This is my first Industrial attachment.

1. 1 | P a g e P r i m e a s i a U n i v e r s i t y
Primeasia University
Industrial Report
on
Fabric Manufacturing Technology
M.S Dyeing, Printing & Finishing Ltd.
(A Sister Concern of Navy Hosiery)
Course Code: Txe- 426 & Txe- 428
Course Title: Industrial Training & Practices I & II
SUPERVISOR
Mr. Zulfiqar Ali
Manager
Knitting Section
M.S dyeing, printing & finishing ltd.
Md. Ariful Islam
Lecturer
Dept. of Textile Engineering
Primeasia University
.
SUBMITTED BY
Mohammad Omar Faruk
ID NO: 121-116-041
Dept. of Textile Engineering

2. 2 | P a g e P r i m e a s i a U n i v e r s i t y
ACCEPTENCE
This project work on Industrial Training & Practices in M.S dyeing,
printing & finishing ltd. is prepared by using the relevant documents
related to the assigned topic written by the student of 25th
batch, ID :
121-116-041, Dept. of Textile Engineering, Primeasia University has
been acknowledge as it is acceptable.
Md. Ariful Islam
Lecturer
Dept. of Textile Engineering
Primeasia University
Banani, Dhaka.

3. 3 | P a g e P r i m e a s i a U n i v e r s i t y
ACKNOWLEDGEMENT
At first I would like to express my gratitude to Almighty God for enabling me to complete my
internship. Special thanks to Mr. Zulfiqar Ali, Manager, Knitting, M.S dyeing, printing &
finishing ltd. and Professor M.A. Khaleq, Dean, School of Egineering, Primeasia University
for giving me the opportunity of internship. A number of people have made significant
contributions on preparing this report. Their advice and suggestions helped me a lot. During the
attachment with M.S dyeing, printing & finishing ltd. I worked in all the departments related
with the knitting and dyeing section. I not only give priority to the Fabric manufacturing but
also worked sincerely in the Dyeing, Maintenance and, warehouse & Store & Inventory,
finishing & specially Knitting.
It is an auspicious for me as a student of Dept. of Textile Engineering, one of the prestigious
academic center of the Primeasia University to express my feeling of gratitude to the dept. &
especially to my Supervisor Md. Ariful Islam, Lecturer, Dept. of Textile Engineering.
I owe a particular debt of gratitude to Mr. Harunur Rashid, Executive Director, M.S DYEING,
PRINTING & FINISHING LTD.. He gave away some of his valuable time regularly in helping
me to achieve my intended goal. I would like to express I sincere appreciation to Md. Jahangir,
Dyeing Manager, M.S DYEING, PRINTING & FINISHING LTD., Md.Kabir QA Manager,
M.S DYEING, PRINTING & FINISHING LTD., for their valuable advice, cooperation,
guidance, encouragement and inspiration throughout the training period. I also express my
gratitude to all the executives of M.S DYEING, PRINTING & FINISHING LTD. Knitting,
dyeing, store & inventory control.
I would like to express special thanks to Md. Ariful Islam, Lecturer, Dept. of Textile
Engineering & Md. Sadaqul Bari, Lecturer, Department of Textile Engineering, Primeasia
University for continuously guiding me about the development and preparation of the report.
He has enriched me with necessary ideas and concepts for incessant improvement of the report.
However, I have prepared my industrial Training report overcoming all the difficulties & also
the shortage of time. Here I would like to present the report.

4. 4 | P a g e P r i m e a s i a U n i v e r s i t y
INTRODUCTION
If the theoretical knowledge is a prescription of medicine then the practical
knowledge would be taking of medicine.
It is always very easy to make a man understand about a firebox by showing and
lighting practically rather than describing theoretically who has not ever seen a
firebox. So, for any technical education the practical experience is the most
important as well as the theoretical knowledge.
As I am studying in Engineering, it is always important for me to gather the
practical knowledge.
Through our study life the only biggest chance for us to combine the theoretical
knowledge with the Practical knowledge is the “Industrial Attachment Period” that
comes only once in the education life when completing undergraduate education.
So we can easily realize the importance of Industrial Attachment and in addition
the knowledge we gather from the industrial training reflects in the report of
industrial attachment note book.
So industrial attachment is the process where a trainee can blend his theoretical
knowledge with practical knowledge which increases the ability of work, skills,
performance and attitude and so on.
It also provides sufficient knowledge about production management, productivity
evaluation, work study & efficiency, industrial management, production planning
and control, production cost analysis, inventory anagement, utility, maintenance
and so on. Industrial attachment makes us reliable to be accustomed with the
industrial atmosphere and also improve courage and inspiration to take self-
responsibility.
I have tried to my best to prepare this note book applying my best efforts. I have
tried to gather all the necessary information to make it valuable for me as well as
for everyone. I think it will help me a lot in future practical life.

5. 5 | P a g e P r i m e a s i a U n i v e r s i t y
TABLE OF CONTENT
Contents Pages
Introduction 4
Chapter 1 : Company Profile
About M.S Dyeing Printing & Finishing Ltd. 8
Vision & mission of the project 8
FACTORY LOCATION 9
Departments of M.S. Dyeing, Printing & Finishing Ltd. 10
Chapter 2: Manpower Management
Manpower Organogram 13
Management System 14
Designation & their Responsibilities 14
Chapter 3: Layout and Machine Description
Layout Plan 17
Knitting Machineries 18
Machine Description 18
Chapter 4: Raw Material
Raw materials 28
Yarn 28
Brand and count and their origin used by M.S. DYEING,
PRINTING & FINISHING LTD.
29
Chapter 5: Production Planning And
Process Sequence
Knitting Planning & Process sequences 34
Process sequences in Knitting Floor 35
GSM & GSM Control 36
Types of Fabric Produced in M.S. DYEING,
PRINTING & FINISHING LTD.
39
Steps to Increase Production 39
Important Components of Circular Knitting M/C 43
Important Accessories of Circular Knitting M/C 45
Gearing Diagram of Power Transmission of a Knitting
m/c
47
Flat Bed Knitting Section 50
Design, Cam and Needle Arrangement of Several Knitted
Fabric
53
Chapter 6: Maintenance
Maintenance 61
Types of maintenance 61
Chapter 7: Utility Services

6. 6 | P a g e P r i m e a s i a U n i v e r s i t y
Available facilities of utility 65
Pump Capacity Setup 65
Chapter 8: Store & Inventory Control
Frequency of inventory control 69
Scope of inventory control 69
Inventory system for raw materials 69
Store capacity 70
Chapter 9: Cost Analysis
Costing of the product 72
Chapter 10: Marketing Activities
Consumer of the products 74
Marketing Strategy 74
Chapter- 11: Conclusion
My Achievement 77
Conclusion 77

7. 7 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter- 1: Company Profile

8. 8 | P a g e P r i m e a s i a U n i v e r s i t y
1.1 About M.S Dyeing Printing & Finishing Ltd.
M.S Dyeing Printing & Finishing Ltd. a 100% export oriented composite knit
textile unit established with the commitment to care the Global needs for knit and
casual clothing. The project has employed the State of Art technology in its very
pieces of investments. Aiming at the context of the changing Global demand
pattern, international environment on trade specially the withdrawal of quota
system and GSP and the availability of craftsmanship in the country, the project
encompassed the knitting, dyeing and processing of fabrics and ready-made
Garments production to be available from one stop service.
The project is established in 2006, but the manpower engaged in the projects to
carry out the day to day business is all highly skilled, purely professional, vastly
experienced. The unique combination of organized Managerial and Technical
term in one hand and latest, advanced and balanced technology on the other hand
made the project one of the top to be referred in this field in the country. The
best use of continuous development of Human Resources by providing them
International Standard Environment and equal opportunity is the keys for
achieving comprehensive competence in all the level Organizational Hierarchy.
1.2 Vision & mission of the project
The mission and vision of M.S Dyeing Printing & Finishing Ltd. is to
manufacture and deliver high quality readymade garments (RMG) to its
customers. The core objective is to attain and enhance customer satisfaction by
providing on time delivery of desired quality readymade garments and also to
increase efficiency of workforce.
To attain these objectives, the management of M.S Dyeing Printing & Finishing
Ltd. has decided to adopt the following-
 To increase awareness regarding customers requirements throughout the
organization.
 By providing training to develop efficiency of the employee.
 To collect customer’s feedback regularly to know about their conception
about their company and to take timely appropriate action.
 To reduce the percentage of wastage / rejection minimum by 2% per
annum’s implement and monitor ISO 9001:2000 quality management
system within the organization.
M.S Dyeing Printing & Finishing Ltd. Is the member Of BGMEA and BKMEA
(www.bgmea.com.bd)

9. 9 | P a g e P r i m e a s i a U n i v e r s i t y
1.3 FACTORY LOCATION
The M.S. Dyeing, Printing & Finishing Ltd. is located in BISIC Commercial
Area, Enayetnagar, Fatullah, under the district of Narayanganj, about 25 km
distance from Dhaka. A well-developed Road Communication is there to reach
the factory from Dhaka City. The head office of the project is Located at BISIC
Commercial Area, Enayetnagar, Fatullah, Narayanganj.
Location of Factory from PAU Source- Google map

10. 10 | P a g e P r i m e a s i a U n i v e r s i t y
M.S. Dyeing, Printing & Finishing Ltd. At A GLANCE
Type Composite knit fabrics & garments (with dyeing & finishing).
(100% export oriented industry).
Year of
Establishment
2006
Address of Factory Plot-237-252, BISIC Commercial Area,
Enayetnagar, Fatullah, Narayanganj.
Corporate Office Plot-A-2,A-3, BISIC Commercial Area,
Enayetnagar, Fatullah, Narayanganj.
1.4 Departments of M.S. Dyeing, Printing & Finishing Ltd.

YARN STORE DEPARTMENT

YARN DYEING DEPARTMENT

KNITTING DEPARTMENT

PHYSICAL AND CHEMICAL LAB

DYEING DEPARTMENT

FINISHING DEPARTMENT

QUALITY CONTROL DEPARTMENT

R & D (RESEARCH & DEVELOPMENT)
Supporting Departments

Finance & Accounting

H R D

Utilities(C R P , ETP)

Security

Administration

Marketing & Merchandising

11. 11 | P a g e P r i m e a s i a U n i v e r s i t y
DAILY PRODUCTION CAPACITY
Section Production/Day
Knitting 20 ton/Day
Dyeing 25 ton/Day
Finishing 50,000 pcs
AN OVERVIEW OF MACHINE
Section No. of Machine
Knitting 83
Dyeing 11
Lab & QC 25

12. 12 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter - 2: Manpower Management

13. 13 | P a g e P r i m e a s i a U n i v e r s i t y
2.1 Manpower Organogram
Chairman
Managing
Director
Exicutive
Director
Director of
Operation &
Finance
General
Manager
Maintanance
Manager
Mechanical
Incharge
Electrical
Incharge
Knitting
Manager
Batch
Incharge
Floor
Incharge
Supervisor
Knitting
Master
Dyeing
Manager
Lab Incharge
Floor
Incharge
Supervisor
Prodouctio
n Manager
Floor
Incharge
Supervisor
HR
Manager
Asst.
Manager

14. 14 | P a g e P r i m e a s i a U n i v e r s i t y
2.2 Management System
Buyer sample is send to G.M.
 Matching is done by lab in charge.
 Sample is prepared by dyeing master.
 Sample is send to the buyer for approval.
 Approved sample is returned and taken as STD. Sample for bulk production.
 Asst. dyeing master gives responsibilities to production officer.
 Then production officer, with the supervisors start bulk production.
 On line and off line quality check is done by lab in charge and asst. dyeing
master.
 After dyeing finishing in charge controls the finishing process with the
supervision of production officer.
 After finishing, the material is checked by dyeing master.
 Finally G.M. checks the result with dyeing master and decision is taken for
delivery.
2.3 Designation & their Responsibilities
General Manager:
 Report to: Reports to the Board of Directors.
 Position objective: To direct promote & coordinate the operations of the
cooperative in a manner that will optimize the cooperative market share
&Savings, improve the cooperatives efficiency, help cooperative’s mission &
goals making result in outstanding customer service.
 Position responsibilities: The General Manager’s responsibilities involve
supervision, public relation, marketing, profitability & sales, service,reporting,
capital requirements & other duties as assigned by the board of directors.
Manager:
 Report to: Reports to the General Manager.
 Position objective: To direct promote & coordinate the operations of the
cooperative in a manner that will optimize the cooperative market share
&Savings, improve the cooperatives efficiency, help cooperative’s mission &
goals making result in outstanding customer service.
 Position responsibilities: To promote and managing the safety of their employees
and their work environment. Overall supervision of dyeing &finishing section &
quality control. The dyeing manager will maintain a positive attitude that
promotes team work within the cooperative & a favorable image of the
cooperative. Managers also must report failures to follow safety standards by
others outside of their departments and take immediate actions to implement
controls for situations that are clearly unsafe.

15. 15 | P a g e P r i m e a s i a U n i v e r s i t y
Supervisor:
 Report to: Manager.
 Position objective: To plan execute & follow up the production activities &
control the quality production with related activities.
 Position responsibilities: Overall supervision of dyeing & finishing, dyes
chemicals requisition issue & check, program making, sample checking, color
measurement.

16. 16 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter-3: Layout and Machine Description

17. 17 | P a g e P r i m e a s i a U n i v e r s i t y
3.1 Layout Plan

18. 18 | P a g e P r i m e a s i a U n i v e r s i t y
3.2 KNITTING MACHINERIES
The entire machines in the knitting floor are divided into 3 sections.
These are following:
 Circular knitting section
 Flat knitting section
 Fabric inspection section
3.3 Machine Description
Types of Knitting Machine
M.S Dyeing Printing & Finishing Ltd. Produces only weft knitted fabric;
therefore they use following kinds of weft knitting m/c:
Circular knitting m/c
S/J circular knitting m/c
Fleece circular knitting m/c
S/J E-Stripe circular knitting m/c
Double jersey circular knitting m/c
Flat V-bed knitting m/c
Machines at a glance:
Machine Type No. of Machine
Single Jersey 64
Rib 4
Interlock 2
Circular Auto Stripe 3
Fleece 4
Velour Fleece 6
Flat 10
Total 93
Machine Description of Knitting Section:

19. 19 | P a g e P r i m e a s i a U n i v e r s i t y
M/c no. M/c
Dia
(inch)
M/c
Gauge
No. of
Feeder
No. of
Needle
M/c Type Brand Origin
1 36 24 108 2712 S/J JIUNN
LONG
Taiwan
2 34 24 102 2562 S/J JIUNN
LONG
Taiwan
3 32 24 96 2411 S/J JIUNN
LONG
Taiwan
4 30 24 90 2260 S/J JIUNN
LONG
Taiwan
5 29 24 87 2185 S/J JIUNN
LONG
Taiwan
6 28 24 84 2110 S/J JIUNN
LONG
Taiwan
7 27 24 81 2034 S/J JIUNN
LONG
Taiwan
8 26 24 78 1959 S/J JIUNN
LONG
Taiwan
9 40 18 80 2260 Rib JIUNN
LONG
Taiwan
10 36 18 72 2034 Rib JIUNN
LONG
Taiwan
11 23 24 92 1733 S/J JIUNN
LONG
Taiwan
12 22 24 88 1657 S/J JIUNN
LONG
Taiwan
13 30 20 90 1884 Fleece JIUNN
LONG
Taiwan
14 24 18 48 1356 Rib FUKAHAMA Taiwan
15 21 24 84 1582 S/J FUKAHAMA Taiwan
16 21 24 84 1582 S/J FUKAHAMA Taiwan
17 22 24 88 1657 S/J FUKAHAMA Taiwan
18 22 24 88 1657 S/J FUKAHAMA Taiwan
19 23 24 92 1733 S/J FUKAHAMA Taiwan
20 23 24 92 1733 S/J FUKAHAMA Taiwan
21 24 24 96 1808 S/J FUKAHAMA Taiwan
22 25 24 100 1884 S/J FUKAHAMA Taiwan
23 22 24 88 1657 S/J JIUNN
LONG
Taiwan
24 24 24 96 1808 S/J JIUNN
LONG
Taiwan
25 20 24 80 1507 S/J JIUNN
LONG
Taiwan
26 21 24 84 1582 S/J JIUNN
LONG
Taiwan
27 22 24 88 1657 S/J JIUNN
LONG
Taiwan
28 42 24 126 3165 S/J JIUNN
LONG
Taiwan

20. 20 | P a g e P r i m e a s i a U n i v e r s i t y
29 44 24 132 3315 S/J JIUNN
LONG
Taiwan
30 44 24 132 3315 S/J JIUNN
LONG
Taiwan
31 38 24 114 2863 S/J PAI LUNG Taiwan
32 44 18 88 2486 Rib JIUNN
LONG
Taiwan
33 44 24 88 3315 Interlock JIUNN
LONG
Taiwan
34 42 24 84 3165 S/J JIUNN
LONG
Taiwan
35 34 24 68 2562 Interlock JIUNN
LONG
Taiwan
36 30 20 90 1884 Fleece JIUNN
LONG
Taiwan
37 44 24 264 3315 S/J JIUNN
LONG
Taiwan
38 34 20 102 2135 Fleece JIUNN
LONG
Taiwan
39 34 20 102 2135 Fleece JIUNN
LONG
Taiwan
40 46 24 138 3466 S/J JIUNN
LONG
Taiwan
41 44 24 132 3315 S/J JIUNN
LONG
Taiwan
42 32 24 96 2411 S/J JIUNN
LONG
Taiwan
43 40 24 120 3014 S/J JIUNN
LONG
Taiwan
44 42 24 126 3165 S/J JIUNN
LONG
Taiwan
45 42 24 126 3165 S/J JIUNN
LONG
Taiwan
46 32 24 96 2411 S/J JIUNN
LONG
Taiwan
47 34 24 102 2562 S/J JIUNN
LONG
Taiwan
48 34 24 102 2562 S/J JIUNN
LONG
Taiwan
49 36 24 108 2712 S/J JIUNN
LONG
Taiwan
50 36 24 108 2712 S/J JIUNN
LONG
Taiwan
51 40 24 126 3014 S/J JIUNN
LONG
Taiwan
52 34 24 48 2562 Auto Stripe JIUNN
LONG
Taiwan
53 34 48 48 5124 Auto Stripe JIUNN
LONG
Taiwan
54 36 24 50 2712 Auto Stripe JIUNN
LONG
Taiwan
55 17 24 68 1281 S/J FUKAHAMA Taiwan
56 18 24 72 1356 S/J FUKAHAMA Taiwan

21. 21 | P a g e P r i m e a s i a U n i v e r s i t y
57 19 24 76 1431 S/J FUKAHAMA Taiwan
58 19 24 57 1431 S/J JIUNN
LONG
Taiwan
59 20 24 80 1507 S/J FUKAHAMA Taiwan
60 20 24 80 1507 S/J FUKAHAMA Taiwan
61 20 24 60 1507 S/J JIUNN
LONG
Taiwan
62 20 24 60 1507 S/J JIUNN
LONG
Taiwan
63 21 24 63 15826 S/J JIUNN
LONG
Taiwan
64 21 24 63 1582 S/J JIUNN
LONG
Taiwan
65 22 24 66 1657 S/J JIUNN
LONG
Taiwan
66 22 24 66 1657 S/J JIUNN
LONG
Taiwan
67 24 24 72 1808 S/J JIUNN
LONG
Taiwan
68 25 24 75 1884 S/J JIUNN
LONG
Taiwan
69 29 24 87 2185 S/J JIUNN
LONG
Taiwan
70 30 24 90 2260 S/J JIUNN
LONG
Taiwan
71 31 24 93 2336 S/J JIUNN
LONG
Taiwan
72 33 24 99 2486 S/J JIUNN
LONG
Taiwan
73 34 24 102 2562 S/J JIUNN
LONG
Taiwan
74 35 24 105 2637 S/J JIUNN
LONG
Taiwan
75 36 24 108 2712 S/J JIUNN
LONG
Taiwan
76 38 24 114 2863 S/J JIUNN
LONG
Taiwan
77 40 24 120 3014 S/J JIUNN
LONG
Taiwan
78 32 20 46 2009 Velour
Fleece
FUKAHAMA Taiwan
79 34 20 48 2135 Velour
Fleece
FUKAHAMA Taiwan
80 34 20 48 2135 Velour
Fleece
FUKAHAMA Taiwan
81 36 20 54 2260 Velour
Fleece
FUKAHAMA Taiwan
82 36 20 54 2260 Velour
Fleece
FUKAHAMA Taiwan
83 36 20 54 2260 Velour
Fleece
FUKAHAMA Taiwan

22. 22 | P a g e P r i m e a s i a U n i v e r s i t y
Flat Bed Machine:
Machine no. : 10
Flat : 80 inch
Feeder no. : 2
Gauge : 14
SINGLE JERSEY CIRCULAR KNITTING M/C:
Brand Name: PAI-LUNG
Origin : TAIWAN
Model : PL-XS 3B/C
PAILUNG S/J Circular Knitting M/C

23. 23 | P a g e P r i m e a s i a U n i v e r s i t y
Fleece Circular Knitting Machine
Brand Model M/C Gauge Total No of No of
Diameter (in) needle Feeder M/C
PAI LUNG PL-XS3B/C 30’’ 20 1872 90 3
Fleece Circular Knitting Machine

24. 24 | P a g e P r i m e a s i a U n i v e r s i t y
Auto Stripe Circular Knitting Machine
Auto Stripe Circular Knitting Machine

25. 25 | P a g e P r i m e a s i a U n i v e r s i t y
Rib Circular Knitting Machine
Rib Circular Knitting M/C
Interlock Circular knitting m/c
Interlock Circular Knitting M/C

26. 26 | P a g e P r i m e a s i a U n i v e r s i t y
Flat bed Knitting Machine
Flat Bed Machine:
Machine no. : 10
Flat : 80 inch
Feeder no. : 2
Gauge : 14

27. 27 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter - 4: Raw Material

28. 28 | P a g e P r i m e a s i a U n i v e r s i t y
4.1 Raw materials
Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in continuous production and for high quality fabric.
4.2 Yarn
Following types of yarns are used to knit fabrics:
Cotton yarn Blend Synthetic
Combed Yarn PC Polyester
Compact Yarn CVC Nylon
Organic cotton Mélange Acrylic
Elastomeric
Sources:
The required yarns are supplied from:
Cotton Yarn : 1. NRG Spinning Mill
2. Akij Spinning Mill
3. Utah spinning Mill
4. Pakiza Cotton Spinning Mills Ltd.
Special yarns are from:
1. Bardhaman (India),
2. Aarti (India),
3. Organic cotton – Indonesia.
The required grey fabrics are produced in this industry.

29. 29 | P a g e P r i m e a s i a U n i v e r s i t y
4.3 Brand and count and their origin used by M.S. DYEING, PRINTING &
FINISHING LTD.
Yarns are collected either from local manufacturer or imported from foreign companies
depending on order requirement like count required, yarn type, time allocations, quality
requirement. Sometimes buyer recommends where to collect yarn. The following table shows a
rough illustration of brand, count, origin of yarn used by M.S. DYEING, PRINTING &
FINISHING LTD.
Count Brand Origin Type
10/s kamal
16/s Square
20/s Prime
Cotton
22/s Pahartoli
Polyester
24/s Markup
Bangladesh CVC
26/s Thermex
Viscose
28/s Akbar
Mélange
30/s Maksons
32/s viellatex
40/s
50/s
60/s
10/s
16/s
20/s Rajasthan
Cotton
22/s
Polyester
24/s Bardhaman
India CVC
26/s
Viscose
28/s Supper
Mélange
30/s
32/s
40/s
50/s
60/s
Cotton
75/s Polyester
150/s PT Indoroma Indonesia CVC

30. 30 | P a g e P r i m e a s i a U n i v e r s i t y
200/s
Viscose
Mélange
20D Creora (spandex) China
40D Investa India Lycra
70D
Different Types of Dyes Used In M.S Dyeing Printing & Finishing Ltd.with Their
Brand Name:
Brand Name Country Name of Dye stuff
DY-STAR. GERMANY
Remazol Blue RR
Remazol Yellow RR
Remazol Deep Black GWF
Remazol Red RR
Remazol Turquoise Blue G
Remazol B/Yellow3GL
Remazol Blue BB new
Remazol Orange RR
Remazol Blue RSP
IMPOCOLOR GERMANY Imcozin Blue E-NR
Imcozin Blue V-CR 150%
Imcozin Brilliant Red V-F3B
Imcozin Yellow E-3R 150%
BENZEMA SWITZER LAND Bezaktive Blue S-GLD 150
Bezaktive Yellow S-3R 150
Bezaktive Red S-3B 150
CLARIANT SWITZER LAND Drimarine Yellow K-4G Cdg
HUNTSMAN SWITZER LAND Terasil Red W-4BS
Terasil Navy W-RS
Novacron Red FN-R-01
Novacron Yellow F-4G
JIHUA CHINA Starfix Black B 150%
Starfix Red EP 150%
SUMIFIX JAPAN Sumifix Supra Blue E-XF
Sumifix Supra Yellow E-XF
UN COLOR KOREA Sunfix Navy Blue

31. 31 | P a g e P r i m e a s i a U n i v e r s i t y
Different Types of Chemicals Used In M.S Dyeing Printing & Finishing Ltd. With
Their Brand Name:
CHEMICAL NAME BRAND NAME COUNTRY NAME
Wetting agent FELSON NOF Germany
Levelling agent N.D.L.S. Con Switzerland
Anti-creasing agent Marla KT Germany
Kapazon H-53
Per Oxide Stabilizer CBB Germany
Rucorit Wez
Caustic Caustic China
Soda Ash Soda Ash Chaina
H2O2 H2O2 Chaina+Korea
Uvitex-BMA
OpticalBrightening Uvitex-BHV Switzerland
Agent Uvitex-BBT
Syno White 4Bk Korea
H2O2 Killer Catazyme 200L Germany
Acetic Acid Acetic Acid India
MS
China
Sequestering Agent SIRIX 2UD
P cone India
Enzyme
BIOPOLISH,AVOCEF China
Cellzyme 335i India
Sodium Sulphate
Electrolyte / Salt Anhydrose India
Glubar Salt
Detergent
Marla OLS Germany
KRCP Switzerland

32. 32 | P a g e P r i m e a s i a U n i v e r s i t y
Rukozen-NZA Germany
Soaping agent Dekol ISN
China
Erapon R
Nerosoft-JS(an-ionic)
China
Softener Nerosoft-NI(non-ionic)
Kappa Soft BD Bangladesh
Stabilizer
Sandofix-EC
Germany
Marla PS 100
Black EX SF
Yellow K 4GB
Blue KFBL
Crimson-XFT
D-Red-XFT
Disperse Dye Orange-HWT
Blue BBL
Orange F-3R
Red KRB

33. 33 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter-5: Production Planning And
Process Sequence

34. 34 | P a g e P r i m e a s i a U n i v e r s i t y
5.1 Knitting Planning & Process sequences
Industrial based knitting needs careful planning & accurate process control to ensure quality and
minimize defects. At starting rearranging cam arrangement, resetting the m/c and knitting the first
course & bringing it down by knitting continuous course to cloth roller requires at least6 hrs.
Therefore it is critical to plan carefully and use the right cam arrangement, suitable most yarn
count, to check quality during manufacturing and quality inspection after production and ensuring
that required quantity of grey fabric of required quantity has been produced.
Production Flow-Charts
Executive director takes order from Buyer
|
Merchandiser estimates total amount of yarn of production
|
Knitting manager gets production order sheet
|
Senior supervisor ordered by Knitting Manager and orders
Supervisor and Technical in-charge
|
Feederman fixes up stitch length and GSM
With mechanical fitter
|
Definite operator operates machine in his full conscious and
Attention.
|
Mechanical fitter fixes machine if there is any m/c fault.
|
Supervisors keep daily production report and assure m/c is OK.
|
Fabric roll is checked by a troop of inspectors in inspection unit
And weighted
|
Final product to the required amount is delivered to dyeing unit.

35. 35 | P a g e P r i m e a s i a U n i v e r s i t y
5.2 Process sequences in Knitting Floor
After receiving production order sheet it passes From AGM through Sr. Manager to Senior
Executive. Then He informs Technical in charge. Technical in charge & leader of mechanical fitter
troops combined together take decision about m/c for production considering m/c condition,
production capacity maintenance complexity etc. Production officer fixes up stitch length and GSM
with mechanical fitter. Supervisors check and record daily production and make operators conscious
about finishing in due time. After production of each role it is inspected by 4 point system. Then if
the role is ok it is send to grey fabric store.
Several Important Steps While Production
Cam Arrangement & Needle Set Up
Cams provide tracks for needle in a knitting m/c, therefore it is used to change the movement of
primary knitting element, needle to produce diff fabric design. While changing cam arrangement for
different fabric design it should be take care that-----
 Cam track and needle butt position has been synchronized accurately.
 It is also been synchronized with fabric design.
This process can be described as follows--
 Each feeding position of circular knitting m/c produce a complete course and all feeders in a
complete revolution produce equal no. of walls as feeder.
 Therefore a single cam box represent the sequence of cams in vertical direction corresponds
to a course of a repeat.
 Each wall of repeat is arranged in different cam box gradually.
Lycra Feeding Method
 In single jersey circular knitting m/c Lycra is fed in cylinder needle.
 In double jersey circular knitting m/c Lycra is fed in dial needle.
There are two methods of Lycra feeding:-
1. Half feeder:
Lycra is fed to half of the active feeder in alternative way leaving one feeder miss and next feeder
threaded.
2. Full Feeder:
Lycra is fed to every active feeder.

36. 36 | P a g e P r i m e a s i a U n i v e r s i t y
Yarn Tension Control in Knitting
Yarn tension is critical in fault free fabric production. If tension varies among yarns almost every kind of fabric
fault can arise. Yarn tension can be controlled by---
By adjusting looseness or tightness of VDQ timing belt; if necessary changing it.

Adjusting the speed of cloth roller.

Adjusting fabric take down speed.

By adjusting cam position fixer wheel in individual cam box.

Keeping the m/c as clean as possible.
5.3 GSM & GSM Control
GSM is a technical term that indicates the weight of the fabric per square meter. GSM is a buyer’s
requirement; hence GSM control is very important which

In older m/c s is controlled by VDQ pulley. By rotating the upper disk in positive Direction will reduce the
pulley diameter and GSM will increase.
Pulley diameter Stitch length GSM Pulley diameter Stitch length GSM

In modern m/c GSM is controlled automatically by the help of variable rpm motor and relanit technology.
Points Needs to Consider while GSM Adjusting

VDQ pulley diameter.

Yarn count.

M/C gauge.

Cam position.

Take up speed

37. 37 | P a g e P r i m e a s i a U n i v e r s i t y
GSM and Yarn Relation
GSM of fabric also depend on yarn count. Following chart show a relation between GSM and yarn count
selection used in M.S. DYEING, PRINTING & FINISHING LTD.
SINGLE JERSEY
Grey GSM Finish GSM Yarn Count
79,88 115 40/s
114 140 30/s
133 160 28/s
128,130,131,132,133,136 160,170 26/s
139,141,142 180 24/s
150,160 190,194 20/s
LYCRA SINGLE JERSEY
165 160 40/s + 20D lycra
170,172 180,160 34/s + 20D lycra
Pique
Grey GSM Finish GSM Yarn Count
136,139,140,141,142 180 30/s
142 200 28/s
Single Lacoste
180 220 30/s
190 230 30/s + 40D lycra
165 220 22/s
292 365 20/s
Double Lacoste
160 220 26/s
FLEECE
275 310 34(Knit) + 30(Loop)
243 300 34(Knit) + 24(Loop)
230,231,232,236,243 300 34(Knit) + 20(Loop)
260 260 20(Knit)+50D+28(Loop)
TERRY
268 340 30(Knit)+75D+20(Loop)
210 250 20(Knit) + 25(Loop)
202,203,208,210,211,2
12 250 20(Knit) + 24(Loop)

38. 38 | P a g e P r i m e a s i a U n i v e r s i t y
Double Jersey
RIB(1x1)
134 190 32/s
162,163,165 220 28/s
171,173 230,240 26/s
210 260 20/s
LYCRA RIB(1x1)
280 350 20/s + 40D lycra
360,380 350,360 34/s + 40D lycra
Interlock
240 260 30/s
183 195 34/s + 40D lycra
165 160 40/s + 20D lycra
170,172 180,160 34/s + 20D lycra

39. 39 | P a g e P r i m e a s i a U n i v e r s i t y
Reliant Technology
The technology of using vertical sinker in circular knitting m/c is called Reliant Technology. In this
arrangement GSM can also be controlled directly by this sinker. It is a modern innovation. It also
allows higher gauge. M.S. DYEING, PRINTING & FINISHING LTD. possessed several modern
FUKAHAMA circular single jersey m/c having reliant installment.
Changes That Required In Case of Fabric Design Change
 Cam arrangement changing.
 Needle butt setting & needle dropping.
 Using of different colored yarn in selected feeder.
 Using of jacquard mechanism.
 Size of the loop and GSM.
5.4 Types of Fabric Produced in M.S. DYEING, PRINTING & FINISHING
LTD.
 Single jersey
 Single jersey with lycra
 Single lacoste
 Double lacoste
 Pk
 Double pk
 Terry
 Terry with lycra
 Fleece
 Polar fleece
 Micro fleece
 Rib
 Rib with lycra
 Interlock
 Waffle design
 Mash design
5.5 Steps to Increase Production
By increasing m/c speed:
Higher the m/c speed faster the movement of needle and ultimately Production will be increased.

40. 40 | P a g e P r i m e a s i a U n i v e r s i t y
By using m/c with higher 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.
By using skilled operator:
Skill operator can utilize production facilities more efficiently.
By using Modern M/C with Advanced Features:
Modern technology like relanit, positive feeder etc. will not only increase production but also reduce
faults.
Types of stripe produced
Horizontal stripe can be produced in two ways.
Feeder stripe: In this, stripe effect is produced by using diff color yarns in diff feeder in an orderly
manner according to repeat.
Engineering stripe: In this, stripe effect is produced by gradually adding different colored yarn in
each feeding position according to repeat with the help of a device called ‘finger mechanism’.
Finger and Its Function
Finger is a device with the help of which in E-stripe circular knitting m/c selection of yarn is altered.
E-stripe m/c is installed with special feeding system, having fingers to allow the feed of several yarns
in a single feeding position and computer controlled cam and gear arrangement to change the active
feed yarn.
On circular m/c striping finger must change whilst needle cylinder rotates, therefore a slight overlap
of two interchanging yarn is essential. When a finger withdraws, its yarn cut free and securely held
for next reselection by finger blade or trapper. A newly selected finger of the same finger box is
introduced to needle line. Its trapper releases cut end of yarn and a yarn carrier feeds the yarn in
needle.

41. 41 | P a g e P r i m e a s i a U n i v e r s i t y
Producing Feeder Stripe
Feeder stripe can be produced in any type of weft knitting machine. In this, stripe effect is produced by using diff
color yarns in diff feeder in an orderly manner according to repeat. But there is a limitation while producing
feeder stripe. In repeat no of course must be equal or less than the no. of feeder in the repeat.
For example let, a stripe, Red = 5 course
Green = 3 course
Black = 2 course
Total = 10 course
While producing this fabric in a 54 feeder m/c active feeder would be = 10x5 =50
The rest 4 feeder will be needle drop or, all miss cam.
Yarn arrangement would be, Feeder (1-4) = miss
Feeder (5-9) = Red
Feeder (10-12) = Green Repeat
Feeder (13-14) = Black
Feeder (15-19) = Red
Feeder (20-22) = Green
Feeder (23-24) = Black. And so on.

42. 42 | P a g e P r i m e a s i a U n i v e r s i t y
Producing Engineering Stripe
Stripe effect is produced by gradually adding different colored yarn in each feeding position according to
repeat with the help of a device called ‘finger mechanism’. In each finger box one of each diff colored yarn is
fed in diff finger. According to repeat the sequence of yarn selection is fed. Then the processor calculates the
sequence of finger selection and stripe fabric production is started. .
Different parts of Engineering Stripe m/c

43. 43 | P a g e P r i m e a s i a U n i v e r s i t y
5.6 Important Components of Circular Knitting M/C
Free Standing Creel
Each creel unit contains 8 stands. Therefore a typicalcapacity of
creel (8unit) = 64. It contains cones with reserve cone for each
feeding position. In case of E-stripe each stand of creel is
marked according finger number.
Standing Creel
Positive Feeder
Positive feeders are those where yarns are driven
positively by any kind ofm/c gearing system. M.S.
DYEING, PRINTING & FINISHING LTD. uses
two kind of positive feeder- one is for yarn and
another one is for Lycra feeding.
Positive Feeder
Yarn Guide
One or several guide guides the yarn to needle.
Yarn Guide

44. 44 | P a g e P r i m e a s i a U n i v e r s i t y
Needle and Cam
Needle is the primary knitting element. Cams create the track for needle movement. Circular knitting m/c
has stationary cams arranges orderly indifferent cam box. In S/J machine there is one set of needle, only
cylinder needle. In double jersey m/c two sets of (cylinder & dial) needle.
Cylinder
Needles are set in the groove of a cylinder. Cam boxes arerranged outside of cylinder.
Cylinder Fabric Spreader VDQ Pulley
Fabric Spreader:
Fabric spreader is stands which spread the endless tubular fabric in a sheet form of two plies which then
can be wound on a cloth roller with maximum efficiency and allows maximum fabric to be wound or
collected in folded form.
VDQ Pulley
VDQ pulley means ‘variable diameter quantity’ pulley that’s diameter can be altered by means of relative
position of upper plate and base plate. VDQ pulley consists of three main components:
 Upper plate
 Base plate
 Pegs

45. 45 | P a g e P r i m e a s i a U n i v e r s i t y
5.7 Important Accessories of Circular Knitting M/C
1. Start, Stop & inching Button:
Complete set of Start, Stop and Inching button at
top of each leg for ease of excess during
operation
2. Ratchet Lever
It permits inching motion by a hand driven lever.
Ratchet Lever
3. Sensors & Detectors
Circular knitting m/c is equipped with several sensors and detectors like –
 Needle detector
 Fabric detector
4. Auto Counter
An automatic counter with display showing revolution of m/c (As for ORIZIO It indicates 1 count for every
2 revolution) and provide facility to predetermine auto stop after certain revolution.

46. 46 | P a g e P r i m e a s i a U n i v e r s i t y
5. Fabric Take up Mechanism
Bevel gear mechanisms beneath fabric platform can automatically adjust with changing rpm and for further
control there is a adjustable gear and belt drive to control the take up speed for different GSM and style of
fabric and to control uniform take up tension.
1. Safety Guard Hatch
M/C cannot run with safety guards open.
2. Auto Lubrication
The automatic central pressurized oil sprayer can be adjusted at cycling time and quantity to make cylinder,
dial, sinker ring’s cam, needles and sinkers lubricated enough, besides it has the function cooling and
clearing.
3. Auto Fly Removing System
One or three fans on a rotating arm remove any dirt or fly on creel or m/c.
4. Air Hose
Every m/c equipped with a air hose which is used for further cleaning and feeding the yarn
Through pipe.
5. Gauge
Gauge means no of needle per inch at the surface of cylinder.
Commonly Used Gauge
 In S/J 24 gauge commonly used. But for fleece 20 gauges is used more frequently.
 In Rib 18 & 20 gauge are most common
 In Interlock 24, 28 are used mostly.
Changing Gauge of M/C
As needles are set at the groove of cylinder, therefore to change the gauge cylinder must be changed.

47. 47 | P a g e P r i m e a s i a U n i v e r s i t y
This process can be –
 Remove the cam box and needles.
 Unscrew the cylinder.
 Replace the cylinder with a same dimension cylinder having needle groove of required gauge.
 Cylinder is leveled by ‘Dial Gauge Meter’. A deflection between 0-0.5 is acceptable.
Set the needle and then set the cam box in required manner.
6. Nozzle
In knitting m/c there are two types of nozzles are in use –
 Air nozzle.
 Oil nozzle.
Air nozzle is to flow air for – cleaning – Latch opening purpose. Oil nozzle sprays oil for lubricating
purpose.
5.8 Gearing Diagram of Power Transmission of a Knitting m/c
Cylinder
Motor
Cloth roller

48. 48 | P a g e P r i m e a s i a U n i v e r s i t y
Auto stop motion List in knitting machine
a) In Case of Gate open.
b) Yarn breakage.
c) Fabric cut & fell down.
d) Needle breakage.
e) Oil & air pressure problem.
f) Completion of selected target.
g) Take up problem.
Adjusting points of the knitting machine
a) Feeder to needle distance.
b) Dial to Cylinder distance.
c) Sinker groove to Cylinder groove.
d) VDQ pulley diameter.
e) Tension control knob on cam box.
f) Change pinion in take up roller.
Needle no
It denotes information about needle and usually expressed as –
(Needle length)×(Thickness)×(Position)
Spare Parts of M/C (Needle and Sinker) on Floor

49. 49 | P a g e P r i m e a s i a U n i v e r s i t y

50. 50 | P a g e P r i m e a s i a U n i v e r s i t y
5.9 Flat Bed Knitting Section
Types of yarn used
Count used
18’s, 20’s, 22’s, 24’s, 26’s, 30’s, 34’s, 40’s
Resultant count for different ply yarn
Yarn count No. of ply
18 3
20 3
22-28 4
30-34 5
40 6
Suitable gauge for collar cuff production
In M.S. DYEING, PRINTING & FINISHING LTD. normally 14 gauge m/c is used for collar cuff
production.
Types of collar
1. Solid collar
2. Tipping collar
3. Dobby collar
4. Double lycra collar
Types of cuff
1. Solid cuff
2. Tipping cuff
3. Dobby cuff
4. Double lycra cuff

51. 51 | P a g e P r i m e a s i a U n i v e r s i t y
Dimension of collar & cuff
Dimension of collar & cuff is mentioned below according to an order sheet. This will provide us
conception about the dimension of collar & cuff.
Buyer name Order no. For Fabric Dia/size
43*9cm
44*9cm
45*9cm
Mascot F#0665/10 Collar FL-KN-COLLAR 46*9cm
47*9cm
49*9cm
50*9cm
28*3.5cm
30*3.5cm
32*3.5cm
Mascot F#0665/10 Cuff FL-KN-CUFF 34*3.5cm
36*3.5cm
38*3.5cm
40*3.5cm
Main parts of flat bed knitting m/c
1. Yarn guide
2. Carriage assembly
3. knitting system
4. Needle beds
5. Fabric take down
6. Control device
7. Display & operating elements.
cam
Figure : Side tensioner

52. 52 | P a g e P r i m e a s i a U n i v e r s i t y
Yarn feeding system
At first yarn packages are held on the package stand. Then it passes through the stop tensioner, side
tensioner,feeder,carriage and reaches to bed and finally on the take down mechanism.Some other
necessary parts are discussed below:
1. Stop Motion
At a bobbin end or in the case of thread breakage the stop motion switches off the machine immediately.
This prevents the fabric from being thrown off.
2. Side yarn tensioner
The side yarn tensioner monitors & tensions the thread. In case of a thread break or end it can switch off
the knitting m/c faster and store a longer piece of yarn than the yarn control unit for yarn tensioner.
Heavy yarns can be processed more easily with it.
3. Yarn feeder
The yarn feeder is selected with the yarn feeder magnets on the carriage part. The yarn feeder is carried
along by the carriage assembly unit the bolt is pulled upwardonly standard yarn feeder.
Figure: yarn feeding system.

53. 53 | P a g e P r i m e a s i a U n i v e r s i t y
Fabric analysis and production calcultion
5.10 Design, Cam and Needle Arrangement of Several Knitted Fabric
Single Jersey
Chain Notation
Knit Stitch –
Cam & Needle Arrangement
⋀ ⋀ ⋀
⋀ ⋀ ⋀
⋀ ⋀ ⋀
3
2
1
Knit Cam: ⋀

54. 54 | P a g e P r i m e a s i a U n i v e r s i t y
Single Pique
Chain Notation
Knit Stitch –
Tuck Stitch -
Cam & Needle Arrangement
⋀ ⊓ ⋀ ⊓
⊓ ⋀ ⊓ ⋀
⋀ ⊓ ⋀ ⊓
3
2 2
1 1
Knit Cam:
⋀
Tuck Cam: ⊓

55. 55 | P a g e P r i m e a s i a U n i v e r s i t y
Single Lacoste
Chain Notation
Knit Stitch -
Tuck Stitch -

56. 56 | P a g e P r i m e a s i a U n i v e r s i t y
Double Lacoste
Chain Notation
Knit Stitch –
Tuck Stitch -
Cam & Needle Arrangement
⋀ ⋀ ⋀ ⋀ ⊓ ⊓
⋀ ⊓ ⊓ ⋀ ⋀ ⋀
2
1
Knit Cam: ⋀
Tuck Cam: ⊓

57. 57 | P a g e P r i m e a s i a U n i v e r s i t y
2 Thread Fleece
Chain Notation
Knit Stitch –
Tuck Stitch –
Miss Stitch -
Cam & Needle Arrangement
⋀ ⊓ ⋀ -
⋀ - ⋀ ⊓
⋀ - ⋀ -
3
2
1 1
Knit Cam: ⋀
Tuck Cam: ⊓
Miss Cam: _

58. 58 | P a g e P r i m e a s i a U n i v e r s i t y
3 Thread Fleece
Chain Notation
Knit Stitch –
Tuck Stitch –
Miss Stitch –

59. 59 | P a g e P r i m e a s i a U n i v e r s i t y
2x2 Rib
Chain Notation
Knit Stitch (Face) –
Knit Stitch (Back) –

60. 60 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter- 6: Maintenance

61. 61 | P a g e P r i m e a s i a U n i v e r s i t y
6.1Maintenance
Maintenance is a process by which equipment is looked after in such a way that trouble
free. Services and increased machine life can be ensured and specific product quality
required by the customers is sustained.
On time maintenance increase m/c lifetime & ensures trouble free services.
6.2 Types of maintenance
Preventive Maintenance:
Preventive Maintenance is a predetermined routine activity to ensure on time inspections /
checking of facilities to uncover conditions that may lead to production break downs or
harmful depreciation.
Corrective Maintenance / Break down Maintenance:
In this case, repairs are made after the equipment is out of order and it cannot perform its
normal functions.
PM Tasks list
Maintenance : Mechanical
Machine : Thies Dyeing Machine

62. 62 | P a g e P r i m e a s i a U n i v e r s i t y
Maintenance : Electrical
Machine : Thies Dyeing Machine

63. 63 | P a g e P r i m e a s i a U n i v e r s i t y
Maintenance tools & equipments :
 Pliers
 Inside Calipers
 Outside Calipers
 Digital Multi
 Meter Heating
 Shoulder Hammer
 Philes
 etc.
Remarks :
Maintenance of machine’s are very essential to prolong the m/c life and good
maintenance is important for economical consideration. In this industry maintenance program
is done by expert maintenance team. So very few times production are stopped due to m/c
problem.

64. 64 | P a g e P r i m e a s i a U n i v e r s i t y
Chapter- 7: Utility Services

65. 65 | P a g e P r i m e a s i a U n i v e r s i t y
7.1 Available facilities of utility
 Electricity
 Gas
 Water
 Compressed air
 Steam.
Electricity:
The main utility electricity is supplied from PDB and also by Generator.
Specification:
Equipment used : Gas generator.
No. of generator : 2 (1 self-start able & other 1 are air+CH4 start able).
Manufacturer : Wartsila-Frank.
Gas engine used.
16 cylinders per engine.
Overall efficiency : 80%.
Heat recovery possible from 4 engines.
Stroke of engine : 176mm.
Cylinder capacity : 71.6dm3
Ignition pressure : 90bar.
Piston speed : 9m/sec.
Air flow of full load : 1.65kg/hour.
Exhaust flow at full load : 1.7kg/hour.
Exhaust gas temp : 500 C.
Pressure of gas : 60-62 milibar.
Air pressure : 7 bar.
Electricity take up from PDB : 1.5MW/sec.
Total power is then distributed as per requirements of different section of M.S Dyeing Printing
& Finishing Ltd.
Gas:
Gas is mainly used for steam production.
The gas is used from TITAS.
Generally 36 m3 gas is required to produce 1 ton steam.
Water:
Continuous supply of water for BTL,BDL&BKL must be ensured by pump.Mainly two pumps
are used for water pick up.
7.2 PUMP CAPACITY SETUP
Submersible pump-I 260 m3/hr Discharge value 100% open
Submersible pump-II 204 m3/hr Discharge value 100% open
Depth of pump: 140ft.

66. 66 | P a g e P r i m e a s i a U n i v e r s i t y
Steam:
Pure steam with required temperature must be produced to meet the continuous demand of
steam in different sections.
Fire tube type boiler is used.
No. of boiler: (2) twine boiler.
1 boiler is operated by using burn gas.
1 boiler is operated by Titas gas.
3 pass heating system.
Measuring meter for water supply.
4" depth greasol insulation so no heat at outside of drum.
The lower drum is 100% water filled & the top drum is 60% water & 40% steam filled.
Proper supply of air for gas burnings.
Boiler capacity : 10ton.
Steam pressure : 8.2bar.
Steam flow : 7 ton (approximately)
Manufacturer : Thermax; India.
Model : TD-100-10-54/6AS/E.
Fuel : Natural gas.
Water pressure : 10.3bar.
Evaporation : 1000*3 kg/hr.
Output : 6.28x3 MW.
Steam Temperature : 185 C
Boiler Temp (inner) :224 C-275 C.
Every result is recorded for 4 hours.
Chemicals used for boiler feed water:
NaCl solution for regeneration.
NALCO-4654(scale remover).
Compressor:
Natural gas is drawn by pipe through the filters above the compressor & the air is
compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to
reduce the temperature of compressed air. Thus the cold water becomes slightly hot &
goes through outlet pipe to the overhead reservoir. Then the water falls slowly
through a sieve and becomes cool & again feed to the compressor. At the other hand
the cooled compressed air along with some vapors are transferred to the reservoir
where the vapors are condensed and outlets drop by drop. The moist compressed air is
transferred to the dryer & a slight warm compressed air is delivered to required sections of
M.S Dyeing Printing & Finishing Ltd.
Parameters Set value
Unloading pressure 7.5 bar
Pressure difference 0.6 bar
Oil pressure 1.2 bar
Motor running time 15 sec
Total no. of compressor : 3+3 =6
Capacity : 774 lt air/compressor/sec.
Manu : Atlas capco.

67. 67 | P a g e P r i m e a s i a U n i v e r s i t y
Country : Belgium.
Oil free air is prepared : By Electronikon.
Chemicals used:
-Shell Turbo-T-68.
-Grease.
-Nalco 7328 & 7330.
Chiller:
Manufacturer :Thermax.
Country : India.
To start a chiller electricity & steam is required.
Capacity :[(21083)+(500*1)] ton = 1130 ton water cooling.
Absorption type Chiller is used.
Settings:
L-cut set point CHWSP : 8 C.
Cooling water inlet temp set point : 20 C.
HTG temperature set point for AC drive : 140 C.
L-cut hysterics : 2 C.
Std. continuous flow : 12.2 C - 6.7 C
Chemicals used:
LiBr (Lithium bromide):-
Components: Li=7,99%;Br=92.01%.
S.G = 3.464 at 25 C.
MP = 549 C.
BP = 1265 C.
Lythium Molybodate.
Octyl Alcohol (2-Ethyl-1 feanol).
Nalco 7328 & 7330.
Refrigerant.
Source of Utility:
Electrically : PDB & Generator.
Steam : Boiler.
Water : Pump.
Compressed air : Compressor.
Temperature control : Chiller.
Gas : TITAS.
Cost:
36 cubic meter gas required for 1 ton steam generation.
Required steam/day = 9500 ton.
PDB:
Pick hour : 4.22 Tk/unit
Off pick hour : 3.70 Tk/unit.
Generator:
Electricity : 2.25 Tk/unit of.

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Chapter- 8: Store & Inventory Control

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8.1Frequency of inventory control
Monthly inventory control
Annual inventory control
8.2 Scope of inventory control
Raw materials
 Dyes store
 Others chemicals store
 Grey fabrics
Finished fabric
Spare parts
General store
 Capital equipment
 Accessories
 Stationary
 Maintenance parts.
8.3 Inventory system for raw materials
Raw materials partially received from production planning & directly
from head office.
Material Receiving & Inspection Report (MRIR) is prepared. Received
quantity is mentioned & noted down.
Submitted to QC department. Some are OK & few rejected.
Entry of data of goods in DATATEX .
Goods are arranged according to OK or rejected group.
Department gives store requisition to warehouse.
As per requisition materials supplied & this record is noted down.
Stages of grey fabric inventory control
After knitting production
Grey inspection
Warehouse
Batch preparation
Dye house.
Stages of finished fabric inventory control
Finishing section
After final inspection
Warehouse.

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8.4 Store capacity
Dyes : 6-7tons
Chemical : 33-35tons
Grey fabric : 20-25 tons
Yarn storage : 50 tons
RFD : 50 tons
Set range of dyes : 80-100kg/day
Set range of Chemicals : 2-2.5ton/day
Remark
The inventory system of M.S Dyeing Printing & Finishing Ltd. covers both
knitting & dyeing inventories.
The space is noticed to be insufficient considerably.
An expansion of space is thus desired for sound inventory.
The department is computer oriented & connected by ERP.

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Chapter- 9: Cost Analysis

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9.1 Costing of the product
Costing system mainly describes how the cost of the final product is fixed by the
company/beneficiary. According to buyers/customers requirement at first the fabric is
collected from local and foreign suppliers. Then it is calculated how much dyestuff and
chemical is required till the end of the processing of that specific fabric. After that, the final
cost is fixed including some profit. Then the unit price is offered to the buyer for approval. If
the buyer approves it, all the transaction of money is carried out by bank.
Costing of the product is done by the consideration of the following factors:
1. Amount of raw materials consumed.
2. Direct labor.
3. Indirect labor.
4. Factory cost.
5. Office and administrative cost.
6. Sales and distribution cost.
7. Profit, etc.
Remarks:
The costing of product is a secret matter of the industry. They are not interested to
flash up the cost related data. So, we could not collect the price of the product and
costing of the product.

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Chapter- 10: Marketing Activities

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10.1 Consumer of the products
M.S Dyeing Printing & Finishing Ltd. is a100% export oriented industry. All the goods
produced in this industry are exported into various foreign countries.
Name of the main buyers of the products of the industry are given below:
 FOX.
 B&C.
 Wilson
 Pimkie.
 StyleTex.
Product label:
Product label differs from buyer to buyer. The product labels are prepared according to
fabric criteria and the buyer requirements.
Package size and label:
Package size and label differs from buyer to buyer. The package size and labels are prepared
according to fabric criteria and the buyer requirements.
Local Market:
M.S Dyeing Printing & Finishing Ltd. is a100% export oriented industry. All the goods
produced in this industry are exported into various foreign countries. So, goods are not
supplied into local markets.
Importing countries:
The countries which are importing goods from M.S Dyeing Printing & Finishing Ltd. are
given below:
USA.
Canada.
Europian countries.
10.2Marketing Strategy
Marketing strategy is a very important factors to sale the products to the buyer. M.S Dyeing
Printing & Finishing Ltd. mainly senior marketing officers, merchandiser and higher deal
with buyer. There are some fixed buyers of the industry. The buyers give their orders
continuously all over the year. The marketing officers and by both side understanding the
rate and the order quantity are fixed.
Duties& responsibilities of marketing officer:
The main duties and responsibilities of a marketing officer are given bellow:
 To prepare cost sheet by dealing with the buyer.
 To take different steps by discussing with the high officials and merchandiser.

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 To maintain a regular & good relationship between commercial officer &
merchandiser.
 To maintain a regular communication with the buyers & buying houses.
 Communicate with the new buyer.
 Display the criteria of the products.
Actually the responsibilities & duties of marketing officer begins from getting order of buyer
& ends after receiving goods by the buyer. so he should be always smart, energetic & sincere.
Remarks:
M.S Dyeing Printing & Finishing Ltd. has a well learned marketing & merchandising
team. They always communicate with the buyers. The marketing section also looks for
the quality & quantity buyers.

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Chapter- 11: Conclusion

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Industrial attachment program send us to the expected destiny of practical life. The completion
of tow month industrial attachment at M.S Dyeing Printing & Finishing Ltd. I have got the
impression that the factory is one of the most modern knit dyeing project in
Bangladesh. This company has earned very good reputation for its best performance over any
other knit dyeing project.
11.1 My Achievement
 I got the general information of such a large factory that gives me the clear idea about
the requirements of a composite industry set up with all necessary manpower &
machineries.
 I have earned some knowledge about the quality management system of different
sections of the industry.
 I have identified the process sequence of different units that gives me the better idea
about running of a program.
 I got the information about related to the amount of wastage of different units that
helped me to calculate the benefit & loss of any project that can be run.
 I have harmonized myself with the industrial environment, work & administration that
will help me to do job in any industry.
 Furthermore I achieved some practical knowledge about every steps related to the
production of a woven fabric that will facilitate me to develop my experience more in
this field.
11.2 Conclusion
Forty two day’s industrial training in M.S Dyeing Printing & Finishing Ltd. was a concluding
part of the B.Sc in Textile Technology course which was to comprehend my theoretical
knowledge along with practical knowledge. It also enables me to orientate myself with the
practical environment where I will work in future. During the training period, the whole 42
days were segmented and scheduled to a systematic routine. There were different sides of
operation in Fabric manufacturing process. First of all, it should be mentioned that the M.S
Dyeing Printing & Finishing Ltd. is a 100% export oriented composite industry. For producing
a quality product above all export quality it is desirable that the processes should be highly
standard. For this purpose M.S Dyeing Printing & Finishing Ltd. has high skilled hard working
officials, management and departments. Last of all I thank all the officers who help me by co-
operation and give information’s to me. I am lucky because I completed my internship in a
well-known industry which will help me to build up my career in Textile sector.