Indutrial Attachment

CHAPTER -01PROJECT DESCRIPTION:

1. Name of the organization : ZABER & ZUBAIR FABRICS LTD.2. Type : HOME COMPOSITE TEXTILE.3. Year of Establishment : 20004. Address : Adamjee Court Main Building(5th floor)

115-120,Motijheel C/A,Dhaka-1000.5. Factory : Pagar, Tongi, Gazipur-1710,Bangladesh.6. Product Mix : 100% Cotton

(50%+50%)Poly Cotton CVC (Chief Value of Cotton)

100% Organic Cotton.7. Medical Facility : Appointed M.B.B.S doctor for coverage

24hrs health facilities.8. Production Capacity :

Dyeing : 3,000,000 Meters per monthPrinting : 6,000,000 Meters per month

9. Supporting Department : Personal Department MIS(Management Information System) Marketing Department Accounts Department Administration Department Compliance Department Processing Department Planning & Co-ordination Automobile Workshop Mechanical Workshop Motor winding Electrical & Electronics Department Folding Department Cost & Account Department Embroidery Department Etc.

To smooth functioning of the organization activities, some department assist these activities as per given below:

Dyeing, Printing & Finishing Section: Preparation Dyeing Printing Finishing Q,C & Lab Section Final inspection & Folding

Garments Section: Sample Section Cutting Section Sewing Section Final inspection Packing Section Etc

Maintenance: Electrical Mechanical

Utility Section: Boiler Generator Compressor Chiller ETP WTP Etc.

Accounts & commercial Section. Administration & Compliance Section. Chemical & Spare parts Store.

Total area of the Industry: 9,97,000 square feet.

Remarks: The company 9,97,000 square feet of land property which is situated near by Dhaka-Gazipur high way far from 20 kilometers of Dhaka city. The future plan of this Organization is to achieve following parameter:

o 100% quality achieve as per buyer requirements.o Buyer Satisfaction.o Time to time delivery of every shipment.o Project Expansion.o Well Satisfaction & Motivation of the Employee.

CHAPTER -02MANPOWER MANAGEMENT:

Organizational Structure:

Figure 1.1 Organizational Structure

Director

Mst. Nur Yasmin

Kaniz Fatema

Director

Talha Mahmmad

Abdulla

Director

Zubair Mohammad

Abdulla

Director

Zaber Mohammad

Abdulla

Managing Director

A.S.M Rafiqul Islam

(Noman)

ChairmanMr. Nurul Islam

Administration

Staff

Officer Asst. OfficerSr. Officer

Manager

Asst. General Manager (Admin)

Asst. General Manager (HR & Compliance)

Finance

Staff

Officer Asst. OfficerSr. Officer

Asst. Manager

Manager

General Manager

Marketing

Staff

Executive Executive (Trainee)Sr. Executive

Manager

Asst. General Manager

General Manager

Mechanical

Sr. Manager

Mechanical fitter WelderMechanical engineer

Asst. Manager


General Manager

Electrical

Sr. Manager

Electrician Electrical engineer

Asst. Manager


Deputy General Manager

Production

Asst. Operator HelperOperator

Supvisor

Production Officer Asst. Production OfficerSr. Production Officer

Asst. Manager

Manager


Management System:

Intercom telephone Fax Written letters & Oral

Shift Change:

There are three shifts in the industry. So the shifts are changed at every 8 hours.

Shift Change/ for worker of Security:

A Shift – 06:00 – 14:00

B Shift – 14:00 – 22:00

C Shift – 22:00 – 06:00

General shift :

09:00 – 18:00

Office Time

09:00 – 18:00

Responsibilities of Production Officer:

1. To give dyeing program slip.2. To match production sample with target shade.3. To collect production sample for sample matching next production.4. To observe dyed fabric during finishing running & also after

finishing.5. To identify disputed fabrics & report to P.M/G.M for necessary

actions.

6. To discuss with P.M. about overall production if necessary.7. To sign the store requisition & delivery challan in the absence of P.M.8. Also to execute overall floor works.9. To maintain loading/unloading khata.10. Any other assignment given by higher authority.

Job Description of P.O & S.P.O:

Job title: Production officer & Senior Production officer

Report to: Production Manager

Purpose:

To control shift according to the plan made by the production manager

Territory: Dyeing section (major)

Batching and Finishing section (minor)

Nature and Scope:

Role within the organization:

Responsible for own shift production with good quality and minimum time.

Environment:

Production officer has to work under huge stress. He has to work in acute heat under physical and mental pressure. Also he has to work in acute heat all the year round.

Job Description of Production Officer:

Report To: Sr. Production Officer

Job Summary:

To plan, execute & follows up the production activities & control the quality production with related activities.

Duties & Responsibilities:

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, color management. Control the supervisors, operator, asst. operator & helpers of dyeing m/c. And also any other work as & when required by the management.

Job Description of Sr. Production Officer:

Report To: P.M (Production)

Job Summary:

To plan, execute & follows up the production activities & control the quality production with related activities.

Duties & Responsibilities:

Overall supervision of dyeing, finishing production. Checks the different log books of different areas & report to management. Checks the sensitive parameters of different machine for smooth dyeing. Checks out the plan to control the best output from supervisor & workers. To trained up & motive the subordinates how to improve the quality

production. Maintenance of machine & equipment. Any other works & when required

by the management. Control the supervisors, operator, asst. operator & helpers of dyeing m/c.

REMARKS:

The manpower management system ZABER & ZUBAIR FABRICS LTD. is well arranged. Every officers & stuffs are responsible for their duty. But there are only nine textile engineers in the industry (3 for pretreatment, 3 for Dyeing & 3

for Finishing). It is sufficient for fluent production. The efficiency of the worker should be increased for more quality production.

CHAPTER NO-03MACHINE DESCRIPTION:Introduction:

ZZTF is an integrated computerized company. It has total above 50, dyeing machines are fully computerized .The machines are centrally controlled by Beacon Controller.

Beacon Controlling System:

The Beacon Controlling System took the main attention in ZZTF. It is fully computerized controlling system. In ZZTF 50 dyeing machine was controlled by the Beacon Controlling System. It consist of-

A Computer A special panel board.

Every machine was conducted with the computer by a local area network (LAN)

The function of Beacon Controlling System:

It can control the water supply of the machine. It can control the dosing. It can control the heating and cooling system. It shows the present condition of the production.

Yellow line : indicate theoretical temperature.

Red line : indicate practical temperature.

Blue line : indicate theoretical chemical dosing to vessel form tank.

Pink line : indicate practical chemical dosing to vessel form tank.

Green line : Liquor level in vessel.

It can give the detail information about the production of a batch.

Can store information about the previous production of last 7 days.

Operation Sequence:

Information input in the computer

Downloading program from computer in the panel board

Calibrate the machine for run

Give necessary information to operator

Run the machine according to the program.

Specification of Different Machines :

Pretreatment Section:

Pretreatment Machine. Oshoff-01+03:

Type Gas Singing & De-singing Machine

Manufacturer name Osthoff

Country Germany

Model No. FO97-4

Year of manufacturing 1999

Temp. Range 00-2000C

Used Utilities Water, Steam, Electricity, Compressed Air

No. of Motor 14

Production Capacity 100000 Meter (P/Day)

Burner Range 0-40 Mbar

Machine Speed 120 m/min

Pretreatment Machine. Oshoff-02:

Type Gas Singing & De-singing MachineManufacturer name OsthoffCountry GermanyModel No. VP-99

Year of manufacturing 2006

Temp. Range 00-2000C

Used Utilities Water, Steam, Electricity, Compressed Air

No. of Motor 14

Production Capacity 100000 Meter (P/Day)

Burner Range 0-40 Mbar

Machine Speed 120 m/min

Pretreatment Machine. Poong Kwang:

Type Gas Singing & De-singing MachineManufacturer name Poong KwangCountry KoreaModel No. PK-G-2A-3200Year of manufacturing 2004.8Temp. Range 00-1000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 10Production Capacity 80000 Meter (P/Day)Burner Range ManualMachine Speed 100 m/min

Pretreatment Machine. Bleaching-01:

Type BleachingManufacturer name Goller Bleaching-01Country GermanyModel No. 9454Year of manufacturing 1998Temp. Range 00-1000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 38Production Capacity 100000 Meter (P/Day)Machine Speed 120 m/min

No of Dryer 18 Pcs Dryer, 2 Pcs Cooling DryerPressure Range (0-7) PSINo of Steamer Box 1 Pcs

No of Washing Chamber 6 Pcs Washing Chamber, 1 Pcs Chemical Chamber, 1 Pcs Acid Chamber

Pretreatment Machine. Bleaching-02:

Type BleachingManufacturer name Goller Bleaching-02Country GermanyModel No. 9831Year of manufacturing 2006Temp. Range 00-1000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 135Production Capacity 100000 Meter (P/Day)Machine Speed 120 m/minNo of Dryer 24 Pcs Dryer, 2 Pcs Cooling DryerPressure Range (0-7) PSINo of Steamer Box 2 Pcs


Pretreatment Machine. Brugman:

Type BleachingManufacturer name BrugmanCountry HollandModel No. 86/600Year of manufacturing 1986Temp. Range 00-1000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 110Production Capacity 100000 Meter (P/Day)Machine Speed 100 m/minNo of Dryer 18 Pcs Dryer, 2 Pcs Cooling DryerPressure Range (0-7) PSINo of Steamer Box 2 Pcs


Pretreatment Machine. Mercerizing-2:

Type MercerizingManufacturer name Goller Mercerizing

Country GermanyModel No. 9833Year of manufacturing 2006Temp. Range 00-1000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 95Production Capacity 60000 Meter (P/Day)Machine Speed 60 m/minNo of Dryer 12 Pcs Dryer, 2 Pcs Cooling DryerPressure Range (0-7) PSI

No of Washing Chamber 6 Pcs Washing Chamber,1 Pcs Acid Chamber

Pretreatment Machine. Mercerizing-4:

Type MercerizingManufacturer name Goller MercerizingCountry GermanyModel No. 9917Year of manufacturing 2008Temp. Range 00-1000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 84Production Capacity 60000 Meter (P/Day)Machine Speed 60 m/minNo of Dryer 16 Pcs Dryer, 2 Pcs Cooling DryerPressure Range (0-7) PSI

No of Washing Chamber 5 Pcs Washing Chamber,1 Pcs Acid Chamber

Chain Length 12 Yards

Finishing Section:

Finishing Machine. Babcock-1:

Type StenterManufacturer name BabcockCountry GermanyModel No. 98146-001Year of manufacturing 1999Temp. Range 00-2000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 38Production Capacity 60000 Meter (P/Day)Machine Speed 100 m/min

No of Burner Chamber 8 PcsPressure Range (0-7) PSIChain Length 30 Meter

Finishing Machine. Babcock-2:

Type StenterManufacturer name BabcockCountry GermanyModel No. 99256-001Year of manufacturing 2000Temp. Range 00-2000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 31Production Capacity 60000 Meter (P/Day)Machine Speed 100 m/minNo of Burner Chamber 6 PcsPressure Range (0-7) PSIChain Length 24 Meter

Finishing & Dyeing Machine. Monforts-1:

Type StenterManufacturer name MonfortsCountry GermanyModel No. Montex 6000-8FYear of manufacturing 2004Temp. Range 00-2000CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 55Production Capacity 60000 Meter (P/Day)Machine Speed 150 m/minNo of Burner Chamber 8 PcsPressure Range (0-7) PSIChain Length 30 MeterIR 1 Pcs

Finishing Machine. Monforts-6:

Type StenterManufacturer name MonfortsCountry GermanyModel No. Montex 6500-8FYear of manufacturing 2008Temp. Range 00-2300C

Used Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 53Production Capacity 60000 Meter (P/Day)Machine Speed 150 m/minNo of Burner Chamber 8 PcsPressure Range (0-7) PSIChain Length 30 Meter

Dyeing Machine. Pad steam:

Type Dyeing MachineManufacturer name Goller Pad steamCountry GermanyModel No. 9834Year of manufacturing 2006Temp. Range 00-2300CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 53Production Capacity 60000 Meter (P/Day)Machine Speed 150 m/minNo of Burner Chamber 8 PcsPressure Range (0-7) PSI

Dyeing Machine. Thermosol:

Type Dyeing MachineManufacturer name Monforts ThermexCountry GermanyModel No. 55A75030Year of manufacturing 2006Temp. Range 00-2300CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 53Production Capacity 60000 Meter (P/Day)Machine Speed 150 m/minNo of Burner Chamber 8 PcsPressure Range (0-7) PSIChain Length Yards

Remark: The Beacon Controlling System is very good software to control the production parameter. It gives very good chance to control the machine and observe the production closely.

CHAPTER NO-04RAW MATERIAL

Raw material:

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

# Types of raw materials:

Yarn Fabric Dyes Chemical & auxiliaries.

Yarn:

Cotton Polyester Lycra Viscose Etc.

Fabric: Basic weave three types-

01. Plain02. Twill03. Sateen.

Dyes:

LIST OF DYES

Sl.No Name Of the Dyes Conpa

nySl.N

oName Of the

Dyes Conpany01 Bemacron Black Se-RDL CHT 26 Sodium by carbonate ANNESHA02 Bezaktiv navy S-LF CHT 27 Drimaren Blue HF-CD Clarint03 Bezaktiv Cosmos S-MAX CHT 28 Novacron Navy CR ANNESHA04 Drimarene navy HFGNcdg Clariant 29 Novacron Yellow C-5g ANNESHA05 Cyclanon ERL BASF 30 Novacron Navy WB ANNESHA06 Drimarene Blue HFRL cdg Clariant 31 Novacron Ruby S-3B ANNESHA07 Drimarene navy CL-R-GR Clariant 32 Novacron Red C-2BL ANNESHA08 Drimarene Blue CL-BR gr Clariant 33 Novacron LemonS-3G ANNESHA09 Drimarene Yellow HF-CD Clariant 34 Novacron OrangeCRN ANNESHA10 Drimarene Red HF-CD cdg Clariant 35 Novacron Deep Red ANNESHA11 Dianix Black S-2B200% Dyster 36 Novacron Red C-4B ANNESHA12 Dianix Navy CC Dyster 37 Novacron Navy CE ANNESHA13 Foron Rubine S-WF Clariant 38 Novacron Red CE ANNESHA14 Foron Blue S-WF Clariant 39 Novacron Yellow CE NNESHAANNESHA15 Foron Navy S-WF Clariant 40 Novacron Blue CE ANNESHA16 Foron Black S-WF Clariant 41 Novacron Olive CE ANNESHA17 Hydrosulphite cone BASF 42 Novacron Yellow NC ANNESHA18 Levafix Blue CA gran Dystar 43 Novacron Grey NC ANNESHA19 Levafix Amber CA gran Dystar 44 Novacron Brown NC ANNESHA20 Levafix Fast Red CA gran Dystar 45 Novacron Ocean S-R ANNESHA21 Ladipur RSK Liq Clariant 46 Ultratex SI ANNESHA22 Mercerol QWLF Liq Clariant 47 Sapamine CWS ANNESHA23 Mono Foam BPD ANNESHA 48 Everzol Navy C-GG ANNESHA24 Remazol Navy RGB 150% Dystar 49 Everzol Black C-GSP ANNESHA25 Remazol Blue RGB Dystar 50 Everzol Black MW ANNESHA

CHEMICAL & AUXILIARIES:

LIST OF CHEMICAL & AUXILIARIES

Sl.No

Name Of Chemical & Auxiliaries

Sl.No

Name Of Chemical & Auxiliaries

01 Arristan ACS 26 Helizarin*Soft SPT02 Arcofix NZK CN liq 27 Heptol DBL03 Appretan N96711 liq 28 Invatex CS04 Avetex SPR 29 Invatex ED05 Arcofix NETLF CN liq 30 Prestogen*F-PL06 Alkaven GAL 31 Reaknitt FF07 Alibigen* A 32 Stabilizer SIFA liq08 Ceranine HCD.ID fla 33 Size CA09 Contavan GAL 34 Printofix Krock ECO10 Elastex 35 Solosoft UP liq11 Evo Soft CF 100 36 Solosoft ACN liq12 Flosperse DT 37 Solosoft FE liq13 Fuchs HD-30 38 Sudiam alginate14 Fixapert *AP 39 Aceti acid15 Glycerin 40 Caustic soda16 Evo Soft CF 100 41 Formic acid17 Fixaprt*AP 42 Sirrix NE liq18 Hostapal UH liq 43 Siligen SIS nano19 Helizerin Binder X 4738 44 Urea20 Helizerin Fixing Agent TX 4737 45 MRN21 Hostalux CPA liq 46 Arriston 6422 Hydroperm RUP liq 47 Condensol F-M23 Helizarin*Binder TOW 48 Catalyst NKD liq24 Helizarin*Binder AP ECO 49 Ceralube PHD liq

25 Helizarin*Binder SPT 50 Enzyme-T

Sources of raw materials :

# Yarn :

o India o Pakistano Bangladesh.

# Fabric :

o India o Pakistano Bangladesh.

# Dyes & chemical :

o Bangladesh (Global, HP Chemical).o Pakistan (ICI Company).o Germany (BASF, Dyster).o Taiwan.o Thailand (Clarient).o Etc.

# Remarks :

It is undoubtedly essential for due time supplying of raw materials, dyes & auxiliaries for smoothly functioning of textile industry. At the

same time quality should be improved which is much more effective for improving quality. But it Is a matter of concern, there is no any company established yet which could fulfill the requirement of Dyes & Chemicals of Bangladesh Textile Industry.

CHAPTER NO-05PRODUCTION PLANNING,

SEQUENCES & OPERATIONS Production planning, Sequences & Operations:

Production planning:

Introduction and Basic Procedure of Planning and Control:

A planned work brings success. Without planning noting is completed within the required time. So planning has its own importance which is intolerable. Planning gives a scheduled task and control completes it successfully. But production planning and control is not an easy task. So Zaber & Zubair Fabrics Ltd has a self-sufficient and high-performance department called production planning & control. Its basic working procedure is as follows-

1. Taking orders from marketing division.

2. Analyzing the orders.

3. Planning for yarn selection.

4. Planning for dyeing the yarn.

5. Planning for finishing the yarn.

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:

Zaber & Zubair Fabrics Ltd marketing division supplies yarn order to ZZTF planning and control division by a special format.

2. Analyzing the orders:

These division sections analyze the orders according to buyers order quantity, type of orders (i.e. type of yarn, color to be dyed), 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 yarn to be collect (order quantity+6% of order quantity), collection balance, yarn need to be dyed. Dyeing balance, RFD balance, delivery yarn and delivery balance.

3. Planning for yarn selection:

This section plans for yarn production .Its selects machine for product the yarn for specific type of yarn, type of cotton used, required count, etc. It also gives delivery data for collect yarn .It also places orders for buying of yarn form spinning mills by a specific schedule planning for dyeing the yarn.

4. Planning for dyeing the yarn:

Production planning for dyeing is Batch plan. According to the batch no. And color count, types the batch plan is made. For easy understand this section gives some batch cards, batch cards are serialized according to the priority of delivery. The batch 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 yarn:

Finishing schedule is same used the dyeing. After dyeing material goes to the finishing section with the batch plan. Finished data written to the batch card & is informed to the planning section.

However, this section always enforces to all the departments to finish all the work within the delivery time given by the buyer. This section delivers materials by truck, micro, air etc. To the customer within the meantime.

DESCRIPTION OF PRETREATMENT: SINGEING. DESIZING. SCOURING. BLEACHING. MERCERIZATION.

A process flow-chart of pre-treatment section is given below-

Roll of fabric

Singeing unit Desizing unit

Pad Batch (Conditioning)

Wash Scouring

Wash (Water +Steam)

Bleaching (hot steam to dry)

Wash Drying

Go to mercerization section

SINGEING

Gas singeing machine is a modern & mostly used in the factory. It is so popular because proper singeing is done by the used this machine. To remove projected fibre, hairy fibre, yarn etc from the fabric surface and then to increase smoothness & high lustier of fabric surface with the help of gas burner in gas singeing process and ready for the next process. Gas singeing machine is a modern & mostly used in the factory. Generally, theses are two types:

1. Brush singeing

2. Gas singeing

Gas singeing is more effective than the brush singeing due to chance of fabric damage and inferior quality. Some features with figures are given below-

Fig: Modern machine of singeing

Heating medium, all types of gas or on request with gas fired petrol or kerosene; gas fired made by Osthoff - Singe.

Proportional gas: air mixing device

Flame intensity adjustable in a wide range

Flame width sleeplessly adjustable

Distance flame – fabric sleeplessly adjustable

Singeing parameters to be set manually or program controlled

Safety installations in accordance with local regulations.

4-burner singers are available for high-speed processes, i.e. rope bleaching lines.

Then the fabric is given to Desizing section for removal of sizing material. Now a day’s enzyme Desizing is more popular than the ordinary way. But conventional process is more effective and cheap. Before Desizing the roll of fabric is keep for a certain time for batching.

DESIZING Stainless steel compartment, single-threaded with 10, 15, or 20m fabric

content Jockey-roller on request,

http://www.osthoff-senge.com/en/seng_matic.html

Driven upper roller on request Bath filter on request

Squeezer, pressure according to need, with conventional or stabilized rolls Singeing is one of the fastest processes in finishing. In order to take advantage of it, singers mostly work as stand-alone unit. Besides preparing and cleaning of fabric, also impregnating for Desizing and/or per-oxide bleaching benefits from line speeds. Combined with corresponding squeezers and batching devices the singeing line is well equipped for highest production speeds.

Fig: Desizing process

Desizing chemicals are given below-

BEISOL T2090: enzyme (amylase)

Hostapol Extra (Wetting Agent)

Sirrix 2ud (Sequestering Agent)

Industrial data:

In this factory Singeing & Desizing both processes is done at the same time & same parameters with the help of the following machine:

1. Osthoff Singe.

2. Poong-Kwang singe.

# Specification of this m/c:

M/C Name M/C Quantity Company Country

1. Osthoff Singe 03 Osthoff Germany

2. Poong-Kwang Singe 01 Osthoff Korea

Singeing & Desizing process used in this factory:

Singeing:

All most Gas singeing process is used in this factory.

Desizing:

Peroxide Desizing, Enzyme based & Acid Desizing is used in this

factory.

M/C Parameters:

No. of burner---------------------02

Burner height---------------------16 inch

PH of bath -------------------------6.5-7.0

Temperature of desizing box----65-700C

Fabric speed------------------------50-100 m/min

Recipe for every Process:

For singeing:

Recipe for PC fabric:

BEISOL T2090: enzyme (amylase)------1.05kg

Hostapol Extra (Wetting Agent)-------------1.5kg

Water------------------1000 Liter

Recipe for cotton fabric:

BEISOL T2090: enzyme (amylase)-----3kg

Hostapol Extra (Wetting Agent)------------3kg

Sirrix 2ud (Sequestering Agent)-------------3kg

Water-----------------1000 Liter

For desizing:

Recipe for peroxide desizing:

Caustic soda-----------------40 g/l

Sandozol HS----------------0.3 g/l

H2O2 -------------------------3.3 g/l

Stabilizer--------------------0.3 g/l

Temperature of bath-------Room

PH of bath-------------------10-10.5

PH of fabric-----------------8.5

# Function of differant chemical agent:

Hostapol Extra-MRN : It is a wetting agent. It’s function is to remove surface tension of the water & minimize interfacial tension.

Enzyme-D: It is a desizing agent. It’s function is to remove the size material’s from the fabcic.

Sirrix-2ud: It is a sequestering agent. It’s function is to remove the water hardness & Deactivate metal ions.

Caustic soda: To neutralize acidic materials. Swell the fibre .

Stabilizer: To maintain the proper power of H2O2 at high temperature.

# Controling point of the singeing & desizing m/c:

Flame intensity Fabric speed Singeing position Distance between flame burner and fabric

Flame width Temperature Time & PH Nip pressure for desizing.

# FIGURE:

Fig: Singeing and Desizing M/C

SCOURING

Scouring, is a chemical washing process carried out on cotton fabric to remove natural wax and non-fibrous impurities (eg the remains of seed fragments) from the fibres and any added soiling or dirt. Scouring is usually carried in iron vessels

called kiers. The fabric is boiled in an alkali, which forms soap with free fatty acids. (Saponification).

A kier is usually enclosed, so the solution of sodium hydroxide can be boiled under pressure, excluding oxygen which would degrade the cellulose in the fibre. If the appropriate reagents are used, scouring will also remove size from the fabric although desizing often precedes scouring and is considered to be a separate process known as fabric preparation.

Preparation and scouring are prerequisites to most of the other finishing processes. At this stage even the most naturally white cotton fibres are yellowish, and bleaching, the next process, is required. A typical recipe for scouring is given below-

NaoH 99% : 25g/l(Be-46)

Hostapol Extra : 5-6g/l

Sirrix 2ud : 4g/l

BLEACHINGBleaching is one of the stages in the manufacture of textiles. All raw textile

materials, when they are in natural form, are known as 'greige' material. Not only the natural impurities will remain on the greige material but also the add-ons that were made during its cultivation, growth and manufacture in the form of pesticides, fungicides, worm killers, sizes, lubricants, etc.

http://en.wikipedia.org/wiki/Lubricant

http://en.wikipedia.org/wiki/Sizing

http://en.wikipedia.org/wiki/Fungicide

http://en.wikipedia.org/wiki/Pesticide

http://en.wikipedia.org/wiki/Textile

http://en.wikipedia.org/wiki/Reagent

http://en.wikipedia.org/wiki/Cellulose

http://en.wikipedia.org/wiki/Oxygen

http://en.wikipedia.org/wiki/Sodium_hydroxide

http://en.wikipedia.org/wiki/Saponification

http://en.wikipedia.org/wiki/Alkali

http://en.wikipedia.org/wiki/Boiler

The next process of decolorization of greige material in to a suitable material for next processing is called bleaching. Bleaching of textiles can be classified in to oxidative bleaching and reductive bleaching.A typical recipe for bleaching is given below-

H2O2(50%) : 15-16g/l NaOH : 4g/l Stabilizer FCB : 5-6g/l Hostapol Extra : 4-5g/l Acid : 5.5-6.0 (If Pigment)

Industrial data:

In this factory scouring& bleaching both processes is done at the same time & same parameters with the help of the following machine:

1. Bleaching m/c.

2. Bleaching m/c.

#Specification of this m/c:


1. Bleaching m/c.-1 02 Goller Germany

2. Bleaching m/c.-2 01 Brugman Holland

Scouring & bleaching process used in this factory:

Scouring:

All most continuous scouring process with NaOH used in this factory.

Bleaching:

All most peroxide bleaching process is used in this factory.

M/C parameters:

PH for printing:

a. Pigment printing-5.5-6.0

b. Reactive Printing-6.5-8.0

PH for dyeing:

a. Pigment dyeing 5.5-6

b. Reactive dyeing-7-7.5

c. Disperse dyeing-3-7.5

Speed:

a. For cotton-70-80 m/min

b. For PC-70-100 m/min

Temperature:

a. For washing bath-70-950C

b. For steaming chember-95-1150C

c. For chemical bath-45-600C

d. For cylinder dryer-150-2000C

PH of bath------------------------10-11

Recipe for every process:

Recipe for scouring process:

NaoH 99% : 25g/l(Be-46) Hostapol Extra : 5-6g/l Sirrix 2ud : 4g/l

Recipe for bleaching process:

H2O2(50%) : 15-16g/l NaOH : 4g/l Stabilizer FCB : 5-6g/l Hostapol Extra : 4-5g/l Sirrix 2ud : 4g/l Acid : 5.5-6.0 (If Pigment)

#Function of differant chemical agent:

Hostapol Extra-MRN : It is a wetting agent. It’s funcion is to remove surface tention of the water & minimize interfacial tention.

Sirrix-2ud: It is a sequestering agent. It’s funcion is to remove the water hardness.Deactivate metal ions.

NaOH(alkali): To neutralize acidic materials. Swell the fibre & saponify glycosides & to remove the oil, fats, wax & additive impurities form the fabric.

H 2O2: It’s a universal bleaching agent. H2O2 is virtually the only bleaching agent available for protein fibres & is extensively used for cellulose

fibres .It’s function to break the cellulose particles & remove the natural coloring matter & produce permanent whiteness to the fabric.

Stabilizer : Stabilizer effects at various condition of PH, temperature, liquor ratio & water hardness. It’s function to maintain the proper power of H2O2 at high temperature.

# Controling point of the scouring & bleching m/c:

PH

Temperature

Speed & Time

Concentration of hydrogen per oxide & NaOH

Liquor ratio

Water hardness

Etc

#Figure:

Fig: Scouring and Bleaching M/C

MERCERIZATION

Mercerization is done for some sevral purposes-

To increase lusture

To increase affinity to dyes

To control fabric width and for dimensional stability

To increase tensile strength and save dye.

Here machine specification with figure is given below-

Industrial data:

In this factory mercerization process is done with the help of the following machine:

1. Mercerize m/c-1

2. Mercerize m/c-2



1. Mercerize m/c-1 01 Brugman Holland

2. Mercerize m/c-2 01 Goller Germany

#Mercerization process used in this factory:

Mercerization process is done in this factory by using NaOH .

M/C parameters: PH for :

a. Pigment --------------5.5-6.0

b. Reactive --------------6.5-8.0

Feed to delivery fabrics------------160 m

Temperature of stabilizer-----------800C

Number of washing bath------------5

Temperature of washing bath ------70-950C

Number of acetic bath----------------01

Maximum m/c speed-----------------60m/min

Normally speed -----------------------25-50m/min

Number of drying cylinder----------10

Temperature of drying cylinder----180-2000C

Number of cooling cylinder---------02

Caustic of Beo:

a.For printing------------Beo (20-24)

b.For dyeing------------- Beo -28

Recipe for mercerization process:

NaOH (Beo-28)

Mercerize oil

Acetic acid

# Function of differant chemical agent:

NaOH(Be o -28): To neutralize acidic materials. Swell the fibre & saponify glycosides & to remove the oil, fats wax & additive Impurities form the fabric.

Mercerize oil: It is a wetting agent. It’s function is to remove surface tension of the water& minimize interfacial tension.

Acetic acid: To maintain proper value of PH .

#Controlling point of the mercerizing m/c:

PH

Temperature

Fabric speed

Time

Concentration of NaOH

#Figure:

Fig: Mercerizing M/C

DESCRIPTION OF DYEING:

CONTINUOUS DYEING PROCESS. SEMI- CONTINUOUS DYEING PROCESS. DIS- CONTINUOUS DYEING PROCESS.

DYEING Dyeing: Dyeing is the process of coloring textile materials by immersing

them in an aqueous solution of dyes called dye liquor.

Dyeing Process

Dye dissolved in the dye bath

Convective diffusion

Dye in the diffusion layer

Molecular diffusion

Dye in the electric double layer

Adsorption

Dye absorbed on the fibre surface

Sorption

Dye diffused in the fibre

Fixation

Dye physically/ chemically bonded with the fibre

Precise Description:

Basically in our country there are three ways to describe woven dyeing techniques. These have been briefed before. Before vast description we have to know the ways in short details. The short details is given below-

Continuous Dyeing Process: Pad-dry-pad-stream process:

Classic procedure for continuous dyeing of woven fabrics. Here the fabric is padded in dye liquor, then the fabric is dried and then again padded in caustic solution and at last the fabric is taken in a stream chamber for fixation of dyes. Primarily for cotton goods and long yardages. Main advantages of the process is high-productivity, good appearance, high color yield.

#Process sequence of pad-dry-pad- steam process:

Padding liquor

Padding liquor bowl with migration inhibitor

Drying chamber

Chemical padding

Steam fixation

Rinse

Soaping & rinse

#Function of different steps:

o Padding liquor bowl (Dye + Urea): 1st bowl is done with dye solution and urea at a temp of 600C-800C. Here urea helps to dissolves the dye completely in water and also to penetrate the dye within the fibre.

o Padding liquor bowl with migration inhibitor: in this industries sodium alginate used which acts as a migration inhibitor .

o Drying chamber : Drying the fabric in this chamber.

o Chemical padding (NaOH + NaCl) : After padding with dyes, urea, and migration inhibitor the fabric is again padded with NaOH & NaCL at 600C which is known as chemical padding.

o Steam fixation : the fabric is passed through in steaming chamber at the temp of 100-1020C for 30-60 seconds for fixing the dyes with the fibre.

o Rinse, soaping, & rinse : The fabric is subsequently rinse, soaped, and finally washed & dried in a dryer.

# Necessary chemical & auxiliaries used in different steps:

Drim Red-CL58

Drim Blue-HFGN

Drim Yellow-CL2R

Drim Navy-HFGN

Primasol-V

Primasol-NFZ

Urea

# Pad-dry-stream process:

This is a one-bath continuous process without an addition of salt. Its advantages over the others are far lower migration of dyes and good washing off.

Pad Thermosol process:

It’s a continuous process of one bath dyeing process. In1949 the DuPont company of USA is established this process for dyeing of synthetic especially nylon, Polyester and orlon dyeing without carrier. In Thermosol process the fabric treat with high temperature then the internal structure of fibre is open and the dye molecule’s are easily entered into the fibre.

Industrial data:

# Process sequence of pad-thermosol process:

Padding of fibre in a padder

Dryer

Curing/ thermofixing

Reduction clearing

Soaping

Rinse

# Function of different steps:

o Padding of fibre in a padder: The fabric is padded with the dye solution in a padder.

o Dryer: The fabric is dried at the temp 1200C in a dryer. o Curing/ thermofixing: Fixation of dyes in a curing chamber at 200-2100C

for 2-3 min’s.o Rinse, soaping, rinse: After fixation the fabric reduction clearing is done

with hydrose & caustic soda and then the fabric is soaped & then again rinsed.


Diamin Yellow S-4G Bema Red SE-4G Diamin Black 5R Premosol-V Setamol-WIS Acetic acid

Industrial data:

# Process sequence of pad - steam process:

Padding liquor bowl

Padding liquor bowl with migration inhibitor

Drying chamber

Chemical padding

Steam fixation

Rinse

Soaping

Rinse


Padding liquor bowl (Dye + Urea): 1st bowl is done with dye solution and urea at a temp of 600C-800C. Here urea helps to dissolves the dye completely in water and also to penetrate the dye within the fibre.

Padding liquor bowl with migration inhibitor: In this industries sodium alginate used which acts as a migration inhibitor .

Drying chamber : Drying the fabric in this chamber.

Chemical padding (NaOH + NaCl) : After padding with dyes, urea, and migration inhibitor the fabric is again padded with NaOH & NaCL at 600C which is known as chemical padding.

Steam fixation : The fabric is passed through in steaming chamber at the temp of 100-1020C when it takes for 30-60 seconds for fixing the dyes with fibre.

Rinse, soaping, & rinse : The fabric is subsequently rinse, soaped, and finally washed & dried to the dyeing.


Drim Red - CL 5B

Drim Blue-HFGN

Drim Yellow- CL 2R

Drim Navy- HFGN

Primasol-V

Primasol-NFZ

Sodium by carbonate

Urea

Industrial data: # Process sequence of pad-dry-thermofix process:

Padding liquor bowl

Drying chamber

Thermofixation unit

Rinse

Soaping

Rinse


o Padding liquor bowl (Dye + Alkali + Salt): In this padding bath dye stuff, alkali, salt, urea and sodium alginate are mixed at room temperature.

o Drying chamber: the padded fabric is dried in the drying chamber.

o Thermofixation unit: The fabric is treated for 5 min’s at 100-1600C temperature in a heating chamber for thermofixation.

o Rinse, soaping, rinse: After thermo fixation the fabric is rinsed, soaped, & again rinsed.


Drim Yellow HFCD

Drim Blue-HFCD

Primasol V

Primasol NF

Sodium by carbonate

Urea

Semi-continuous Process:

Pad-batch process: In this process the cellulose fibre fabric is padded with a reactive dye solution in the presence of an alkali, usually sodium bicarbonate stored in the wet condition for a pre-determined period and finally washed off. Depending upon the temperature during storing two sequences is employed-

a) Pad (alkali) - Batch (cold) process.

a) Pad (alkali) - Batch (warm or hot) process.

In the first sequence the padded cloth is covered with a polyethylene sheet (to prevent evaporation of water) and stored for hours and finally washed.

Industrial data: # Process sequence of pad-batch process:

Padding

Roll/batch at 200C

Rinse

Soaping

Rinse

# Function of different steps:o Padding (Dyes + Alkali + NaCL + Urea + Na-alginate): The fabric is

padded with dye, urea, & Na-aginate at a temperature of 20-250C.

o Roll/batch at 20 0 C: The padded fabric in roll form is transferred to a chamber where the temperature at 200C and relative humidity is 100% for 10-12 hour’s.

o Rinse, soaping, rinse: The fabric is rinse, soaped,& again rinsed.


Drim Red - CL 5B Drim Yellow- CL 2R Caustic (380 Bo) Soda ash Urea

Pad-pad-stream process: This process is only for specific heavy fabric qualities. A special pad liquor applicator is required. This is a “wet-on-wet” process without intermediate drying.

Dis-continuous process:

Jigger dyeing process: This is most commonly used piece dyeing process for dyeing almost all kinds of cotton fabrics. The fabric moves while the liquor stands still, except for the very latest machines, which are also equipped with a circulation pump.

Industrial data:

# Process sequence of jigger dyeing process:

Padding mangle

Jigger to develop color

Fixation

Rinse

Soaping

Rinse


o Padding mangle (Dyes): The fabric is padded with dye liquor in a padding mangle. No alkali & salt is used in this stages.

o Jigger to develop color (NaOH + NaCL): The fabric is transferred to jigger dyeing machine to developed the color with the addition of salt & alkali. dye is fixed-up in this stages.

o Rinse , soaping, rinse: After fixation the fabric is rinsed, soaped, & again rinsed thoroughly.


Drim Yellow CL-2R

Drim Red CL5B

Nova Black G

NaOH

NaCL

Pirmasol NF

Comparative Discussion: In industries continuous and semi-continuous dyeing process is more popular than the dis-continuous process of dyeing. Here the discussion on the process with figure, flow chart, technical data, typical recipe and manufactured fabric can be given. The draw-backs with probable solutions are given for further paper work.

Before discussing on dyeing process the preview of pretreatment is given for understanding the whole process. At first the fabric is taken for singeing. Singeing can be done in two ways-

Pad-dry-pad-steam process: The dyeing process can be applied on open-width pieces, on fabrics that are particularly sensitively to creases and crush marks. Pad dyeing differentiates from exhaust dyeing in the dye bath application and fixation process. Very reduced water quantities are required, resulting in lower energy consumption.

A greater measure of continuity is achieved in the pad-dry-pad-steam process in which the cloth is first dye-solution padded, dried, padded with sodium hydroxide and hydrosulphite, passed through a steam chamber to reduce and fix the dye molecule into the fibre, and finally finished off in a soaping and rinsing range. The sequence of operation can be illustrated by the figure. It is customary to add a small proportion of the dye to the liquor in the padding mangle containing the reducing agent to compensate for any tendency for the leuco compound to migrate. A typical recipe is given below-

Mikentren Grey MS/F U/C: 18.5g/l

Mikentren Blue RSN : 10.6g/l

Indentren Red FBB : 5.1g/l

Sodium hydrosulphite : 60g/l

Glubar salt : 50g/l

NaoH : 25g/l

Booster chamber are some times used instead of the steam chamber. The liquor is maintained at 75C to 100C and the reduction and fixation of the pigment of the dye is very rapid in the aqueous phase because temperatures are used which are very much higher than would be employed when dyeing with the leuco compounds by conventional methods. Industrial pad-thermosol process is given below-

One reason is that the adsorption of leuco compounds is very rapid at high temperatures and the associated tendency for unlevelness can be overcome by pigment padding.

These continuous methods, however, are used with reactive dye. There are a few vat dyes which are not stable at high temperatures. Thus leuco derivatives of vat dyes containing benzoylamino groups tend hydrolyze under high-temperature reduction conditions.

Cold Pad Batch Process: In this process, a cold pad dyeing cycle is carried out using auxiliaries and dyestuffs.The fabric is then wound up in rolls and covered with a plastic sheet to prevent the drying and oxidation of the outer layers. It’s then rotated slowly for 8 to 24 hours to avoid percolation due to the gravitational effect on the liquid, which could distort the roll and create dyeing defects. The fabric is then finally washed with auxiliaries. A typical recipe is given bellow-

Remizol Red RB : 36.5 EverzolYellow 3RS : 22.0

Remazol Blue BB : 0.04 Sodium silicate : 30.0 Caustic soda 99% : 9.0 Soda ash : 6.0 Primasol NF : 3.0 Batching for 12 hours washing

Soda ash, sodium met silicate and caustic soda may be used depending on the depth of shade dyed. Because of high reactivity of cold brand reactive dyes with these alkalis, a short fixation time is enough. However, the pad liquor (containing the dye and alkali)

is stable only for a short time. Hence the dye and alkali solutions should be prepared separately and mixed immediately before use.

In actual practice, properly prepared fabric is padded with the liquor containing the cold brand dye and the suitable alkali at 20 to 30C (the lower temperate is preferred on the grounds of bath stability). The temperature should be kept constant to avoid variation in shade, especially when mixtures of dyes of different reactivity are dyed. High padding speed with adequate wetting-out of the fabric is preferred.

.

Pad-Steam Process: In this process at first the fabric is padded and then passes through a steam chamber. This steam chamber is working as fixation chamber. The use of this continuous process is given below-

A wide range of shades can be found. Economical advantage. The control of shade is maintained accurately and fastness property is great.

The padder pressure, and padder type is responsible for dye pick-up%. One of the figures is given below-

Fig: padding mangle

In the continuous process of dyeing the dryer make an effective roll to go to the fabric at last stage for finishing. Two type of dryer is used-

Infrared dryer

Drum dryer

Jigger Dyeing Process: The fabric pieces are sewn together tail to head, forming a sort of ribbon. At the head and at the tail of the ribbon two cloths are added (4.5m long) to allow the regular dyeing of the whole pieces, also leaving the machine drawn-in once the dyeing process has come to an end. The assembled pieces are taken down from a roll, pass through the liquor( they are kept in the correct position by means of transport cylinders and a tension equalizer, which avoids the formation of wrinkles). The fabric is then wound on a take up roll until the dyeing process has ended.

Figure:

Fig : Jigger dyeing machine

The piece through speed and tension are adjusted by special devices to avoid any change in dimensional stability, above all when treating light-weight fabrics or delicate fibres, the maximum diameters of the roller can be 1450 mm with a width of the cloth ranging between 1400 and 3600 mm. The piece through speed is adjusted between 30to 150m/min, and kept constant during the whole operation.

Also the tension must be constant and it can be adjusted between 0 to 60kg. The composition of the liquor absorbed must be uniform as possible on the whole width and length of the fabric piece; for big lots, many additions may be necessary to avoid the so called head-tail defects. Light-weight fabrics (viscose, nylon) that are stretched excessively during the take up step can

show shading defects. Jiggers work with a quite low liquor ratio (from1:1 to 1:6). Together with standard atmospheric systems, builders also offer HT jiggers inside autoclaves working at high pressure. Jiggers are suitable for dyeing all type of fibres.

There are some certain draw-backs of the techniques used in woven dyeing. They are-

Long time batching may cause faulty fabric. Chance of crease mark In batching improper rotation of batches

So some measures should be taken for an effective follow-through. As batching is less effective than pad thermosol, so pad-thermosol is the most effective & popular technique in woven dyeing.

Suggestions are using skilled labors and proper observation can minimize production cost and makes profit higher.

Figure:

Fig: Thermo sol M/C

DESCRIPTION OF PRINTING:

Printing: The printing is described as localized dyeing I;e dyes or pigments are applied locally or discontinuously to produce the various design. The main objective in textile printing is the production of attractive designs with well defined boundaries made by the artistic arrangement of a motif or motifs in one or more colors.


M/C Name M/C Quantity Company CuntryPrinting M/C (Rotary) 4 Zimmer AustraliaPrinting M/C(Flat Bed) 1 Zimmer Australia

# Sequence of pigment and reactive printing:

PIGMENT PRINTING REACTIVE PRINTING

Printing Printing

Curing Steaming

Finishing Washing

Folding Finishing

Curing

Calendaring

Folding

# Steps in textile printing:

Preparation of fabric to be printed. Preparation of the print paste (by using printing ingredients). Making an impression of the print paste on the fabric. Drying of the fabric.

Steaming of the printed fabric. After treatments (Neutralization/ Soaping etc).

# Main unit of printing machine:

Tension roller Guider Pressure roller Blanket Glue tray Washer Brush Screen unit Conveyor Curing unit Plaiter

# Function of main unit of printing m/c:

Tension roller: Control tension of the fabric.

Guider: Control fabric direction.

Pressure roller: Fabric pressing on the blanket surface as it is not displaced.

Blanket: Glue is added on the blanket surface as a result fabric is firmly attached with the blanket & carrying the fabric forward under the screen.

Glue tray: Glue solution is supplied from the glue tray.

Washer: Residual paste on the blanket is removed by water spray.

Brush: Brush assist to remove residual color paste.

Screen unit: Rotary screen is setting this unit (capacity 12 screens).

Conveyor: Fabric conveyed to the curing unit by conveyor.

Curing unit: After printing fabric is cured for fixation of color.

Plaiter: Printing fabric is delivered on the trolley by plaiter.

Figure:

Fig: Flat bed M/C

DESCRIPTION OF FINISHING: STENTERING MACHINE. CURING MACHINE. CALENDERING MACHINE. SANFORIZING MACHINE.

FINISHINGThe term “Finishing” in its widest sense covers all the processes which

fabrics undergo after leaving the loom or knitting machine. A simple definition of finishing is the sequence of operations, other than scouring, bleaching & coloring, to which fabrics are subjected after leaving the loom or knitting machine. By these finishing processes the fabric becomes more attractive, improves their appearance & also changes their properties. These are the main processes of finishing, calendaring, schreinering, embossing, milling, raising, laminating, mercerizing, parchmentising, water proofing, moth proofing, mildew proofing, fire proofing, anti crease finishing, sanforizing etc.

The finishing process may be classified into two main classes:

a. Physical finish.b. Chemical finish.

The physical or mechanical processes range from simple drying over steam- heated cylinders, or on a stenter which both dries stretches the cloth, to a complicated series of calendaring.

Chemical finishes indicate the application or deposition of chemical compounds on fabrics to improve the appearance The chemical finishing is performed by treatment with starch, dextrin, glue, gums, china clay, epsom-salt, glycerol, soaps, & soluble oils, for stiffening, weighting, & softening, as required.

The compounds used in finishing may be classified as follows:

a. Long-chain fatty compoundsb. Synthetic resins c. Cellulose derivativesd. Quaternary ammonium compounds.

The finishing can also be divided into temporary & permanent. A finish can only be considered permanent if it remains unaffected through all the conditions of wear& treatment to which a fabric may be subjected during its life.

On the basis of “temporary” & “permanent” effects, the following may be regarded as impermanent or temporary finishes : calendaring, beetling, schreinering, embossing, & glazing, breaking, & stretching.

Chemical: Mercerizing, parchmentizing, immunizing, treatment with ethylene oxide, formaldehyde finishes, wet chlorination & other non-felting effects, permanent setting of wool.

At one time it was customary to classify the finishes for cotton under three headings:

a. Pure finisha. Assisted finishb. Stiffened finish

The pure finish is mainly for goods which are intended for subsequent printing & dyeing & may be called intermediate finish. Pure finish generally consists in opening the cloth which has been bleached in rope- form, washing & drying during the drying processes, the opportunity may be taken to rectify the width of the cloth & to adjust any distortion warp & weft which may have occurred during bleaching.

The assisted finish relies to some extent on the presence of material other than the cotton, & small amounts of some stiffening or binding agent are applied before the mechanical finish in order to improve the general effect, but these additions should not be obviously apparent.

The stiffened finish relies to a much greater degree on the presence of stiffening, binding, filling, & weighting agent in considerable quantity. On other hand, there has been a tendency sell starch & china clay instead of cotton merely to give the effect of a thickener, better & more robust fabric.

STENTER MACHINE

Industrial data:



Stenter 02 Babcock Germany

Stenter 01 Muzzi Italy

Stenter 06 Monforts Germany

Stenter 01 Artos Germany

Stenter 01 Sunsuper Korea

Description:

To remove shrinkage that occurs due to different wet processing (e g. Desizing, scouring, bleaching, mercerizing, dyeing etc)In this process to include the anti shrinkage on the fabric and come back of the fabric of it’s original position and to dry the fabric.

In this process the fabric brings a uniform width form & to straight the weft yarn in a 900 angle with the warp yarn. A stenter has clip chain in both side of the machine which drive by the mechanical device.

To required stentering after wet dyeing, printing or wet finishing to treatment the fabric by using drying unit at 2000C-2200C for 30-50 seconds.

# Machine parameter:

No. of chamber--------- 8

Over feeding

Temperature of each chamber :-

c. 1st & 2nd chamber------1650C

d. 3rd to 7th chamber------1700C

e. 8th chamber-------------1650C

Temperature is create with the help of gas burner

No. of gas burner--------8

# Controlling point:

Over feeding

Temperature for each chamber

Speed of fabric

Chemical used for finishing

PH of chemical liquor.

Figure:

Fig: Stenter m/c.

# Main unit of stenter machine:

Feed roller. J-Box. Guide roller. Padder. Mahlo. Over feed roller. Under feed roller. Heating chamber (burner). Width control device (width sensor). Selvedge control device. Exhaust fan. Blower. Delivery roller(tension roller). Etc.

# Recipe for finishing (pigment print):

Arco fix NETLF = 40g/l

Catalyst(MgCl2) = 10g/l Solo soft UP = 15g/l MRN = 01g/l Acetic acid = 0.3g/l Temperature = 180c Speed = 60m/min

# Recipe for finishing (Rective print):

Arco fix NZK = 70g/l Ceranine = 20g/l Siligen SIS =10g/l Ceralob PHD =20g/l Urea = 10g/l Acetic acid =0.8g/l Temperature = 180c Speed = 50m/min

Figure :

Fig: Stenter M/C

CURING MACHINE

Purpose of curing: Curing is a process in which fabric passes over a

chamber which maintains temperature range 140-160c for dwelling 5-8 mints. For pigment printing curing is necessary due to fixation of color.

Objective of loop steaming: After printing and drying, the dye is not transferred into the fabric in fact. During steaming the printed & dried fabric is exposed to the action of moist, saturated or super heated steam at atmosphere or higher pressure over a range of temperature 100-103cfor 6-7 mints. As a result high concentration of the dye ,is rapidly transferred into the fabric from the thickener film.



Curing 05 The sitara eng. Pakistan

Loop steamer 02 Ariolly Italy

Figure:

Fig: Curing M/C

CALENDERING MACHINE

Industrial data:

Description:

TO treat the fabric in the vertically heavy roller / bowl with the help

of heat & pressure to produce some properties of fabric e.g. luster,

smoothness, brightness, closeness of thread, lining effect, water mark etc.

It is a mechanical finishing process. In this process to use 3-11

rollers. 3, 5 or 7 rollers of machine is mostly use in industry. 3 or 5 roller are

use for cotton, silk & 7 roller is use for jute.

Calendar rollers are two types are follows:

a. Metallic roller

b. Compressed material roller

To set the metallic roller in the compressed roller & to heated them by the use of

steam or gas burner. And than the pressure is applied on the fabric as follows:

a. Compound liver & weight

b. Hydrolic pressure.

To completed calendaring when the fabric is passing between this roller by the

maximum hydrolic pressure.



Calender 02 Ramesh Italy

#Machine parameter:

No of roller--------------03

a. Steam roller

b. Nylon roller

c. Cot roller

Roller pressure-------12-15

Roller temperature---70-750C

Steam pressure

#Controlling point:

Roller pressure

Steam pressure

Roller temperature

Fabric speed

No. of roller etc.

Figure:

Fig: Calendar m/c.

SANFORIZING PROCESS

Industrial data:

Description:

In this machine has a larger size cylinder or drum. In this process the fabric is treated of tight condition on the contact of larger cylinder with the help of a hot shoe and a endless woolen blanket and give to the fabric of anti shrinkage by a proper sanforizing range.

It is a mechanical finishing process which remove the tendency of shrink from the fabric in warp & weft wise of the fabric. In sanforizing process to create shrinkage by a rotate elastic felt blanket on the fabric. To produce equal shrinkage when the blanket is tension free& the fabric contains on the surface of the blanket. So, after produce shrinkage rearrangement of yarn in the fabric.



Sunforise 01 Monforst Germany

# Machine parameter:

Pressure of rubber blanket-----------2-2.5

Steam pressure------------------------2-3

Hot shoe

Clipexpender roller

Endless woolen blanket

Skyer

Hot cylinder

Water spraying unit.

# controlling point:

Pressure of rubber blanket.

Steam pressure

Fabric speed

Speed of endless woolen blanket

Width of clipexpender roller etc.

Figurer:

Fig: Sanforizing m/c.

Figurer:

Fig: Sanforizing M/C

CHAPTER NO-06

QUALITY ASSURANCE SYSTEM Quality assurance system:

The quality department is assigned to maintain consistently uniform quality of the material in process & various stage of its manufacturing.

In ZABER & ZUBAIR Fabrics Ltd quality is controlled in the following way-

# LAB & QC

Off line On line Color pilot plant (Lab dip).

# Off line: Color fastness to rubbing

Color fastness to washing

Color fastness to light

Perspiration test (Acid & Alkali)

Pilling

Tear strength

Tensile strength

Dimensional change

Fabric analysis (Count, EPI, PPI, GSM, Blend test)

Abrasion test

Chemical purity test

Etc.

# On line:

Pick up check

Size check

Titration

Whiteness

Absorbency

Drop method

Wicking method

Core pH

Barium activity of mercerized fabric

Shade continuity of running dyed fabric

Dye liquor pH check

Fastness properties of running printing fabric

Chemical purity test

Water hardness test, TDS, Water pH checking

Etc.

# Color pilot plant:

At first customer given dyed sample swatch through Marketing department to Lab & QC department then it is matched by color pilot plant unit which is performed in the following sequence:

Fabric swatch

Color analysis

Dyeing recipe analysis

Dyeing recipe formation

Recipe entered into the computer

Dyes & chemical stock solution preparation

Preparation of dyeing solution

Sample dyeing

Comparison with swatch

Pass

Customer

Color check

Production Bulk

# Remarks:

Zaber & Zubair Fabrics Ltd is always aware about the quality of their product. The quality of the product is maintained as per requirement of the buyer. Organization is well equipped for checking the quality of the product. They always performed precise report and sent them accurate time.

CHAPTER NO-07Maintenance

Maintenance:

Maintenance:

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 but 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 :

1.To keep the factory plants, equipments, machine tools in an optimum working condition.

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

3.To keep the downtime of machines to the minimum thus to have control over the production program.

4.To keep the production cycle within the stipulated range.5.To modify the machine tools to meet the need for production

Maintenance of Machinery:

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 can not perform its normal functions.

Routine Maintenance:

Maintenance of different machines are 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

Mechanical

Maintenance

Electrical

Maintenance

Mechanical

Maintenance

Electrical

Maintenance

Break Down MaintenancePreventive Maintenance

Maintenance

A Shift 6 AM - 2 PM B Shift 2 PM - 10 PM General Shift 9AM - 6 PM

Maintenance Manager

Mechanical Electrical

Mechanical In charge - 02 Electrical foreman

Diploma (Mechanical) - 02 Diploma (Electrical) – 02

Welder and fitter – 01 Electrician - 02

Fitter – 01

Maintenance Procedure:

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

Maintenance : Mechanical

Machine : Pretreatment machine

SL. No. Items need to be checked & Serviced

1 Machine bearing check.

2 Complete cleaning of machine.

3 Cleaning of drain valves, replace seals if required.

4 Check air supply filters, regulators auto drain seals

5 Clean filters element.

6 Greasing of unloading roller bearing.

7 Checking of oil level and bolts of unloading roller gearbox.

8 Checking of unloading roller coupling and packing.

9 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 modulating valves

12 Check all door seals.

Maintenance : Electrical

Machine : Pretreatment machine


1. Check & clean fluff and dirt at dirt at all motor fan covers.

2. Check all motor’s terminals

3. Check main panels (by using compressed air)

4. Check panel cooling fan & clean its filter

5. Clean main pump inverter and its cooling fan.

6. Check all circuit breaker, magnetic conductors and relays.

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

8. Visual checking of all power & control cables.

9. Check all pressure switches

10. Check calibration of main vessel & all addition tank

11. Check all emergency switches

12. Check all indicating lamps

13. Check all on/off switches

Maintenance of finishing department:

Equipment name:

Mahlo zone of Stenter:

SL. No.

Items need to be checked & Serviced

1. Check and tightening all motor terminals and clean the motor fan (30days).

2. Check activity of wide and sensor and pneumatic regulator.

3. Check and clean pressure sensor and tightening terminals

4. Clean the A/C ventilation fans of panel board

5. Check the fan and the heat sink o the inverters in the panel board.

6. Check and tightening the edge sensors.

7. Check and tightening the photo sensor terminals.

8. Check and tightening the safety light barrier and tightening the terminals.

9. Inspection, cleaning and tightening all the terminals in the panel.

10. Check and tightening limit switch, safety door guard and the emergency switch.

Check List of Different Parts

Maintenance : Mechanical

Machine : Dyeing machine


1 Crease the m/c bearing.

2 Complete cleaning of machine.

3 Cleaning of drain valves, replace seals if required.

4 Check air supply filters, regulators auto drain seals

5 Clean filters element and blow out.

6 Greasing of unloading roller bearing.

7 Checking of oil level and bolts of unloading roller gearbox.

8 Checking of unloading roller coupling and packing.

9 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 modulating valves

12 Check all door seals.

Maintenance : Electrical

Machine : Dyeing machine


14. Check & clean fluff and dirt at dirt at all motor fan covers.

15. Check all motor’s terminals

16. Check main panels (by using compressed air)

17. Check panel cooling fan & clean its filter

18. Clean main pump inverter and its cooling fan.

19. Check all circuit breaker, magnetic conductors and relays.

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

21. Visual checking of all power & control cables.

22. Check all pressure switches

23. Check calibration of main vessel & all addition tank

24. Check all pneumatic solenoids

25. Check calibration of heating/cooling modulating value

26. Check setting of tangle sensor.

27. Check setting & operation of lid safely switches.

28. Check all emergency switches

29. Check all indicating lamps

30. Check all on/off switches

31. Check all signal isolators.

Maintenance Tools & Equipments:

1. Combination tools / spanner

Function: Tightening & loosening of nuts & bolts.

2. Socket ratchet set

Function: Tightening of nuts & bolts.

3. Slide range


4. Monkey pliers


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 marking on metal & wood.

11. Easy opener

Function: To open the broken head bolt.

12. External threat die

Function: For external threat cutting.

13. Heavy scissor

Function: Cutting of gasket & steel sheet.

14. Oil can

Function: Oiling of moving parts.

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. Hammer

Function: For scaling & right angling.

22. Circlip tools

Function: Circlip opening & closing.

23. Hacksaw blade

Function: For metal cutting.

24. Handsaw (wood)

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.

CHAPTER NO-08Utility services

Utility services:

Introduction:

ZABER & ZUBAIR FABRICS LTD. is a big project and so of course having a vast project of utility service. Here the total account of utility facilities are available. The utilities are

a) Waterb) Gas

c) Electricityd) Compressed Aire) Steam.

WATERWater treatment plant:

(Water Softening Method – Base Exchange Process)

Source of water is deep tube well.

Production capacity – 80 m3 /hr = 1920000 liter/day

Actual Production – 1500000 liter/day

Required water - 1300000 liter/day

Technical Details

Raw Water tank Filter Tank (1) Filter Tank (2) Hardness Removing Tank

Size Length – 30´

Width - 15´

Height – 6’

Diameter – 6´

Height - 15´

Diameter – 6´

Height - 15´

Salt reqd:

190 kg/day/tank

Regeneration time 1.30 hr

Capacity 360 Ton

Source Natural source

Deep tube well

Raw Water Tank Filter Tank (1) Filter Tank (2)

ELECTRICITY

Gas Generator is used for supplying electricity for the dyeing & office of the ZABER & ZUBAIR FABRICS LTD.

Total power produced by Gas Generator – 945 KW = 1134 KVA

Factory (Dyeing) Power Needed for Installation – About 1200 KW

Factory (Dyeing) Power Needed at Running stage – About 720 KW

Power Needed for Office – About 250 KW

Specification of Gas Generator is given below:

Technical Details Generator Data

Type Gas Generator

Manufacturer Cummins Power Generation

No. of Gas Generator 03

Model No. 315 GFBA

Manufactured Country England

Year of Construction 2002

Rated Power Prime

Rated 315 KW

Power Factor 0.8

Voltage 400

Rated Current (amp) 568

Frequency (Hz) 50

Rotating Speed (RPM) 1500

Battery Volts 24

Control System PCCP

Site altitude before derate 800 MASL

Site ambient temp. before derate 400C

Source of Power used for Garments – DESA

Power Capacity – 750 KVA = 900 KW

There is a diesel Generator in the industry.

Capacity of Diesel Generator – 800 KW

Specification of Diesel Generator is given below:

Technical Details Generator Data

Type Diesel Generator

Manufacturer CATERPILLAR

No. of Diesel Generator 02

Model No. SR4B | SR4

Manufactured Country U.S.A.


Rated 649 H.P. or 484.0 KW

Rotating Speed (RPM) 1500

Voltage 400

Rated Current (amp) 723

Maximum Temp. 1050C by Resistance

COMPRESSED AIR

Compressed air is produced by air compressor.

There are two air compressors for producing compressed air.

Specification of the air compressor is given below:

Technical Details Air Compressor 1 Air Compressor 2

Type Atlas Copco Atlas Copco

Manufacturer Atlas Copco Airpower Atlas Copco Airpower

Model No. GA 30 GA 55

Manufacturer Country Belgium Belgium

Year of Construction 2002 2004

Maximum Working Pressure 10 bar 10 bar

Free air delivery 78 liter/sec 145 liter/sec

Nominal Shaft Power 30 KW 55 KW

Rotational Shaft Speed 3000 r/min 3000 r/min

Gross Weight 995 Kg 1550 Kg

STEAMSteam is produce by Boiler.

From the Water Treatment Plant, water is stored in a reserve tank and from there water goes to boiler & steam is produced.

Specification of the Boiler is given below:

Technical Details Boiler Data

Type Fire Tube Boiler

Manufacturer OMNICAL BORSIG ENERGY

Model No. DDHI 60 – 10

Manufacturer Country Germany


Thermal Capacity 3.9 MW

Maximum Steam Out 6 ton/hour

Maximum Working Pressure 10 bar-g

Content up to NW 10940

GAS

The source of Gas is TITAS GAS LTD.The gas is supplied to gas generator or different section (Boiler- for heating water) from the main line of the TITAS GAS LTD.

Sources of Utility:

Electricity : PDB & Generator

Steam : Boiler

Water : Pump

Compressed air : Compressor

Gas : TITAS GAS LTD.

Remarks:

As the biggest project the ZABER & ZUBAIR FABRICS LTD., so the vast utility systems. There is a skill manpower group of engineers and other technical staffs to look after these utility services. They have to remain aware of solution on a great sense of responsibility for any type of problem due to utility supply.

CHAPTER NO-09STORES AND INVENTORY CONTROL

Inventory control:

Inventory control is a wider sense is a defined as any idle resource of an enterprise; however it is commonly used to indicate materials-raw materials, finished, semi finished, packing, spares, & other stocked in order to meet an expected demand or distribution. Even through inventory of materials is an idle resource in the sense, it is not meant for the most immediate use but it is almost necessary to maintain some inventories for the smooth functioning of an organization.

# Necessity of inventory control:

The necessity of inventory controls is to maintain a reserve of goods that will ensure manufacturing according to a production plan based on sales requirement & the lowest possible ultimate cost. Losses from improper inventory control include purchases in excess than what needed. The cost of slowed up production resulting from material not being available when wanted. Each time a machine must be shut down for lack of materials or each time sale must be postponed or cancelled for lack of finished goods. Thus factory losses money.

To promote smooth factory operation or to prevent pilling up of stock or idle machine time proper material must be on hand when it is wanted. Proper inventory control can reduce such losses to a great extent.

# Categories of Inventories:

Raw materialo Dyeo Chemical & auxiliarieso Grey fabric

Finished fabric Spare parts.

# Types of inventory control:

Monthly inventory control. Annual inventory control.

Raw material: Materials and components scheduled for use in making a product.

Inventory system of dye and other chemicals:

At first dyes or chemicals is indent from the processing department. Store department send this indent to purchasing department. Purchasing department purchase dyes or chemicals from the local

market or by L/C. After purchasing chemical or it is verified or tested by quality

department. Then it is stocked by store department. If material needed then processing department send requisition to

store department. All documents are recorded by store department. Inventory team checks the inventory status monthly or annually.

Inventory system of grey fabric:

At first fabric is produced as per instruction of the marketing department.

After producing fabric then it is inspected by the quality department. Quality fulfilled fabric stocked by the grey store department grade

wise. As per production planning grey fabric is supplied from the store to

processing department. Al documents are recorded by the store department. Inventory team checks the grey status monthly or annually.

Inventory system of finished fabric:

If the quality is fulfilled by quality department then it is inspected by the inspection section by four point system.

After finishing, the fabric is kept in package before their transfer to the garments department.

It is controlled by the inspection in charge who keeps a list of total finished product; he also keeps a list of delivery products.

He supplies the fabric as per requirement and records the date, type of material, quantity and section in which supplied, in his register book.

Inventory team checks the all documents monthly or annually.

Inventory system of dye and other chemicals:

Store officer keeps the spare parts in store and make a list of spare parts.

If the spare parts are little in stock he gives requisition to maintenance manager.

Maintenance manager gives requisition to head office. Head office imports spare parts or buy’s from the local market as per requirement.

As new spare parts arrive to store office, he receives and catalogues them.

He supplies the spare parts as per requirement and records the date, type of material, quantity and section in which supplied, in his register book.

Inventory team checks the status monthly or annually.

# Remarks:

The Zaber & Zubair Fabrics Ltd having individual store to promote smooth functioning of organization work. The store is always remaining neat and clean.

CHAPTER NO-10

COST ANALYSIS

Cost analysis:

o Cost of the fabrics.

o Cost of the accessories.

o Cost of the transport.

o Clearing and forwarding cost.

o Total utility cost.

o Commission.

o Salary expenses.

CHAPTER NO-11

MARKETING ACTIVITIES

Marketing:

Marketing is the societal process by which individuals and groups obtain what the need and want through creating, offering and freely exchanging products and services of value with others.

# Core concept of marketing:

Needs

Wants

Demands

Marketing offers

Product Services Experiences

Value

Satisfaction

Exchange

Transactions

Relationships

Markets

Customer of the products Country of Export

IKEA Sweden H&M Sweden

Joint max USA Hemtex Australia Caree four USA Character world Canada

Herding USA Domotess Australia Bjorna UK Laredoute UK Verbedoute UK

Vanes Holand Otto international UK Nitori UK Spring Canada Canada Heritage Canada Fran Textile Holand Tissery German Recttla German

Ellos Australia Bonprix UK Ekkel boom German Newtop UK Vandilan, Asiatex UK Maurice Philips UK Sandown & Boure UK Linen croup USA

Beco Canada

# Importance of Good marketing:

Marketing is very important to sell the product to the customer. If the marketing team is well organized then the company easily reaches their goal. In these sense marketing team of Zaber & Zubair Fabrics Ltd. is much more precise and perfect. In case of garments marketing the dealings with the buyer very important factor.

In Zaber & Zubair Fabrics Ltd. Marketing officer deal with buyer. There is some fixed buyer they always given order all the year round so there is no hesitation of order.

# Duties of the marketing officer:

Marketing officer always try to convincing buyer for collecting order as well as price of the product. They are having intension to motivate new buyer by offering new quality of product.

Besides above they have also some responsibility-

To prepare cost sheet by dealing.

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

To maintain good relationship between commercial officers & merchandisers.

To maintain communication with the buyers and buying house. Communicate with better knowledge of the products.

Actually the responsibility and duties of marketing officer begin from getting order of buyer and ends after receiving payment by the buyer. So, he should be always smart, energetic and sincere.

# Remarks:

Zaber & Zubair Fabrics Ltd is one of the 100% export oriented and quality based textile mill. Well reputation and recognition of these factories, buyers of the different courtiers come forward for purchasing product.

CHAPTER NO-12

CONCLUSION

Conclusion:

The Zaber & Zubair Fabrics Ltd is one of the well reputed 100% export oriented quality based textile mill. The management body of this textile is well organized and always follows the chain of command. Their objectives are to achieve 100% quality and meet the demand as per buyer requirements.

Besides above characteristics, organization having following intention which could be mentioning as follows-

Reduction of wastage at 2%. Reduce the stoppage time of machine at 5% within 2012. Fulfill the demand of customer by time to time shipment.

Organic productivity increase as soon as possible. Reduce the re-process and save cost of the company. Ensure all kind of facilities of the employee of the organization. To eliminate environmental adverse effect by using effluent plant.

If the company meet up those criteria all the time. I am sure the organization progressed will be up ward day by day. I am very lucky University of South Asia has given me the opportunity to perform the industrial attachment in this type of organization.

Undoubtedly, this attachment experienced me the textile technology as well as gaining adequate knowledge for the management and production process. I believe that, this experience will much more help in my future life for carrier growth.

Education

Indutrial Attachment