Mill Training Report

1. Acknowledgements
First of all, our gratefulness goes to Almighty Allah who gave us strength and ability to complete the industrial training and prepare this report; may your name be exalted, honored & glorified.
We are highly delighted to express our regards & gratitude to honorable Vice-Chancellor Prof. Dr. Nitai Chandra Sutradhar & Prof. Dr. Md. Zulhash Uddin; Dean, Faculty of Textile Chemical Processing Engineering & Applied Science, for providing us the opportunity to complete our industrial attachment with Viyellatex Group.
Our heartiest gratitude to our supervising teacher, Mrs. Sharfun Nahar Arju; Head, Department of Wet Processing Engineering to whom we are extremely indebted for her tremendous support and guidance throughout our training period, without her help it would not have been possible to complete the training successfully.
We also take the opportunity to express our sincere thanks to the management, administration & personnel of Viyellatex Group for giving us permission to complete our training period in this industry.
We are really grateful to our industrial coordinator Engr. Dewan Mahbub Kamran, Executive Dyeing, Viyellatex Group for his encouragement, inspiration, support, supervision, special care & co-operation during training period.
We would also like to thank specially Engr. Faridul Hasan, Executive Dyeing and also Engr. Mr. Mahmud, Engr. Mr. Arif, Engr. Mr. Faisal, Engr. Mr. Fayez for their Cordial Cooperation during the intern period.
Above all, we would like to acknowledge our deep debt to all teachers of our university & particularly of Wet Processing Department for their kind inspiration & help, which remain as the backdrop of all our efforts.

2. Table of Contents
S.N.
Contents
Page No.
1
Introduction
3
2
Project Description
4
3
Manpower Management
11
4
Knitting Section
16
5
Batch Section
27
6
Dyeing Section
30
7
Raw Materials
56
8
Finishing
60
9
Laboratory
75
10
Garments Section
86
11
Printing Section
90
12
Embroidery Section
95
13
Washing Section
96
14
Maintenance
101
15
Utilities
108
16
Effluent Treatment Plant
114
17
Inventory Control
118
18
Costing
120
19
Marketing
124
20
Recommendations
127
21
Conclusion
128

3. Introduction
By means of practical knowledge it is possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge.
The industrial attachment is the process which builds understanding skill and attitude of the performer, which improves his/her knowledge in boosting productivity and services. Academic education provides us vast theoretical knowledge as well as more practical attachment, despite all these industrial attachment help us to be familiar with the technical support of modern machinery, skill ness about various operation stages.
It also provides us sufficient practical knowledge about production management, Productivity evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory management, purchasing, utility & maintenance of machinery and their operation techniques etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to be accustomed with the industrial atmosphere & improve courage & inspiration to take self- responsibility.
At Viyellatex Limited, cutting-edge technologies merge seamlessly with human ingenuity and deep seat recommitment to ensure excellence in every stage and area of their activities. From fiber to fabric, Viyellatex Limited is truly integrated undertaking. The Viyellatex Limited has the capability to offer a complete product range for the export textile markets. The goal of Viyellatex Limited is to become the preferred partner for sourcing high quality fabrics and clothing from Bangladesh with highly advanced technology and an emphasis on developing local human resources.

4. Project description

5. Project Description
 Company Name: Viyellatex group ltd.
 Status: Private Ltd. Company
 Type: 100% Export oriented composite knit Dyeing Industry.
 Sponsor: Mr. Rezaul Hasnat.
 Annual Production Capacity for dyeing: 75000tons
 Product Mix:
 100% cotton
 100% polyester
a) Spun
b) Filament
 Nylon
 Chief Value Cotton (CVC)
 Polyester Cotton blend
 Gray mélange (15% Viscose 85% cotton
10% Viscose 90% cotton
30% Viscose 70% cotton)
Ash mélange (1% Viscose 99% cotton)
 Year of establishment: 2001
 Year of starting production: 2002
 Address:
Factory: 297, Khortoil, Tongi, Gazipur- 1712
Head office: 297, Khortoil, Tongi, Gazipur- 1712
Telephone no. +880-2- 9813001
Fax No. +880-2-9811400
Website: www.viyellatexgroup.com
 Project cost: 20 million $ for dyeing and finishing in the year 2008.

6. Sections of Viyellatex:
Knitting Section Yarn Store Circular Knitting V-bed Knitting Inspection Grey Fabric Store Garments Section Merchandising Sample Section CAD/CAM Section Cutting Section Sewing Section Maintenance Section Mechanical Electrical Washing Section Embroidery Section Printing Section Store Section Dyeing Section Batch Section Dye House Dyeing Machine Finishing Quality Control

7. Location from Dhaka:
Physical Infrastructure:
Viyellatex Group is a Knit Composite Garments Manufacturer & Exporter, having all state of the art facilities with the annual turnover US$ 106.6 Million (2006-2007). They have different types of Knitting, Dyeing, Cutting, Sewing, and Finishing machines supplied by mostly Germany, Japan, Taiwan, China, U.K, U.S.A, Singapore, etc. which are very latest. It has high production where 30 tons of dyed and finished fabrics are produced per day. The production is controlled by technical persons. All of the decision makers of production sector in Viyellatex Group are textiles graduates. All the chemicals and dyes use for dyeing and finishing are well branded.
They produce product for their buyer and client coming from international market like U.K, Sweden, Netherland, France, U.S.A, Germany and Spain. Their customer profile is big and top end such as Esprit, M&S, S-Oliver, Puma, G-star, Gap, Tesco and Grew waver etc. They follow all the system for their machines maintenance so production cannot hamper.
The mill is built in such a way that there is possibility for further expansion of the mill. The structure such as mill, office buildings, record rooms, guard room etc. are made of solid hard concrete & brick materials. . The whole area is surrounded by safety brick wall .The main set up for m/c‘s are built of corrugated iron & iron sheet, transparent hard plastics with enough ventilation & scope for passing light & air. Dyeing, finishing and knitting section have shade roof. The garments section is in corporate building. The mill has water treatment plant and Dhaka-Mymensingh Highway KAI Alluminim Co.Ltd. Masco Industries Ltd. SMP Design Pvt. Ltd. FH Fabrics Ltd. Gajipura Tongi Board Bazar Dhaka ViyellaTex

8. effluent treatment plant also.it has a large canteen with facilities for 6000 employer. The mill has official quarter for higher rank officers, which is build the previous year.
 Vision: To be the most regarded company in Bangladesh by 2015.
 Mission: We strive to provide quality services on time, based on best practices for the satisfaction of our Partners & Stakeholders. We foster friendly working environment through open communication and mutual respect. We encourage initiative, innovation and teamwork. Workers welfare and right is our premier focus. We are committed for cleaner and greener environment. We are driven by our responsibility to the society as a Corporate Body.
 Viyellatex Values:
 Integrity
 Commitment
 Customer Satisfaction
 Innovativeness
 Fairness
 Environment
Major buyers of Viyellatex Group:
» PVH
» S-Oliver
» Puma
» Espirit
» G-Star
» M & S
» Ito Yokoda
» WoolWorths

9. Business Achievement of the Group:
 Corporate Social Responsibility Commitments:
 Execute business with transparency and integrity
 Comply with all legal requirements to conduct business.
 Emphasizing and rewarding for better job.
 To become environment friendly as much as possible.
 Emphasizing on the up-liftment of the community around the company.
 Focusing on improved service to the customers and stakeholders.
 Social contribution:
Green (Environment) initiative:
Viyellatex is most renowned environment friendly textile production facility in the world. Our renowned environment initiatives have been well recognized not only by other international business organization but also by World Bank & Asian Development Bank as well.
Our few exemplary initiatives:
 More than 280000 liters of treated effluent water is being used for 7000 worker‘s toilet flush every day, saving 75M liters of underground water every year.
 250000 square feet roof top is being used to collect approx. 45 million liters of rain water which is later used in textile wet processing without utilizing the valuable underground water and saving extra chemicals of water softening.
 5 MW gas generator exhaust used in co-generation chiller to support 750 MT of air cooling in the Viyellatex Spinning Mill. Also in the fabric plant, it is planning to use 3MW generator exhaust in the Boiler. Both technology saves substantial energy and reduced carbon emission.
 Re-condensed steam water is being transported to the boiler feeder tank which increases the temperature by 15-20C, saves hefty energy and minimizes global warming.

10.  Fabric dryer exhaust is being redirected to air inlet and feed into the burner to reduce the energy consumption. A simple innovative technique which Viyellatex started to use 3 years back and now incorporated by famous GMBH Textile Machine Manufacturer, Bruckner in their latest series of Stenter.
 Per year approx. 50 Tons of food residue created during lunch of 7000 employees, are being used to develop natural fertilizer and being distributed among the neighboring farmers at free of cost- an initiative which avoids environment pollution and supports the community.
 Instead of air condition Viyellatex installed Energy Saving Evaporating Cooling System to apparel production floors.
 Viyellatex is constantly doing projects with International Partners to develop eco- friendly textile products. It did the Carbon foot print project to minimize the carbon emission in the wet processing with the assistance of world recognize company BASF.
 Became self-reliant in the society & unique return for any business group of Bangladesh.

11. Manpower management
Viyellatex Group contains a no. of departments and each department is controlled by a chief operating officer. The board of directors maintains control on overall departments. Viyellatex limited possess a strong management system and all the activities are done in efficient way and in a systematic process.
 Board of Directors:
1. Mr. K. M. Rezaul Hasanat, Chairman & CEO
2. Mr. Ahasan Kabir Khan, Vice Chairman
3. Mrs. Kaniz Fatema Zareen, Director
4. Amina Salima Khan, Director
 Organogram of Viyellatex Group:
Chairman & CEO Vice ChairmanGroup HR Group FINANCE FABRICS GDL VSL VTG ISML FPPL Group IT Group Commercial LM&S Ruthna Tea Estate

12.  BUs Head of Viyellatex:
 Organogram of Knitting department:
Mr. Syed Fatemy Ahmed Roomy
Director
Mr. Md. Masudul Hoque
MD & COO, GDL
Mr. Md. Abu Haider Rumi
MD & COO, FPPL
Mr. Arif Bhuiyan
COO, Viyellatex Garments
Mr. Kazi Monjurul Islam
COO, Viyellatex Fabrics
Mr. Fateh Ul Islam
COO, Interfab
Mr. Yakub Ali
COO, Ruthna Tea Estate
Mr. Md. Sharif Dad Khan
DGM, VSL
Mr. Kazi Shahidul Karim
DGM, Commercial, VG
Mr. Ruhul Amin Chowdhury
Head of ISS DGM/AGM Manager / Asst. Manager (Store) Sr. Executive / Executive Jr. Executive (Yarn) Jr. Executive (Grey Fabric) Store Asst. (Yarn) Store Asst. (Grey Fabric) Loader (Yarn) Batch Helper/LoadeManager/Asst. manager Sr. Fitter / Fitter Asst. Fitter Servicing man Needle man Servicing helper Manager / Asst. Manager (Prodn & Plan) Knitting Master/Executive (Flat) Operator/Asst. Operator Sr. Fitter / Fitter Helper Sr. Executive (Prodn, Plan & Sample) Executive/Jr. Executive (Prodn, Plan & Sample) Sr. Supervisor / Supervisor Asst. operator Sr.Operator / Operator Production Helper Sample supervisor Sample asst.

13.  Organogram of dyeing:
 Organogram of finishing:
DGM/AGM Manager Planning Asst. Manager Sr. Executive/ Executive Jr. Executive Sr. Supervisor/ Supervisor Production Asst. Manager Sr. Executive/ Executive Jr. Executive Sr. Supervisor/ Supervisor Store Asst. Manager Sr. Executive/ Executive Jr. Executive Sr. Supervisor/ Supervisor Washing Asst. Manager Sr. Executive/ Executive Jr. Executive Sr. Supervisor/ Supervisor

14. Management system:
 Intercom telephone
 Fax
 Written letters &
 Oral
Shift change:
Viyellatex limited maintain three shifts at every day‘s work. So the shifts are changed at every three hours. The shifting times are –
A Shift – 06:00 – 14:00
B Shift – 14:00 – 22:00
C Shift – 22:00 – 06:00
General shift & Office time:
09.00 – 18.00
Responsibilities of production officer:
 To give dyeing program slip.
 To match production sample with target shade.
 To collect production sample for sample matching next production.
 To observe dyed fabric during finishing running & also after finishing.
 To identify disputed fabrics & report to P.M/G.M for necessary actions.
 To discuss with P.M. about overall production if necessary.
 To sign the store requisition & delivery challan in the absence of P.M.
 Also to execute overall floor works.
 To maintain loading/unloading khata.
 Any other assignment given by higher authority.
Job Description of P.O & S.P.O:
Job title: Production officer & Senior Production officer
Report to: Production Manager
Purpose:
To control shift according to the plan made by the production manager
Territory:
Dyeing section (major)
Batching and Finishing section (minor)
Nature and Scope:
Responsible for the production during his own shift with good quality and minimum time.
Environment:
Production officer has to work under huge stress. He has to work in acute heat under physical and mental pressure. Also he has to work in acute heat all the year round.

15. Job Description of Production Officer:
Report To: Sr. production officer
Job Summary:
To plan, execute & follows up the production activities & control the quality production with related activities.
Duties & Responsibilities:
 Overall supervision of dyeing, finishing production.
 Batch preparation & PH check.
 Dyes & chemical requisition issue & check.
 Write fabrics loading & loading time from m/c.
 Program making, sample checking, color management.
 Control the supervisors, operator, asst. operator & helpers of dyeing m/c.
 And also any other work as & when required by the management.
Job Description of Sr. Production Officer:
Report To: P.M (production)
Job Summary:
To plan, execute & follows up the production activities & control the quality production with related activities.
Duties & Responsibilities:
 Overall supervision of dyeing, finishing production.
 Checks the different log books of different areas & report to management.
 Checks the sensitive parameters of different machine for smooth dyeing.
 Checks out the plan to control the best output from supervisor & workers.
 To trained up & motive the subordinates how to improve the quality production.
 Maintenance of machine & equipment. Any other works & when required by the management.
 Control the supervisors, operator, asst. operator & helpers of dyeing m/c.

18. Process flow chart for knitting:
Yarn in package form

Place the package yarn in the yarn

Feeding the yarn

Set the machine as per design & GSM

Knitting

Withdraw the roll fabric and weighing

Roll marking

Inspection

Numbering
Yarn types:
1. 100% cotton
 Carded
 Combed
 Rotor
2. Man made
 Polyester
 Lycra
3. Blended
 CVC (Cotton + Polyester)
 PC (Polyester + Cotton)
 Mélange (Cotton + Viscose)
 White/Ecru Mélange (Dyed fiber – 0.2-2.0%)
 Grey Mélange (Dyed fiber – 2.0-15.0%)
 Anthra Mélange (Dyed fiber – 15.0-30.0%)
4. Regenerated cellulose
 Viscose
 Modal
Commonly used yarn count:
 Carded yarn – 18,20,24,26,30,32,34,36 Ne
 Combed Yarn – 20,22,24,26,28,30,32,34,36,40 Ne
 Rotor yarn – 7,10,12,14,16 Ne
 Polyester yarn – 75,100,150 Denier
 Lycra yarn – 20,30,40,50,70 Denier

19. Sources of yarn:
1. Cotton (Both Carded & Combed)
- Viyellatex Spinning Limited
2. Polyester
- Kader Synthetic
- China
3. Mélange
- Patartoli
- Prime
- Sohagpur
- Thermax
4. Lycra
- China
- Korea
- Taiwan
- Japan
List of machines:
Name of the machine
Quantity
Single jersey
35
Fleece
10
Double jersey
19
Auto striper (S/J)
06
Auto striper (Rib)
02
Flatbed knitting machine
25
Fabric inspection machine
03
Brands of the machine:
 Fukuhara
 Matsuya
 Mayer & Cie.
 Keumyong
 Pai Lung
 Terrot
 Uzu

20. Specification of different types of machine:
Single Jersey machine:
Brand name: Pai Lung
Origin: Taiwan
Model: PL XS 3B
Feeder: 108
Gauge: 24
Diameter: 36‖
No of needle: 2712
Machine speed: Up to 35 rpm
Auto Striper machine:
Brand name: Pai Lung
Origin: Taiwan
Model: PLXD CS 6U
Feeder: 54×6c
Gauge: 18
Diameter: 36‖
No of needle: 2040
Machine speed: Up to 16 rpm
Fabric Inspection machine:
Brand: Uzu cloth inspection machine
Manufacturer: AATPR Industry Co. Ltd.
Model: UZ 900-3
Origin: Thailand
Different parts of the machine:
1. Start/Stop/Inch buttons: This set of buttons is used to start/stop/slow running of machine.
2. Ratchet lever: This lever permit the hand movement of the machine.
3. Auto stop motion: Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicator lamps are on individual stop 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.
4. Side creel: For each feed, there are two cones of yarn on the creel.
5. 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.
6. Feeder: Feeder is used to feed the yarn.
7. VDQ pulley: This is one of the important parts of the machine. Through VDQ pulley, the GSM of the fabric is controlled. If the value of the VDQ pulley is increased, then the loop Double Jersey machine: Brand name: Pai Lung Origin: Taiwan Model: PL XRA CE Feeder: 76 Gauge: 18 Diameter: 38‖ No of needle: 2124 Machine speed: Up to 24 rpm Flat Bed Knitting machine: Brand name: Matsuya Origin: Japan Model: M-100 Feeder: 6 Gauge: 14 Head: 2 Bed length: 102‖

21. length of the fabric will be less and the GSM of the fabric will be high. Vice versa for make low GSM fabric.
8. Auto counter: Two shift revolution with display counter with predetermined stop, to settle freely the weight or yardage of fabric.
9. 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 brake to prevent damages in case of needles or yarn breakage.
10. Fabric take up system: With variable speed control by a belt drive set canbe adjusted the speed for different course of fabric-constant and uniform fabric tension.
Points should be considered for GSM changing:
1. VDQ (Variable Dia. Quality Control) pulley diameter.
2. Yarn count.
3. Machine gauge.
4. Cam position
5. Take up motion
Factors that should be considered for changing of fabric design:
1. Cam arrangement changing.
2. Needle butt setting & needle dropping.
3. Using of different colors in selected feeder.
4. Using of jacquard mechanism.
5. Size of the loop shape
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 follows-
1. Diameter of the fabric
2. Design of the fabric
3. GSM of the fabric
4. Total wt. of the fabric
5. Yarn count
6. Types of yarn
7. Color of the fabric
8. Finishing of fabric.
9. Handling & fastness property.

22. End products of the knitting machine:
1. Single Jersey machine:
- Plain jersey
- Lycra jersey
- Single Lacoste
- Double Lacoste
- Single Pique
- Double Pique
- Fleece (Three thread)
- Terry Fleece (Two thread)
Production parameters:
- Machine Diameter
- Machine rpm (revolutions per minute)
- No. of feeds or feeders in use
- Machine Gauge
- Count of yarn
- Required time (Machine running time)
- Machine running efficiency
Production calculation:
1. Production/shift in kg at 100% efficiency:
Yarncount
RPM No of Feeder No of Needle SL mm
    
    

10 2.54 36 840 2.2046
. . ( ) 60 12
Yarncount
RPM No of Feeder No of Needle SL mm

  

3527.80
. . ( )
2. Production/shift in meter:
/ 100
. 60 12
/
/min .

   


Course cm
RPM No of Feeder Efficiency
Course cm
Course
3. Fabric width in meter:
/ 100
.
/ 100
.




Wales cm
Total no of Needles knitting
Wales cm
Total no of wales
2. Double Jersey machine:
- 1×1 Rib
- 2×1 Rib
- Interlock
- Mesh
- Flat back Rib
- Waffle
3. V-bed knitting machine:
- Collar
- Cuff
- Emboss

23. Methods of increasing production:
There are few ways of increasing production of the machine –
1. By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased.
2. By increasing the number of feeder:
If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time
3. By using machine of higher gauge:
The more the machine gauge, the more the production is. So by using machine of higher gauge, production can be increased.
4. By imposing automation in the m/c:
a) Quick starting & stopping for efficient driving system.
b) Automatic m/c lubrication system for smoother operation.
c) Photo electric fabric fault detector.
5. By imposing other developments:
a) Using creel-feeding system.
b) Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage.
c) Using yarn feed control device.
d) Using auto lint removal.
Commonly found fabric faults in the Knitting floor:
 Needle mark:
Appearance: Spot of line is found at wales direction.
Causes:
 Due to decayed needle.
 Due to bended needle.
 Due to old needle.
Remedies:
 Change the needle.
 Sinker mark:
Appearance: Spot of line is found at wales direction.
Causes:
 Due to decayed sinker.
 Due to faulty adjustment of sinker with sinker cam.
Remedies:
 Change the sinker.
 Make necessary adjustments of sinker with sinker cam as required.

24.  Hole:
Appearance: Hole on the fabric.
Causes:
 If needle latch is not working properly.
 Due to uneven tension.
 Due to needle head breakage.
 Due to improper cam setting.
Remedies:
 Change the needle.
 Adjust the tension as required.
 Adjust cam setting properly.
 Loop:
Appearance: As like small size holes.
Causes:
 Due to uneven tension.
 If cam box is loose, during the cam box setting.
 Any type of problem is occurred in m/c setting.
Remedies:
 Change the needle & sinker.
 Adjust the tension as required.
 Baree Mark/Patta:
Appearance: Found stripe effect towards the coarse on knit fabric.
Causes:
 If yarns of different lot are mixing together.
 If different counts of yarn are mixing together.
Remedies:
 Operator should be careful about that different lots of yarn cannot be mix up.
 Yarn should be tested before knitting.
 Slub:
Appearance: A thick place is made in a particular place on fabric surface.
Causes:
 Due to using of low quality yarn.
Remedies:
 Yarn quality should be good.
 Yarn testing should be done very carefully.
 Thick & Thin Place:
Appearance: Higher & lower counts of yarn are knitted at a time.
Causes:
 Due to using of different counts of yarn during knitting.
 Due to irregular yarn dia.

25. Remedies:
 Operator should be careful during the operation that for a particular design.
 Count of every cone package should be same.
 Tension Mark:
Appearance: Found spot at wales direction of knit fabric.
Causes:
 Due to excessive tension in yarn.
Remedies:
 Tension should be adjusted as required.
 Oil Spot:
Appearance: Oil spot on fabric surface.
Causes:
 Due to excessive bleeding of oil in the m/c.
 If there is any type of problem in needle & sinker, oil can be bled on the fabric.
Remedies:
 Change the faulty needle & sinker.
 Machine should be cleaned time to time.
 Pin Hole:
Appearance: Small size of hole as like pin.
Causes:
 Due to wrong adjustment of cam box.
 If the yarn quality is low especially yarn with less strength causes pin hole in the fabric.
Remedies:
 Make required adjustment of cam box.
 Use high quality yarn.
 Lycra Out:
Appearance: A Lycra yarn is missing at vertical direction.
Causes:
 If Lycra yarn missed or breakage happened.
Remedies:
 Operator should be more cautious to make necessary adjustment or replacement or joining the yarn.
 Lycra Drop:
Appearance: Tension caused in Lycra out.
Causes:
 Due to excessive tension on Lycra yarn when knitted (within its tolerance limit).
Remedies:
 Make necessary adjustments to the tension of Lycra yarn.

26.  Set Off:
Appearance: Found loop gap on knit fabric.
Causes:
 Set off occurred when needle & sinker both inactive simultaneously in the process of knitting.
Remedies:
 Machine should be stopped as early as possible.
Remarks:
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.

28. Batching:
Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order. In other words—
Batching means separation of fabric according to specification, Dyeing machine capacity & availability, urgency of the order.
Batch contains body of garments as well as collar-cuffs according to the design.
Types of Batching:
1. Solid
2. Assorted
Batch Quantity = Total required quantity X Dia Quantity/ Total quantity
Batch Ratio = Total batch quantity + total parts/ Batch Quantity
Batch distribution:
 Batch is distributed according to nozzle capacity.
 During distribution maximum equilibrium of different parts is taken into consideration.
 Lycra fabrics are slit-cut to heat-set. That‘s why before dyeing they need to re-sewn. This is done by ‗Bag-sewing‘ machine.
 Tubular fabrics are turned into their backside by turning machine.
Function or Purpose of Batch Section:
- To receive the grey fabric roll from knitting section or other source.
- Turn the grey fabric if required.
- To prepare the batch of fabric for dyeing according to the following criteria –
 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. Sometime planning is adjusted according to m/c condition or emergency.

29. Machines used in Batching:
1. Bag Sewing machine: There are total 2 sewing machines—
Brand: Juki,
Model: G39/0141
Power: 10A, 230V
Type: 2 Needle 2 Looper chain stitches. 1 Needle 2 looper in use.
Origin: Japan
Brand: Pegasus,
Model: M7S2-181
Specification: 2 Needle 4 Loopers. 1 Needle 2 Looper in use
Device: BT/88
Origin: Japan
2. Turning machine: There are two turning machines also. Both of them have same specification.
Brand Name : Taida
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company : Shandong Taida Dyeing & Finishing Machinery Co. Ltd.
Origin : China
3. Light box:
Brand: Verivide
Model: CAC60
No. of light sources: 4, TL84, D65, F, UV
Serial no.: E 614506
Manufacturing year: 2002
Power: 220-230V, 270W
Origin: England

31. Layout plan of dyeing floor
Number of machine:
Turning machine: 02
Bulk dyeing machine: 15
Sample dyeing machine:
There are two brands of dyeing machine used in Viyellatex. They are:
1. Fong‘s
2. Thies
Fong‘s machines are from China and Thies machines are from Germany.

32. Number of Fong‘s Machine:
Bulk machine: 10
Sample machine: 6
Total number of Thies machine:
Bulk machine: 5
Sample machine: 1
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 per day:
• Maximum Loading capacity 100% (11.36 tons)
• Possible maximum loading 80% (9.088 tons)
• Total production per days (3 shifts) = 9.088 x 2.5 (considering 2.5 batch in 3 shifts)
= 22.72 tons.
Bulk machine specification
M/C
No.
Brand
Model
Year of
Mfg.
Origin
Capacity
Kg
No. of
Nozzle
Maxm
temp
0C
Maxm
Pressure
KPa
Dimension
(inch)
1
Fong‘s
ECO 38 2T
2003
China
500
2
140
380
12×18
2
Thies
Farbavessel
ECOSOFTPLUS
2004
Germany
1000
4
140
550
20×18
3
Thies
Farbavessel
ECOSOFTPLUS
2003
Germany
1000
4
140
550
20×18
4
Thies
Farbavessel
ECOSOFTPLUS
2002
Germany
250
1
140
550
12×18
5
Thies
Farbavessel
ECOSOFTPLUS
2002
Germany
500
2
140
550
14×18
6
Thies
Farbavessel
ECOSOFTPLUS
2002
Germany
750
3
140
550
16×18
7
Fong‘s
ECO 61T
2005
China
200
1
140
380
9×18
8
Fong‘s
ECO 61T
2005
China
250
1
140
380
9×18
9
Fong‘s
ECO 61T
2005
China
750
3
140
380
20×18
10
Fong‘s
HSJ-4T
2007
China
1120
4
140
350
21×18
11
Fong‘s
HSJ-3T
2007
China
840
3
140
350
18×18
12
Fong‘s
HSJ-SR-2T
2007
China
560
2
140
350
15×18
13
Fong‘s
HSJ-SR-6T
2007
China
1680
6
140
350
33×18
14
Fong‘s
HSJ-SR
2007
China
840
3
140
350
18×18
15
Fong‘s
HSJ-SR
2007
China
1120
4
140
350
24×18

33. Sample machine specification
M/C
No.
Brand
Model
Year of
Mfg.
Origin
Capacity
Kg
Maximum
Temp.
0C
Maximum
Pressure
KPa
Dimension
(Inch)
1
Fong‘s
ALLFIT-30
2003
China
25
140
400
9×13
2
Thies
N/A
2002
Germany
25
140
350
6×13
3
Fong‘s
ALLFIT-30
2005
China
30
140
400
3.5×11
4
Fong‘s
ALLFIT-30
2005
China
120
140
400
6×16
5
Fong‘s
ALLFIT-30
2006
China
30
140
350
4×11
6
Fong‘s
ALLFIT-30
2007
China
60
140
350
4×15
7
Fong‘s
ALLFIT-30
2007
China
60
140
350
4×15
MACHINE DESCRIPTION
Technology of the dyeing machine:
Viyellatex 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 are-
1. Main tank
2. Reserve tank/PT tank
3. Additional/Mixing tank
4. Main pump
5. Heat exchanger
6. Filter

34. The description of the main parts of the machine is as follows –
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.
Fig: Main Tank
Reserve/PT 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.

35. 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.
Mechanism of Heat-exchanger:
1. Heat-exchanger consists of no. of tubes surrounded by a shell body.
2. 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.
3. One flows through the tube other flows through the shell.
4. The temperature of the two fluids is different, so transfer of heat occurs from one fluid to another through shell.

36. Figure: Mechanism of Heat exchanger Figure: Heat exchanger
5. 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.
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 the lose fibers are not eliminated, then the running of fabric is disturbed & entanglement can be occurred.
Ways of Liquor Flow from Additional Tank:
Liquor from additional tank flow to the main tank is mainly done in two ways. They are –
1. Inject: In this system, all amounts of liquor flows directly to the main tank at a time. This is done when the chemicals need to pass at short time. This system ensures high rate of flow of the liquid.
2. Dosing: In this system, the liquor does not pass to the main tank at a time. There are few chemicals which have very severe action to the fabric if it flows directly like sodium hydroxide (NaOH). These chemicals pass to the main tank in an increasing or decreasing way with time so that the harsh effect of these chemicals is minimized. There are three
3. types of dosing:
- Linear Dosing - Progressive Dosing - Decreasive Dosing

37. Linear dosing Progressive dosing Decreasive 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
Types of machine according to temperature:
 Atmospheric machine
 High temperature machine

38. There are one atmospheric machine of Fong‘s brand in Viyellatex. Others are high temperature machine (both Fong‘s and Thies). Also there are special types of high temperature machine used in Viyellatex named as Fong‘s High Speed Jumbo (HSJ) Machine.
Features of Fong‘s atmospheric machine:
 The machine is designed for pre-treatment, dyeing & after-treatment under atmospheric condition.
 Nozzle is sized for smooth passing through by the fabric and extensive exchange with the liquid.
 Two standard nozzle sizes with sufficiently large diameter are available.
 Circulation pump is sized for heavy fabric
 Production capacity: 500 kg maximum per batch.
 Maximum temperature: 98o C.
 Maximum pressure: 1 atm.
Figure: Fong‘s atmospheric machine
Features of high temperature machine (Both Thies & Fong‘s):
 The machine is designed for the pretreatment, dyeing and after treatment which can provide temperature up to 1400C.
 Nozzle lead gets interlocked after temperature exceeds 800C.
 Loading per nozzle 250kg
 Design pressure: 350-550kpa
 Design Temp : 1400C
 Hydraulic Test Pressure: 585Kpa
 Manufacturer: Germany (Thies), China (Fong‘s)
 No of nozzles: 1-8.

39. Figure: High temperature machine
Features of Fong‘s High Speed Jumbo (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
Figure: Fong‘s high speed jumbo machine

40. Some additional features of Fong‘s HSJ machine:
There are few additional features of Fong‘s HSJ machine which gives more productivity, better control and less stoppage times of the machine. These are –
 Dissolution Pump
 Variable Loading Chamber
 MIR Rinsing System
 MSR Rinsing System
Dissolution pump:
 Dissolution pump makes the chemical concentration (salt, soda, dye, auxiliaries) low before passing it to the main tank from additional 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.
Figure: Dissolution pump
Variable Loading Chamber:
This is one of the advanced techniques of space utilization of the round shaped dyeing machine. Experiment shows that the volume of the chamber can be increased per nozzle up to 30 Kg of fabric depending upon the linear density of the fabric.
Few advantages of variable loading chamber are –
 Better alignment of the fabric.
 More loading facility.
 Less entanglement of the fabric.

41. Linear Density Variable chamber setting
Up to 350 g/m 0%
Up to 350-450 g/m 50%
Above 450 g/m 100%
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.
Figure: MIR Rinsing System
Figure: Schematic diagram of Variable Loading Chamber

42. 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.
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 & heat-exchanger
Filter and heat-exchanger are separate.
Have dissolution pump for mixing chemical in
1:4 ratio.
Not present.
Horizontal heat-exchanger.
Vertical heat-exchanger.
Two additional tank.
One additional tank.
Variable loading chamber.
Not present.
Loading per nozzle 280 kg (HSJ).
Loading per nozzle 250 kg
Winch speed can be above 450 m/min.
Up to 350 m/min.
Calculation of Winch Speed:
Let,
Fabric weight = 1000kg
Per nozzle fabric weight =250kg
Fabric Diameter (open) = 56 inch
Cycle time or Dwell time = 2.5-3.0 m per minute
G.S.M =180
We know, GSM = gram / meter2
= gram / (Length × Diameter)
Or, Length = gram / (GSM × Diameter)
= (250×1000×100) / (56×2.54×180)
= 976 meters.
So, Winch or Reel Speed = Per nozzle Fabric length / Cycle time
= 976 / 3 meter/minute
= 325 meter/minute.
Calculation of Linear Density:
Linear Density = (Diameter×GSM×2.54) / 100 gram/meter

43. Production planning and sequence of operation:
Dyeing process flow chart:
Grey fabric receive from knitting section
↓
Batching
↓
Turning of fabric (only for Single Jersey)
↓
Selection machine no
↓
Fabric loading
↓
Select production program
↓
Select recipe for dyeing
↓
Pretreatment
↓
Dyeing
↓
After treatment
↓
Fabric Unload
Production Parameters:
1) PH
- Scouring PH – 12.5
- During H2O2 bleaching PH 10.5-11
- Enzyme PH – 4.5
- Before dyeing (Leveling) PH – 6.5
2) Temperature:
-For cotton fabric scouring: 105ºC
 During NaOH addition 65oC
 During H2O2 addition 70oC
 Peroxide killing at 80oC
- Sequestering at 90oC
- Bio-polishing at 55oC
- For cotton dyeing:
 Low brand – 45oC
 Medium brand - 600C
 Hot brand – 80oC
- Salt PH – 7-8
- During reactive dyeing PH 10.5-11.5
- During disperse dyeing PH 4.5-6.0
- Softener PH – 6.5
- Migration for turquoise color at – 90oC
- Optical brightening agent (OBA) at – 80oC
- Polyester dying: 1000-1300C
- Softener at – 45oC

44. 3) Time:
- For white fabric 4-5hrs
- For 100% cotton 8-10hrs
- For 100% polyester 5hrs
- CVC 2 parts 13-14 hrs.
4) M: L ratio:
- For reactive dyeing M: L ratio maintained between 1:6
Pretreatment process:
Typical recipe for scouring: (all in g/l)
Felson NOF – 0.7
Kapazon H53 – 0.5
Caustic – 2
H2O2 – 2.5
Recorit wez/Peroxide killer – 0.75
Acetic acid – 0.8
Biopolish B-11 – 1.5
Securon 540 – 0.5
Pretreatment flow chart
Fresh water and fabric Load at 45oC

Temperature raise to 60oC

Detergent, Peroxide Stabilizer inject

Run for 5 min

Inject Caustic and run 5 min

Raise temperature to 70oC

H2O2 inject and run 5 min

Temperature raise to 105oC

Run for 30 min

Lower the temperature to 80oC

Bath drain

Peroxide killer inject and run 10 min

Rinsing and unload the fabric.

45. Curve for scouring of fabric:
Types of shade:
 Light
 Medium
 Dark
 White
Dyeing
process
Isothermal
dyeing
Migration
dyeing

46. evel in at 60 C
↓
Color dosing 60˚C x 35ʹ( linear dosing)
↓
Run time 60˚C x 15ʹ
↓
Salt dissolving 15ʹ (recirculation process)
↓
Run 15ʹ
↓
Soda dosing for 50ʹ( 70% progressive)
↓
Check the sample after 10ʹ
Migration Dyeing
evel in at 60 C
↓
Color dosing for 35ʹ
↓
Run time 10ʹ
↓
Salt dissolving 15 min
↓
Run time 10ʹ
↓
Temperature rise at 80oC
↓
Run time 20 ʹ
↓
Temperature drop at 60oC
Order of Color and Salt dissolving/dosing:
 In case of 0-1.0 % (light) shade color is dosed first then salt dissolving is
performed.
 In case of 1-2.5% (medium) shade salt is dissolved at first then color is dosing.
 In case of 3 & above % (dark) shade salt is dissolved at first then color is dosing.
Dyeing procedure for dark shade: (Black)
Typical recipe: (all in g/l)
A41/Leveling agent – 0.5
RS Yell 3RFN – 0.424 %
RS Red 3BFN – 0.21 %
RS Black EDGH – 9.27 %
Salt – 90
Soda ash – 5
Caustic – 1.75
Isothermal Dyeing

47. Process Flow Chart
Fresh Water taken at 60oC
↓
Inject Leveling agent and keep for 7 min
↓
Salt dosing 20 min & runtime 20 min
↓
Color dosing 35 min and run for 15 min
↓
Soda dosing for 30 min (70% progressive) and run 10 min
↓
Caustic dosing for 25 min and run 20 min
↓
Sample check after 10 min
↓
Wash and unload.
Curve for black shade (dark) cotton dyeing
Dyeing procedure for Light/Medium Shade:
Typical recipe:
SV/Sequestering agent – 1.5 g/l
ADM/Leveling agent – 1 g/l
R Yell RR – 0.106 %
R BR Blue R (SPL) – 0.172 %
Salt – 24 g/l
Soda ash – 8 g/l

48. Flow Chart:
Fabric load and then Water taken
Rise temperature to 60oC
PH control to 6.5
Inject leveling agent and run for 10 min
Color dosing for 45 min + add ½ SV
Run the bath 10 min
Other ½ SV inject and run 20 min
½ Salt add and run 10 min
Extra ½ Salt addition and run for 20 min
Soda dosing for 60 min
After 10 min Sample check
Rinsing and unloading
Curve for Cotton part Dyeing

49. Production flow chart for white shade:
Typical recipe: (all measurement in g/l)
Felson NOF – 0.5
Kapazon H53 – 0.5
Caustic – 2.5
H2O2 – 6
4BK/Whitening agent – 0.15
Acetic acid – 1
Biopolish B-11 – 1.5
Securon-540 – 0.5
FPG/Softener– 1.5
Process flow chart
Detergent, Peroxide stabilizer added at 600C

Fabric load and run for 5 min

Caustic dosing for 5 min at 600C

Temperature rasied to 70oC

Peroxide added and raise temperature to 80oC

Optical brightening agrnt dosing for 10 min and temperature raise to 105oC

Run for 50 min and lower temperature to 80oC

Bath drain and water taken at 80oC

Rinsing for 10 min then bath drain

Fresh water taken and Acetic acid at 60oC

Run for 10 min then again drain the bath

Acetic acid at 55oC and PH control to 4.5

Enzyme is added and run for 50 min at 55oC

Bath drain and fresh water at 60oC

Inject Sequestering agent and temperature raise to 90oC

Run 10 min and add Softener, againg run 20 min

Fabric unload

50. Curve for White shade
Dyeing of 100% Polyester
Typical recipe :
Antifoaming agent – 0.15 g/l
T Yellow W-4G – 0.0012826 %
DIA BR Red SF – 0.1333904 %
T Blue WBLS – 0.00153912 %
AB-45 – 0.5 g/l
Process Flow Chart :
Fabric Load

Water Level – As Required

Raise temp to 600C

Add Felson NOF

Raise temp.to 900C & run time 10 min

Bath drain

Water in

Raise temperature to 450C

Add acetic acid & runtime 10 min

Bath drain

Water taking

Raise temperature to 450C

Dye dosing for 10 min

51. 
Raise temperature to 1300C & run for 45 min

Drain

Water taking

Cooling at 700C & sample cheek if shade ok then bath drop

Hydrose + Caustic at 800C for 20 min

Hot wash
Curve for Polyester dyeing:
Production flow chart for CVC:
For CVC fabric dyeing, at first polyester part is dyed at 1300C according to dyeing procedure
of 100% polyester dyeing.
Then cotton part is first scoured & bleached. Then cotton part is dyed according to
dyeing procedure of 100% cotton.
Turquois color dyeing:
Typical recipe:
Kapavon CL/Anticreasing agent – 0.5 g/l
SV/Sequestering agent – 1.5 g/l
R BR Yell 3GL – 0.0814 %
R Turq B1G – 3.4556 %
R BR Blue RSPL – 3.14 %
Salt – 90 g/l
Soda – 5 g/l
Caustic – 1.75 g/l

52. Flow chart of turquoise color dyeing:
Water taken at 60oC and PH = 6.5

Raise the temperature to 80oC

Ant creasing and Sequestering agent inject and run 10 min.

Color + ½ SV dosing for 50 min and run 10 min.

½ SV inject and run for 10 min.

½ Salt dosing for 10 min. then run 10 min.

Again ½ Salt dosing and run 10 min

Temperature to 90oC (1oC/min) and run 20 min

Temperature reduce to 80oC

Soda dosing (70% progressive) for 40 min then run 10 min

Caustic dosing (70% Progressive) for 40 min then run 10 min

Sample check
Curve for dyeing with turquoise color:

53. Washing of grey mélange fabric:
Level in
↓
Wetting agent at 60ºC
↓
Bath Drain
↓
Level in
↓
PH 5.5 and temperature 55oC
↓
Enzyme
↓
Run time 60min
↓
Rise temperature to 80ºC
↓
MIR rinse for 15ʹ
↓
Level in
↓
Softener 45ºCx10'
↓
Bath Drain
↓
Cold rinse
After treatment
After treatment Process flow chart:
Wash off at 95 C*15 (soaping agent 1-1.5 g/l)
↓
Overflow Rinse/MIR 50˚C x 15´
↓
Acid 0.35 g/l
↓
Softening treatment 45 C x 20 at PH - 4.5~5
↓
Rinse 15ʹʹ
↓
Unload
After treatment process may vary according to byer requirement like whether softener,
anticreasing or enzyme should be applied or not.

54. Process Loss:
Fabric types Loss of percentage
Puma (CVC fleece) 14%
S.Oliver (s/j) 13.5%
G.Star (s/j) 12%
M&S (s/j) 10%
Espirit (s/j) 12%
Lycra (S/J) 14%
YID fabrics 7%
Grey mélange
( Puma & M&S)
10%
Grey mélange
(G.Star)
12%
Common dyeing faults with their remedies:
1. Uneven dyeing:
Causes:
- Uneven pretreatment (uneven scouring & bleaching).
- Rapid addition of Dyes and Chemicals.
- 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.
- Liquor ratio changed.
- Different dyeing procedure for each batch.

55. 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.
2. Dye Spots:
Causes:
- Not proper agitation of dyestuffs.
- Dye bath hardness.
- Operators ignorance about mixing and dissolving the dyestuffs and
chemicals.
Remedies:
- Proper agitation of dyestuffs.
- Use adequate amount of sequestering agent to minimize hardness.
Remarks:
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.

57. Types of raw material:
1. Yarn
2. Fabric
3. Dye stuff
4. Chemical and auxiliaries
List of Chemicals used in Viyellatex
Serial No. Material Description Agent
1 Acetic Acid Basic Chemicals
2 Caustic Soda Basic Chemicals
3 Glauber Salt Basic Chemicals
4 Hydrogen Peroxide (H2O2) Basic Chemicals
5 Soda Ash Basic Chemicals
6 Hydrose(BASF) Reduction Clearer
7 Hydrose(China) M/C Wash
8 Feloson -NOF Detergent
9 Rucozen WBL Detergent
10 INVADINE-LUN Detergent
11 Nearpon BW-LF Detergent
12 LUBRIMAX-TL Anti-creasing
13 Kappvon -CL Anti-creasing
14 BREVIOL PAM-N Anti-creasing
15 Kappazon -H-53 Stabilizer
16 OXISTAB-C Stabilizer
17 Invatex -PC Peroxide Killer
18 Kappatex -PKS Peroxide Killer
19 Rucorit WEZ Base Peroxide Killer
20 Kilat Sequestering
21 Securon-540 Sequestering
22 GENENCOR BP NANO Enzyme
23 Genencor BF 1600L Enzyme
24 BIOPOLISH -B14 Enzyme
25 ALBAFLOW-JET Antifoam
26 PROFOAM-SLK Antifoam
27 Sarabid -LDR Leveling
28 Kappquest -A41 Leveling
29 OPTAVON SV Leveling
30 CROSCOLOR ADM Leveling
31 Rucozen -NZA Soaping
32 DEKOL-SN Soaping
33 Cycalonan -X-C-W Soaping
34 ULYSIN S Soaping
35 Protnin -FCE-375 Fixing
36 Sapamine -CWS Color Softener
37 Nearsopht JS-100 Color Softener
38 KAPPASOFT-BD Color Softener
39 SAPAMINE-FPG White Softener
40 Nearsopht -NI White Softener
41 Rucofin -GWE Silicon Softener
42 Rucofin -HHS Silicon Softener

58. 43 Syno White 4BK Optical Brightener
44 Uvitex -CB Optical Brightener
45 Uvitex -BAM Optical Brightener
46 Uvitex -BBT Optical Brightener
47 Uvitex -BHB Optical Brightener
48 ALVATEX-AB-45 C.V.C Chemicals
49 ALBATEX-AR C.V.C Chemicals
50 UNIVADINE-DIF C.V.C Chemicals
51 Repellan SRF Stain release chemicals
52 Repellan XL-E Stain release chemicals
53 Adalin NI Stain release chemicals
54 Foryl LN Stain release chemicals
55 Common Salt WTP Chemicals
56 Cogulant ETP Chemicals
57 Lime ETP Chemicals
58 BLUE J OCEAN MAGIC R Washing Chemicals
59 AVOLAN IS Washing Chemicals
Dyes with Brand name
Serial No.
BEZEMA
1 Bezactive Yellow S-3R
2 Bezaktive Red -S2B
3 Bezaktive Red -S3B
HUNTSMAN
4 Cibacrone -Blue -FNR
5 Cibacrone Yellow -F-4G
6 Cibacrone Yellow -FN-2R
7 NOVACRON BRILL BLUE H-GR
8 NOVACRON BRILL. RED FN-3GL
9 NOVACRON SCARLET FN-6G
10 Terasil Black -WNS
11 Terasil Navy -WRS
12 Terasil Red -W-4BS
13 Terasil Yellow -W4G
14 TERASIL BLACK -SRL
JIHUA
15 Reactive Starfix Black-WM
16 Reactive Starfix Red -3-BFN
17 Reactive Starfix Red -EP
18 REACTIVE STARFIX BLACK ED HG
DYSTER
19 Dianix Yellow -SEG
20 Dianix Sport Red-SF
21 DIANIX BRILL RED SF
22 Remazol Blue-RGB

59. 23 Remazol Navy Blue-RGB
24 Remazol Brill Red -F-3B
25 Remazol Deep Black -RGB
26 Remazol Red -RR
27 Remazol Red-RGB
28 Remazol Ultra Carmine -RGB
29 Remazol Yellow -RR
IMPOCOLOUE
30 Imcozin Brill. Blue -VR Special
31 Imcozin Golden Yellow -V-RNL
32 Imcozin Red -E-3BF
33 Imcozin Turquise -VG
34 Imcozin Brill. Yellow -V-4GL
SUNFIX
35 Sunfix Red -MF-3BD
36 Sunfix Red-SPD
37 Sunfix Yellow -SPD
38 Sunfix Navy Blue -MF-D
39 Sunfix Navy Blue -SBF

61. Finishing
Textile finishing, in a restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed & certain greige fabrics are subjected before they are put to market.
It‘s one of the most important operations in knit processing.
Objectives of Finishing:
-Improving the appearance, luster, whiteness etc.
-Improving the feel, this depends on the handle of the material & its softness, suppleness,
fullness etc.
-Wearing qualities, non- soiling, anticrease, antishrink comfort etc.
-Special properties required for particular uses like water -proofing flame-proofing etc.
-Covering of the faults in the original cloth.
-Increasing the weight of the cloth.
Effects of Finishing:
-Easy care.
-Crease recovery.
-Dimensional stability.
-Good abrasion resistance.
-Improved tear strength.
-Good sew ability.
- Soft or stiff handle.
-Shine or luster.
Layout of Finishing Section:

62. Types of Finishing:
 Mechanical Finishing (Used to control dimension to improve appearance & handle)
 Chemical Finishing (Used to make glossy protection. To improve performance or
serviceability)
Finishing Process
Knit fabrics require finishing process after dyeing. During dyeing all knit fabrics are dyed in
tubular form. According to buyers requirement dyed fabrics are finished in either tubular
form or Open-width form.
Depending on which Finishing sections are separated into two sections – OPEN & TUBE section.
1. Tubular finish:
Dewatering
↓
Dryer
↓
Tube Compactor
2. Open finish:
Slitting
↓
Stenter
↓
Open Compactor
3. Special Finish (Raising & Sueding):
Slitting
↓
Stenter
↓
Raising/Sueding
↓
Stenter
↓
Compacting
No. of Machines of finishing section:
Name of the m/c No. of the m/c
Dewatering 2
Slitting 2
Dryer 2
Open compactor 2
Tube compactor 2
Rasing m/c 3
Sueding m/c 1

63. 1. Dewatering Machine
Machine Specification:
Brand - Heliot International
Model – EXP 226
Origin – France
Capacity – 3 tones/shift
Function of Dewatering m/c:
- Removal of excess water (70-75%)
- Removal of residual dirt
- De-twisting of the rope fabric
- Make the fabric Tubular from Rope form
- Improve the hand feel of the fabric by using
softener
Controlling points:
- Width control (can be increased up to 3‘‘)
- Pressure variation according to GSM
(higher GSM-3-3.5bar, Lower GSM-2-2.5bar)
- Fabric speed - 15m/min
Checking points:
 Hand feel
 Color spot
 Softener spot
Fabric Path of Dewatering machine

64. 2. Slitting machine:
Fabric path of slitting machine
Parameter:
- Padder pressure (1-6 bar)
- Fabric speed (200 m/min)
- Maximum fabric width – 86‘‘-88‘‘
Checking points:
- Needle mark
- Dirty spot
Power consumption:
 Voltage: 400V
 Frequency: 50Hz
 Maximum power: 24kwatt
Machine Specification:
Brand - Corino
Model - Strada Monticell 0.231
Origin - Italy
Year - 2005
Capacity – 3 tones/shift
Voltage – 400V
Frequency – 50Hz
Function:
- Slit the fabric to make it into open form
- Removal of excess amount of water
- De-twisting of the tube fabric

65. Dryer Machine:
Two types of dryer machine:
o Heliot dryer – for drying only tube fabric
o Santex AG dryer – for drying both tube and open fabric
Heliot Dryer:
Specification–
Brand – Heliot international
Model – D700 HWT
No of heating chamber – 3
No of burner – 3
No of nozzle - 35
Capacity – 8 tons/day
Origin – France
Fabric path of Heliot Dryer

66. Function:
 To dry the fabric
 To control the shrinkage
Controlling points:
 Overfeed
 Temperature (Maximum-1700C, Min- 900C)
 Fabric speed – Maximum 30m/min
Checking Points:
 Shade check
 Fabric width
Santex Dryer
Fabric path of Santex AG dryer
Specification:
Brand: Santex AG
Type: Santashink
Year: 2008
No of chamber: 5
Capacity: 12 tones/day
Origin: Switzerland
Function:
- To dry the fabric
- To control fabric dia
- To control Fabric shrinkage
- To control the fabric GSM
(can be increased 10-15 GSM)
- To apply special chemical
finish

67. Controlling points:
 Overfeed (0 – 50%)
 Temperature (Maximum – 1800C)
 Vibration – 800
 Fabric speed (Maximum 80m/min)
 Fabric width (open fabric
Checking Points:
 Shade check
 Width check
 GSM check
Temperature:
 White/light shade: 100-120`C
 Medium shade; 110-130`C
 Dark shade: 140-160`C
Stenter Machine
Two types of Stenter machine:
1. Bruckner Stenter machine
2. Sun Super Stenter machine
Bruckner Stenter machine:
Specification:
Brand name: BRUCKNER
Type/model no: 72276-0463
Country: Germany
Total no of chamber: 5
Maximum temp.: 2500C
Steam pressure: max. 2 bar
Air pressure: max. 10 bar
Capacity: 3 tones/shift
Main parts of the machine:
i) Feed zone
- Centering device
ii) Chemical padding zone
- Squeezing roller
- Chemical tray
iii) Bowing control zone
- Bowing roller (rubber roller, no of roller -2)
- Sensor (no of sensor -6)
- Uncurling roller
iv) Chain entry zone
- Uncurling device (both side of the chain entry)

68. - Sensor (both side of the chain entry)
- Brush roller (for attaching the fabric with the pin of the chain, no of brush roller
-4)
- Selvedge gumming device with gum box under the chain entry
v) Drying zone
- Gas rotamatic burner (10)
vi) Cooling zone
vii) Delivery zone
Function:
 Drying
 GSM control
 Width control
 Shrinkage control
 Decrease spirality
 Decrease Bowing effect
 Heat setting for cotton lycra fabric
Controlling points:
- Overfeed (45-60%)
- Temperature (max 2500C)
- Fabric Speed (18-28m/min)
- Padder pressure (1.5 – 2 bar)
Checking points:
 Shade
 GSM
 Width
 Faults (Uneven, Color spot, Shrinkage, Hole, Needle mark etc.)
Finishing parameters for different types of fabrics in BRUCKNER machine:
Fabric type GSM Dia Temperature Overfeed Padder
pressure
Speed Blower
RPM
s/j 115-150 2''plus 110-140ºC 45-55% 2 bar 20-25 60-70
s/j 160-220 2''plus 120-170ºC 45-50% 2.5 bar 18-23 65-75
L.S/J 160-220 4''plus 130-160ºC 60% 2 bar 18-23 60-70
L.S/J 200-250 4''plus 140-160ºC 60% 2 bar 12-20 65-75
Pique 160-250 3''plus 130-160ºC 50-55% 1.5-2bar 20-25 70-80
Fleece/terry 260-300 4"plus 140-170ºC 50-55% 2 bar 20-25 70-80
1*1rib 160-220 2"plus 130-160ºC 50% 2bar 24-28 70-80
2*2rib 190-220 2"plus 140-160ºC 50% 2 bar 20-25 60-70
Interlock 190-220 3"plus 130-160ºC 50% 2 bar 20-25 70-80

69. Sunsuper Stenter Machine
Specification:
Brand name: SUN SUPER.
Country: KOREA.
Total no of chamber: 8
Capacity: 4 tones/shift
Speed: Max. 110m/min
Temperature: Max 2200C
Steam pressure: 2 bar
Air pressure: 10 bar
Function:
 To dry the fabric.
 Heat-set the synthetic fiber fabric.
 Controlling the width of fabric or maintain dimensional stability.
 Controlling the GSM of fabric.
 Skew ness & Bowing controlling of stripe fabric.
 Spirality & Twisting control.
 Fabric hand-feel modification-like-Softening or Hardening.
 Shade control.
 Gumming & Cutting.
Controlling Points:
 Overfeed (0 – 50%)
 Temperature
 Speed
 Padder pressure
Checking Points:
 Shade
 Width
 GSM
 Faults
Finishing parameters for different types of fabrics in Sunsuper stenter:
Fabric type GSM Dia Temperature Overfeed Padder
pressure
Speed Blower
RPM
s/j 115-150 2''plus 110-140ºC 40-45% 2 bar 30-35 1100-1300
s/j 160-220 2''plus 120-170ºC 40-45% 2.5 bar 25-30 1200-1400
L.s/j 160-220 4'plus 130-160ºC 50% 2 bar 25-30 1200-1400
L.S/J 200-250 4'plus 140-160ºC 50% 2 bar 24-28 1200-1400

70. Utility for stenter machines:
 Gas
 Electricity
 Compressed air.
Compacting machine:
Two types of compacting machines are used in Viyellatex-
1. Open compacting machine
2. Tube compacting machine
1. Brand: FERRARO 2. Brand: Heliot
Type/model: COMPTEX-RE 2800 Overfeed: 50-60%
Country: ITALY Temperature: 90-1300C
Year: 2006 Teflon pressure: 16-18 PSI
Capacity: 3.5 tons/shift Origin: France
Function:
 Fabric compaction
 Make glossy, luster effect
 To control the shrinkage
 To maintain proper width and GSM
Controlling points:
 Overfeed
 Temperature
 Speed
Pique 160-200 3'plus 130-160ºC 40-45% 1.5-2bar 25-30 1200-1400
Fleece/terry 260-300 4"plus 140-170ºC 40-45% 2 bar 20-25 1300-1400
1*1rib 160-220 2"plus 130-160ºC 45% 2bar 24-28 1300-1400
2*2rib 190-220 2"plus 140-160ºC 45% 2 bar 20-25 1200-1400
Interlock 190-220 3"plus 130-160ºC 50% 2 bar 20-25 1200-1400

71. Checking Points:
 Fabric Diameter
 GSM
 Shrinkage
 Fabric faults
Main parts of the machine:
1. Heating chamber
2. Blower (2, one at the entry chain zone for uncurling and another at the entry of
compacting zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder
7. Belt cylinder
8. Uncurling device at entry of compacting zone.
9. sensor
Finishing parameters for different types of fabrics in compactor (Ferraro, open width
compactor):
Fabric type Color Speed Overfeed Temperature Blanket
pressure
Teflon
pressure
s/j White color 15-18 25-30 90-100ºC 1.5-2(bar) 33(P.S.I)
L.s/j White color
12-16 12-16 90-100ºC 1.5-2(bar) 33(P.S.I)
Pique White color
15-18 30-35 100-110ºC 1.5-2(bar) 33(P.S.I)
Fleece/terry White color
15-20 25-30 100-110ºC 1.5-2(bar) 33(P.S.I)
1*1 rib White color
15-20 20-30 110-120ºC 1.5-2(bar) 33(P.S.I)
2*2 rib White color
12-15 25-30 100-110ºC 1.5-2(bar) 33(P.S.I)
Interlock White color
12-16 Full over
feed
100-110ºC 1.5-2(bar) 33(P.S.I)
Tube compactor

72. Specification:
 Brand name: HELIOT INTERNATIONAL
 Model: HC99PI
 Company: France.
 Capacity: 3 tones/shift
Function:
 To control the shrinkage
 To maintain proper width of fabric
 To control fabric GSM
Controlling Points:
 Overfeed
 Temperature
 Fabric Speed
Special Finishing machine:
1. Sueding machine
Specification:
 Brand name: Lafer SPA
 Type/model no: GSI106
 Company: Italy
 Year: 2002
 Fabric speed: 110 m/min
Function:
 To make the fabric smooth(Face side of the fabric)
 To increase the handle property
 Improve heat insulation properties.
Controlling Points:
 Drum speed
 Fabric tension
 Plaiter tension
Fabric path of sueding machine
Taker in
Front Drag Roller
Drum
Plaiter
Delivery
Feed
Rear Drag Roller
Checking points:
 Fabric GSM
 Shrinkage
 Fabric diameter
 Crease mark
Utility for Compacting machine:
 Steam
 Electricity
 Compressed Air

73. Checking Points:
 Hole
 Improper Sueding
 Line mark
 Quality of Sueding
2. Raising machine:
Specification:
 Brand name: Lafer SPA
 Type/model no: GRI 224A
 Country: Italy
 Year: 2003
 Capacity: 3.5 tones/shift
 Fabric speed: 90rpm
Function:
 To produce pile on fabric surface
 To increase hand feel of the fabric
 To make the fabric soft
 Increase the warmth of the fabric.
Fabric path of raising machine
Inspection in Finishing Section
Steps of Inspection:
1st step- Shade Check
2nd step- Running Shade Check
3rd Step- Dia Check
4th Step- Faults & G.S.M Check
Controlling Points:
 Pile & Counter pile speed
 Drum speed
 Fabric tension
 Plaiter tension
Checking Points:
 Hole
 Uneven raised
 Line mark
 Quality of raising

74. 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:
Average points/100 yds. = total points /total inspected yds. * 100
Faults appeared in finishing
Defects Source
Hole Knitting
Oil Stain Knitting
Fly Yarn Knitting
Barrie Mark Knitting
Chemical Stain Dyeing
Dye Stain Dyeing
Patches Dyeing
Uneven Shade Dyeing
Crease Mark Dyeing + Knitting
Neps Fiber Problem
Yarn Contamination Spinning
Bowing Finishing
Crumple Mark Finishing

76. Working procedure of laboratory:
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 Color Fastness to washing
Crocking
Evaluate the sample Pre-production Sample Final sample
Report Making Test Test
Prepared the report prepared the report
Pass Fail
Deliver Refinish Pass Fail Pass Fail
Need to test again 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 Fail
Ready to delivery Refinish
Need to test again

77. Machines used in Laboratory:
1. Digital button tester
Imada, Japan
2. Apollo light & weather
James H.heal & co. Ltd. Halifax, England.
3. Incubator
Test name: Color fastness to water, sea water, perspiration &phenolic yellowing test
Test method: ISO 105-E01, ISO 105-EO2, ISO 105-E04 etc.
James H.Heal & Co ltd. Halifax, England.
4. Rubbing & Crocking tester
Healink
James H.Heal
5. Spray rating tester
James H.Heal & Co ltd.
6. Pilling & Snagging tester
M/c name: Orbitor pilling & snagging tester
Test name: Pilling resistance test
Test method: BSENISO 12945-1, B55811
James H.Heal & Co ltd.
7. Truburst
Brusting strength tester
James H.Heal & Co ltd.
8. Impulse
Random tumble pilling tester
James H.Heal & Co ltd.
9. Matendel abrasion tester
James H.Heal & Co ltd.
10. Elmatear
Digital tear tester (woven)
James H.Heal & Co ltd.
11. Fastness tester (color fastness to wash)
Graywash for 40ºC
12.Test name:Colour fastness to washing, dry cleaning
M/C name: Rota wash
Test method: ISO105-C06,ISO 105-D02
13. Washing machine
Healink
James H.Heal & Co ltd.
Fig: Apollo Light & Weather
Fig: Rubbing & crocking tester

78. 14. Lap dyeing m/c
M/C name: Ahiba Nuance lab dyeing m/c
James H.Heal & Co ltd.
15. Perspiration tester
James H.Heal & Co ltd.
16. Digital PH tester
17. Lab rotator
18. Rotawash
Test name: C/F to washing dry cleaning
Test method: ISO 105-C06.ISO 105-DO2
Quality Assurance System:
The quality assurance department is assigned to maintain consistency for uniform quality of the
material in process & various stages of its manufacturing.
Objects of quality control:
 Research
 Selection of raw material
 process control
 Process development
 Product testing
 Specification test
Quality Control system mainly two types:
1. Online QC
2. Offline QC
1. Online QC
Online quality control comprises with the raw material quality control and the process control.
Raw material control:
As the quality of product depends on the raw materials quality so we must provide the best
quality raw material with an economical consideration. The fabric must be fault-free, with
proper absorbency, whiteness as per requirement of the subsequent process. The Grey
inspection report gives the condition of the raw fabric.
Process control:
The method chosen for the process must be provided with the necessary accurate parameters.
Here the specific gravity, water level, residual hydrogen per oxide etc. at each stage is checked.
Laboratory:
Lab is the important part of a textile industry. Higher precision in a trial can aid easily to achieve
the goal of the organization. Before bulk production a sample for the approval from industry is
sent to the buyer. As per the requirement of the buyer the shade is prepared in a lab
considering the economic aspects.

79. Lab line:
1. Standard sample: It is obtained from buyer. The sample is measured by the CCM to
get the recipe.
2. Lab trial: Getting the recipe the lab officer produce lab trial and match with standard
according to buyer requirement. Lab trial is made by the AHIBA dyeing machine. There are
some programs for dyeing. The programs will be described later.
2. Offline QC
Off-line tests: All the Offline tests for finished fabrics can be grouped as follows:
A. Physical tests
B. Chemical tests
Physical Tests:
 GSM test
 Shrinkage test
 Spirality test
 Tensile strength
 Abrasion resistance
 Pilling resistance
 Button Strength Testing
 Crease resistance
 Dimensional stability
 Bursting strength test
Fabric Inspection:
The fabric inspection is done for both grey and finished fabric.
1. Grey Fabric Inspection:
Grey fabric inspection is performed according to 4-point system.
2. Finished Fabric Inspection:
4 point numbering system is followed for finished fabric inspection. Defects found in the
final inspection:
1. Uneven shade
2. Oil spot
3. Neps
4. Crease mark
5. Machine Stoppage mark
6. Listing
7. Line mark
8. Pick missing
9. Double yarn
10. Dead cotton
11. Bowing
12. Fly yarn contamination
Chemical Tests:
 Color Fastness to washing.
 Color Fastness to light.
 Color Fastness to heat.
 Color Fastness to Chlorinated
water.
 Color Fastness to water
spotting.
 Color Fastness to perspiration.
 Color Fastness to Sea-water.
 Fiber analysis.
 PH test.
 Spray test (water repellency).

80. Procedure of the Different Tests:
Physical test:
1. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample: Two pieces of 50 cm  50 cm fabric is taken for test.
Procedure:
a. Conditioning: Put the sample in table for 4 hrs. for conditioning before starting
test.
b. Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample (3
sides) by over lock sewing machine.
c. Put sample in washing machine and run according to buyer‘s choice.
d. Drying: All Buyers‘ requirement is tumble Dry except ECHO SCOURING is flat dry.
2. Pilling test:
Procedure:
Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using template. Then sew the
fabric so that it can be firmly fit in the tube molded polyurethane tubes. 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
3. 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.
4. GSM TEST:
Procedure:
GSM is the most important factor. There is a GSM cutter. The sample is 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.
5. Bursting Strength Test:
 Cut sample of 250x250 mm2 shape and see how much air pressure is needed to tear
apart.
 160-250 KPa is the allowable range for all.
Chemical Test:
1. Color Fastness to Wash Test:
Required materials:
1. Sample size 10cm x 4cm
2. Multi-fiber of 10cm x 4cm
3. ECE detergent (WOB) – 4g/L
4. Sodium Perborate (Na2BO3.H2O2.3H2O2-1g/L) - 1g/L
5. Distilled water
6. Normal cold water
7. Steel balls

81. Required instrument:
1. Rota Wash machine
2. Scissors
3. Stitch machine
Procedure:
1. Cut sample & multi-fiber at 10cm x 4cm and then stitch.
2. 5g/l ECE detergent (WOB) & 1g/l ml Sodium per borate tetra hydrate is taken with
the sample.
For Marks & Spencer, the solution is taken by the following formula:
3. The sample is kept in 600C for 30 minutes in Rota Wash Machine. Weight this
composite specimen to calculate the volume of wash liquor required to give a 1:50
liquor ratio. (i.e. 50 ml of liquor of 1gm of composite specimen.)
4. Rinse the sample twice with cold water.
5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not be more
than 150°C.
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey
Scale & Staining Scale.
2. Color Fastness to Perspiration Test:
Test specimen:
 Sample fabric – 50 mm  50 mm
 Multifiber fabric 50 mm  100 mm
 Cut the multifiber into two pieces
 Sandwich the test specimen between two pieces of multi-fiber.
Testing Solution:
1. Alkaline Solution:
Histadine monohydro chloride monohydrate (C6H10ClN3O2.H2O) – 5.00 g/L
NaCl – 5.00 g/L
Di sodium hydrogen orthophosphate (Na2HPO4.2H2O) – 2.5 g/L
PH – 8 (Adjust by 0.1 N NaOH)
2. Acidic Solution:
Histadine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/L
NaCl – 5.00 g/L
Sodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.5g/L
PH – 5.5 (Adjust by 0.1 N NaOH)
Method:
- The composite specimen is put in a petri dish (2 specimen of a sample).
- Solution (Alkaline & Acidic) is taken in the two petri dishes. Here, M:L is taken 1:20.
- Bubble is made out from the specimen by tapping.
- The specimen is kept for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Petri dish with composite specimen & glass plate is placed into the incubator at
(372) 0C for 4 hours.
- The specimen is dried (temp  600C)

82. Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
3. Color Fastness to Water Test:
Test specimen:
 Sample fabric – 50 mm  50 mm
 Multi fiber fabric – 50 mm  100 mm
 Cut the multi-fiber into two piece
 Sandwich the test specimen between two pieces of multi-fiber.
Testing Solution:
 Water is taken as required
Method:
- The composite specimen is put in a petri dish (2 specimen of a sample).
- Water is taken in the petri dish as required.
- Bubble is made out from the specimen by tapping.
- The specimen is kept for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Petri dish with composite specimen & glass plate is placed into the incubator at
(372) 0C for 4 hours.
- The specimen is then dried (Temp  600C)
Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining Scale.
4. Color the Fastness to Rubbing (Dry & Wet) Test:
Sample:
- Dyed fabric dimension of 15 cm  5 cm
- White Test Cloth of 5 cm  5 cm
Procedure:
- White test cloth is put on to the grating and stag by steel wire.
- The sample is run twenty times manually for ten seconds and the rubbing fastness
of the sample cloth and degree of staining is accessed.
- For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked and
squeeze. The wet rubbing cloth is placed on to the grating and stag with stainless
steel wire and run ten times manually. Then assess the staining on to the rubbing
cloth and the rubbing fastness of the sample cloth is accessed.
Report:
- Change of shade of the sample is measured with grey scale and degree of staining
of the white test cloth is measured by Staining Scale.
Shrinkage Test Calculation:
Shrinkage % = (Before wash – After wash)/Before Wash*100

83. Spirality test calculation:
S = (S1+S2) / 2
Spirality = (S+S  L)/100.
Suppose,
S1 = The right side distance of the specimen from the stitch line after wash.
S2 = The left side distance of the specimen from the stitch line after wash.
L = Length before wash
Lab. Dip Dyeing
Sample:
- Weight – 5gm.
Procedure:
- At first the recipe for the sample is calculated according to the sample weight.
- The fabric is kept in the dyeing chamber.
- Then the dyes, chemicals, salt & required amount of water is taken in that dyeing
chamber by digital pipetting on the basis of stock solution.
- Then the beaker is set into the lab. Dip. Dyeing machine for dyeing.
- The program for dyeing is started for 20 min at 400C.
- After 20 min soda is added by pipetting.
- Then the dyeing program is set for 60 min at 600C for normal colour,80ºC for
turquois colour,130ºC for PET.
- When the dyeing time is finished the sample is taken out from the machine at 400C.
- Then the sample is washed off. At first cold wash & then hot wash is done. After it
soaping is done.
- Then the sample is dried and compared with standard
Dyeing Curve:
600C60 ´
400C20 ´
Wash off
Soda
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey Scale
& Staining Scale.
Finished fabric Inspection:
The final product should pass against the norms given by the buyer. The following tests are
done--
-Shade check
-GSM test
-Width or diameter test
-Shrinkage test
Dyes + Salt +
Material+Water

84. -Crocking test
-Pilling resistance test
-Color fastness to test
-Color fastness to perspiration
-Dimensional stability
Quality Standard:
Viyellatex Ltd. maintains the ISO: 9002 standard in case of quality. Therefore, four point
system is followed to inspect the body & rib fabric. The defects found and points given against
are recorded in the inspection sheet. Following table shows the four point grading system
followed by inspection at Viyellatex Ltd.
Four point grading system
Size of defects Penalty
3 inches or less 1 point
Over 3 inch but not over 6 inch 2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point
Following table shows common body and rib faults and response by inspection section at
Viyellatex Ltd.:-
Rejection criteria for body & ribs
No. Faults Response
1. Needle mark Major needle line is rejected
2. Stripe Major needle line is rejected
3. Barre mark Rejected
4. Contamination & fly
Approved for color but for white
shed 1 point is assigned
5. Slubs 1 point
6. Thick thin place Reject
7. Birds eye 1 point
8. Pin holes 1 point
9. Wrong design Reject
10. Mixed yarn Discuss with manager
11. Sinker mark Major sinker mark is rejected.
12. Missing yarn Use 4 point
13. Holes Do
14. Oil line/stain Do
15. Chemical Do
16. Dirt stain Do
17. Crease line Do
18. Uneven tension Discuss with manager

85. Following table shows common collar and cuff fault and response taken by inspection
section at Viyellatex Ltd:-
Rejection criteria for collar & cuff
No. Faults Response
1. Wrong ply Reject
2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7.
Fly & contamination
Acceptable for color but not for
white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
15. Wrong tube Reject
Remarks:
Viyellatex have a well-equipped Testing laboratory for all kinds of Textile Testing. All of them
are fully featured. The laboratory of Viyellatex is approved by world renowned buyers. Every
kind of textile testing can be done with great accuracy and ease.

87. Production Capacity:
Total line 80
Total floor 8
Total m/c 2600(approximately running)
Production/day 60000 pcs/day (minimum) 2.5-3 Million pcs/month
Input Process Flow Chart:
Inform The Corresponding Officer about completion of garments production Target
Corresponding Officer Forward a requisition form to the Planning Department
Planning Department Gives a token Containing new style No
.
Showing the token collect fabric from Cutting & Accessories from Store
Quality Check
Ready for Sewing
Sewing process flow Chart:
Input
Measurement Check
Print & Embroidery Check
Sewing Started
Get Full garments as output
Garments Inspection
Forward it to the Finishing Section
ist of M/c‘s:
Machine Name Brand
1-Needle lock Stitch
(Auto thread Time)
Juki, Brothers
4-Thread Overlock with electric chain cutter Sunstar
2/3 Needle Covering stitch Juki, Kansai
1-Needle chain stitch(flatbed) Pegasus
2-Needle Chain Stitch(flatbed) Joje
2-Needle Piping(backtape) Kansai, Joje, Zusan
2-Needle lock stitch Pegasus, Kansai
Vertical Trimmer Sunstar
Multi Needle Chain Stitch(PMD) Juki, Sunstar

88. Bartack Machine(Computerized) Kansai
Buttonhole(computerized) Juki, Sunstar, Brothers
Button Sewing(Computerized) Juki, Brothers
Zigzag Machine(Computerized) Juki, Brothers
Smocking Machine(12 & 33 Needle) Juki, Brothers
Shirring Machine(12 Needle elastic threads) Kansai
Picoting Machine Kansai
Shading Stitch Kansai
Blind Stitch(Overlock) Kansai
Rib Cutting Machine Joje
Heat Transfer Machine Lee Way, Loca
Hot Fixing Machine Salli
Snap Button Nyoto, Uzu, Max
Fusing Machine(Ranning)
Fusing Machine(R Hat)
Hashima
Needle Used in different Machine & It‘s Sizes:
Machine Name Needle Group Size
Plain Machine DB x1 9,11,14
Overlock Machine DC x1 9,11
Flatlock Machine UY x128 9,11
2-Needle Chain Stitch Machine UY x128 14
2-Needle Lock stitch DP x5 9,11
Button Hole(Two Needle) DP x5 11,14
Button Stitch DP x7 14
Kansai Special(PSF) UO x113 11
Saddle Stitch CP x12 9,11
Vertical Trimmer DB x1 9,11
Smocking DV x57 9,11

89. Garment finishing
Process flowchart of garment finishing:
Finishing input (style, color & size wise)

Ironing

Inspection

Hang tag

Get up change

Folding

Poly

Bar code (buyer wise sticker)

Metal check

Cartooning

Final inspection by buyer
Remarks:
We learned a lot from previous weeks visiting these sections of the garments. The Peoples
around these sections are very helpful and willingly helped us in our work. This will help in our
further visit to other sections also.

91. Printing Section:
There are two floors in the printing section. Here are the details about the Gothic Printing-
Gothic Printing
Details Quantity
1. Tables 24 pcs
2. Auto Screen Printing
m/c
4 pcs
3.Conveyer Dryer 4 pcs
4. Heat Press 3 pcs
Development flow chart:
Order received from customer
Different types of Printing:
 Pigment Print
 Rubber print
 High Density Print
 Plastisol Print
 Puff print
 Gliter print
 Rainbow print
 Pearl scent
 Radium print
 Foil print
 Jel print
 Metallic print
 Heat transfer (this system is not used)
 Flock Print (this system is not used)
 Discharge print
Development
Sample make
Design
Expose room
Send to production
Sample approval

92. Sequence of printing:
Garment parts count
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
Screen Preparation:
Mesh fabric tight with frame
Applied chemical auto sol and potassium dichromate 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.

93. Different types of print used in Viyellatex with their chemical name:
1. Pigment print:
Print perfect 226 EC (ready paste)+color basic=various types of shade are produced.
Supplier name:
Dysin
CHT
Brand name:
 CHT
 Seikafix
Brand name of CHT:
 Red KGC
 Red HBB
 Violate FB
 Orange RG
 Yellow 3GT
 Yellow RR
 Violate KB
 Black BDC
 Turquoise GT
 Green GT
Brand name of seikafix:
Seikafix red
Seikafix yellow
And so many color
Dysin:
PTSD (red,yellow,blue etc.) (Chemical group or brand name)
SERICOL (red,yellow,blue etc.)(Chemical group or brand name)
CHT:
Printop (chemical group)
Uniflux(chemical group)
3. High density & Plasticol:
Shade can be produced to mix ready color and basic. If the density of the plastisol is high then
it is called high density.
4. Puff:
Dysin chemical:
 SP37(for puff)
 White paste 101
 Orient paste 251
 Clear 594
2. Rubber:
Supplier name:
 Daysin
 White paste 101
 Orient paste 251
 Clear 594
 Oxal
Rubber paste of CHT:
 Balance 600(white paste)
 Laclf(matty type)
 Mc 230(glossy type)
 Oxal

94. CHT chemical:
 PPEXTS-2(for puff)
 Balance 600(white paste)
 Laclf(matty type)
 Mc 230(glossy type)
5. Gliter print:
 Daysin paste BF733/ST60(paste)
 CHT pasteGD200
 Gliter
 Oxal
6. Rainbow:
 Dysin paste BF733/ST60(paste)
 CHT pasteGD200
 Rainbow
 Oxal
7. Pearlscent:
Ready paste & basic
Paste type:
Asuchem (supplier)
 Asugold 80 (chemical type)
 Asusilver 70(chemical type)
Printing faults:
1. Print color shading 19. Print gap
2. Print slarted 20. Print over
3. Color spot 21. Wrong side
4. Bleeding 22. Color wrong
5. Print wrong 23. Size mistake
6. Print burn 24. Bundle card mistake
7. Air hole 25.Fabric hole
8. Print bubble 26.Fabric shade
9. Print missing 27.Crease mark
10. Wrong place 28. Oil spot
11. Not properly attached 29. Fabric burn
12. Hand feels 30.Needle mark
13. Migration 31. Cutting problem
14. Dirty mark 32. Sticker wrong
15. Uneven shade 33. Dye migration
16. Shade variation 34.Yarn hole
17. Print sticky 35. Yarn contamination
18. Print not coverage 36. Fly yarn.
8. Radium:
Ready paste
9. Foil print:
Foil paste (k-40) Dysin
10. Jel paste:
CHT (supplier)
GD200 (gel paste)
11. Metallic:
Same as pearlscent
12. Discharge:
Asuchem (supplier)
Asurongent EB

95. Embroidery Section
Embroidery machine specification:
No. of machine: 08
(1) 7 M/C of 12 heads
(2) 1 M/C of 8 heads.
Electronic multi-head automatic Embroidery M/C
Brand: Tajima
Country: Japan
Model: TFGn-920
No. of head: 20
No. of Needle per head: 9
M/c‘s computer: screen touch monitor
Stitching types:
 Satin stitch
 Tatami stitch
 Eve design
 Run stitch
 Single run
 Double run
 Fly stitch
 Chain stitch
 Motif run stitch
Thread information:
Threads brands Types Country Thread contain m/cone
Coats Bangladesh
Silko (polyester 120/2)
Rapose (polyester 120/2)
Bangladesh
3000
Madera
(polyester 135/2)
Super twist 135/2
Germany
2500-3000
Airplane
(polyester 120/2)
(polyester 120/2)
Korea 5000
Well (polyester 120/2) Bangladesh 3000
Metallic thread (polyester 120/2)
Bangladesh
Japan
Korea
3000-10000
Pearl thread (polyester 120/2) Bangladesh 3000
Basic thread Polyester 120/2 Bangladesh 5000
Marathons Polyester 120/2 Korea 5000
Embroidery faults:
 Stitch gap
 Bobbin out
Lining:
o Soft lining
o Discreet lining
o Fusing lining
o Hard lining
 Oil spot
 Miss thread
 Measurement up-down
 Needle hole

96. Washing

97. Washing Machine Layout:
1 Cosmotex sample dryer (70 0C)
2-5 Cosmotex dryer (70 0C)
6-9 Automatic steamer & dryer (100 0C)
(Brand: Greenmac International Pte. Ltd.
Country: Singapore)
10-11 Centrifugal extractors
(Brand: Greenmac International Pte. Ltd.
Country: Singapore)
12,14 Cosmotex sample garments dyeing & washing m/c
(Capacity: 20 Kg)
13,15-21 Cosmotex garments dyeing & washing m/c
(Capacity: 250 Kg)
Entrance
8 7 6
5 4 3 2
1
Table
13 15 14 16 17 18 19 20 21
10
9
11
12
2
Table

98. Washing flow chart:
Garments from store house
↓
Count
↓
Quality check
↓
Batch
↓
Washing
↓
Hydro extractor
↓
Drying
↓
Quality check
↓
Packing
↓
Delivery
M/C brand and no of M/C
1. No of washing m/c: 4
2. No of garments dyeing m/c: 4
 Brand name: Cosmotex
 Origin: Spain
3. Sample washing m/c: 2
 Brand name :Cosmotex
 Origin: Spain
Types of wash:
 Normal garments wash
 Vintage wash
 Enzyme wash
 Acid wash
 Super softener wash
 Spray wash
 Dip dyeing wash
4. Hydro extractor: 2
 Brand :Green mac
 Origin : China
5. Dryer: 8
 4 Cosmotex
 4 Green mac
6. Sample dryer: 1
 Brand name: Compotex
Recipe:
1. Normal garments wash:
M:L : 1:10
Felosan nof : 5g/l
Temperature : 50-55ºC
Time : 8 min
Softener : 1-2 g/l

99. 2. Vintage wash:
 Applies heavy stonewashing or a cellulose enzyme wash, with or without bleach.
 Gives an old and worn look.
M : L :1:10
Felosen nof : 0.5g/l
Soda : 3-4 g/l
Caustic : 0.5g/l
Temperature: 60ºC
Time : 35-40´
Acetic acid : 1g/l
Softener : 2g/l
4. Acid wash:
It is done by tumbling the garments with pumice stones presoaked in a solution of sodium
hypochlorite or potassium permanganate for localized bleaching resulting in a non-uniform
sharp blue/white contrast.
5. Super softener wash:
Silicon: 8g/l
Softener: 2g/l
Over dye:
 Dyeing over the fabric or jeans to add another tone of color.
 Also can be applied with spray gun or paintbrush for local coloring.
A typical recipe of over dyeing method:
Fabric weight 2 kg
Water 16 liter 700C x5 min
NOF (Wetting agent) 8 gm
(After Normal wash)
DBC (leveling agent) 8 gm 600C x5 min
R.G. Yellow- RGB 0.368% 8 gm
R.ul.Car-RGB 0.63% 12 gm 600C x (10+10) min
R.Navy-RGB 1.48% 31 gm
Salt 960 gm 600C x (10+10)
Soda 256 gm
(After normal wash)
R (soaping agent) 1 g/l 16 gm 600C x5 min
Acetic acid 1 g/l 16 gm Room temp. for 5 min
E.C. (fixing agent) 1 g/l 16 gm 400C x5 min
3. Enzyme wash
Enzyme : 0.5g/l
Fesoson nof : 0.5g/l
PH : 4.5
Time : 25´-30´
Temperature: 55ºC

100. Problems occur in washing:
Before wash:
 Dirty spot
 Dyeing/color spot.
 Needle damage.
 Fabric hole.
 Measurement problem.
 Shade variation.
 Printing problem.
After wash:
 Measurement problem.
 Shrinkage problem.
 Color bleeding.
 Needle line.
 Spirality problem
REMARKS:
We have learned a lot of from this section of washing. The employers and employee helped us
so much during our working. This will help further visit to other sections also.

102. Maintenance of machinery is a very essential mechanical effort for achieving smooth
running of different machines. Machines, buildings and other service facilities are subjected to
deterioration due to their use and expose to industrial conditions. 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.
Necessity of maintenance:
 To keep the downtime of machines to the minimum thuds to have control over the
production program.
 To prolong the useful life of the factory plant and machine by retaining their acceptance
level of accuracy of performance.
 To keep the factory plants, equipment‘s, machine tools in an optimum working
condition.
 To ensure specified accuracy to product and time schedule of delivery to customer.
 To keep the production cycle within the stipulated range.
 To modify the machine tools to meet the need for production.
Major Maintenance points for different machines:
 Routes of different utilities like water, steam, gas, electricity, compressed air etc.
 Dyestuff & chemical dosing system.
 Drainage system of waste water, color & chemical.
 Driving arrangement of different machines.
 Power transmission to different machineries.
 Fabric guiding system through the machineries.
 Cleanliness of machine parts.
Different types of Maintenance procedure:
In Viyellatex, three types of maintenance procedure is performed –
1. Routine/Schedule Maintenance.
2. Preventive Maintenance.
3. Breakdown Maintenance.
1. Routine/Schedule Maintenance:
After a particular period of operation, the machines are cleaned & reordered, that is routine or
schedule maintenance. The maintenance department does it once in a month. Routine/Schedule
maintenance varies, time in time & also depends on situation according to types of machines,
because maintenance is directly related to production.

103. Maintenance schedule for dyeing & finishing section –
S.N. Machine Schedule
1 Dyeing m/c-1+sample-1 1 0 th day of the month
2 Dyeing m/c-2+ dyeing m/c-9 + sample m/c-5 1 1 th day of the month
3 Dyeing m/c-3+ dyeing m/c-10 1 2 th day of the month
4 Dyeing m/c-4+sample-2+dyeing/c-15 1 3 th day of the month
5 Dyeing m/c-5+sample-3 1 4 th day of the month
6 Dyeing m/c-6+ dyeing m/c-11 1 5 th day of the month
7 Dyeing m/c-7+ dyeing m/c -12+dyeing m/c-14 1 6 th day of the month
8 Dyeing m/c-8+ dyeing m/c-13 1 7 th day of the month
9 Open compacting m/c+tube -1 1 st &18th day of the month
10 Open compacting m/c+tube -1 2 nd &19th day of the month
11 Dewatering m/c-1&2 3 rd&20th day of the month
12 Corino slitting m/c+Bianco slitting m/c 4 th & 21st day of the month
13 Slitting m/c+sample dyeing m/c-4 5 th &22nd day of the month
14 Sueding m/c+ sample dyeing m/c-5 6 th &23rd day of the month
15 Raising m/c+ sample dyeing m/c-6 7 th & 24th day of the month
16 Dryer m/c+sample dyeing m/c-7 8 th & 25th day of the month
17 Santex dryer 9 th & 26th day of the month
18 Stenter m/c(bruckner) F r i d a y e v e r y week
19 Stenter m/c(sun super) Friday every week
Maintenance schedule for utility section:
S.N. Machine Schedule
1 Boiler la s t F r i d a y o f m onth
2 Substation 1st Friday of month
2. Preventive Maintenance:
This type of maintenance is 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.
Maintenance schedule for dyeing & finishing section –
S.N. Machine Schedule
1 Open compacting m/c-1+tube -1 1 st &19th day of the month
2 Open compacting m/c+tube -1 2 nd &20th day of the month
3 Dewatering m/c-1&2 3 rd&21th day of the month
4 Slitting m/c 1&2 4 th &22nd day of the month
5 Slitting m/c 03+sample dyeing m/c-4 5 th &23nd day of the month
6 Sueding m/c+ sample dyeing m/c-5 6 th &24rd day of the month
7 Raising m/c-1, 2, 3 7 th & 25th day of the month
8 Dryer m/c-1+sample dyeing m/c-6 8 th & 26th day of the month