Industrial Attachment of itramex by zareen a.abedin

Industrial Attachment Intramex Group Introduction Textile and garments sector is the biggest and fastest growing sector in Bangladesh. It is also the highest foreign currency earning sector in Bangladesh. Among this sector, Knit garment is growing very rapidly due to smaller investment requirement, greater backward linkage facility & higher profit than woven garments. That’s why export knit garments is increasing steadily for last few years and up to now. Industrial training is very much important for textile education. I have gathered a lot of information’s from this Industrial training which will help me to lead my future life and as well as the greater development in textile fields. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at INTRAMEX GROUP, which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing. General information about the company Name of the company: INTRAMEX GROUP Factory: INTRAMEX Group Laxmipura, Jaidebpur, Gazipur. Bangladesh Email: info@intramex group.com

Different Sections of

Different Sections

INTRAMEX Knit-Dyeing Composite Unit: a) knitting Section: Knitting Inspection b) Dyeing section: Batch section Dye house Dyeing lab. Quality control Finishing c) Garments section: Merchandising Sample Cutting Section Sewing Section Finishing Section d) Maintenance section: Electrical Mechanical e) Store Section f) Administration Section g) Security Section h) Marketing Section i) Production Planning & Control j) Human Resource & Development Section

INTRAMEX GROUP INFORMATION: Nature of company

100% Export Oriented Knit composite Factory.

Certification : FARE TRADE As a textile conglomerate having, 40320 spindle spinning. Given by, FLOCERT GmbH of Germany in 2007. Qualify Certification:

ISO 9002 Marks & Spencer NANOTEX TUV DuPont Teflon Puma DOTS by Cu (Control union) OE by CU (Control Union)

Capacity:

Cotton yarn yarn/year

BGMEA from compliance Award-2009 Garments – 3.2 million pcs/Month Embroidery – 8000 pcs/day Printing – 30000 pcs/day Knit Fabric – 600 tons/month Dye Fabric – 30 metric tons/.day Washing – 12000 pcs dyeing & 40000 pcs Wash/day –8142 metric ton ring spoon & 2124 metric Ton rotor spoon cotton Woven RMG – 24000 pcs/day Hanger – 50000 pcs/day (Average) Poly –PE-2.5 tons/day 7 pp-1500 kg/day

Buyer: Name of The Buyer Marks & Spencer S.Oliver Li fung Gap Puma Esprit G-Star PVH Celio Abercrombie& Fitch Gerry Weber

Country U.K Germany Japan U.S.A Germany Germany Netherland U.S.A France U.S.A Germany

Unit History, Location, Manpower & Item of Product Unit INTRAMEX Garments 1996

Location

Laxmipura, Gazipur. Bangladesh INTRAMEX Laxmipura, Fabrics Gazipur. 2002 Bangladesh INTRAMEX Laxmipura, Spinning 2005 Gazipur. Bangladesh Interfab Shirt Mfg. Laxmipura, Ltd 1998 Gazipur. Bangladesh Gothic Design Ltd. Laxmipura, 2007 Gazipur. Bangladesh

Manpower

Finished Goods

Jaidebpur, 5500

Readymade Garments ( knit) + Embroidery)

Jaidebpur, 1200

Knit Fabric ( Dyeing, finishing & washing)

Jaidebpur, 1100 Cotton Yarn Jaidebpur, 2400

Readymade (Woven)

Garments

Jaidebpur, 400 Printing of fabric

Fashion Plastic & Laxmipura, Packaging Ltd. Gazipur. 2003 Bangladesh

Jaidebpur, 100

Poly, Hanger Button Poly,Hanger Button

& &

RAW MATERIAL Raw material Raw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric. Types of raw material: 1. Yarn 2. Fabric 3. Dye stuff 4. Chemical and auxiliaries Name and source: Yarn: The raw material (cotton yarn) used in Knitting are the product of INTRAMEX Spinning Ltd. They produce carded and also combed yarn according to their buyer requirement. The yarn count range vary for carded yarn from (34/1) to (7/1) Ne. The yarn count range vary for combed yarn from (40/1) to (20/1) Ne. Mellange: Mellange is produced by blending different amount of top dyed fibre with grey fibre. Different types of mellange used in knitting are: Mellange

White/Ecru mellange (Dyed fibre 0.2-2%)

Sources of mellange: Patartoli Prime Shohag pur Thermax Sources of polyester: Kader Synthetic. China. Count: 75den, 100den, 150den. Sources of Lycra:

Grey mellange (Dyed fiber 2-15%)

Anthra mellange (Dyed fibre 15-30%)

* Brand : Texlon Country : Korea. *Brand : Acelen Country: China *Brand : Creora Country: Japan *Brand : Lioli (In INTRAMEX used mostly) Country: China Count: 20 den, 40 den, 70 den. Price list of different types of yarn: Cotton: Yarn Count 40/1 34/1 32/1 30/1 28/1 26/1 24/1 22/1 20/1

Combed Yarn 3.65 $/Kg 3.00 $/Kg 2.90 $/Kg 2.70 $/Kg 2.70 $/Kg 2.65 $/kg 2.60 $/Kg 2.55 $/Kg 2.50 $/Kg

Polyester Yarn: Kader Synthetic - 2.40 $/Kg China - 1.60 $/Kg Lycra Yarn: 20 den - 12.70 $/Kg 40 den - 8.40 $/Kg 70 den - 7.50 $/Kg Knitting section Lay Out Of Knitting Section:

Carded Yarn 2.65-2.7 $/Kg 2.5-2.6 $/Kg 2.30 $/Kg 2.30 $/Kg 2.25 $/Kg 2.25 $/Kg 2.25 $/Kg 2.20 $/Kg 2.15-2.2 $/Kg

ViyellaTex Group

Lay Out Of Grey Store Section:

Organogram of Knitting Section: DGM / AGM Manager /Asst. Manager (Production & Plan) (02)

Manager (Technical) Asst. Manager (01)

Sr. Executive (Production, Plan & Sample) (02) Sr. Feeder/Feeder (07) Executive / Jr. Executive (Prod. & Sample) (05) Asst. Feeder (04) Sr. Supervisor/Supervisor (06)

Sample Supervisor (02) Needle Man (03)

Sr. Operator/Operator (135)

Sample Asst. (05) Servicing Man (06)

Asst. Operator (33) Servicing Helper (06) Production Helper (21) Manager / Asst. Manager (Store)(01) Sr. Executive / Executive (02) Jr. Executive (Yarn) (02) Store Asst. (Yarn) (03) Loader (Yarn) (26) MANPOWER OF KNITTING SECTION:

Jr. Executive (Grey Fabric) (03) Store Asst. (Grey Fabric) (07) Batch Helper/Loader (35)

Section

No. of Person

Office staff

Q.C

Grey Store

Collar

Operators

107

Helper

Total

249

Recommended points of buyer: When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as followsDiameter of the fabric Design of the fabric GSM of the fabric Total wt. of the fabric Yarn count Types of yarn Color of the fabric Finishing of fabric. Handling & fastness property Machine List of Knitting Section in INTRAMEX GROUP : Machine name Circular Knitting(Single jersey) m/c

Machine Quantity 51

Circular Knitting(Rib) m/c

Engineering Stripe m/c

V-bed Knitting m/c

Grey Fabric Inspection m/c

All m/c specification of knitting section:

M/C NO: 01 Machine type: Rib Brand name: Pai Lung Origin Country: Taiwan Model: Pl-X2B/CE Cam Box: 80 Cylinder dia: 38 Gauge: 18 Needles: 2124 Safety rpm: 28 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 02 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: Pl-X2B/CE Cam Box: 80 Cylinder dia: 36 Gauge: 24 Needles: 2714 Safety rpm: 25 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 03 Machine type: Rib Brand name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 72 Cylinder dia: 36 Gauge: 18 Needles: 2035 Safety rpm: 25 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 04 Machine type: Rib Brand Name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 72 Cylinder dia: 36 Gauge: 18 Needles: 2035 Safety rpm: 26 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 05 Machine type: Rib Brand name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 72 Cylinder dia: 36 Gauge: 18 Needles: 2036 Production: 150kg/shift Date of Manufacturing: 2006

M/C NO: 06 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2035 Production: 150kg/shift Date of Manufacturing: 2006

M/C NO: 07 Machine type: single Jersey Brand name: Fukuhara Origin Country: Japan Model: Cam Box: 72 Cylinder dia: 30 Gauge: 24 Needles: 2222 Production: 85kg/shift Date of Manufacturing: 2006

M/C NO: 08 Machine type: Single Jersey Brand Name: Pai lung Origin Country: Taiwan Model: Pl-X2B/CE Cam Box: 84 Cylinder dia: 28 Gauge: 24 Needles: 2111 Production: 150kg/shift Date of Manufacturing: 2006

M/C NO: 09 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXC-3S Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2222 Production:100 kg/shift Date of Manufacturing: 2006

M/C NO: 10 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXC-329 Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2222 Production:105kg/shift Date of Manufacturing: 2006

M/C NO: 11 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXC-3S Cam Box: 78 Cylinder dia: 26 Gauge: 24 Needles: 2222 Production: 80 kg/shift Date of Manufacturing: 2006

M/C NO: 12 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXC-329 Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2222 Production: 105kg/shift Date of Manufacturing: 2006

M/C NO: 13 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XS3D/A/CE Cam Box: 78 Cylinder dia: 26 Gauge: 24 Needles: 1944 Safety rpm: 34 Production:150kg/shift Date of Manufacturing: 2007

M/C NO: 14 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XS3D/A/CE Cam Box: 78 Cylinder dia: 26 Gauge: 24 Needles: 1944 Safety rpm: 40 Production:100kg/shift Date of Manufacturing: 2007

M/C NO: 15 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XS3DB-V1/A/CE Cam Box: 74 Cylinder dia: 25 Gauge: 24 Needles: 1872 Safety rpm: 28 Production: 150kg/shift Date of Manufacturing: 2006

M/C NO: 16 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XS3D/A/CE Cam Box: 77 Cylinder dia: 36 Gauge: 24 Needles: 2772 Safety rpm: 25 Production: 100kg/shift Date of Manufacturing: 2006

M/C NO: 17 Machine type: Singly jersey Brand name: Terrot Origin Country: Germany Cam Box: 82 Cylinder dia: 20

M/C NO: 18 Machine type: Rib Brand Name: Terrot Origin Country: Germany Cam Box: 82 Cylinder dia: 22

M/C NO: 19 Machine type: Singly jersey Brand name: Terrot Origin Country: Germany Cam Box: 82 Cylinder dia: 34 Gauge: 18

M/C NO: 20 Machine type: Rib Brand Name: Terrot Origin Country: Germany Cam Box: 82 Cylinder dia: 22 Gauge: 24

M/C NO: 21 Machine type: Rib Brand name: Terrot Origin Country: Germany Cam Box: 82 Cylinder dia: 26 Gauge: 18 Safety rpm: 25 Production: 100kg/shift

M/C NO: 22 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Models: PL- XS3D/A/CE Cam Box: 82 Cylinder dia: 22 Gauge: 24 Needles: 2772

Date of Manufacturing: 2006 M/C NO: 23 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XS3D/A/CE Cam Box: 84 Cylinder dia: 24 Gauge: 24 Needles: 2112 Safety rpm: 37 Production: 120kg/shift Date of Manufacturing: 2007

Safety rpm: 25 Production: 100kg/shift Date of Manufacturing: 2007 M/C NO: 24 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XS3D/A/CE Cam Box: 80 Cylinder dia: 40 Gauge: 18 Needles: 2356 Safety rpm: 28 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 25 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XS3D/A/CE Cam Box: 72 Cylinder dia: 36 Gauge: 24 Needles: 2712 Safety rpm: 25 Date of Manufacturing: 2006

M/C NO: 26 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XS3D/A/CE Cam Box: 74 Cylinder dia: 25 Gauge: 24 Needles: 1872 Safety rpm: 28 Date of Manufacturing: 2006

M/C NO: 27 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XS3DB-V1/A/CE Cam Box: 90 Cylinder dia: 30 Gauge: 20 Needles: 1872 Safety rpm: 30 Production: 120kg/shift Date of Manufacturing: 2006

M/C NO: 28 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XR/A/CE Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2256 Safety rpm: 28 Production: 100kg/shift Date of Manufacturing: 2006

M/C NO: 29 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-X-2B/A/CD Cam Box: 72 Cylinder dia: 36 Gauge: 22 Needles: 2484

M/C NO: 30 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XRA/CE Cam Box: 76 Cylinder dia: 38 Gauge: 18 Needles: 2160

Safety rpm: 28 Production: 150kg/shift Date of Manufacturing: 2006

Safety rpm: 37 Production: 105kg/shift Date of Manufacturing: 2006

M/C NO: 31 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-X2B/CE Cam Box: 76 Cylinder dia: 38 Gauge: 18 Needles: 2124 Safety rpm: 30 Production: 120kg/shift Date of Manufacturing: 2007

M/C NO: 32 Machine type: Singly jersey Brand Name: Pai lung Origin Country: Taiwan Model: PL- XRA/CE Cam Box: 76 Cylinder dia: 38 Gauge: 18 Needles: 2124 Safety rpm: 30 Production: 105kg/shift Date of Manufacturing: 2007

M/C NO: 33 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XRA/CE Cam Box: 96 Cylinder dia: 38 Gauge: 18 Needles: 2124 Safety rpm: 37 Production: 120kg/shift Date of Manufacturing: 2007

M/C NO: 34 Machine type: Singly jersey Brand Name: Mayer & Cie Origin Country: Germany Model: Relanit 3.2 Cam Box: 76 Cylinder dia: 30 Gauge: 28 Needles: 2640 Safety rpm: 30 Production: 105kg/shift Date of Manufacturing: 2007

M/C NO: 35 Machine type: Singly jersey Brand name: Mayer & Cie Origin Country: Germany Model: Relanit 3.2 Cam Box: 96 Cylinder dia: 30 Gauge: 28 Needles: 2640 Safety rpm: 30 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 36 Machine type: Singly jersey Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XRA/CE Cam Box: 80 Cylinder dia: 40 Gauge: 18 Needles: 2256 Safety rpm: 30 Production: 120 kg/shift Date of Manufacturing: 2007

M/C NO: 37 Machine type: Rib Brand name: Pai Lung Origin Country: Taiwan Model: PL-XRA/CE Cam Box: 80 Cylinder dia: 40

M/C NO: 38 Machine type: Rib Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XR2B/CE Cam Box: 84 Cylinder dia: 42

Gauge: 18 Needles: 2256 Safety rpm: 28 Production: 130kg/shift Date of Manufacturing: 2006

Gauge: 18 Needles: 2376 Safety rpm: 30 Production: 120 kg/shift Date of Manufacturing: 2007

M/C NO: 39 Machine type: Rib Brand name: Pai Lung Origin Country: Taiwan Model: PL-X2B/CE Cam Box: 84 Cylinder dia: 36 Gauge: 18 Needles: 2376 Safety rpm: 28 Production: 130kg/shift Date of Manufacturing: 2006

M/C NO: 40 Machine type: Rib Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XRA/CE Cam Box: 72 Cylinder dia: 36 Gauge: 16 Needles: 1800 Safety rpm: 28 Production: 130 kg/shift Date of Manufacturing: 2006

M/C NO: 41 Machine type: Rib Brand name: Pai Lung Origin Country: Taiwan Model: PL-XBA/CE Cam Box: 74 Cylinder dia: 25 Gauge: 24 Needles: 1872 Safety rpm: 28 Production: 140kg/shift Date of Manufacturing: 2006

M/C NO: 42 Machine type: Rib Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XRA/CE Cam Box: 74 Cylinder dia: 25 Gauge: 24 Needles: 1872 Safety rpm: 28 Production: 130 kg/shift Date of Manufacturing: 2006

M/C NO: 43 Machine type: Singly jersey Brand name: Pai Lung Origin Country: Taiwan Model: PL-XS3B/CE Cam Box: 78 Cylinder dia: 26 Gauge: 24 Needles: 1941 Safety rpm: 28 Production: 130kg/shift Date of Manufacturing: 2006

M/C NO: 44 Machine type: Singly jersey Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XS3B/CE Cam Box: 78 Cylinder dia: 26 Gauge: 24 Needles: 1941 Safety rpm: 28 Production: 130 kg/shift Date of Manufacturing: 2006

M/C NO: 45 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXC-25

M/C NO: 46 Machine type: Single Jersey Brand Name: Pai Lung Origin Country: Taiwan Model: PL-X-2D/CE

Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 1941 Production: 100 kg/shift Date of Manufacturing: 2006 M/C NO: 47 Machine type: Rib Brand name: Fukuhara Origin Country: Japan Model: VXC-22 Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2222 Production: 100 kg/shift Date of Manufacturing: 2006

Cam Box: 40 Cylinder dia: 36 Gauge: 24 Needles: 2712 Production: 105kg/shift Date of Manufacturing: 2007 M/C NO: 48 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXC-3.29 Cam Box: 90 Cylinder dia: 30 Gauge: 24 Needles: 2222 Production: 105kg/shift Date of Manufacturing: 2006

M/C NO: 49 Machine type: Auto striper (S/J) Brand name: Pai Lung Origin Country: Taiwan Model: PL-XCS/6 Feeder: 42F x 6C Cylinder dia: 30 Gauge: 24 Needles: 2956 Safety rpm: 28 Production: 130kg/shift Date of Manufacturing: 2006

M/C NO: 50 Machine type: Auto striper (S/J) Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XCS/6 Feeder: 42F x 6C Cylinder dia: 30 Gauge: 24 Needles: 2256 Safety rpm: 28 Production: 130 kg/shift Date of Manufacturing: 2006

M/C NO: 51 Machine type: Auto striper (S/J) Brand name: Pai Lung Origin Country: Taiwan Model: PL-XCS/6 Feeder : 54 Cylinder dia: 36 Gauge: 18 Needles: 2040 Safety rpm: 16 Production: 130kg/shift Date of Manufacturing: 2006

M/C NO: 52 Machine type: Auto striper (S/J) Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XCS/6 Feeder: 54 Cylinder dia: 30 Gauge: 24 Needles: 2040 Safety rpm: 16 Production: 130 kg/shift Date of Manufacturing: 2006

M/C NO: 53 Machine type: Auto Striper (S/J) Brand name: Pai Lung Origin Country: Taiwan Model: PL-XSCS-6

M/C NO: 54 Machine type: Auto Striper (S/J) Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XSCS/6

Feeder: 54 Cylinder dia: 30 Gauge: 24 Needles: 2256 Safety rpm: 22 Production: 150 kg/shift Date of Manufacturing: 2007

Feeder: 42F x 6C Cylinder dia: 30 Gauge: 24 Needles: 2256 Safety rpm: 16 Production: 130 kg/shift Date of Manufacturing: 2007

M/C NO: 55 Machine type: Auto Striper (S/J) Brand name: Pai Lung Origin Country: Taiwan Model: PL-XSCS-6 Feeder: 52F x 6C Cylinder dia: 36 Gauge: 24 Needles: 2712 Safety rpm: 19 Production: 150 kg/shift Date of Manufacturing: 2007

M/C NO: 56 Machine type: Auto Striper (S/J) Brand Name: Pai Lung Origin Country: Taiwan Model: PL-XSCS/6 Feeder: 42F x 6C Cylinder dia: 36 Gauge: 24 Needles: 2712 Safety rpm: 19 Production: 130 kg/shift Date of Manufacturing: 2007

M/C NO: 57 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 86 Cylinder dia: 36 Gauge: 18 Needles: 3096 Production: 120 kg/shift Date of Manufacturing: 2007

M/C NO:58 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 84 Cylinder dia: 26 Gauge: 24 Needles: 2016 Production: 105kg/shift Date of Manufacturing: 2007

M/C NO: 59 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 86 Cylinder dia: 26 Gauge: 26 Needles: 3096 Production: 120 kg/shift Date of Manufacturing: 2007

M/C NO: 60 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXL-3.2S Cam Box: 84 Cylinder dia: 26 Gauge: 24 Needles: 2016 Production: 100 kg/shift Date of Manufacturing: 2007

M/C NO: 61 Machine type: Rib Brand name: Fukuhara Origin Country: Japan Model: VXL-3.2S

M/C NO: 62 Machine type: Single Jersey Brand Name: Fukuhara Origin Country: Japan Model: VXL-3.2S

Cam Box: 96 Cylinder dia: 30 Gauge: 24 Needles: 3096 Production: 120 kg/shift Date of Manufacturing: 2007

Cam Box: 96 Cylinder dia: 30 Gauge: 24 Needles: 2016 Production: 105kg/shift Date of Manufacturing: 2007

M/C NO: 63 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXC-DF3D Cam Box: 90 Cylinder dia: 30 Gauge: 20 Needles: 2700 Production: 120 kg/shift Date of Manufacturing: 2007

M/C NO: 64 Machine type: Rib Brand Name: Fukuhara Origin Country: Japan Model: VXC-DF3D Cam Box: 60 Cylinder dia: 30 Gauge: 24 Needles: 1800 Production: 100kg/shift Date of Manufacturing: 2007

M/C NO: 65 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXC-39 Cam Box: 84 Cylinder dia: 28 Gauge: 24 Needles: 2352 Production: 120 kg/shift Date of Manufacturing: 2007

M/C NO: 66 Machine type: Rib Brand Name: Fukuhara Origin Country: Japan Model: VXC-29 Cam Box: 106 Cylinder dia: 32 Gauge: 24 Needles: 3392 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 67 Machine type: Single Jersey Brand name: Fukuhara Origin Country: Japan Model: VXC-3.29 Cam Box: 106 Cylinder dia: 32 Gauge: 24 Needles: 3392 Production: 150 kg/shift Date of Manufacturing: 2007

M/C NO: 68 Machine type: Rib Brand Name: Fukuhara Origin Country: Japan Model: VXC-3.29 Cam Box: 96 Cylinder dia: 36 Gauge: 24 Needles: 2304 Production: 150kg/shift Date of Manufacturing: 2007

M/C NO: 69 Machine type: Top Knit Brand name: Keumnong Origin Country: Korea Model: KM-30F Cam Box: 90

M/C NO:70 Machine type: Top Knit Brand Name: Keumnong Origin Country: Korea Model: KM-30F Cam Box: 90

Cylinder dia: 30 Gauge: 20 Needles: 1800 Production: 100 Production: 100kg/shift Date of Manufacturing: of Manufacturing: 2007 M/C NO: NO:72 Machine type: Machine type: Top Knit Brand name: Keumnong Origin Country: Korea Model: KM-30F Cam Box: 90 Cylinder dia: 30 Gauge: 20 Needles: 1800 Production: 100 kg/shift Date of Manufacturing: 2007

Top

Cylinder dia: 30 Gauge: 20 Needles: 1800 kg/shift 2007

Date

M/C

Knit Brand Name: Keumnong Origin Country: Korea Model: KM-30F Cam Box: 90 Cylinder dia: 30 Gauge: 20 Needles: 1800 Production: 100kg/shift Date of Manufacturing: 2007

Specification of Flat Bed Machine (1-25): M/CNO.(01-15) M/c type: Rib (collar) Brand name: Matsuya Origin: Japan Model: M-100 Bed Length: 102 inch Head: 2 Feeder: 6 Type: Fully Automatic Flat Knitting Machine Manufacturing no: 8103 Gauge: 14 Date of manufacturing: 2004

Fig: Flat Bed Machine Product of v-bed knitting m/c 1. Collar 2. Plain collar

M/C NO. (16-25) M/c type: Rib (collar) Brand name: Strickmaschinen GMBH Origin: Germany Needle: 2040 Gauge: 16 Date of manufacturing: 2002

3. Tipping collar 4. Raising collar 5. Folding collar 6. Peacot collar 1. Cuff 2. Waist Band/ Hem Others Machines in Knitting Section:

Weight

GSM Cutter

Digital Balance

Fig: Inspection M/C Knitting Flow chart: Collect the approved sample and parameter  Analyze the work order and select yarn  Arrange yarn source and yarn in house in store  Set the cam design  Collect yarn from yarn store  Cone set the creel and yarn pass through the positive to the guide tension  Set the GSM/stitch (it control by VDQ pulley)  Inspect the fabric after making approximately half match 

If ok, then continue the m/c be run  If not ok, then identify the problem and solve  Roll cut after making 20-25kg  Roll making (Dia, GSM, Gauge Order no. Color, Buyer etc)  Roll send to the inspection section  After inspection roll grading according to the quality  Then it sends to the grey fabric store  Fabric delivery from the store according dyeing batch card Knitting: The process in which fabrics are produced by set of connected loops from a series of yarns is called knitting. Warp knitting Weft knitting When fabric is produced by this method in weft direction then it’s called weft knitting & warp direction then it’s called warp knitting.

Loop formation of Knitting Picture of knitting M/Cs:

Pilung

Fukuhara

Auto Stripe

Single Jersey Circular Knitting m/c:

Fig: Knitting m/c DIFFERENT PARTS OF KNITTING MACHINE: Start/Stop/Inch buttons: This set of buttons is used to start/stop/slow running of machine Ratchet lever: This lever permit the hand movement of the machine. Auto stop motion: Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicator lamps are on individual stop p motions & on the main control panel. While the yarn is broken we can find the location which is broken as well as to repair, meanwhile the motor can brake and stop operation at once to keep the security of the machine. Side creel: For each feed, there are two cones of yarn on the creel. Creel is used to place the cone Tensioning device: The yarn goes to the feeder of the machine from the creel through different tensioning devices. These devices are used to maintain the proper tension of the yarn. Feeder: Feeder is used to feed the yarn. VDQ pulley: This is one of the important parts of the machine. VDQ pulley is used to control the GSM by controlling the stitch length. If the value of the VDQ pulley is increased, then the loop length of the fabric will be less and the GSM of the fabric will be high. Vice versa for make low GSM fabric. Guide: Guide is used to guide the yarn. Sensor: Sensor is used to seen & the machine stops when any problem occurs. Spreader: Spreader is used to spread the knitted fabric before take up roller.

Auto counter: Two shift revolution with display counter with predetermined stop, to settle freely the weight or yardage of fabric. Variable speed drive with machine break: Transistor inverter provided for free controlled, the process of V.S. motor-drive from slow operation to normal operation is quite & fast break to prevent damages in case of needles or yarn breakage. Fabric take up system: With variable speed control by a belt drive set can be adjusted the speed for different course of fabric-constant and uniform fabric tension. Rethom: These devise are used in Electrical Auto Striper Knitting machine. Take up roller: Take up roller is used to take up the fabric. Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger Typical Parameter at knitting section: Yarn count Gsm Stitch length Points should be considered for GSM changing: VDQ (Variable Dia. Quality Control) pulley diameter. Yarn count. Machine gauge. Cam position Take up motion Factors that should be considered for changing of fabric design: Cam arrangement changing. Needle butt setting & needle dropping. Using of different colors in selected feeder. Using of jacquard mechanism. Raw material used for knitting in Yiyellatex ltd. Size of the loop shape YARN TYPES: 5%

4% 1% Cotton Millange PC Blend Multi filament Lycra

100%

85%

COTTON YARN SOURCE: INTRAMEX Spinning Ltd. INTRAMEX Spinning an export oriented 40320 spindle ring & 1280 spindle rotor spinning industry equipped with all brand new state of the art European machines. It was established in the year 2004. MELANGE YARN SOURCE: Prime Spinning Ltd. 04. Shohagpur Spinning Ltd. Phartoli Spinning Ltd. 05. China

Thermax Spinning Ltd. PC / CVC YARN SOURCE: Arif Spinning Ltd. Akij Spinning Ltd.

06. India 03. Square Spinning Ltd.

Type of Machines Single Jersey = 35 Fleece = 10 Double Jersey =19 Auto Stripper (S/J) = 06 Auto Stripper (Rib) = 02 Flat Bed Knitting M/C = 25 Fabric Inspection M/C = 03 Grand Total = 100 Buyers: S. Oliver G STAR PUMA Marks & Spencer ESPIRIT PVH

Products of Circular Knitting Machine: Single Jersey M/C: a) Plain jersey b) Lycra jersey c) Single Lacoste d) Double Lacoste e) Single Pique f) Double Pique g) Fleece (Three threads) h) Terry Fleece (Two thread) Double M/C: 1Ă&#x2014;1 rib 1 1 lycra rib Yarn dyed rib 2 1 rib 2 2 rib 2 2 lycra rib

Buyers Logo:

Interlock Type of Collar: Tipping Solid collar Raising collar Folding collar Cuff Emboss Faults, Causes & their Remedies in Knitting: Hole Mark: Causes: Holes are the results of yarn breakage or yarn cracks. During loop formation the yarn breaks in the rejoin of the needle hook. If the yarn count is not correct on regarding structure, gauge, course and density. Badly knot or splicing. Yarn feeder badly set. Remedies: Yarn strength must be sufficient to withstand the stretch as well as uniform. Use proper count of yarn. Correctly set of yarn feeder. Knot should be given properly. Needle Mark: Causes: When a needle breaks down then needle mark comes along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies: Needle should be straight as well as from broken latch. Sinker Mark: Causes: When sinker corrodes due to abrasion then some times cannot hold a new loop as a result sinker mark comes. If sinker head bend then sinker mark comes. Remedies: Sinker should be changed Star : Causes: Yarn tension variation during production. Buckling of the needle latch. Low G.S.M fabric production. Remedies: Maintain same Yarn tension during production. Use good conditioned needles. Drop Stitches: Causes: Defective needle. If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.

Take-down mechanism too loose. Insufficient yarn tension. Badly set yarn feeder. Remedies: Needle should be straight & well. Proper feeding of yarn during loop formation. Correct take up of the fabric & correct fabric tension. Yarn tension should be properly. Oil stain: Causes: When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies: Ensure that oil does not pass on the fabrics. Well maintenance as well as proper oiling. 07. Rust stain: Causes: If any rust on the machine parts. Remedies: If any rust on the machine parts then clean it. Proper maintenance as well as proper oiling. Pin hole : Causes: Due to break down or bend of the latch, pin hole may come in the fabric. Remedies: Change the needle Grease stain: Causes: Improper greasing Excess greasing Remedies: Proper greasing as well as proper maintenance. 10. Fly dust: Causes: In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies: Blowing air for cleaning and different parts after a certain period of time. By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor. Over all ensure that lint does not attach to the fabric. 11. Yarn contamination: Causes: If yarn contains foreign fiber then it remains in the fabric even after finishing, If lot, count mixing occurs. Remedies: By avoiding lot, count mixing. Fault less spinning. 12. Yarn Faults:

Neps. Slubs. Yarn count variations. Thick/Thin place in yarn. Quality Assurance of knitting Section Yarn Test after Receiving Yarn

Sample Fabric Preparation before Bulk Production

Online Quality Control

Offline Quality Control

Fabric Inspection using 4 point system Measurement of Fabric Faults: Four Point System: Defect Length Assigned Point 0-3” 1 point 3.1-6” 2 point 6.1-9” 3 point >9.1” 4 point Calculation: Avg. Points/100 yds = total points /total inspected yds * 100 Maintenance: During servicing or maintenance the following things are cheekedNeedle Sinker Cam Box Cylinder Oil Belt Type of Maintenance: Breakdown Maintenance Scheduled Maintenance

This is basically the servicing of the machine. This is done because To maintain the quality of the fabric To reduce the fabric fault Removal of the lint from the machine Cleaning the different parts of the machine Production Calculation: Production / shift in Kg at 100% efficiency:

Production / shift in Meter :

Fabric Width in Meter:

Efficiency : Actual production Calculated production Sample of various Type of Knitted fabric: Fabric Type Single jersey Lycra Single jersey Single Lacost Double Lacost Fleece (1*1) Rib (2*2) Rib Lycra Rib Stripe Single jersey

100

Sample

Remarks & conclusion: Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good so that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements. BATCH SECTION Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order. Function or Purpose of Batch Section: To receive the grey fabric roll from knitting section or other source. Turn the grey fabric if require. To prepare the batch of fabric for dyeing according to the following criteria â&#x20AC;&#x201C; Order sheet (Received from buyer) Dyeing shade (color or white, light or dark) M/C capacity M/C available Type of fabrics(100% cotton, PE, PC, CVC) Emergency To send the grey fabric to the dyeing floor with batch card. To keep records for every previous dyeing. Proper batching criteria: To use maximum capacity of existing dyeing m/c. To minimize the washing time or preparation time & m/c stoppage time. To keep the no. of batch as less as possible for same shade. To use a particular m/c for dyeing same shade. Batch management: Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency. Machines in batch section M/c quantity: 02 M/c Specification: Machine Name M/c No Brand Name Origin M/c Speed Model Max up clothing

: Air turning m/c : 01 : Taida : China : 300-500m/min : DF 200 : 150 kg

Company

: Shandong Taida Dyeing & Finishing Machinery Co.Ltd

Machine Name M/c No Brand Name Origin M/c Speed Model Max up clothing Company

: Air turning m/c : 02 : Taida : China : 300-500m/min : DF 200 : 150 kg : Shandong Taida Dyeing & Finishing Machiner

LABORATORY Laboratory MACHINEries with its specification: 1. Tearing Strength Tester: No. of m/c-01 Brand Name: Elmatear Origin : U.K 2. Button Strength Tester: No. of m/c-03 Brand Name : Titan Origin : U.K Max.Pressure: 10 bar Capacity : 3000N 3. Bursting Strength Tester: No. of m/c-01 Brand Name: TruBurst Origin : U.K 4. Pilling Resistant Tester: No. of m/c-04 Brand Name: Impulse Origin : U.K 5. Sprectra Flash: No. of m/c-01 Brand Name: Data Color Origin : U.S.A 6. Test Name : Colorfastness to Washing, Dry cleaning. Name of the m/c: Rota Wash Origin : U.K No. of m/c : 02 Test Method : ISO105-C06, ISO105-D02

7. Test Name : Dimensional Stability, Spirality, and Appearance after washing. Name of the m/c : Eltrolux wascator. Origin : U.K No. of m/c : 01 Test Method : ISO 6330, ISO 26330 8. Test Name : Shrinkage Test. Name of the m/c: Eltrolux Origin : U.K No. of m/c : 01 Test Method : 9. Test Name : Color Fastness to Wash Test. Name of the m/c: Gyro wash Origin : U.K No. of m/c : 02 Test Method : ISO 105-C06 10. Lab Dip m/c: No. of m/c: 02 M/C NO- 01 Brand name: Ahiba Nuance Lab Dip Dyeing m/c Origin : U.S.A M/C NO- 02 Brad name: Ahiba Nuance Lab Dip Dyeing m/c Origin : U.S.A Color Matching Cabinet (Light box): No. of Light Box: 02 Light Box no: 01 Brand : Spectralight-111 Origin : U.S.A Light Source: Day Light (D-65) Cool White Horizon UV TL-84 A (F11-10 degree) Light Box no: 02 Brand : Verivide Origin : U.K Light Source: Day Light (D-65) UV TL-84 A (F11-10 degree)

Lab Working Procedure: Sample in (Fabrics) Check & note the Lot no, Style no, Item no& Collar Sample Preparation Run the test Physical test

Wet lab

Color Fastness to wash Bursting strength Pilling Crocking Evaluate the sample

Color Fastness to washing Pre-production Sample

Report Making

Final sample

Test

Prepared the report Pass Deliver

prepared the report

Fail Refinish

Pass

Need to test again

Fail

Pass

Fail

Go for the final

Refinish

Need to test again Dimensional stability. Prepare the sample Wash the sample according to buyer method. Tumble dry Keep the sample flat in the conditioned temperature at least four hours before, after measurement. Measure the sample Prepared the report Pass Ready to delivery Need to test again

Fail Refinish

Quality Management System The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. Objects of quality control: Research. Selection of raw materials. Process control. Process development. Product testing. Specification test Quality management system in INTRAMEX :

On-Line

Off-Line

Online Quality control: There are two types of online quality control. These are as follows: Raw material control: Raw material control means control the quality of raw materials (e.g.- Quality of Grey fabric, Dyes, Chemicals and Auxiliary) Process control: Process control means the selection of right process and controlling of some parameters. Such as PH, Water hardness, water volume, Temperature, Reel Speed, Pump pressure, etc. Online Tests: Dyed fabric. Shade check. Wash fastness. Water fastness. Crocking fastness. Laboratory: Laboratory is the heart of dyeing Industry. An efficient laboratory can increase the efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before bulk production a sample is sent to buyer for approval. Laboratory supplies the recipe to the floor. Purpose of Laboratory: Get color approval from buyer.

Recipe supply to the floor. Shade correction. Minimize the deviation between bulk and laboratory. Laboratory line: Standard sample: At first recipe % of standard sample is measured by CCM (computer color matching) system. Laboratory Trial: Then by taking those recipe laboratory officers produce laboratory trial and match with standard according to buyer requirement. Approved Sample: Then sample swatch, which is matched with the standard, is send to buyer for approval. Off-Line Tests: Off-Line tests for finished fabrics are divided into two groups. These are as follows: Physical tests Chemical tests Physical Tests: GSM of Fabric. Abrasion resistance / Pilling. Dimensional stability test. Spirality test. Color fastness to rubbing test (Dry / wet). Bursting strength test (For Knitted fabric). Tensile Strength test (For Woven fabric). Chemical Tests: Color Fastness to washing. Color Fastness to light. Color Fastness to heat. Color Fastness to actual laundering Color Fastness to Chlorinated water. Color Fastness to water spotting. Color Fastness to perspiration. Color Fastness to Seawater. Flammability test. Fibre analysis. PH test. Spray test (water repellency). Phenolic yellowing. Quality standard: Here in the factory they are following ISO standards for their testing purpose. But testing standard depends on buyer requirements. SOME TEST PROCEDURE Color fastness to rubbing (wet & dry): Procedure:

At first take a sample of size (14 × 5) cm at Wales & Course wise. Put the crocking cloth on to the finger & stag by finger clip & run 10 times in 10 seconds manually & assess the crocking cloth with gray scale. Place the crocking cloth on the water, it will sucked some water and then squeeze the crocking cloth. Then place the wet rubbing cloth on to the finger and stag with finger clip and run 10 times in 10 seconds manually. Then assess the crocking cloth by gray scale for wet rubbing. Wet and dry rubbing are checked according to buyer’s requirement. Color fastness to washing. (ISO/05-CO6): Procedure: Size of specimen: Cut sample & multifibre at (10 × 2) cm then stitch. Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in distilled water & cooled at 20°C & measured PH (where necessary). Run the program in the following way: Test no. Temp°C Liq.volume ml Time min.Steel balls Adjust pH C2S 60°C 50 30 25 10.5±1 Rinse the sample twice with cold water. Dry at 60°C by hanging or by flat iron pressing but temperature should not less more than 150°C. Pilling test: Procedure: Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using template. Then sewn the fabric so that it can be firmly fit in the tube a moulded polyurethane tube. Then four tubes are placed in a box & start 60±2 rev/min for 5 hrs or according to buyer requirement. Here mainly used 3hrs (1100 cycle). Then assess the pilling by putting tested specimen on the viewing cabinet & compare with standard photographs. Shrinkage & Spirality test: Buyer’s requirements: Template size: 50cm & 35cm, 25.5cm &18cm (use after quick wash). Shrinkage: length wise--- 5% Width wise----5% Spirality:

Left -------- 5% Right -------- 5%

Procedure: At first take two ply of fabric & put the template (50cm) on to the fabric. The template has 8 holes. Both length & width wise the template holes can measure 35cm at 3 places. Then we mark the 8 holes by permanent marker & also at the edges of the template. Then sewn the fabric & it is given to the washing m/c for run at 60°C for 60minutes with water. After that dry the sample & then measure the fabric Spin speed --- 500rpm Drum speed--500rpm Calculation

Shrinkage Test: Lengthwise: After wash – Before wash = ----------------------------------×100 Before wash Width wise: After wash – Before wash = ----------------------------------×100 Before wash Spirality test: Left side + Right side 2 Length(wid th for H & M) × 100 % =

Color fastness to water (ISO 105 EO1& EO2): Sample size: Cut the specimen & multi-fiber at 10×2cm & sewn together. Solution: Wet in distilled water at room temperature & it will suck water. Place it in acrylic resin plates & put the weight on to the plates. Keep it in oven & keep the temperature at 37± 2°C for 4hrs. Open the specimen & dry it in the air hot exceeding 60°C. Assess the staining & shade change with gray scale. Color fastness to perspiration Alkaline & Acid solution (Method: ISO 105 E04): 1) Procedure: Cut the specimen & multifibre at 10×2cm & sewn together. 2) Prepare solution: Alkaline Solution: 0.5g/l of 1-histadine mono hydrochloride monohydrate 5g/l of sodium chloride This solution is brought to pH -8 with 0.1 mole/l caustic solution. Acid solution: 0.5 g/l of 1-histadine monohydrochloride monohydrate 5g/l of sodium chloride. 2.2 g/l of sodium dihydrogen orthophosphate dehydrate. This solution is brought to pH-5.5 with 0.1 mole/l caustic solution. 3) M: L = 1: 50 4) Wet the specimen in flat dish containing acid & alkaline solution & keep for 30min. Then take the specimen & squeeze the excess solution by two glass rods. 5) Put the specimen in to the acrylic resin plates & put wt. on the plates. 6) Keep it in the woven at 37°C ± 2°C for 4hrs. 7) Open the specimen 6 multi fibre & dry separately in the air temperature not exceeding 60°C. 8) Access the staining & shade change with grey scale. 6.17 PH Test:

Procedure: Take 2gm sample fabrics and cut into small pieces. Then put it conical flax with 100cc water (M: L -1:50). Then shake it 15 min, then place it in a shaker m/c for 1 hour. Then check PH by PH meter. GSM TEST: Procedure: GSM is the most important factor. There is a GSM cutter. The sample cut by the GSM cutter is weighted in the electronic balance. The reading (in gm) from the balance is multiplied by 100 to get the value of GSM. RESPOSIBILITY OF OFF-LINE quality control: To check the following things: Inspection of fabric in the inspection M/C under 4-point system. Yarn count and lot no. Buyer. Design. Stitch length of grey fabric. Shade of grey fabric within one order. RESPOSIBILITY OF ON LINE quality control: To check the following things: M/C Dia/Gauge Buyer Design Grey fabric GSN & Stitch Length Yarn count & Lot no Yarn whether approved or not by Q.C. Department Finished dia & grey dia. Fabric quality checking under 4-point system. Responsibility of IN CHARGE of quality control: Making report. Supervise the grey Q.C. Check machine is running according to program or not Check program can meet the requirement. Which is mentioned in the order sheet or not. Check yarn is approved by Q.C. or not. Maintain resister khata. Make daily batch re-process job card. Remarks & conclusion: Grey fabrics from knitting are used in dyeing. So the quality of the fabrics should be good so that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements. DYE

A colorant that becomes molecularly dispersed at some point during application to a substrate and also exhibits some degree of performance. DYEING The application of color producing agents to fibre, yarn, or fabric or part usually fibrous or flim, in order to impart a degree of color permanence demanded by the projected end use, usually by immersing in a bath of dye. Lay out of dyeing floor:

Organogram of Dyeing: DGM/AGM Manager

Planning

Production

Store

Washing

Asst.Manager

Sr.Executive /Executive

Jr.Executiv e

Jr.Executiv ee

Jr.Executiv e

Sr.Supervisor /Supervisor

Machines of fabric dyeing floor: Turning machine: 02 Bulk Total bulk dyeing m/c: 15 Total sample dyeing m/c: 7 Fongâ&#x20AC;&#x2122;s machine: Bulk m/c: 10 Sample m/c: 06 Thies machine: Bulk m/c: 05 Sample m/c: 1 Specification of different machines: Bulk dyeing section: Dyeing Machine. 01(Fongs): Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor

Jet Dyeing Machine FONGâ&#x20AC;&#x2122;S China ECO-38-2T 2003 00-980C Water, Steam, Electricity, Compressed Air 7

Production Capacity

500 KG

Dyeing Machine.02(Thies): Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No Of Nozzle

Jet Dyeing Machine THIES Germany D-48653 COESFELD 2004 00-1400C Water, Steam, Electricity, Compressed Air 7 1000 KG 04

Dyeing Machine. Thies-03: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Jet Dyeing Machine THIES GERMANY D-48653 COESFELD 2003 00-1400C Water, Steam, Electricity, Compressed Air 7 1000 KG 4

Dyeing Machine. THIES-04: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Jet Dyeing Machine THIES GERMANY ECOSOFT PLUS 2002 00-1400C Water, Steam, Electricity, Compressed Air 7 250 KG 1

Dyeing Machine. THIES-05: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range

Jet Dyeing Machine THIES GERMANY 41350 2002 00-1400C

Used Utilities No. of Motor Production Capacity No. of Nozzle

Water, Steam, Electricity, Compressed Air 7 500 KG 2

Dyeing Machine. THIES-06: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

HTHP Dyeing Machine THIES GERMANY 41354 2002 00-1400C Water, Steam, Electricity, Compressed Air 7 1000 KG 4

Dyeing Machine. FONGS-07: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities

BULK Dyeing Machine FONGS CHINA ECO-6-1T 2005 00-1400C Water, Steam, Electricity, Compressed Air No. of Motor 9 Production Capacity 200 KG No. of Nozzle 1 Permissible Working 380 Kpa Pressure Test Pressure 585 Kpa Dyeing Machine. FONGS-08: Type Jet Dyeing Machine Manufacturer name FONGS Country CHINA Model No. ECO-6-1T Year of manufacturing 2005 Temp. Range 00-1400C Used Utilities Water, Steam, Electricity, Compressed Air No. of Motor 7 Production Capacity 250 KG No. of Nozzle 1 Permissible Working 380 KPA Pressure

Test Pressure

585 Kpa

Dyeing Machine. FONGS-09: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities

BULK Dyeing Machine FONGS CHINA ECO-6-3T 2005 00-1400C Water, Steam, Electricity, Compressed Air No. of Motor 7 Production Capacity 750 KG No. of Nozzle 3 Permissible Working 380 Kpa Pressure Test Pressure 585 Kpa Dyeing Machine. FONGS-10: Type High Speed jumbo Dyeing Machine Manufacturer name FONGS Country CHINA Model No. HSJ-4T Year of manufacturing 2007 Temp. Range 00-1400C Used Utilities Water, Steam, Electricity, Compressed Air No. of Motor 8 Production Capacity 1120 KG No. of Nozzle 4 Permissible Working 350 Kpa Pressure Test Pressure 520 KPa Dyeing Machine. FONGS-11: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities

HSJ Dyeing Machine FONGS CHINA HSJ-3T 2007 00-1400C Water, Steam, Electricity, Compressed Air No. of Motor 8 Production Capacity 840 KG No. of Nozzle 3 Permissible Working 380 Kpa

Pressure Test Pressure

520 Kpa

Dyeing Machine.FONGS-12: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities

HSJ Dyeing Machine FONGS China HSJ-SR-3T 2007 00-1400C Water, Steam, Electricity, Compressed Air No. of Motor 3 Production Capacity 560 KG No. of Nozzle 3 Permissible Working 380 Kpa Pressure Test Pressure 520 KPa Dyeing Machine.FONGS-13: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

HSJ Dyeing Machine FONG’S CHINA HSJ SR 6T 2007 00-1400C Water, Steam, Electricity, Compressed Air 9 1680KG 6

Dyeing Machine.FONGS-14: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

HSJ Dyeing Machine FONG’S CHINA HSJ SR 3T 2007 00-1400C Water, Steam, Electricity, Compressed Air 9 840 KG 3

Dyeing Machine.FONGS-15:

Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

HSJ Dyeing Machine FONG’S CHINA HSJ SR 4T 2007 00-1400C Water, Steam, Electricity, Compressed Air 9 1120 KG 4

Sample Dyeing Machine.FONGS-01: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

ALL FIT-30 Dyeing Machine FONG’S CHINA P-D 5500-2000-CAT -2 2003 00-1400C Water, Steam, Electricity, Compressed Air 9 25KG 1

Sample Dyeing Machine.THIES-02: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Inhalt Capacity No. of Nozzle

Sample Dyeing Machine THIES GERMANY D-48653-COESFELD 2002 00-1400C Water, Steam, Electricity, Compressed Air 9 523 Litre 1

Sample Dyeing Machine.FONGS-03: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range

ALL FIT-30 Dyeing Machine FONG’S CHINA P-D 5500-2000-CAT -2 2005 00-1400C

Used Utilities No. of Motor Production Capacity No. of Nozzle

Water, Steam, Electricity, Compressed Air 9 30KG 1

Sample Dyeing Machine.FONGS-04: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities

ALL FIT-120 Dyeing Machine FONG’S CHINA P-D 5500-2000-CAT -2 2005 00-1400C Water, Steam, Electricity, Compressed Air No. of Motor 9 Production Capacity 120 KG No. of Nozzle 1 Sample Dyeing Machine.FONGS-05: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

ALL FIT-30 Dyeing Machine FONG’S CHINA P-D 5500-2000-CAT -2 2006 00-1400C Water, Steam, Electricity, Compressed Air 9 30 KG 1

Sample Dyeing Machine.FONGS-06: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

ALL FIT-60 Dyeing Machine FONG’S CHINA P-D 5500-2000-CAT -2 2007 00-1400C Water, Steam, Electricity, Compressed Air 9 60 KG 1

Sample Dyeing Machine.FONGS-07: Type Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

ALL FIT-60 Dyeing Machine FONG’S CHINA P-D 5500-2000-CAT -2 2007 00-1400C Water, Steam, Electricity, Compressed Air 9 60 KG 1

Dyeing Floor Area: Total length of dyeing floor: 412 feet Total width of dyeing floor: 34 feet Area of the dyeing floor: 412×34 = 14008 square feet.

Production capacity: Sample Production: Sample dyeing machine = 07 pcs Total machine capacity of sample m/c = 355 kg Total production capacity of sample m/c = 275 kg

Bulk Production Dyeing machine = 15 pcs Total machine capacity = 11,710 kg /shift =35,130 kg/ day Total effective capacity* = 9,953 kg / shift = 29,859 kg/day * With 85 % machine loading For 100 % cotton fabric dyeing total capacity (2.5 batch/day) =24,883.75 kg/day For CVC dyeing total capacity (1.5 batch /day) = 14,929.5 kg / day FEATURES OF FONG’S ATMOSPHERIC M/C: The M/C is designed for the pretreatment, dyeing and after-treatment under atmospheric condition. Nozzle is sized for smooth passing through by the fabric and extensive exchange with the dyeing liquid. Two standard nozzle sizes with sufficiently large diameters are available. Circulation pump is sized for heavy fabric Production capacity:500kgs Max temperature:98◦C Max pressure:1atm

Features of high temperature machine (Thies M/C): The M/C is designed for the pre-treatment, dyeing and after-treatment which can Provide temperature up to 140◦c nozzle lead get interlock after temperature exceed 80◦C Loading per nozzle 250kg Design pressure:350-550kpa Design Temp :140◦C Hydraulic Test Pressure:585Kpa Manufacturer: Germany(Thies), Taiwan (Fong’s)

No of nozzles:1-8 Features of fong’s (hsj) machine: Variable Loading (VL) storage chamber design gives extra capacity to carry loading up to 280 kg per tube. Heat Exchanger of extreme efficiency gives the largest heating rate with minimum heat loss to the environment. Multi Saving Rinsing System (MSR) Shortens the dye cycle and reduces the water consumption. Advanced Intelligent Rinsing System (MIR) controls the rinsing water consumption and shortens the rinsing process. Highly optimized machine structure reaches the lowest possible liquor ratio of 1:4.5 to run the machine. Dissolution pumps for proper circulation of liquor. Safety valve test: 350kpa. Maximum fabric speed: 400 m/min. Maximum working temperature: 140°C. Design pressure: 350kpa. Hydraulic test pressure: 510kpa. Unique features of thies & fong’s m/c: Thies machine: Fong’s machine: CCR Function MIR Winch dia can be controlled MSR One addition tank Dissolution Pump Nozzle pressure is 0.5-0.6 bar Two Addition Tank Vl chamber setting is not possible in thies Filter & Heat Exchanger Is In Same ecosoft plus.* Tube Separate filter & heat exchanger Variable Chamber Setting Is Present Heat exchanger is at vertical position Nozzle Pressure Is 8-8.50psi Heat Exchanger Position Is Horizontal Comparison between Fong‘s and Thies dyeing machine: Fong‘s Thies Have heat-exchanger for preparation tank.

Such facilities are not present.

Liquor pass through the filter & heatexchanger

Filter and heat-exchanger are separate.

Have dissolution pump for mixing chemical in 1:4 ratio. Horizontal heat-exchanger.

Not present.

Two additional tanks.

One additional tank.

Variable loading chamber.

Not present.

Vertical heat-exchanger.

Shell

Loading per nozzle 280 kg (HSJ).

Loading per nozzle 250 kg

Winch speed can be above 450 m/min.

Up to 350 m/min.

Technology of dyeing machine: INTRAMEX dyeing unit used special types of dyeing machine. In these machine, the Jet and Winch technology is combined i.e. during dyeing, dye liquor circulate through the machine like jet dyeing machine also the fabric is circulated through the winch as like winch dyeing machine. This combination is made for better dyeing of the fabric. Main parts of dyeing machine: The main parts of the dyeing machine areMain tank Reserve tank/PT tank Additional/Mixing tank Main pump Heat exchanger Filter The description of the main parts of the machine is as follows â&#x20AC;&#x201C; Main tank: Main tank is the largest part of the dyeing machine. This is the main dye bath which contains the dye liquor & the fabric. The size of the tank depends on the capacity of the machine. Liquor & fabric circulates in the main tank during dyeing process. There may have different number of nozzle connected to main tank according to the machine capacity. Each nozzle may handle 300-900m of fabric.

Main tank Reserve/ PTtank: This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for heating the water in the main tank which results in the reduction of total dyeing time.

Fig: Reserve/PTtank Additional/Mixing tank: This tank is mainly used for storage of hot water that will be used for the dyeing of fabric. The temperature of water in the P.T. tank is maximum 800C. By using this hot water in the machine during dyeing there is a reduction of time for heating the water in the main tank which results in the reduction of total dyeing time.

Fig: Mixing tank

Main pump: This is one of the essential parts of the dyeing machine. This is used for displacing of dye bath liquor causing a flow from main tank to heat exchanger through filter. That means the pump ensures the liquor circulation throughout the dyeing process. Heat exchanger: During the different stage of dyeing (also pre-treatment, after-treatment), there is a need of increasing or decreasing the temperature of dye liquor gradually. We cannot use liquor of required final temperature directly because there may be possibilities of thermal shocking of the fabric. So, the temperature should be increased or decreased in a controlled manner. This controlling is done by heat exchanger. Actually it is an indirect heater. During the circulation of dye bath liquor, the liquor passes through the heat exchanger. A heat exchanger is a device built for efficient heat transfer from one medium to another, whether the media are separated by a solid wall so that they never mix, or the media are in direct contact. Rate Of Heat Exchange IS Proportional To Temp Difference Between Hot Fluid And Cold Fluid *Counter Flow * Parallel Flow

Mechanism of Heat-exchanger: Heat-exchanger consists of no. of tubes surrounded by a shell body. Two fluids of different temperature flow through the heat exchanger. The fluids can be either gas or liquid on either the shell side or the tube side. One flows through the tube other flows through the shell. The temperature of the two fluids is different, so transfer of heat occurs from one fluid to another through shell. The fluids which flow through the tubes come in and pass out from the heat-exchanger on the same side. On the other hand the fluid used in shell comes in and pass out from the different side of the shell. Theory of Application of Heat exchanger: Two fluids, of different starting temperatures, flow through the heat exchanger. One flows through the tubes (the tube side) and the other flows outside the tubes but inside the shell (the shell side). Heat is transferred from one fluid to the other through the tube walls, either from tube side to shell side or vice versa. The fluids can be either liquid or gases on either the shell or the tube side. In order to transfer heat efficiently, a large heat transfer area should be used, so there are many tubes. In this way, waste heat can be put to use. This is a great way to conserve energy. Heat exchanger control pointsSteam Pressure 7 Bar (101.5 PSI) Cooling Water Temperature 25 ⁰C At 3 Bar Max Heating 140 ⁰ C (HTHP) Cool Down Temp 85 ⁰C (HTHP) Filter: During the treatment of fabric in the machine, lots of lose fiber is produced from the fabric. To eliminate these lose fibers, filter is used. It also reduces the lose fibers loads from the fabric. If they lose fibers are not eliminated, then the running of fabric is disturbed & entanglement can be occurred. Fig.: Filter ComponentsFilter Service Door Filtration Section

Filter TypeStainless Steel Sieve Fabric And Steel Sieve Filter ChangeFilters Needed To Be Changed To Maintain The Accurate Nozzle Pressure To Supply Filtered Liquid To Heat Exchanger Time of ChangeAfter Enzyme Wash After Dyeing Bath Drain After Rinsing Features of Filter: The filter eliminates the loose fibres in the dye bath,consequently it reduces the loose fibre loads on the fabric. Changing and cleaning the filters is sometimes forgotten, with the result that the dyeing machine's nozzle pressure decreases, with the effect that running is disturbed and tangles can occur.

automatic self cleaning filter systemNo cleaning of filter. No pressure variation in the nozzles due to lint buildup due to automatic regulation system. No lint on fabric due to 100 % filtration of the circulation liquor. Additional Tank: Additional tank is used forColor dosing Soda dosing Salt dissolving Auxiliaries injection Chemical dosing Ways of liquor flow from additional tank: Two waysInjection Dosing Linear dosing Progressive dosing Decreassive dosing

Linear dosing

Progressive dosing

Decreassive dosing

Liquor circulation system: During the treatment of fabric, the liquor is circulated throughout the machine. At first, the required amount of liquor is taken in the main tank. Then the liquor goes to the filter through pump and then it goes to the heat-exchanger. From the heat-exchanger, the liquor goes to the main tank through nozzle. The schematic diagram of liquor circulation system is given below-

Figure: Liquor circulation system Function of dissolution pump: Dissolution pump makes the chemical concentration (salt, soda, dye, auxiliaries) low before passing it to the main tank. This concentration is reduced in 1:4 ratios (liquor from additional tank: liquor from main tank). As a result rate of chemical dosing become slow which gives better fixation. Thus better color yield and even dyeing can obtain.

mixing zone Liquor from main

Fig.: Dissolution pump Nozzle: Controlling PointsNozzle Pressure Adjuster Nozzle Dia Adjuster Pressure RangeNozzle Pressure 0.5-0.6 bar In Thies M/C And 8-8.5 Psi In Fongâ&#x20AC;&#x2122;s M/C ProblemsFabric Entanglement* Fabric Slippage

Variable chamber: FunctionVariable Chamber Settings Are Used To Avoid Fabric Entanglement

To Place The Fabric In “J” Box In Pile Manner Control pointsAdjustable Gear Box Small Profile For S/J Large Profile For D/J Indicator with % GSM or linear density & Chamber Size %* Take off roller & fabric plaiter:

Fig: Variable Chamber

Used to unload the fabric Move forward or reverse direction With plaiter can plait the fabric Fig.: Take off roller Winch/ lifter reel: It is Used To Take Up The Fabric And Deliver It from the Storage Chamber Into Nozzle The Fabric Rope Passes To System Namely the Winch and the Nozzle Speed Synchronization Is Necessary No Tension Between Winch And Nozzle Fig.: Winch/ lifter reel Kier chamber: Kier Service Door (open <45 ⁰C) Spray Cleaning Device Spot Light Steam Pressure Releaser Fabric Plaiter Fig.: Kier chamber The control system of fong’s & thies: T 737 XL Controllers is available in THIES M/C. It can be used in centralized PC system like Orga Tex*. FC 28 Controller is available in Fong’s M/C. It can be used in centralized PC system like Orga Tex*. Fig.: The control system Of fong’s & thies MIR Rinsing System: Multi-function intelligent rinsing system. If the temperature is below 80°C It is

a Low Level Continuous Rinsing Shorten Rinsing time. Save Rinsing Water. Fill and Drain at the same time at low level. Fig.: MIR Rinsing System MSR Rinsing System: Multi- saving rinsing system. If the temperature above 80°C it is Combined Cooling and Rinsing at high temperature. Save Steam in Hot Rinsing. Rinsing efficiency at higher temperature is faster, so rinsing time is shortened. Orga tex: Orga texis the Management & controller software for textile wet processing. Orgatex Includes Modules ForProgram Editing Recipe Management Stock Control Production Planning Costing Online Control Of Machine 2th to 9th machine is under orgatex. Fig.: Orga tex Raw materials for dyeing: Raw materials used in the dyeing section are: 1. Grey fabrics 2. Dyes 3. Chemicals. Grey fabrics: Following types of gray fabrics are dyed: Single jersey Single jersey with lycra Polo pique Back Pique Single lacost Double Lacost Fleece Rib Rib with lycra 1Χ1 rib 2Χ2 rib

Different types of collar & cuff. Different Types of Dyes Used In INTRAMEX With Their Brand Name: Reactive Dyes:

BRAND NAME

COUNTRY NAME

DY-STAR

GERMANY

IMPOCOLOR

GERMANY

BENZEMA

SWITZER LAND

CLARIANT

SWITZER LAND

HUNTSMAN

SWITZER LAND

JIHUA

CHINA

SUMIFIX

JAPAN

SUN COLOR

KOREA

NAME OF DYE STUFF Remazol Golden Yellow RGB Remazol Deep Black RGB Remazol Deep Black GWF Gran Remazol Red RGB Gran Remazol Turquoise Blue G133% Remazol Brilliant Blue R Spec Remazol Brilliant Blue BB 133% Gran Remazol Ultra Carmine RGB Remazol Ultra Carmine RGB GR Levafix Rubine CA Gran Levafix Red CA Gran Levafix Olive CA Gran Levafix Fast Red CA Gran Levafix Brilliant Red E-4BA Gran Dianix Navy CC Dianix Turquoise S-BG Imcozin Blue E-NR Imcozin Blue V-CR 150% Imcozin Brilliant Red V-F3B Imcozin Brilliant Yellow V-4GL Imcozin Yellow E-3R 150% Bezaktive Blue S-GLD 150 Bezaktive Yellow S-3R 150 Bezaktive Red S-3B 150 Drimarene Yellow K-4G Cdg Terasil Red W-4BS Terasil Navy W-RS Novacron Red FN-R-01 Novacron Yellow F-4G Star fix Black B 150% Star fix Red EP 150% Sumifix Supra Blue E-XF Sumifix Supra Yellow E-XF Sunfix Navy Blue MF-D

Different Types of Chemicals Used In INTRAMEX With Their Brand Name:

CHEMICAL NAME Wetting agent Levelling agent Anti-creasing agent Per Oxide Stabilizer Caustic Soda Ash H2O2 Optical Agent

BRAND NAME Feloson NOF A-41 Kapavon CL Kapazon H-53 CBB Rucorit Wez Caustic Soda Ash

H2O2 Uvitex-BMA Brightening Uvitex-BHV Uvitex-BBT Syno White 4Bk

H2O2 Killer Acetic Acid Sequestering Agent Enzyme Electrolyte / Salt Detergent Soaping Agent

Softener Fixing Agent

Kapatex-PKS Acetic Acid Securon-540 CS Polyclean-SP Bio-ACE Biopolish-B41 Sodium Sulphate Anhydrose Glubar Salt Rukozen-WBL Diwet PIUS Rukozen-NZA Dekol ISN Cyclonon XEW Nerosoft-JS(an-ionic) Nerosoft-NI(non-ionic) Purrustol-IMA Sandofix-EC Protan FCE-375

COUNTRY NAME Germany China Germany Germany China China China+Korea Switzerland Korea Germany India China India China Srilanka India Germany India Germany China China Germany Germany

Tread Name Of Commonly Used Auxiliaries in INTRAMEX ltd.: Wetting Agent :Felson-NOF, Leveling Agent : Kappaquist-A41, Peroxide Stabilizer :Kappazon-H53, Peroxide Killer :Rocorit-WEZ, Kapatex-PKS, Anticreasing Agent :Kappavon- CL, Sequestering Agent :Sequron-540, Wash off Agent : Cibapon-R.

Optical Brightener :Uvitex-BAM/CB, Synowhite-4BK, Fixing Agent : Tobicott FIX-FC, Kappafix-GG. Softening Agent :Sapamine-CWS, Enzyme :BIO ACE, BIO POLISH-B11 Pictures of Dyeing of INTRAMEX

Dyed Fabric Unloading from Fong’s Dyeing m/c

UnDyed Grey Mellange Fabric Loading To Thie’s m/c

Flow Chart for Dyeing: Process Flow Chart for Pretreatment: Scouring, Bleaching & Enzyme Treatment: Fabric Load Level in

Nof + Stabilizer (600C by injection) Caustic Dosing (600C X10 min) H2O2 Dosing (700C X10 min) Temperature raise at 1050C Run time 30 min Drain H2O2 Killer hot wash (800C X10 min) Drain Acetic Acid (600C X10 min) MIR Rinse (10 min) Acetic Acid (550C injection) Check PH-4.5 Enzyme Dosing (550C X 5 min) Run time 30 min Drain CS hot washes (900C X10 min) MIR Rinse (20 min) Pretreatment Curve for 100% cotton knit fabric in INTRAMEX ltd:

Flow Chart for CVC (blended fleece fabric) Dyeing: PREWASH WATER FILL & FABRIC LOAD

HOT WASH WITH NOF (RUN 10´ AT 80°C) RINSING BATH DRAIN

Polyester part dyeing: Acid (Injection) Run time (5 min x 450C) PH Check (PH- 4.5) Color dosing (15min x 450C) Dispersing agent Raising Temp at 1300C Run time 45 min Sample Check Drain Normal hot wash Drain

Reduction cleaning: Caustic Dosing (600C X 6 min) Raising Temp at 1300C Hydrose injection Run time (10 min x 800C) Drain Normal wash Drain Cotton part dyeing: Level In (water from P.T) Leveling agent injection Salt dosing (10 min x 60˚C) Run time 20 min Color dosing (30 min x 60˚C) Run time 20 min Soda dosing (50 min x 60˚C) Run time 10 min Caustic dosing (30 min x 60˚C) Check pH Sample check Normal hot wash Drain MIR rising 10 min Bath drop Dyeing Procedure for Light Color: Water fill

PH Check (6.5-7.0) Leveling agent (Inject & run 10 Min.) Dye (Dosing 30 Min. & run 20 Min.) Salt (Dosing for 10 min. & run 20 min. Shade check Soda (70% Pro Dosing 50´ & run 10´ & check PH sample check) Shade check Bath drain Dyeing Curve for Light-shade:

Dyeing Procedure for Dark Color: Water fill Check PH (Req. 6.5-7.0) Leveling agent (Inject & Run 10 Min.) Salt (Dosing 10´ & Run 20´) Dye (Dosing 30 Min. & Run 20 Min.) Shade check Soda (70% Progressive dosing 50´ & Run 10´ & Check PH) Shade check Bath drain

Dyeing process Curve for Dark Shade:

Dyeing Procedure for Turquoise Color: Level In (Water from p.t at 800C) Check pH Leveling agent injection Run 10 min Color dosing linear (800 c x 40 min) Run 20 min Salt dissolving (800 c x 15 min) Run 200 Soda dosing (70% Progressing) (800 c x 50 min) Check pH Sample check MIR rising 10 min Bath drop

Dyeing Curve for Turquoise Color:

Flow Chart for OBA Treatment: Level in (Water from PT) NOF + H53 new Fabric Load Caustic Dosing 650 ×10 min Run 3 min H202 Dosing 700 ×10 min OBA Dosing 780 ×15 min Temp Raise to 1050 C Run 60 min Drain (B.D) Level in (Water from PT) Normal Hot 700 × 5 min Drain (B.D) Acid 500 × 10 min Level In

CS HOT 900 Ă&#x2014; 5 min Drain Rinse 10 min Acid Drain Rinse 3min Unloa Dyeing Sequence for Black Shade: Level In Leveling agent injection Run 10 min Salt dosing (600 c x 10 min) Run 15 min Color dosing linear (600 c x 30 min) Run 20 min Soda dosing (70% Progressing) (800 c x 50 min) Check ph Sample check MIR rinsing 10 min Bath drop Dyeing Sequence for 800 C Isothermal: Level In (Water from p.t at 800C) Check pH Leveling agent injection Run 10 min Color dosing linear (800 c x 35 min) Run 20 min Salt dosing (800 c x 15 min) Run 20 min Soda dosing (70% Progressing) (600 c x 50 min)

Check pH Sample check MIR rising 10 min Bath drop Dyeing Sequence for 80 0C Light Shade: Level In (Water from p.t at 600 ) Check pH Leveling agent injection Run 10 min Color dosing linear (600 c x 35 min) Run 20 min Salt dissolving (600 c x 15 min) Run 20 min Soda dosing (70% Progressing) (600 c x 50 min) Check pH Sample check MIR rising 10 min Bath drop Dyeing Sequence for 800 C Medium Shade: Level In (Water from p.t at 600 ) Check pH Leveling agent injection Run 10 min Salt dosing (600 c x 10 min) Run 20 min Color dosing (600 c x 30 min) Run 20 min Soda dosing (70% Progressing) (600 c x 50 min) Check pH Sample check MIR rising 10 min Bath drop

After treatment: Water fill MIR washes 10´ Normal Hot 70°C & run 15´ MIR wash 15 Acid at 45°C & run 10´ Hot with Nof + Soaping agent (Run 10´ at 80°C) Sample check Wash at 90°C for 10´ Sample check at 80°C Rinsing Fixing agent + Softener Sample check If OK then drain, If not OK then addition is given

Addition: Dye (Dosing for 20´ & Run 20´) Sample taken If OK then bath drain & If not OK then Topping Topping: Bath drain Water fill & Temp. Raised at 60°C

Check pH (Required 6.5) Leveling agent (Inject & Run 10´) Color dosing 30´ at 60°C Salt dosing 10´ & Run10´ Sample check If OK then ½ Soda Dosing 30´ & Run 20´ & then drain If not OK then Addition is done

Stripping: Water fill & Fabric load NOF & Caustic dosing 10´ Temp. Raised to 90°C Hydrose dosing 10´ Temp. Raised to 105°C & Run 40´ Hot wash at 90°C Bath drain Common dyeing faults with their remedies: Uneven dyeing: Causes: - Uneven pretreatment (uneven scouring & bleaching). - Improper color dosing. - Using dyes of high fixation property. - Uneven heat-setting in case of synthetic fibers. - Lack of control on dyeing m/c Remedies: - By ensuring even pretreatment. - By ensuring even heat-setting in case of synthetic fibers. - Proper dosing of dyes and chemicals. - Proper controlling of dyeing m/c 2. Batch to Batch Shade variation:

Causes: - Fluctuation of Temperature. - Improper dosing time of dyes & chemicals. - Batch to batch weight variation of dyes and chemicals. - Dyes lot variation. - Improper reel speed, pump speed, liquor ratio. - Improper pretreatment. Remedies: - Use standard dyes and chemicals. - Maintain the same liquor ratio. - Follow the standard pretreatment procedure. - Maintain the same dyeing cycle. - Identical dyeing procedure should be followed for the same depth of the Shade. - Make sure that the operators add the right bulk chemicals at the same time and temperature in the process. The pH, hardness and sodium carbonate content of supply water should check daily. 3. Roll to roll variation or Meter to Meter variation: Causes: - Poor migration property of dyes. - Improper dyes solubility. - Hardness of water. - Faulty m/c speed, etc Remedies: - Use standard dyes and chemicals. - Proper m/c speed. - Use of soft water. 4. Crease mark: Causes: - Poor opening of the fabric rope. - Shock cooling of synthetic material. - If pump pressure & reel speed is not equal. - Due to high speed m/c running. Remedies: - maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature. - Reducing the m/c load. - Higher liquor ratio. 5. Dye spot: Causes: - Improper Dissolving of dye particle in bath. - Improper Dissolving of caustic soda particle in bath.

Remedies: - By proper dissolving of dyes & chemicals. - By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the large un-dissolved particles are removed. 6. Wrinkle mark: Causes: - Poor opening of the fabric rope. - Shock cooling of synthetic material. - High temperature entanglement of the fabric. Remedies: - Maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature. - Higher liquor ratio. 7. Softener Mark: Causes: - Improper mixing of the Softener. - Improper running time of the fabric during application of softener. - Entanglement of the fabric during application of softener. Remedies: - Maintaining proper reel sped & pump speed. - Proper Mixing of the softener before addition. - Prevent the entanglement of the fabric during application of softener. Remark &Conclusion: We have seen that in dyeing different production parameters like temperature, time, PH, M:L ratio etc. are strictly followed. Sometimes the original dyeing process may not be found according to dyeing curve as they produce some complicated shade. One thing is clearly noticeable that production manager and officers are committed to try their best for reducing production time. FINISHING The final processing of the fabric to increase the natural properties or attractiveness before the fabric is cut into apparel or made into any articles of textiles is called finishing. The finishing process depends on the properties required in the fabric with respect to its use. Objective of finishing To improve the attractiveness and service ability of textile material. To accestiate or inhabit some natural characteristics on textile materials,(such as softening , stiffing , delusture , etc) To impact new characteristics/properties to the textile materials(such as durable press, flame retardant) To increase life & durability of the textile material. To set the fabric, so that it can be maintaining its shape and structure. E.T.C Types of Finishing

Two types of Finishing Mechanical(Used to control dimension &To improve appearance and handle) Calendaring Napping & sue ding Sanforizing Brushing Shearing Dolly press Tunnel press Chemical(Used to make glossy protection & To improve performance or serviceability) Ant creasing Softening Stiffing Soil release Anti-static Rot-proofing Anti-bacterial Resin finishes Fiber retardant Finishing process Tubular Finish: Dewatering Dryer Tube Compactor Final Inspection Open Finish: Slitting Stenter Open Compactor

Final Inspection

Special Finish (Raising & Sueding): Slitting Stenter Raising/Sueding Stenter Compacting Final Inspection

Total M/C of Finishing Section M/c Name DewateringSlittingDryerOpen compactor – Tube compactor Raising m/c – Sueding m/c -

DEWATERING MACHINE Machine specification: Brand name: HELIOT INTERNATIONAL MOIS: 06, ANNEE: 02

Number of M/C 2 2 2 2 2 3 1

Dewatering Machine Company: France. Capacity: 3 tones/shift. Function of dewatering m/c: -Reduce water content -Apply chemicals -Apply overfeed to give some compaction -Open the fabric from the rope form Working principle of Dewatering: After completing the dyeing process from the dyeing m/c then the fabrics are ready for dewatering. In de-watering m/c tubular fabrics are mainly processed. There is a magnetic sensor which scene the twist of the fabric and its direction and turn the fabric in opposite direction to remove twist automatically. Here dewatering is performed De-watering is the process to remove the water from the fabric completely by squeezing and it is done by the padder. A suitable expander is used before the fabric is passed through the nip of the padders, which expands the fabric flat wise and adjust the width. The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%, Lacoste-40% wider than the required width. There is a pair of rubber coated padder, where water is removed from fabric when passed through the nip of it. Normally squeezer contain single or double padders where, - One for removing water and - Other for applying finishing chemicals such as softener. But this finishing is done only for the tubular fabric. Open widths knitted fabrics are applied finishing treatment later in stenter. Here present the compressor which given compress air to form ballooning before passing through the padder. This balloon remove crease mark but not form the maximum balloon otherwise shrinkage increase SLITTING MACHINE Slitting Machine specification:

No of Slitting m/c: 02 Slitting m/c-1: Brand name- Corino (SH) Country- Italy Year of manufacturing-2007 Capacity: 3 tones/shift. Slitting m/c-2: Brand name- Bianco (SH) Country- Italy Year of manufacturing-2007 Velocity maximum-90m/min

Fig: Slitting 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.

Machine parts: Rotary blade: To cut the fabric through break Wales line. Ring: To help cutting. Guide Roller: To guide the fabric to plaiting. Plaiting: To plait the fabric. Sensor: Sense for cutting through break Wales line. Working principle: The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After dyeing completed and falling of water from fabric the fabric is fed in slitting m/c. So it is necessary to remove some water initially for the case of further processing in this m/c. The initial squeezer does this work. The de-twisting unit removes twists that may present in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2 feeler rollers with sensors. By these rollers it detects twist in fabric and removes by rotating rope fabric in opposite direction. Before slitting there is a blower which blows air to open the tubular fabric & makes it easy to pass over cigger. The cigger can be extended in circumference and opens the tubular fabric in full circumference. Slitting is done by using open mark detecting golden eye by around knife. Then the fabric passes through the padder where washing or chemical treatment is done. Squeezer is used to remove 60-70% of water. After removing water width is controlled by stretcher and fabric is delivered by folding device. Operational parameter:

-Set the padder pressure as required (3-7bar) -Set the speed as much as possible (30-80m/min). Function of the Machine: Used to remove excess water after pretreatment and dyeing. To slit the tube fabric by the knife for opening of the fabric and ready for stentering. Delivered fabric increase free state. Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer. It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism. DRYER MACHINE Two types of dryer machines are used in INTRAMEX Heliot machine (tube fabric) Santex machine (tube & open fabric) Santex machine (tube & open fabric) Machine specification: Brand name: SANTEX Type: SANTASHINH Electr. Voltage: 3*400/50(Volt/Hz) Year: 2008 Capacity: 12 tons/day Made in Switzerland. Heliot machine (tube fabric) Machine specification: Brand name: HELIOT INTERNATIONAL MOIS: 06, ANNEE: 02 Capacity: 8 tones/day. Made in France Function of dryer -To dry fabric -To control GSM -To control fabric dia Working principle of dryer: After de-watering, the fabric passed through the dryer. The main function of the dryer is given below: To dry the fabric. To control the overfeed system. To control the vibration which increase the G.S.M. This machine contains two chambers. Two mesh endless conveyors are placed lengthwise to the chamber named conveyor net and filter net, each chamber contain a burner, which supply hot air .This hot air is guided through the ducting line by suction fan .There are nozzles placed in between filter net and conveyor net .When the fabric pass on the conveyor net, hot

air is supplied to the wet fabric to dry it. There are exhaust fan which such the wet air and deliver to the atmosphere through the ducting line. The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric. If the m/c temp. is high then m/c speed also high and the m/c temp. is low then m/c speed also low . The vibration speed of the m/c for heavy fabric is 730 m/min and normal fabric is 480 m/min. STENTER MACHINE Two types of Stenter machines are used in INTRAMEX Sun super Bruckner Sun super M\c specification: Brand name: SUN SUPER. Country: KOREA. Capacity: 4 tones/shift. Other specification: Speed range: Max: 110m/min. Use: 45 m/min. Temperature range: Max: 500 C Stenter machines (Sun super) Use: 180 C (For heat set). Steam pressure: 2 bar Air pressure: 10 bar Machine parameter Padder pressure =1.5 bar Speed=8m/min Pick up=at least 75% Temp: 1st chamber=120⁰c 2nd chamber=150⁰c Last five chamber=170⁰c Over feed=full BRUCKNER Machine specification: Brand name: BRUCKNER Type/model no: 72276-0463 Country: Germany Year: 2004 Steam pressure max. 2 bar

Fig:

Air pressure max. 10 bar Capacity: 3 tones/shift Important parts of stenter: Burner Exhaust air fan(16) Overfeed roller Suction fan Nozzle Chain arrangement

Fig: Stenter machines (Bruckner)

Function of stanter: -Drying -Shrinkage control -Heat setting -Width control finishing chemical application -Loop control -bowing control -Spirility control -GSM control Checking points (m/c parts): To check m/c area clean To check m/c motor To check burner To check blower To check chain & roller To check delivery roller Fabric checking points: -To check GSM -To check dia -To check fabric faults (crease mark, dye spot.) COMPACTING MACHINE Two types of compacting machines are used in INTRAMEX : Open compacting machine Tube compacting machine OPEN COMPACTING MACHINE Machine specification: Brand name: FERRARO Type/model : COMPTEX-RE 2800 Country: ITALY Year: 2006 Capacity : 3.5 tons/shift TUBE COMPACTING MACHINE Machine specification:

Brand name: HELIOT INTERNATIONAL MOIS: 06, ANNEE: 02 Company: France. Type: HC99PI. Capacity: 3 tones/shift. Important parts: -Overfeed roller -Expander -Blanket Operational parameter -Set the temperature 120⁰c (as required) -Set the speed as much as possible (1525m/min). GSM m/c speed. -Set the overfeed % as required; to increase GSM, overfeed need to increase to a certain limit. Function: -Width control -Shrinkage control -GSM control SPECIAL FINISHING MACHINE Sueding machine Machine specification: Brand name: Lafer SPA Type/model no: GSI106 Company: Italy Year: 2002 RAISING MACHINE Machine specification of Raising Machine: No. of Raising m/c: 02 Raising m/c - 01(Single drum) Brand name - Lafer Country - Italy Cylinder -1 Drum Speed - 110 Drum Dia - 68 inch Machine Speed - 40 m/min Pile Roller - 12 Counter Pile Roller – 12 Year: 2003 Capacity: 3.5 tones/shift Raising m/c-02(Double drum)

Brand name – Lafer Country – Italy Cylinder- 2 Drum Speed - 110 Drum Dia - 68 inch Machine Speed - 40 m/min Pile Roller - 24 Counter Pile Roller - 24 Manufacturing Year –2002 FUNCTION OF RAISING MACHINE: ≈ To produce the brush effect. ≈ To produce the fleece fabric. ≈ To raise the fibre on the fabric surface. INSPECTION IN FINISHING SECTION Process Flow Chart of Final Inspection :( Q.A.D) After completing finishing process here firstly check the shade as per buyer standard with dimensional stability from lab. Secondly check dia / width fabric weight or G.S.M Thirdly check fabric surface or appearance as per buyer standard. The every roll with every meter check as per four (04) point system. Make a report. If OK then ready for delivery. If not OK then identify the fault. If it is knitting fault then inform the knitting department by job card and mail, & requested the fabric for replacement.

If it is dyeing fault & If make sure that it is reprocess able then give job card to dyeing department correction. And if is not reprocess able then reject the fabric & inform the dyeing department to replace the rejected quantity. Steps of Inspection: 1st step- Shade Check 2nd step- Running Shade Check 3rd Step- Dia Check 4th Step- Faults & G.S.M Check Measurement of Fabric Faults: Four Point System: Defect Length 0-3” 3.1-6” 6.1-9” >9.1” Any hole mark:

Assigned Point 1 point 2 point 3 point 4 point 4point

Calculation: Avg. Points/100 yds = total points /total inspected yds * 100 GARMENTS & CUTTING SECTION Garments Cutting Section M/C Specification: Auto Spreader (4): M/C No.: 01 Brand Name: Jutex Country: Germany Year of Manufacturing: 2006 M/C No.: 02 Brand Name: Gerber Country: Germany Year of Manufacturing: 2006 M/C No.: 03 Brand Name: Gerber Country: Germany Year of Manufacturing: 2007 M/C No.: 04

Brand Name: Gerber Country: Germany Year of Manufacturing: 2006 Hand Cutter (20): Brand Name: Mack (10) Country: Japan Speed: 3000/3600 Volt: 220 Frequency: 50/60 Hz Phase:1 Blade: Straight bar blade Brand Name: Blue Streak (10) Country: USA Speed: 2850 Volt: 220 Frequency: 50Hz Phase:1 Blade: Straight bar blade Auto Cutter (1): Brand Name: Gerber Country: Germany STANDARD OPERATING PROCEDURE OF CUTTING SECTION: Cutting department receives Tech Pack from merchandiser and PP sheet of a style from IE. Cutting department checks whether sample, master pattern and fabrics are ready or not. If ready cutting department collects sample, marker and fabric (for size set) from the sample section, CAD section and fabric store. Cutting department gives a lay for size set sample, cut, sew in the size set line, print, wash, embroidery all are done and measurement are taken in all the steps.

If it is found that an adjustment is required in the master pattern, than cutting manager, buyer QC and pattern master check and make necessary correction as per grading and informs pattern and CAD section.

Then cutting department collects fabrics for bulk production from store and checks whether the GSM of every roll is fine or not and check the width of fabric for that lot.

If fabric GSM is ok, cutting department sends information to CAD section containing in which width and ratio of fabric they are going to cut that particular cutting.

CAD prepares marker and sends it to the cutting section.

If in that style self fabric for neck is required, Cutting in charge informs the spreading machine operator to keep particular amount of fabric from each roll.

Spreading starts and completed. Marker is placed on the lay and then costape is attached. Cutting starts and completed.

Cutting parts are transferred to stickering Table.

Stickers are made ready. Stikering starts and completed and sticker attached parts are send to bundling area.

A spread sheet containing number of layer in that cutting, how many parts in a garment goes to the stickering Section by spreader machine operator. Bundle cards are made ready.

Bundle cards come to bundle area.

Bundling starts and completed. Rejection cutting starts and completed.

If other operations are needed such as Print, Embroidery, cutting department sends the cut panels to the store and later collects them from the store and checks whether there is any alter or not. Print and Embroidery panels are checked and if some alter and rejects are found the bundle cards are re-written making necessary adjustments.

Solid parts.

Store in the cutting input rack.

SEWING SECTION List of machines in Sewing Unit: Machine name

M/C quantity

Plain Stitching m/c

1290

Over Lock Stitching m/c

600

Flat Lock m/c

400

Button Hole m/c

Button Stitching m/c

Bar Tack m/c

Picoting m/c

Plain zig zig m/c

Kansai m/c

Two Needle Chain Stitching m/c

Two Needle Lock Stitching m/c

Suttle Stitching m/c

Fusing m/c

Heat Transfer m/c

9.4 Machine Specification: Brand Name Juki Pegasus Kansai Brother Pup Sun Star

GARMENTS FINISHING SECTION Process Sequence of Garments Finishing: Receive Garments Steam Ironing Folding Garments

Country Japan Japan Japan Japan Japan Korea

Final Inspection Attach Labels in the Garments Packing with Tissue, Board & Hanger in Polybag Metal Inspection in Metal Detector m/c Cartooning the Garments Store in the Wire House Shipment

Layout of washing section: South North East

S. D. M/c-2

West

Hydroex -tactor01

E X I T

Hydroex -tactor02

G. W. M/c-04 Tumble Dryer-01

S. D. M/c-1

Tumble Dryer-02

G. D. M/c-04

Inspection Table G. W. M/c-03

G. D. M/c-03

Tumble Dryer-03 Tumble Dryer-04 Tumble Dryer-05 Tumble Dryer-06

G. W. M/c-02

G.D-Garments dyeing m/c. G.W-Garments washing m/c

Tumble Dryer-07 Tumble Dryer-08

G. D. M/c-02

S.Dry er m/c

G. W. M/c-01

G. D. M/c-01

Office Gate

Washing / Garments Dyeing Machine Specification: No. of Sample Garments Dyeing / Washing m/c: 02 Brand Name: Cosmotex Origin: Spain Capacity: 20 Kg Max. Temp: 100˚ C No. of Garments Dyeing / Washing m/c: 08 Brand Name: Cosmotex Origin: Spain Capacity: 200 Kg Max. Temp: 100˚ C No. of Sample Drying m/c: 08 Brand Name: Green Mac Origin: China Capacity: 10 Kg Max. Temp: 110˚ C No. of Drying m/c: 08 Brand Name: Green Mac Origin: China Capacity: 100 Kg

Max. Temp: 110˚ C

Flow Chart for Garments dyeing (Medium / Dark Shade): Garments Load– 2 Kg M: L-1:8 Level In water 16 liter Wetting agent 0.5 g/l NOF ( 700 x 5’) Normal Wash Leveling agent LDR ( 600 x 5’) Color dossing (60˚C x 10’) {RG Yellow RGB- ( 0.44%) RG Red RGB- (0.254 %) RG Blue RR - (0.898%)} Run 10’ Salt dossing {(50g/l) 600 c x (10’+10’)} Soda dosing {(16g/l) (600 c x 10’)} Run Time 35’ (sample check) A- acid (1 g/l x 5’) Fixing agent (E.C) (1g/l) - ( 400 c x 5 min) Raise temp. 500 c Run Time 5 min Drain Level in Cold wash ( 270 c x 2min)

Flow Chart for Garments dyeing (Light Shade): Level in Raise temp ( 700 c x 5min ) Wetting +Detergent (NOF) Leveling agent (LDR) 600 c x 5min Color dosing {600 c x (10+10)} {CIBA Yellow FNR-0.048% CIBA Red FNR-0.048% CIBA Blue FNR-0.048%} Salt dosing (24g/l)[600 c x (10+10)] Soda dosing {(8g/l) (60Ë&#x161;c x 10â&#x20AC;&#x2122;)} Run Time 35 min (sample check) Normal Wash Acitic Acid (1g/l) Cold wash Fixing agent (E.C) (1G/L) - (400 c x 5 min) Raise temp. 500 c Run Time 5 min Drain Level in Cold wash ( 270 c x 2min) Garments Washing Process: Garments receive

Measurement check Check before wash Quality check Batch preparation Load to washing M/C Hydro extractor Dryer Measurement check Check after wash Quality check Packing Delivery Faults found in garments after washing Needle damage Fabric damage Print problem Spot

10.6 Picture of Washing Machi

Garments Dyeing / Garments Washing m/c PRINTING SECTION Printing System: Hand screen printing Sereen Printing Automatic Flat (Revolving) screen printing Specification (Automatic Flat screen printing) M/C no -1 Brand name: Diamond back Red chili Country : USA No. of Head :6 Max. Color used : 5 Drying head :1 M/C NO:2 Brand name: Diamond back Red chili Country : USA No. of Head :8 Max. Color used : 6 Drying head :2 M/C NO:3 Brand name: Diamond back Red chili Country : USA No. of Head : 12

Max. Color used : 8 Drying head :2 M/C NO:4 Brand name: Diamond back Red chili Country : USA No. of Head :8 Max. Color used : 6 Drying head :2 Type of printing Pigment Printing Rubber Printing Discharge Printing High density Printing Crack Printing Pup Printing Curing Temp: Pigment -160-1700c Rubber -150-1700c Discharge -2000c High density -1800c Screen Preparation: Mesh fabric tight with frame Applied chemical TXR (sensitizing emulsion) on the mesh & dried 8 min in air. Placed design paper under the mesh. Light passes through the design paper & mesh fabric for 3-4 min. Remove the colored TXR from the design area by water spraying.

Sequence of printing: Count garment parts Screen preparation Printing paste preparation Applied garment part on the printing bed by (adhesive) gum in the marked portion Printing the garment part by using screen Drying the printed portion by hard dryer applying hot air flow Curing the printed portion by passing through the conveyor dryer at 1600 - 1800 c Inspection is done in qualify control department Foil Printing: Temp -1500c Pressure -100 psi Time -6 sec Pressing -2 times Process for Foil Printing Add adhesive on the require design by screen Place the fabric part on to the Pressing M/C Pressing the upper part of the M/C at 100PSi, Temp-1500 For-6 Sec

Picture of Printing Machine of INTRAMEX

Automatic Revolving Flat Screen Printing m/c

EMBROIDERY SECTION MAINTENANCE SECTION Maintenance: Maintenance is a procedure by which we can maintain active functioning in operation according to the behavior and utility of a particular element. In engineering, we use this terminology for maintaining smooth and uninterrupted performance of machines, tools and metallurgical characteristics in practical uses. Objective of maintenance: To keep the factory plants, equipments, machine tools in an optimum working condition. To ensure specified accuracy to product and time schedule of delivery to customer. To keep the downtime of machines to the minimum thuds to have control over the production program. To keep the production cycle within the stipulated range. To modify the machine tools to meet the need for production. Three types of maintenance are performed in INTRAMEX Group. Preventive Maintenance. Routine/ Schedule Maintenance. Breakdown Maintenance. Preventive Maintenance: Actions performed periodically (or continuously) prior to functional failure to achieve the desired level of safety and reliability for an item. These actions are performed to prevent or reduce consequences of failures. Schedule maintenance: It is time-based maintenance and pre-planned to perform on machine and equipments. This plan usually made on monthly basis.

Breakdown maintenance: In this type of maintenance when the machine remains stop that time the maintenance is done.

Maintenance Tools, Equipments & their functions: Name of Tools Hammer Slide Wrench Spanner Pliers Hacksaw Pipe Wrench Chisel File Clamp Vice

Function To give shape Tightening and opening bolt Tightening and opening bolt Cutting, Holding, Joining, wire, Gripping Cutting Tightening, opening, gripping pipe Shaping, Cutting Shaping Gripping

Name of Equipments Grinding m/c Cutting m/c Drill m/c Shaping m/c Lathe m/c Bending m/c

Function Grinding Cutting Drilling Shaping To make something Bending

Maintenance Procedure: Preventive Maintenance: They always follow preventive maintenance. Breakdown Maintenance: When a problem occurred the operator informed the supervisor, then the supervisor informed the production officer, then the production officer called the maintenance officer. The maintenance officer visits the problem and takes necessary steps to solve the problem. Flow chart of maintenance Problem occurred Operator Supervisor Production officer

Maintenance officer Solution

Utility facilities available: The following utility facilities are available in INTRAMEX group: Gas Electricity Water Steam Compressed Air Generator house The list of machine: Generator 3 Panel 3 Distribution Board 1 Generator Control Panel 1 1. Generator: To generate the power (volts & amps) for every section in the Factory. 2. Panel: To store the power (volts & amps) from the generator for every section in the factory. There are two types of panel:

UTILITY UTILITY

PFI (Power Factor Improvement) panel LT panel PFI panel: To store the power (volts & amps) from the generator for the boiler house, finishing section & dyeing section in the factory. Supply AC current. 4 Amps & 400 volts. LT panel: To store the power (volts & amps) from the generator for the boiler house, finishing section & dyeing section in the factory. According there need. Supply AC current. 4 Amps & 400 volts. 3. Distribution: To supply the power (volts & amps) for the light, AC, fan etc in the different section. Supply AC current. 4 Amps & 400 volts. 4. Generator control panel: To control the generator for generate power. BOILER Boiler: The equipment used for producing steam from water is called steam generator or boiler. The boiler used for producing steam in GKL is Cochran boiler which is a fire tube type boiler. This produced steam is supplied by the steam line in different section. Simple vertical boiler of fire tube type is mainly used in small plant requiring small quantity of steam and where floor area is limited. Classification of boilers: Fire – tube boiler( gas ) : Low pressure , low running cost , less chance of busting but greater risk of damage. Water – tube boiler: High pressures, high running cost high chance of bursting & don’t damage the whole boiler. As this factory used fire tube boilers and its description is given below. In boiler house, steam is produced at high temperature and pressure. This produced steam is supplied by the steam line in different section. Uses: Steam use for – Power generation ( steam engine / turbine ) . Processing in industries ( dyeing & finishing mill , sugar mill , paper mill etc. ). Heating purposes ( houses , offices , hospitals etc in cold countries ). Hot water supply. Essentials of a good boiler: Required pressure and quality at minimum fuel . Initial installation and maintenance cost low . Parts approachable for repairs .

Quick starting capacity . Conform to the safely regulations of boiler act . Working principle: The gas is fed through the front side to the furnace where fire created by electric spark. The blower move the fire into the flue pipe by compress air and then the flue gases enter through the combustion chamber which is lined with fire bricks on the outer wall of boiler. The hot gases passing through the horizontal smoke tubes give their heat to the water and convert water into steam. This steam gets accumulated in the upper portion of shell from where it can be supplied to the users. Finally, the flue gases are discharged to the atmosphere through the smoke box and chimney. Feed water tank

Gas

Burner

Boiler

Blower

Steam Factory house Figure: Steam produces procedure mechanism The list of machineries: Three Boilers Boiler water softener plant De-alkalize Four Condensed pump One hot water tank One water feed tank. Boiler Specification: Boiler No:01 Machine Name (Functional) : Boiler Type Brand Name Model Name Max. Steam Output Test Pressure Volume Year of Manufacture : Country Name :

: : : :

Steam Generate Fire Tube Boiler : OMNICAL BOILER : 20424 6 t /h 20.5 bar 12540 L 2008 Germany.

Boiler No:02 Machine Name (Functional) : Brand Name Model Name Max. Working Pressure Minn. Steam Temp. Max. Steam Temp. Test Pressure Volume Year of Manufacture : Manufacturer's Name : Boiler No:03 Machine Name (Functional) : Boiler Type Brand Name Model Name Max. Steam Output Test Pressure Volume Year of Manufacture : Country Name :

: : : : :

Steam Generate : SCHNEIDER-KESSEL BERLIN : HDD-P5000-10 10 bar 20Ë&#x161;C 185Ë&#x161;C 13.5 bar 5200 L 2006 German Thai Boiler Manufacturing Ltd.

Steam Generate Fire Tube Boiler : OMNICAL BOILER : 20424 : 6 t /h : 20.5 bar : 12540 L 2008 Germany.

WATER TREATMENT The back wash & regeneration process: The back wash process to clean the vessel no-1,2 & 3. The back wash process should be done after 8-12hrs. After 40-48 hrs later the regeneration process should be done. It should be done after back wash process. After back wash the common salt dissolved with water in to the STT (salt saturated tank) the solution of common salt is ringing the resin by the injector. The use of 18% salt in the total solution. (Suppose, 5000 lit of solution the amount of salt 600kg). The resin is activated by the salt rising. Here used cationic resin (NaHSO3). If the PH of the water increase or decrease it should be control by the dosing chemical (Sodium Hypochlorite) from the chemical tank.

Figure: Water treatment plant

Where, A=Hard water storage tank B=Stone filter C=Carbon filter D=Resin filter E=Soft water storage tank F= Pump Standard water quality for dye house: Minimum standard Color Smell Water hardness PH Value Dissolved solid Inorganic salt Iron (Fe) Manganese (mn) Copper (Cu) Nitrate (NO3) Nitrite (No2)

Permissible concentration Colorless No bad smell < 50 7-8 Neutral < 1 mg/1 < 500 mg/1 < 0.1 mg/1 < 0.01 mg/1 < 0.005 mg/1 < 50 mg/1 < 5 mg/1

Hardness check: The hardness should be checked after every 6 hrs. It should be checked by the hardness test kits. The using hardness test kits are Hanna Instrument. Made in Italy. If the hardness is going to be 0.5 on the syringe scale. Then have to do the regeneration process. The capacity of the vessel 115m3/ hr or 115 ton/hr. 14.10 Effluent treatment plant Picture of E.T.P

E.T.P Plant of VIYELLATEX

Flow chart of ETP: Effluent Water from Dyeing

Equalizer Tank

PH Control Tank

Reaction Tank

Flocculation Tank

Primary Clarifier

Sludge Bed

Discharg e Effluent Multi filter

Chlorination Tank

Reserve tank For Re-using Water.

Effluent treatment plant (ETP) Process: Biological. Capacity: 110 m3 / hour. The major sources of liquid discharge are: - scouring. Bleaching. Dyeing. Washing. Dye wastes content: Carbon, nitrogen, phosphorus.

Secondary clarifier

Aeration Tank

Bleaching: Dilute hypochlorite solution. H2O2 Raw materials: main raw material: - Cotton yarn. mixed yarn Dyes Chemical dye include: Reactive. Disperse. Chemical includes: Detergent Soda ash Caustic soda. H2O2 Stabilizer. Acetic acid. Step wise function of different unit of E.T.P Equalizer Tank: Use chemical: Acid solution. Function: To neutralize raw waste water by dozing smaller particle. PH Control Tank: Use chemical: Fe2So4, Fitcary. Function: To control PH. Reaction Tank: Use chemical: Lime. Function: To agglomerate smaller particle. Flocculation Tank Use chemical: Polyelectrolyte & alum. Function: To produce flock.

Primary Clarifier: Function: To monitor performance of flocculation clarifier & separate solid waste. Sludge Bed: Function: Solid waste dried & send to outside for burial Aeration Tank::

Use chemical: Bacteria, Urea, Cow dung. Function: Bio logical oxygen demand & Chemical oxygen demand reduced here & diffused aeration system ensures high oxidation efficiency. Secondary Clarifier: Function: Remaining solid waste separate here. Reduced total solid. Chlorination Tank: Used chemical: Sodium hypochloride Function: Disinfection done here. Multi filter: Function: Extra suspended impurities separation by passing into the sand. Here removed suspended solution and correction the water color. Conclusion: First of all we want to give great thanks to ALLAH for successfully completed our industrial attachment in INTRAMEX group, which is a 100% export oriented composite textile industry. During the training period we completed our industrial attachment to a systematic routine which was provided by INTRAMEX group Ltd. We get help from different section, officers and workers which was helpful to gain a very good practical knowledge. Sometimes we operate machine for various jobs during operation. Last of all we give thanks all the officers and workers who helped us by co-operating & giving reliable information.