Neps : Neps may be termed as small light balls of tangled fibers.

Contamination : When yarn contains hair, foreign matter, other fibre and speed pot
etc along with fibre, it is called yarn contamination.

Dead cotton and hairiness : Hairiness arises from the fibres that
protrude outside the fabric surface, it causes pilling. Cotton which are
dead can not absorb dye.

White speaks : Undyed area due to unwanted fibre mixed with

cotton.

Some definition of knitting faults :

Oil mark : When excess lubricant use for knitting m/c then Oil mark
arises on fabric.
Hole : faulty or damage yarn creates hole in fabric.
Needle mark : Due to faulty needle this fault caused along wales
direction.
Sinker mark : Due to faulty sinker this fault caused.
Barre mark : Different lot mixing cause this problem.

Some definition processing faults :

Crease mark : Uneven heat control during process.

Unlevelness : If dyestuffs are not fixed with fabric uniformly causes

this problem.
Patches : This problem causes due to different color on some portion of
fabric.
Crumple mark : This problem is as like crease mark but looks meeting
effect over PC fabric.
Dye stain : Marks of color on fabric surface cause this problem.

m/c:

Dirty mark : This mark can appear any where in fabric.

Rub mark : Caused by friction with metallic component of
Water sports : One to accumulation of water.
Chemical stain :
Stain caused by chemical during dyeing or finishing.
Rust strain:

If m/c is affected by rust then rust stain appears on fabric.

Bowing :
Bowing means ratio of bow depth at highest point of arc to fabric
width. It is expressed in percentage.

CHAPTER 06

QUALITY ASSURANCE SYSTEM

LAB
Before bulk production buyer give a sample to lab. Lab produces similar
or nearer shade of it. If buyer approve this shade then this sample is gone for
bulk production. If buyer don't approve that shade, Lab again produces similar
or nearer shade of standard and give it to buyer for approval.
Equipment used in Lab :
a)

Rota Dyer:
Manufacturer : Qayyum Textile Ltd.,Pakistan.
Capacity : 12 beaker per m/c
Purpose :

b)

Sample dyeing ,Measure wash fastness.

Ahiba Nuance dyeing m/c:

Manufacturer : Data color International

c)

Capacity :

12 beaker per m/c

Purpose :

Sample dyeing.

Ahiba Spectra dye:

Manufacturer : Data color International
Capacity : 24 beaker per m/c.
Purpose :

d)

Sample dyeing.

Incubator :
Purpose :

e)

Pre-drying., Water fastness.

Taba Gs :
Purpose : To boil water.,Washing fastness.

f)

Electrolux Washcator :
Manufacture : James H. Heal & Co. Ltd. Halifax.
Country : England.
Purpose : Washing & Hydro-extraction.

g)

Tumble dryer :
Country : UK (Electra).
Purpose : Drying.

h) Pilling Tester:
Manufacturer: James H. Heal & Co. Ltd. Halifax.
Speed:30-60rpm.
i)Electronic Balance:
Manufacturer: ohaus corp. USA
Readability:0.001gm
Maxm Capacity:210gm

Some Fabrics used in BKL Lab:

1.

Single jersey.

2.

Polo Pique.

3.

Back Pique.

4.

Normal Rib.

5.

Interlock.

Fabric composition :
In BKL, 100% cotton, CVC, T/C, TTC fabric is used. A chemical test is
applied to find out cotton & polyester percentage that is present in fabric.
The chemical test is followed by :

1.

At first weight of a sample is taken

2.

Then put it 70% H2SO4.

3.

Stir for 10 min.

4.

Then wash the sample.

5.

Then dry the sample.

6.

At last weight of this sample is taken.

Some CVC fabric compositions :

a)

80% cotton + 20% Polyester.

b)

70% cotton + 30% Polyester.

c)

65% cotton + 35% Polyester.

T/C fabric composition :

65% Polyester + 35% cotton.

TTC fabric composition :

80% polyester + 20% cotton.

Chemicals & Auxiliaries Used :

For reactive Dyeing:
For Cibacron Dyes:
L: R = 1: 8
600C Dyeing:

Ciba
F/w

<0.3

Salt

G/L

10

20

30

40

50

60

Soda ash

G/L

7.5

10

Nil

Nil

Nil

Nil

0.3

0.5

1-1.5

0.2-1

1-2

2-3

3-5

>5

20
5
0.3
1-1.5

30
8
0.7
1

40
10
0.9
1

50
10
1.2
1

60
12
1.4
1

NaOH(50%) G/L
Cibacel
DBC

G/L 1-1.5

Anti-Crease

G/L

For Levafix

Dyes:

0.3-0.5 0.5-1.0 1.0-2.0 2.0-3.0

>3.0

L: R = 1: 8
600c Dyeing:
% <0.2
Levafix
Salt
Soda ash
NaOH(50%)
Cibacel
DBC
Anticreasing
agent

G/L
10
G/L
2
G/L Nil
G/L 1-1.5
G/L

For Remazol Dyes:

L: R = 1: 8
600C Dyeing:

Remazol

<0.2

0.20.5

0.5-1

1-2

2-3

3-5

>5

Salt

G/L

10

20

30

40

50

60

80

Soda ash

G/L

7.5

10

Nil

Nil

Nil

Nil

0.5

0.5

0.7

NaOH(50%) G/L
Decol SN

G/L

Anti-Crease

G/L

<0.5

05-1 1-1.5

1.5-2

2-2.5

>2.5

For Procion Dyes:

L: R = 1: 8
820C Dyeing:
Procion

Salt

G/L 30

60

60

70

80

90

Soda ash

G/L 5

10

15

15

15

20

Dekol SN

G/L 1

Anti-Crease

G/L 1

L: R = 1: 8
920C Dyeing:

Procion

<0.5

.5-1

1-1.5

1.5-2

2-2.5

>2.5

Salt

G/L

40

60

70

80

90

90

Soda ash

G/L

10

10

15

15

15

20

Dekol SN

G/L

Anti-Crease

G/L

For Disperse Dyeing :

:

1300c

i)

Temp.

ii)

Dispersing agent :

0.8-1 g/L

iii)

Acetic acid

0.5-1 cc/L

iv)

PH

4.5-5

For medium and dark shades reduction clearing is required after dyeing :

Chemicals

Medium shade Dark shade

Detergent

G/L

0.5

0.5

Caustic Soda

G/L

Sodium hydrose

G/L

Acetic acid

G/L

0.5

0.5

Lab line :
a)

Standard Sample :

At first Recipe % of standard sample is measured by CCM (Computer

Color Matching) system.
B)

Lab trial :

Then by taking that recipe lab officer produce lab trial and match with
standard according to buyer requirements.
c)

Approved sample :

Then sample swatch which is matched with the standard & send to buyer
for approval.

After approving to this sample this sample is send for bulk production
with the recipe.

Program Number in Ahiba Dyeing Machine:

Program no.

Temperature

Time

1000c

68

800c

90

400c

20

600c

50

500c

37

620c

60

900c

96

600c

40

800c

40

10

600c

45

11

600c

70

12

700c

30

13

950c

30

14

950c

10

15

950c

60

16

1300c

76

17

1100c

30

18

1000c

40

Reactive dyeing procedure :

1.

Stock solution of Dyes is prepared.

2.

Scouring & Bleaching sample is weight for light shade. But for dark
shade only scouring.

3.

Sample is weight m/c beaker is washed. Then pipetting of dye

solution is completed into beaker according to requirement.

4.

Water is taken according to requirement into that beaker.

5.

Then Glauber salt is weighted and put it into beaker in solid form.

6.

Scouring & bleaching or only scouring weighed sample is wet with

cold clear water and squeeze then put it into the beaker.

7.

Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

8.

Set program no. 8.

9.

After complete this program cover of m/c beaker is opened and put
Soda ash or Soda ash + caustic according to requirement.

10.

Then cover the beaker & again put it in Ahiba dyeing m/c.

11.

Set program no. according to dye types.

12.

After completion of that program dyed sample is taken out from

beaker.

13.

Then wash the sample with cold water.

14.

Then wash with hot soap water.

15.

Then again washed with cold water.

16.

Then dried.

CVC or T/C Dyeing procedure :

At first polyester part is dyed with disperse dye. Then cotton part is dyed
with reactive dye.

Disperse dyeing procedure :

1.

Stock solution of disperse dyes is prepared.

2.

Scouring & Bleaching Sample is weight for light shade. But for dark
shade only scouring sample is weighted.

3.

M/C beaker is washed and pipetted the dye solution, dispersing agent
& acetic acid into the beakers.

4.

Water is taken according to requirement into the beaker.

5.

Then sample is wet with cold clear water & squeezed, then put it into
the beaker.

6.

Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

7.

Set program no. 16.

8.

After complete of the program cover of beaker is opened and sample

is washed but if it is medium on dark shade then reduction clearing is
carried out.

9.

Stock solution of reactive days is prepared.

10.

M/C beaker is washed and pipetting of dye solution is completed into

beaker.

11.

Water is taken according to requirement into that beaker.

12.

Then Glauber salt is weighted and put it into beaker in solid from.

13.

Then disperse dyed sample is wet with cold clear water and squeeze
then put it into the beaker.

14.

Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

15.

Set program no. 8.

16.

After complete this program cover of m/c beaker is open and put soda
ash or soda ash + caustic according to requirements.

17.

Then covered the beaker and again put it in Ahiba dyeing m/c.

18.

Set program no. according to dye types.

19.

After complete of that program dyed sample is taken out from beaker.

20.

Then wash the sample with cold water.

21.

Then wash with hot soap water.

22.

Again wash with cold water.

23.

Then dried.

On line quality control

ON line Knit quality is the process of evaluating the greige, finishing
and checking the knit circular & flat machine parameter, in order to ensure
conformity with the fabric specifications required by the customer.
WORKING AREA OF ON LINE QUALITY CONTROL :
a)

On line circular knit :

Function :

b)

1.

Design & shade approval.

2.

Yarn & m/c evaluation.

3.

QC parameter checking.

4.

Body & Rib Inspection.

On line flat knit :

Function :
1.

Design & shade approval.

2.

Yarn & m/c evaluation.

3.

QC parameter checking.

4.

Collar & cuff. Inspection.

c)

Greige inspection :
Function :

d)

1.

100% Fabric Inspection.

2.

Fabric transfer to store.

3.

Area cleaning.

4.

Co-ordinating & reporting.

On line finishing :
Function :
1.

100% Fabric Inspection

2.

Problem Identification.

3.

Problem Rectification.

4.

Fabric Transfer for reprocesses.

Response to faults:
Following response are to be taken :
Faults

Response

Greige inspection

Inform yarn supplier & knitting

department.

Knitting fault

Inform knitting Department

Finishing fault

Inform Finishing Department

Off line quality control

All quality control tests relates to Finished fabric (body, collar/cuff &
rib) testing as per customer's required quality standard or international
standard.
Typical Quality control in BKL:

a)

a)

Shade Check.

b)

Gram per square meter (GSM) test

c)

Width on dia check.

d)

Shrinkage test

e)

Spirility test

f)

Crocking/Rubbing Fastness test.

g)

Pilling resistance test.

h)

Wash fastness test.

i)

Water fastness.

j)

Color fastness to perspiration.

Shade check :
Shade check after finishing of fabric is done according to customer's
recommended light source.
Equipment used : Verivide Light box.
Manufacturer : James H. Heal & Company, Halifax, England.
Light sources :

b)

Artificial day light D65

TL 84

F(Filament)

UV (Ultra violet) light etc.

Gram per square Meter :

After finishing of fabric gram per square meter is check by GSM

cutter.
Equipment used : GSM cutter.
Manufacturer : James H. Heal & Company, Halifax, England.
c)

Width on Dia Check :

After finishing of fabric width on dia of the fabric is check by

measuring tape.
d)

Shrinkage test :
After finishing of fabric shrinkage is tested.
Equipment used : Electrolux wascator
Manufacturer : James H. Heal & Co. Ltd. Halifax, England.
Procedure :
1)

Two layer of 1212 sample is cut.

2)

Then stitch the layers.

3)

Then wash the sample by

Test Method

BS 26330 3A
60 +/- 30c
Prog 13
BS 26330 4A
50 +/- 30c
Prog 14
0
BS 26330 5A
40 +/- 3 c
Prog 15
4) Then dried the sample according to customer requirements :
a)
b)
5)

Tumble drying or,

Line drying

Then measured the dried sample.

Standard Shrinkage % :
Length (max) : 5% after domestic washing
Width (max) : 5% after domestic washing .

e)

Spirility test :

After finishing of fabric spirilily is tested.

Equipment used : Electrolux wascator.
Manufacturer : James H Heal & Co. Ltd. Halifax, England.
Procedure :
1.

Two layer of 21 & 21 sample is cut.

2.

Then stitch the layers.

3.

Then wash the sample by :

Test Method

BS 26330 3A

60+/-30c

Prog 13

BS 26330 4A

50+ /-30c

Prog 14

BS 26330 5A

40+/-30c

Prog 15

4.

5.

Then dried sample according to customer requirements :

a)

Tumble drying or,

b)

Line drying.

Then measured the sample following way :

L
D1

L
D2

1st Side

Where,

2nd Side

L= Length of Sample.
D1, D2 = Distance of seam movement.
Calculation :
D1 D2

Spirility % =

100

Standard spirility % :
Maximum : 5% after domestic washing.

f)

Rubbing / Crocking fastness :

After finishing of fabric rubbing fastness is measured.
Equipment used : Crock meter.
Manufacturer : James H. Heal & company, Hali fax, England.
Method : AATCC 8
Standard result :
Dry rub : 4s
Wet rub : 2s

g)

Pilling resistance test :

After finishing of fabric pilling resistance test is carried out.
Equipment used : ICI pilling box
Manufacturer : James H. Heal & Company, Halifax, England.
Method : BS 5811 or according to customer requirement.

Revolutions for BS 5811 method :

a)

7000 cycle for low pilling

b)

9000 cycle for Medium pilling

c)

11000 cycle for High Pilling.

Procedure :

1.

A marker of 55 with two hole line at required distance is put on

fabric.

2.

Mark the fabric around the marker & draw line through the hole line.

3.

Then cut the sample at mark.

4.

Then join the draw lines by stitching and put it around rubber tube. 4
Rubber tube is prepared this way.

5.

Then put rubber tube in ICI pilling box. Take similar no. of rubber
tube in both box.

6.
7.

Then put cycle no and start the m/c.

After complete cycle rubber tube bearing the sample is taken out from
box.

8.

Then sample which is pilled compare with

Double Jersy std. Pilling
Photograph Nos. 1-5
Stock code 766-464

Standard result :

h)

Grade :

Wash fastness test :

After finish of fabric wash fastness is checked :
Equipment used :
a)

AG machine.
Manufacturer : Quyyum textile Engineering, Pakistan

b)

Ahiba Nuance.
Manufacturer : Data Color International, U.K.
Method : ISO 105-C06

Procedure :

1.
2.
3.

4.

Take multi fabric and take also same size of dyed sample and stitch
them at one end.
Then multi fabric sample put in a m/c beaker and take 20 balls into
the beaker.
Then take 50 cc solutions of following recipe :
4 g/l detergent
1 g/l Na-perborate
600c temp
30 min.
Then dried the sample & Measured fastness with staining scale.
Standard result :
Light shade

Staining scale

i)

Dark shade
3/4

Water fastness :
After finishing of fabric water fastness is checked.
Equipment used :
a)

Perspirometer

b)

Carbolite (Thermostat Oven)

Manufacturer :
James H. Heal & Company, Halifax, England.
Method : ISO 105-E01/BS 1006 EO1
Procedure :

1.
2.
3.
4.

Take multi fabric & take same size of dyed sample & stitich at one
end.
Dip the sample in distilled water for 20-30 min.
Then wet sample is put in perspirometer and kept it in carbolite
thermostat oven for 4 hrs. at 370c.
Then dried the sample not more than 60 0c and measured with staining
scale.
Standard result :

Staining

j)

Light shade

Dark shade

Color fastness to perspiraion :

After finishing of fabric color fastness to perspiration is checked
Equipment used:
a)
Perspirometer
b)
Carbolite
Manufacturer :
James H. Heal & Company, Halifax, England.

Method : AATCC 15.

Procedure :
1.

2.

A test solution is prepared with :

10 g/l Sodium chloride.
1 g/l
Lactic acid, USP 85.
1 g/l
Di-sodium hydrogen phosphate,
0.25 g/l Histidine mono hydrochlorite
PH : 4.3 0.2
Take multi fabric and sample of same size & stitch at one end.

3.
Immerse the test specimen for 15-30 min.
4.
Then put the test specimen in perspirometer with 8 lbs load.
5. Then put the perspiromenter in carbolite thermostat over for 6 hrs at 38 0
10c temperature.
6.
Then dry not more than 600c and measure with staining scale.
Standard result :

Staining scale

Light shade

Dark shade

3/4

CHAPTER 07

Maintenance

Maintenance :
Maintenance is a process by which equipment is looked after in such
a way that trouble free. Services and increased machine life can be ensured
and specific product quality required by the customers is sustained.
On time maintenance increase m/c lifetime & ensures trouble free
services.

Types of maintenance :
Maintenance

Preventive Maintenance

Mechanical
Maintenance

Electrical
Maintenance

Corrective Maintenance

Mechanical
Maintenance

Electrical
Maintenance

Preventive Maintenance :
Preventive Maintenance is a predetermined routine activity to ensure
on time inspections / checking of facilities to uncover conditions that may
lead to production break downs or harmful depreciation.
Corrective Maintenance / Break down Maintenance :
In this case, repairs are made after the equipment is out of order and it
can not perform its normal functions.

PM Tasks list
Maintenance :

Mechanical

Machine : Thies Dyeing Machine

Sl.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Item need to be checked & Serviced

Crease the winch bearing (Grease Staburag NBU-12)
Complete cleaning of machine
Cleaning of drain valves, replace seals if required
Check air supply filters, regulators, and auto drain seals
Clean filters element and blow out
Greasing of Unloading Roller Bearings by BP Energrease LS-2
Checking of Oil level and bolts of Unloading Roller Gearbox.
Checking of unloading roller coupling and packing
Checking and cleaning (if required) of Main Vessel Level Indicator
Check the oil level of pump bearing and refill if required by BP Energol
THB-100
Check the function of heat and cool modulating valves
Check all belts and belt tension
Check all door seals

Maintenance :

Electrical

Machine :

Thies Dyeing m/c

Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Items need to be checked & Serviced

Check & clean fluff and dirt at all motor fan covers
Check all motor's terminals
Check main panels (by using compressed air)
Check panel cooling fan & clean it filter
Clean main pump inverter and its cooling fan
Check all on/off switches
Check current setting of all circuit breaker & motor over loads.
Visual checking of all power & control cables
Check all emergency Switches
Check DC drive of neel motors
Check all pressure switches
Check calibration of main vessel & all additional tank
Check all pneumatic solenoids
Check calibration of heating/cooling. Modulating value.
Check all indicating lamps

Maintenance tools & equipments :

1.
2.
3.
4.
5.
6.
7.
8.

Pliers
Inside Calipers
Outside Calipers
Digital Multi Meter
Heating Shoulder
Hammer
Philes
etc.

Remarks :

Maintenance of m/cs are very essential to prolong the m/c life

and good maintenance is important for economical cosideration.
In this industry maintenace program is done by expert maintenance
team .
So very few times production are stopped due to m/c problem .

CHAPTER 08

UTILITY SERVICES

 Available facilities of utility:

Electricity
Gas
Water
Compressed air
Steam.
Electricity:
The main utility electricity is supplied from PDB and also by Generator.
Specification:
Equipment used: Gas generator.
No. of generator: 8 (1 self start able & other 7 are air+CH4
start able).
Manufacturer
: Wartsila-Frank.
-Gas engine used.
-16 cylinders per engine.
-Overall efficiency : 80%.
-Heat recovery possible from 4 engines.
-Stroke of engine
: 176mm.
-Cylinder capacity
: 71.6dm3
-Ignition pressure
: 90bar.
-Piston speed
: 9m/sec.
-Air flow of full load : 1.65kg/hour.
-Exhaust flow at full load : 1.7kg/hour.
-Exhaust gas temp
: 500 C.
-Pressure of gas
: 60-62 milibar.
-Air pressure
: 7 bar.
-Electricity take up from PDB : 1.5MW/sec.
Total power is then distributed as per requirements of different section of Beximco
industrial park.
Gas:
Gas is mainly used for steam production.
The gas is used from TITAS.
Generally 36 m3 gas is required to produce 1 ton steam.

Water:
Continuous supply of water for BTL,BDL&BKL must be ensured by pump.
Mainly two pumps are used for water pick up.

PUMP
CAPACITY
Submersible pump-I 260 m3/hr
Submersible pump-II 204 m3/hr

SETUP
Discharge value:100% open
Discharge value:100% open

Depth of pump: 140ft.

Also pumps for chemical dosing & Centrifugal pump for yarn dyeing.

Steam:
Pure steam with required temperature must be produced to meet the
continuous demand of steam in different sections.
-Fire tube type boiler is used.
-No. of boiler: (4+1) twine boiler.
1 boiler is operated by using burn gas.
4 boiler is operated by Titas gas.
-3 pass heating system.
-Measuring meter for water supply.
-4" depth greasol insulation so no heat at outside of drum.
-The lower drum is 100% water filled & the top drum is 60% water & 40%
steam filled.
-Proper supply of air for gas burnings.
-Boiler capacity; 10ton.
-Steam pressure; 8.2bar.
-Steam flow = 7 ton(approximately)
-Manufacturer: Thermax;India.
-Model: TD-100-10-54/6AS/E.
-Fuel: Natural gas.
-Water pressure: 10.3bar.
-Evaporation= 1000*3 kg/hr.
-Output: 6.28x3 MW.
-Steam Temperature: 185 C
-Boiler Temp(inner) =224 C-275 C.
Every result is recorded for 4 hours.
Chemicals used for boiler feed water:
-NaCl solution for regeneration.
-NALCO-4654(scale remover).
Compressor:
Natural gas is drawn by pipe through the filters above the compressor & the air is
compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to educe
the temperature of compressed air. Thus the cold water becomes slightly hot & goes through

outlet pipe to the overhead reservoir. Then the water falls slowly through a sieve and
becomes cool & again feed to the compressor. At the other hand the cooled compressed air
along with some vapors are transferred to the reservoir where the vapors are condensed and
outlets drop by drop.
The moist compressed air is transferred to the dryer & a slight warm compressed air
is delivered to required sections of Beximco Industrial Park.
Parameters

Set value

Unloading pressure
Pressure difference
Oil pressure
Motor running time

7.5 bar
0.6 bar
1.2 bar
15 sec

-Total no. of compressor = 3+3 =6

-Capacity: 774 lt air/compressor/sec.
-Manu: Atlas capco.
-Country: Belgium.
Oil free air is prepared by Electronikon.
Chemicals used:
-Shell Turbo-T-68.
-Grease.
-Nalco 7328 & 7330.
Chiller:
Manufacturer: Thermax.
Country: India.
-To start a chiller electricity & steam is required.
-Capacity :[(21083)+(500*1)] ton = 1130 ton water cooling.
-Absorption type Chiller is used.
Settings:
L-cut set point CHWSP:8 C.
Cooling water inlet temp set point = 20 C.
HTG temperature set point for AC drive = 140 C.
L-cut hysterics = 2 C.
Std. continuous flow: 12.2 C - 6.7 C(Temperature reduction).
Chemicals used:
-LiBr (Lithium bromide):Components: Li=7,99%;Br=92.01%.
S.G = 3.464 at 25 C.
MP = 549 C.
BP = 1265 C.

-Lythium Molybodate.
-Octyl Alcohol (2-Ethyl-1 feanol).
-Nalco 7328 & 7330.
-Refrigerant.

Source of Utility:
Electrically
Steam
Water
Compressed air
Temperature control
Gas

: PDB & Generator.

: Boiler.
: Pump.
: Compressor.
: Chiller.
: TITAS.

Cost:
36 cubic meter gas required for 1 ton steam generation.
Required steam/day = 9500 ton.
PDB:
Pick hour: 4.22 tk/unit
Off pick hour: 3.70 tk/unit.
Generator:
2.25 tk/unit of electricity.

The effluent treatment plant:

The effluent generated from different sections of a textile mill must be treated
before they are discharged to environment. Various chemicals & physical means are
introduced for this purpose. The effluent treatment plant in beximco is chemical-bio9logical
combination process developed by India.
Objects:
This process is provided for treating the effluents of dyeing, printing,
finishing, weaving & thus allow to discharge it as per norms given by world bank dept of
environment of Bangladesh. This process comprises of collecting, pumping, clarification,
filtering, setting, aeration, pH correction, discharging, etc.
Characteristics of raw effluents:
Volume
: 3600 cubic meter/day
Peak flow
: 225 cub met/hr
pH
: 10-12.5
BOD
: 500-800 PPM
COD
: 1300-2000 PPM

TDS
SS
Colour

: 2000-5000 PPM
: 100-400 PPM
: Black/ Blue

Requirement of dischargeable effluent as per World Bank:

pH
BOD
COD
SS
TDS
Colour

: 6-8
: <50
: <250
: <100
: Not stated
: Clear

Chemicals used & their colours:

Chemicals used
Ferrous sulphate
Lime
Polyacrylate
Sulphuric acid
Alum
Na-hypochlorite
Hydrochloric acid

Appearance
Granular solid, greenish colour
White bulk form
White granular solid
Clear liquid
White bulk form
Clear liquid
Clear liquid

Flow chart of effluent treatment:

Raw effluent
Skin chamber
Collection Sump
Pump station
Dissolved Air Floatation Tank
Clarifier
Aeartion tank
Setting tank
Clear water, pH check

Sand filter
Carbon filter
Drain
Sludge separation:
Sludge of DAF
Sludge thickening plant
Sludge drying be
Product quality check:
Following chemical tests are carried out to check the quality:
- BOD
- COD
- Total suspended solids
- Total dissolved solids
- Colour
- pH
Typical output of the plant:
Raw effluent treated
Raw effluent colour
Raw effluent pH
Treated effluent colour
Treated effluent pH
Treated effluent temp.
To0tal suspended solids

15000 LPH
Black
11
Light greenish
8.5
38 C
35 PPM

IRON REMOVAL PLANT :

For Textile dyeing Iron free water is required. This plant removes Iron
and makes water 0.03-mg/l iron content.
Procedure :
1. Raw water is collected in raw water tank (1) from deep tubewell.

2.

Alkali dosing by flow meter (f) to maintain PH 8.

3. Then raw water is passed through MnO2 bed (2) here ferrous iron
formed insoluble ferric iron oxide and coagulated.
4.

Then water is passed through nozzle (3).

5.

Water then passed through sand & stone filter (4).

6.

Then filtered water (5) is collected to store tank (6).

7. For back wash of MnO2 water in through nozzle (3) and back wash
water is drain (7)
8. For back wash of sand & stone filter water passes through the end
of 5 and out let of is done at 4 and drain at 8.
9.

Excess water of MnO2 or filter is drain out by 9 and 10.

CHAPTER- 09

STRORE & INVENTORY

CONTROL

Frequency of inventory control:

- Monthly inventory control
- Annual inventory control

Scope of inventory control

-

Raw materials
Dyes store
Others chemicals store
Grey fabrics
Finished fabric
Spare parts
General store
Capital equipment
Accessories
Stationary
Maintenance parts.

Inventory system for raw materials

-

Raw materials partially received from production planning & directly

from head office.
Material Receiving & Inspection Report (MRIR) is prepared. Received
quantity is mentioned & noted doewn.
Submitted to QC department. Some are OK & few rejected.
Entry of data of goods in DATATEX .
Goods are arranged according to OK or rejected group.
Department gives store requisition to warehouse.
As per requisition materials supplied & this record is noted down.

Stages of grey fabric inventory control

-

After knitting production

Grey inspection
Warehouse
Batch preparation
Dyehouse.

Stages of finished fabric inventory control

-

Finishing section
After final inspection
Warehouse.

 Store capacity
- Dyes
- Chemicals
- Grey fabric
- Yarn storage
- RFD
- Set range of dyes
- Set range of Chemicals

6-7tons
33-35tons
20-25 tons
50 tons
50 tons
80-100kg/day
2-2.5ton/day

Remark
-

The inventory system of BKL covers both knitting & dyeing

inventories.
- The space is noticed to be insufficient considerably.
- An expansion of space is thus desired for sound inventory.
The department is computer oriented & connected by ERP.

CHAPTER 10

COST ANALYSIS

Costing of the product:

Costing system mainly describes how the cost of the final
product is fixed by the company/benificiar. According to buyers/customers
requirement at first the fabric is collected from local and foreign suppliers . then
it is calculated how much dyestuff and chemical is required till the end of the
processing of that specific fabric. After that, the final cost is fixed including
some profit. Then the unit price is offered to the buyer for approval. If the buyer
approves it, all the transaction of money is carried out by bank.

Costing of the product is done by the consideration of the following

factors:
1.Amount of raw materials consumed.
2.Direrct labour.
3.Indirect labour.
4.Factory cost.
5.Office and administrative cost.
6.Sales and distribution cost.
7.Profit,etc.

Remarks:
The costing of product is a secret matter of the industry. They are not
interested to flash up the cost related data.So, we could not collect the price of
the product and costing of the product.

CHAPTER 11

MARKETING ACTIVITIES

Consumer of the products:

Beximco knitting LTD. is a100% export oriented industry. All
the goods produced in this industry are exported into various foreign countries.
Name of the main buyers of the products of the industry are given below:

1.Ash city.
2.B&C.
3.Wall mart.
4.Haddad.
5.Pimkie.
6.Zara.
7.Charter House.
8.H&M.
Product label:
Product label differs from buyer to buyer. The product labels are
prepared according to fabric criteria and the buyer requirements.

Package size and label:

Package size and label differs from buyer to buyer. The package
size and labels are prepared according to fabric criteria and the buyer
requirements.

Local Market:
Beximco knitting LTD. is a100% export oriented industry. All the
goods produced in this industry are exported into various foreign
countries. So,goods are not supplied into local markets.
Importing countries:
The countries which are importing goods from Beximco knitting Ltd are given
below:
1.USA.
2.Canada.
3.Germany.
4.Europian countries.

Marketing Strategy:
Marketing strategy is a very important factors to sale the products to
the buyer. Beximco knitting Ltd mainly senior marketing officers, merchandiser
and higher deal with buer. There are some fixed buyers of the industry. The
buyers give their orders continuously all over the year. the marketing officers
and by both side understanding the rate and the order quantity are fixed.
Duties& responsibilities of marketing officer:
The main duties and responsibilities of amarketing officer are given bellow:
to prepare cost sheet by dealing with the buyer.
To take different steps by discussing with the high officials and
merchandiser.
To maintain a regular & good relationship between commercial officer &
merchandiser.
To maintain a regular communication with the buyers & buying houses.
Communicate with the new buyer.
Display the criteria of the products.
Actually the responsibilities & duties of marketing officer begins from getting
order of buyer & ends after receiving goods by the buyer. so he should be
always smart, energetic & sincere.

Remarks:
Beximco knitting Ltd has a well learned marketing & merchandising
team. They always communicate with the buyers. The marketing section also
looks for the quality & quantity buyers.

CHAPTER 12

CONCLUSION

Industrial attachment program send us to the expected

destiny of practical life. The completion of tow month industrial
attachment at Beximco knitting Ltd I have got the impression
that the factory is one of the most modern knit dyeing project in
Bangladesh. Though it was established only few years ago, it has
earned very good reputation for its best performance over any
other knit dyeing project.

During my industrial attachment program I had tried to

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

In our industrial attachment program contents some

secret subject of factory is included. To collect this information
like history of project development, costing of products,
marketing strategy etc every student face a great problem as it is
a secret. so we proposed our college authority to exclude these
topics from the contents.

LIMITATION OF THE REPORT

Because of the secrecy act, the data on costing and
marketing activities has not been supplied and hence this
report exclude these chapters.
we had a very limited time. In spite of our willing to
study more details it was not possible to do so.
Some of the points in different chapters are not
described as these were not available.
These whole process is not possible to bind in such
a small frame as this report, hence our effort spent on
summarizing them.

LASTLY:
what special is this report is that the
information, data and description is very much
subjective and practical. So, one can easily have an idea
about the whole dyeing unit of BKL at a single look on
it.

The new comer can use this report for further

details study or can know Beximco knitting Ltd without
much work. But what should be remembered the
chemicals, some process steps may be modified within
the period this paper goes to the reader.