Dye House Projectonly

Dye House Project- Ocean Lanka (Pvt) Ltd.
Contents
• Declaration
• Chapter 1
1. Curriculum vitae
2. Reference letter from the current Employer
3. Certified copies of Qualifications and Academic Records
4. Continuing professional Development Record
• Chapter 2
1. Career Episode 1
2. Career Episode 2
3. Career Episode 3
• Summary statement

DECLARATION
I do hereby declare that the details mentioned herein with regard to my personnel details,
Academic details, professional training are true to my Knowledge. All the particulars
mentioned in each section of my Curriculum Vitae can be verified individually.
This Project is a unique experience I have gone through while in the service of Ocean Lanka.
Calculations, adopted theories, calculated risks, assumptions are all used in the designing or
initial stage of each episode.
…………………………………….. …………………………………….
K.H.Sanjaya Silva Date

DYE HOUSE PROJECT
Company & Process……………
Established in 1994, Ocean Lanka is the largest manufacturer of Weft Knitted Fabrics in the
island located in Biyagama Export processing Zone and jointly owned by Fountain Set (Hong
Kong), Brandix and Hirdaramani with over 1800 employees. A well-established, respected and
fast moving company manufacturing and supplying weft knit fabrics (Single Knits, Double
Knits, Flat Knit, Prints & Yarn Dyed) to the Sri Lankan apparel industry for a growing number
of international brands, including Victoria’s Secret, Next, Marks and Spencer and Nike.
Ocean Lanka possesses the total Textile manufacturing process and facility except for Yarn
making. This includes Yarn, greige (Raw cloth) & finished fabric ware houses which can
accommodate more than production & output demand. The process mainly comprised of
Yarn processing, Yarn dyeing, Piece (raw cloth) Dyeing, Fabric treatment & finishing, Fabric
Printing and Quality Control. There are few other sub processes which support the main
process units. Generally Ocean lanka makes approximately 2,000,000 lbs. of finished fabrics
per month (there could be higher or lower values depending on the Brand and season
demands).

Problem & Cause……………………..............
In general, a Project is defined as a collaborative enterprise, involving research or design that
is intentionally planned to achieve a particular Goal or a solution to a prevailing problem. But
it is rather temporary than permanent social systems or work systems that are constituted
by teams within or across organizations to accomplish particular tasks under time
constraints. Or in simple terms a temporary specified task with scope, time, cost and quality
limitations. In that context, the Project in this Episode was designed to provide a reliable
solution the said production capacity problem which has hampered the Dyeing Department
performance for a long time. Hence this episode will be segmented to present a clear view
relate to the cause, remedy, design, works and the final result.
In order to achieve the expected finished fabric quantity, there are certain Dye production
quantity have to be met. This depends on the machine output/cycle /Day. Further, there are
more than 3,000 Fabric types Ocean lanka has developed and has the capacity to manufacture
–this is an on-going process and new fabrications (total fabric making process) are being
added continuously. This has added more dye batches where existing number of Dye
machines cannot handle in given time. All these incidents has created an unwanted delay time
in Dye process due to elongated Queue time in Dye machines. There are 68 Dye Machines
with only 10 machines which have high temperature recipe.
This problem has created 17-14 days queue in most of the smaller capacity machines ranging
from 30 lbs to 250lbs. The analysis has shown that this trend has created by the Brand
Demand; created by the consumer Demand & trend; which has reduced more Bulky Dye
orders and demand was focused on smaller Quantities. –Refer Table 1

In order to find the cause for this, machine queue data from 2012 & ongoing (2013) were
compiled. The purpose of this exercise was to come up with the right combination of machine
capacities.
Table 1
Ocean Lanka Data – Dyeing Department Machine Queue in days up to 2013 January
Dye M/C GN 8T ECO6T EC04T TSF6T TSF 3T
Type , No
# 28,29
#
30,31,38,40
#
34,37,39,41 # ,12,13,14 # 17,18,19
& Capacity
3600 Lbs. 3000 Lbs. 2000 Lbs.
1500-2100
Lbs.
700 - 1050
Lbs.
2012 m/c
queue 3.3 5.3 7.6 5.9 6.8
2013 m/c
queue 6.9 7.6 13.5 9.2 14.4
Average
m/c
queue 5.1 6.45 10.55 7.55 10.6
# of
batches
@ mc
queue 16.32 41.28 67.52 48.32 50.88
Dye
M/C
ECO2T ECO1T TSF 2T ECO1T AU 1T
AU
1T
AU
1T
AU 1T Winch
Type & No
# 36,42 # 43,46 # 15, 16 #44,45
#
47,48,49 # 50,52 # 51
#
53,54,55,56 # 1,2,3
Capacity
1000 Lbs. 500 Lbs.
450 -
700 Lbs.
250 <
Lbs.
130 <
Lbs.
66 <
Lbs.
11 <
Lbs. 22 < Lbs.
90 <
Lbs.
2012
m/c
queue 4.9 10.2 14.4 15.4 14.1 12.4 5.3 3.8 5.9
2013
m/c
queue 6.9 12.6 16 13.3 15.7 8.7 8.5 6.2 6.9
Average
m/c
queue 5.9 11.4 15.2 14.35 14.9 10.55 6.9 5 6.4
# of
batches
@ mc
queue 18.88 36.48 48.64 45.92 71.52 33.76 11.04 32 30.72
Dye M/C Winch Winch AK S T AF1T
Type & No # 8,9,4,5 #6,7,10, 11 # 1,2 #57
Capacity
50 < Lbs. 30 < Lbs. 15 Lbs.
660 <
Lbs.
2012 m/c
queue 4.8 7.3 7.4

2013 m/c
queue 4.2 5.75 3.4 1.8
Average
m/c queue 4.5 6.525 5.4 1.8
# of
batches @
mc queue 28.8 41.76 17.28 2.88
This analysis was the prime evidence to raise a case against Production delays and On-Time-
Delivery issues. Hence it was decided to replace existing machines with high temperature,
low-liquor ratio machines which will consume less Electricity, Steam , Chemicals (Dye stuff)
etc..
Assumptions & Aims………………………
--- The Obvious primary aim of this project is to reduce the prevailing machine delays, which
has caused the company in terms of On-Time-Delivery rating, defects appeared after Dyeing
due to greige fabric in idle for longer periods, low production.
----The second aim of the project is to reduce the water usage as Textile Dye process is one of
the most water consuming production process anywhere in the world. Although there are
other inventions like Air Flow machines (a Forced draft is used to create the turbulence inside
the machine to support the dye absorbing process) and most advanced models like
“Waterless Dye machines” (Already one of the most sought after Brand has started an
Experimental Factory process in Asian region) . In the Textile Dye terminology, the water
contribution is known as Liquor ratio (L/R); the ratio between Dry weight of the Fabric and
the water requirement for dyeing process (Although there are more sub processes connected
to the total Dye process like Scouring, Washing –as many washing cycles as the particular
fabrication specified, Rinsing etc. which may need different water quantities, the Liquor ratio
is referred to the water quantity required for the total process as an average). In the Ocean
Lanka case, the average L/R was between 8:1 to 9:1. The magnitude of this number will be
visible when we consider an average monthly Dye production of 2,000,000 lbs. (this may vary
between 2 million – 2.5 million)
Hence monthly average Dye production – 2,000,000 lbs (909,090 Kgs)
Water consumption @ Dyeing 8:1 Liquor ratio + - 7,272,720 ltr
(But total water consumption was averagely 50ltr/ lbs of finished fabric)
The Specifications of the Machine Model selected for the Project mentions the factory tested
L/R as 4:1 but we assume the practical value to be between 5:1- 6:1 due to waste between
sub processes, drain efficiencies etc... Hence this was one of the Intended targets of this
Project. As per the manufacturer’s specifications, they will achieve this through the inside
structure- the change in the fabric path inside the Dye chamber, the high temperature option
will reduce the water quantity needed to dissolve the specified dye quantity and the final

absorption will be faster, Change in the Dye Process Recipe will reduce the time taken for the
process through improved methodology, Change in the Dye Cycle
---- The third aim is to regularise the working temperature of Dye machines. Cotton fabrics
needs lower Temperature surrounding whereas Lycra based or Polyester needs high
temperature dye solution to achieve high efficiency. With existing machines, the Production
Planning & Control Department have to choose Dye batches & swap them across varying
Machine capacities and varying Temperature classes.
----The High Temperature option will give the total Dye cycle time to be shorter than the
current process as the Dye solution will reach the desired temperature faster. This is the most
important goal in this venture as it will give the Machine Cycles per Day from 1.6 (current
value) to a minimum of 2 or could be more (the target would be to reach 2.5)-Refer the
projected values.
Estimated targeted reduction in Dye cycle time –Sub processes in start to finish
Sub Process Old machines New machines Time saved
Scouring 3 hrs. 2 hrs. 1 hr
Dyeing 4 ½ - 5 hrs. 3 ½ hrs. 1 hr
Soaping
Softening & Fixture
3 hrs.
1 hr.
2 hrs.
1 hr.
1 hr.
11 ½ hrs. 8 ½ hrs. 3 hrs.
In order to achieve this, we have look in to several machine manufacturers and finally
decided on a Model which can provide (as per the specifications),
Fongs TEC3 high temperature Dyeing machines
Model MINITEC3-1T
Lift reel speed < Max. > - 350 M/min
Capacity - 120 kg
Basic machine
Main kier with self-lubricating PTFE tube, pipework, base frame & layout roller, Variable
loading adjuster, Fabric lifting system with frequency inverter speed control, Nozzle
Fabric tangling releasing device, Heat exchanger with Fuzzy Logic temperature control, - Pre-
filter, Lint collector, Stainless steel centrifugal pump with driving motor, Modulation fill,
Programmable drain and rinse valves, Frequency inverter for varying the speed of main pump
motor, Fresh water metering fill by level control,
Service tank, includes:
* Analog dosing system
(Valid in main tank temperature below 105 deg.C)
* Pneumatic operating valves
* Modulation dosing valve
* A feed pump with stirring function
-Seam detector
-Stainless steel control cabinet with power unit

* FC30 program controller
* Operating panel
* Pneumatic control box
* CF card assembly (capacity not less than 1GB)
Programmable fills & drains, Constant temperature control for service tank by indirect steam
heating instead of the standard -1, AIR+ Advanced intelligent rinsing system
MSR-D Multi-saving rinsing system (For connecting to high temperature underground tank)
- Salt dissolving tank 1
- Second service tank, capacity equal to the first service tank
- Constant temperature control for the second service tank (capacity equal to the first service
tank) by indirect steam heating instead of the standard
- MST Multi-function vertical stock tank
Machine
Fabricated with SS, grade 316Ti/316L/316/1.4571/1.4404/
1.4401 for major parts wetted by dyeing liquid and subject to pressure loading (whilst parts
wetted by dyeing liquid only are fabricated from grade 316L/1.4404).
PD5500 by BSI. Design temperature 140 deg.C. Design pressure 3.0 bar (44 psi). Safety
pressure relief valve for kier, set at 3.0 bar (44 psi) with normal operating pressure at 2.8 bar
(41 psi). Fabric storage chamber, self-lubricating PTFE tube, An XL size nozzle suitable for
fabric weight ranging from 300g/m to 700g/m is provided for each tube.
The nozzle pressure is indicated by a pressure gauge;
Fabric Transportation System
Fabric Lifting System - lifter reel with high traction bars. Each lifter reel is driven by motor
with frequency inverter for speed control. A lifter reel speed indicator in m/min is provided
Automatic tangle release system, the fabric is unloaded from the machine by stainless steel
take-off roller with reduction motor, Seam detector.
Circulation System
The collecting channel is suitably located inside the storage chamber to enhance the rinsing
process. With overflow valve, a centrifugal pump driven by a 3-phase AC motor with
Frequency inverter for controlling the nozzle pressure, Pre-filter, Lint collector, Pipework and
Level Measurement, A safety valve is also provided, The machine is filled and drained by
pneumatic control valves, A level indicator with magnetic float and red-white roller indicator
show the process liquid inside the machine, Fresh water metering fill by level control.
Service Tank
The dyestuff and chemical additives can be prepared in the service tank which is equipped
with pneumatic injection valve (valid in main tank temperature below 80 deg.C
Feed pump stirring function, analog dosing system (valid in main tank temperature below
105 deg.C) and salt dissolving function.
Heat Exchanger
The temperature of the process liquid is controlled by heat exchanger with modulation valve,
diaphragm ON/OFF valves and steam trap.
The performance
Heating rate: from 25 - 100°C, average 5 °C/min from 100 - 130°C, average 2.5 °C/min

(At saturated steam pressure of 7 bar)
Cooling rate: from 130 - 100°C, average 3 °C/min, from 100 - 80°C, average 2 °C/min
(At cooling water supply pressure of 3 bar, 25 °C)
The main switch cabinet is arranged to provide the following programmable machine
functions
(When it is set in the auto mode):
* Programmable fill / drain / overflow rinsing
* Main pump and lifter reel auto control
* Programmable temperature control
* Operator call signal for loading, unloading, sampling, add and program end
* Programmable dosing function
Process time
Standard
Loading
profile
Regarding the working pressure and temperature of TEC machines,
- That temperature inside the kier (Dye vessels of the machine) is created by heat
exchanger (outside the kier). 2.8 bar pressure allows temp inside kier goes above 100
degree Celsius without evaporating dye bath;
Dye Machine Replacement Project -PHASE 01

M/C
No Type
Priority of
removal Replaced by
Capacity
(Kg)
Replacing
Priority
Adding
Capacity
(Lbs.)
Removal of
Current Effective
production (Lbs.)
25 GN 1 1C MINI 264 1 150 -
26 GN 2 1C MINI 264 2 150 -
27 GN 3 1C 550 3 500 -
5 AK 4 1C 550 4 500 -
7 AK 14 2C 1,100 5 1,000 -
8 ECO 18 3C 1,650 6 1,500 2,000
3 AK 15 2C 1,100 7 1,000 -
4 AK 6 1C MINI 264 8 150 -
6 AK 7 1C MINI 264 9 150 150
22 AK 8 1C MINI 264 10 150 400
23 AK 9 1C 550 11 500 -
20 GN 10 1C 550 12 500 300
21 GN 12 1C 550 13 500 3,500
9 ECO 16 2C 1,100 14 1,000 1,600
10 ECO 17 3C 1,650 15 1,500 1,600
32 MK 13 1C 550 16 500 3,500
33 GN 11 1C MINI 264 17 150 200
35 AK 5 1C MINI 264 18 150 -
36 ECO 18 1C 550 19 1,000
37 ECO 19 3C 1,650 20 1,500 2,000
13,948 12,550
1C MINI 7
1C 8
2C 3
3C 3
4C 0
6C 0
21

Methodology……………………..
It was discussed and decided by the Project team to carry out the necessary works as below,
Procedures planned…………..
Project Brief
Project includes replacing of New Dyeing machines with existing & machine relocation
Department –Dyeing
New Machines – total of 34 machines, 22 in phase 1 (2013) and 12 in phase 2 (2014)
Relocation of selected existing machines – Selected locations in the Yarn Dyeing Building

Project Staff
Project Supervisor –Roy Britton
Steam, Compressed air, Condensate, Water, waste water -Dhammika Udage
Electricity –Wijitha Prishantha
Floor & Civil works – Mahesh Laknath
Machine handling – Prabhath Ramanayake
Objective
Reduce waiting time in the Dyeing department
Optimize the Production, Reduce water, Steam, Chemical usage
Project Definition
Scope, Description & Process
Main Project – Machine removal & New Machine installation
Engineering team selected –
Dhammika Udage– Removal & New connections of all Steam lines, Compressed air Lines,
Water Lines, Machine drains including Steam flow meter, ADU’s, Water meters
Wijitha Prishantha– Removal & New connections of all Electrical connections including Total
load calculation+ 15% extra capacity, New Distribution board and line drawing.
Mahesh Laknath- Preparation of Floor with chipped concrete sufficient gradient towards the
Shoe drain, Shoe drains, Mounting Structure concrete, 3 step stairs, Roller Ramp, common
platform for machines, main drain connections, and Floor finish.
Prabhath Ramanayake- Dismantling & removing Old Machines transferring to New Dyeing
area, Exhaust line, Mount, Install & commission.
Project Resourcing
Budget
Allocation for New machines – CIF US$ 2,200,000/- (Phase 1) & CIF US$ 2,100,000/- (Phase 11)
Allocation for Removing, Relocation & Installing new machines - US$ 850,000/-

Documentation & Logistics…
TITLE : AIRFLOW MACHINE INSTALLATION
BOQ NO : DH 5
Bills of Quantities
Labour
Cost
Material
Cost
Total Cost
General
Summery Rs.
72,000.0
0
190,880.0
0
262,880.0
0
Total Machine Nos 13.00
Total Cost Rs. 262,880.00
Contingency @
5% Rs. 13,144.00
Total Cost Rs. 276,024.00
Ite
m
No
Description Unit Qty.
Labour
Rate
Amount Rs.
Material
Rate
Amount
Rs.
Total Cost
Rs.
1
"H iron
150X100/6mm)
Lth 2.00
22,000.0
0
44,000.00 44,000.00
2
"C" Channel
(150X100/6mm)
Lth 4.00 9,500.00 38,000.00 38,000.00
3 Tore steel (10 mm) Lth 20.00 800.00 16,000.00 16,000.00
4
MS plate 10mm
Nos
1.00
30,000.0
0
30,000.00 30,000.00
5
Anchor bolt (12
mm) Nos 18.00 145.00 2,610.00 2,610.00
6
Anchor bolt (14
mm) Nos 15.00 160.00 2,400.00 2,400.00
7
Anchor bolt (16
mm) Nos 20.00 175.00 3,500.00 3,500.00
8 Cement Bgs. 20.00 930.00 18,600.00 18,600.00
9
River Sand Cub 1.00
11,000.0
0 11,000.00 11,000.00
10 Metal 3/4" Cub 1.00 9,000.00 9,000.00 9,000.00
11
Anticorrosive
paints (Green)
4Lts
1.00 3,000.00
3,000.00 3,000.00
12 Oil primer 4Lts 1.00 3,500.00 3,500.00 3,500.00
13 Thinner Nos 2.00 1,000.00 2,000.00 2,000.00
14 Paint Brush 2" Kg 2.00 350.00 700.00 700.00
15 Paint Brush 3" Nos 2.00 385.00 770.00 770.00
16
Grinding wheel 4
1/2"
Nos 4.00 525.00 2,100.00 2,100.00
17 Wire brush Nos 4.00 300.00 1,200.00 1,200.00
18
Welding rods
2.5mm
Kg 10.00 250.00 2,500.00 2,500.00
19
Labour charges of
fabricating cost
/footing
concreting/finishin
g work
Ite
m
1.00 72,000.00 72,000.00 72,000.00
TOTAL CARRIED TO SUMMERY 72,000.00 190,880.00 262,880.00

Project progress…………………
Floor (Foundation)
The existing floor is craggy and damaged. It was decided to Re-concrete the Floor to have an
even surface in order to support smooth mounting of machines
Hence to have a sufficient mass and stiffness to permit the machine to operate in or near a
state of equilibrium we’ve decided to lay Grade 30 concrete since lack of mass and stiffness
causes normal operating forces to generate abnormal vibration levels that reduce useful life .
GRADE 30 Concrete Delivery specification

To lay the new foundation, Old machine Plinths were removed and the floor was prepared
with dowel pins (6” x6”). Although the new Concrete layer was laid, 14 out of 34 new
machines will be mounted on plinths in order to make the working level (machine operator’s
hip level). Hence individual concrete plinths were formed with the floor re-concreting.
Anchoring
Anchor bolts were used to secure the machine to its foundation. Marking for machine
placement was started soon after the 14 day concrete curing period. J-bolts were fixed into
the concrete as it is poured. Size bolts to ensure adequate holding torque and to prevent
them from loosening over time. Exercise care when selecting the grade of bolt, and
determine if the mounting pattern will be rigid enough to lock mounting plates to the
foundation.
Leveling
Before the machine was placed in line with anchor bolts, leveling of the allocated area was
finally checked. It was found that with few exceptions, machinery is designed to operate on a
true horizontal plane. When taking the old plinth level (highest level) & the craggy floor level
(lowest level) the difference was 156mm. To have an economical concrete solution, old
plinths were demolished but even then in actual concrete pouring period some areas were
filled to 200mm whereas the lowest was 72mm.
Initially a Survey telescope was used to level the new concrete floor. The results were within
the tolerance limit, it was not necessary to level each allocated area but a liquid level was
used to level each machine properly. Shims with different thicknesses were used to provide
full footprint support giving a rigid connection between the mounting feet and the
foundation.
Alignment

As for the total alignment of all parts of the machine, final requirement is proper alignment of
the machine's Main vessel, Plaiting Device, Salt Tank, Service Tank, Preparation Tank and
Heat Exchanger. Total machine Leveling was done to ensures that the entire machine-train is
level to the earth.
In progress----
Moving new machine parts to
the designated location

For the Mintec3-1T-120kg machines, as per the description of 0.7 m height drainage, 0.8
height concrete base for dyeing machines and 1 m height working platforms, attached
please see the reference layout drawing. Regarding the 1 m working platform:
- Due to piping arrangement, service tank cannot be move closer to ground level. For
operator to input the chemical / dyestuff, would you consider to plan
some steps in the machines’ 0.8 m height concrete bases.
- When you prepare the 1 m height platform, please also prepare handle around the
platform to protect the workers.
- Please note that the fabric trolley cannot be move too close to the machine. However
for the 120kg which does not carry too much fabric, we don’t think it will create
problem.
Dismantling existing machines
while other machines are in
operation

The commissioning procedure of the high temperature Dye machines all share a common
procedure as,
Post Installation review……..
Ocean Lanka has reviewed the performance of replaced Dyeing machines after the first year
of operation (first 21 machines –other 12 machines were commissioned on 3rd
quarter 2014)
• Remove old technology, costly spare parts in different type of machines.
• Improved its technical features including more reliable measures. Instead of old
MIR/MSR function, introduced AIR+ function to automatically control the salt level
inside the machine.
• Can measure the energy consumption (Electricity) machine itself and can monitor
them well.
• Water fill controls through flow meter (Main process inlet), all the controls, and
programs operated to the accurate water flow meter readings. Improved the accuracy
of water consumption levels.
• Reduced the batch cycle time. Could improve the batches per day from 2 to 3. In some
ISO thermal programs it is 2 to 4 per day.
• The reduced liquor ratio-led to reduce the water, steam, power consumption and
enormous saving on the chemicals.
• Improved evenness in internal Dye concentration.
• Improved internal fabric movement by controlling plaiter and the lifter reel.
• Introduced new internal lint (fabric dust) collection pump which improve the quality of
the fabric, reduce loose lint.
• Improved ergonomics-worker operational easiness. They can work on the floor –
previously they have to work on platforms.
• Use of Preparation tanks saved the batch cycle time, heated exit water when cooling,
prepared chemicals.

Post Project Machine Queue data
Mini
Chamber
01 (250)
Chamber
02 (500)
Chamber
03 (750)
Chamber
04
(1000)
Chamber
06
(1500)
Jan 4.9 4.5 1.6 2.4 1.9 2.7
feb 6.5 7.6 1.9 4 3.1 3.3
mar 11.6 6.2 2.2 5.2 3.8 5
apr 12.6 9.6 3.2 9 6.8 6.5
may 13.4 10.8 4.5 9.8 11.1 13.6
jun 10.6 12.1 7 22.4 17.1 14.1
jul 12.1 12.5 10.9 11 14.6 14.1
aug 9.1 8.3 13.9 10.2 12.7 12.5
sep 11 11.6 17.5 11.9 9.1 5
oct 5.7 12.2 8.1 8.8 4.2 3.4
nov 5.2 6.9 6.4 5.7 4.8 4.3
dec 3.1 2.8 3.6 5.7 2.7 3.7
The sequence of old machine capacity reduction & new machine capacity addition
Year / month
Old Machine
Capacity in Old
Dye House
New Machine
Capacity in Old Dye
House
Dec-12 45440
Jan-13 45440
Feb-13 45440
Mar-13 45440
Apr-13 45440
May-13 38640
Jun-13 41940
Jul-13 41940
Aug-13 41940
Sep-13 37450 0
Oct-13 28850 8575
Nov-13 28850 13525
Dec-13 28850 15725
Jan-14 28850 15725
Feb-14 28850 15725
Mar-14 28850 15725
Apr-14 24300 15725
May-14 17100 15725
Jun-14 0 26175
Jul-14 33875
Aug-14 35,625.00
Sep-14

Oct-14
Nov-14
Dec-14
• Remove old technology, costly spare parts in different type of machines.
• Improved its technical features including more reliable measures. Instead of old
MIR/MSR function, introduced AIR+ function to automatically control the salt level
inside the machine.
• Can measure the energy consumption (Electricity) machine itself and can monitor
them well.
• Water fill controls through flow meter (Main process inlet), all the controls, and
programs operated to the accurate water flow meter readings. Improved the accuracy
of water consumption levels.
• Reduced the batch cycle time. Could improve the batches per day from 2 to 3. In some
ISO thermal programs it is 2 to 4 per day.
• The reduced liquor ratio-led to reduce the water, steam, power consumption and
enormous saving on the chemicals.
• Improved evenness in internal Dye concentration.
• Improved internal fabric movement by controlling plaiter and the lifter reel.
• Introduced new internal lint (fabric dust) collection pump which improve the quality of
the fabric, reduce loose lint.
• Improved ergonomics-worker operational easiness. They can work on the floor –
previously they have to work on platforms.
• Use of Preparation tanks saved the batch cycle time, heated exit water when cooling,
prepared chemicals.
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
Dec-12
Jan-13
Feb-13
Mar-13
Apr-13
May-13
Jun-13
Jul-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Jan-14
Feb-14
Mar-14
Apr-14
May-14
Jun-14
Jul-14
Aug-14
Sep-14
Oct-14
Nov-14
Dec-14
Machine capacity change in New & old Dyeing machines
Old Machine Capacity NewMachine Capacity

----The second aim of the project is to reduce the water usage as Textile Dye process is one of the
most water consuming production process anywhere in the world. Although there are other
inventions like Air Flow machines (a Forced draft is used to create the turbulence inside the machine
to support the dye absorbing process) and most advanced models like “Waterless Dye machines”
(Already one of the most sought after Brand has started an Experimental Factory process in Asian
region) . In the Textile Dye terminology, the water contribution is known as Liquor ratio (L/R); the
ratio between Dry weight of the Fabric and the water requirement for dyeing process (Although there
are more sub processes connected to the total Dye process like Scouring, Washing –as many washing
cycles as the particular fabrication specified, Rinsing etc. which may need different water quantities,
the Liquor ratio is referred to the water quantity required for the total process as an average). In the
Ocean Lanka case, the average L/R was between 8:1 to 9:1. The magnitude of this number will be
visible when we consider an average monthly Dye production of 2,000,000 lbs.
The Specifications of the Machine Model selected for the Project mentions the factory tested L/R as
4:1 but we assume the practical value to be between 5:1- 6:1 due to waste between sub processes,
drain efficiencies etc... Hence this was one of the Intended targets of this Project. As per the
manufacturer’s specifications, they will achieve this through the inside structure- the change in the
fabric path inside the Dye chamber, the high temperature option will reduce the water quantity
needed to dissolve the specified dye quantity and the final absorption will be faster, Change in the
Dye Process Recipe will reduce the time taken for the process through improved methodology,
Change in the Dye Cycle
---- The third aim is to regularise the working temperature of Dye machines. Cotton fabrics needs
lower Temperature surrounding whereas Lycra based or Polyester needs high temperature dye
solution to achieve high efficiency. With existing machines, the Production Planning & Control
Department have to choose Dye batches & swap them across varying Machine capacities and varying
Temperature classes.
----The High Temperature option will give the total Dye cycle time to be shorter than the current
process as the Dye solution will reach the desired temperature faster. This is the most important goal
in this venture as it will give the Machine Cycles per Day from 1.6 (current value) to a minimum of 2 or
could be more (the target would be to reach 2.5)-Refer the projected values.
Estimated targeted reduction in Dye cycle time –Sub processes in start to finish
Sub Process Old machines New machines Time saved
Scouring 3 hrs. 2 hrs. 1 hr
Dyeing 4 ½ - 5 hrs. 3 ½ hrs. 1 hr
Soaping
Softening & Fixture
3 hrs.
1 hr.
2 hrs.
1 hr.
1 hr.
11 ½ hrs. 8 ½ hrs. 3 hrs.

Ocean Lanka (Pvt) Ltd
DYE HOUSE PROJECT
(Project Pre-Costing Approval)
Job Details.
Budget.
Value
Estimated
Value
Contract
Offered
Contract
Offered
(Rs.) (Rs.) (Rs.) (US$)
(1 US$= SLR
128/= )
(1 US$= SLR
128/= )
(1 US$= SLR
128/=)
1 CIVIL
1 Ready mixed concrete (GR30) 1,818,750.00
2 MATERIAL PURCHASES
2.1
Material charges for floor
concreting/slop
maintaining/expansion joint
cutting/chipping/dowelling/BRC
mesh laying/power
troweling/shoe drain foaming
1,620,500.00
2.2
Material charges for machine
footing frame fabricating
platform fabricating
4,370,010.00
2.3
Material charges for machine
footing concreting
666,605.00
LABOUR CHARGES
3
Labour charges for floor
concreting/slop
maintaining/expansion joint
cutting/chipping/dowelling/BRC
mesh laying/power
troweling/shoe drain foaming
1,580,000.00
4
Labour & material charges for
expansion joint sealing
1,300,000.00
5
Labour charges for machine
footing frame fabricating
Platform fabricating
230,000.00
6
Labour charges for machine
footing concreting
514,000.00
7
Epoxy flooring at trolley path
way
568,750.00
8
Material charges for wall &
truss painting
145,660.00
9
Labour charges for wall & truss
painting
176,000.00
10
Mac foil relaying/sheet
removing & relaying/finishing
work
715,000.00
11
AL doors & windows repairing
& replacing
150,000.00
12 Contingency (10% from total) 1,385,527.50
Total For civil(with 10%
contingency) 15,240,802.50

2 ELECTRICAL
1 Electrical Cables 5,279,287.50
2 Cable Trunking 2,769,000.00
3
Power Distribution Panels (2
Panels) 716,950.00
4 Wiring Accessories 199,400.00
5 Panel Earthing 200,000.00
6
Labour charges Cable Trunking
& Cable Laying 400,000.00
7 Trunking Supports & Fasteners 400,000.00
8
Printing Sub Power distribution
Panel Modification 200,000.00
9 Contingency (5% from total) 508,231.88
Total For Electrical(without 5%
contingency) 10,672,869.38
3
MECHANICAL, Piping ,
Accessories
1 Service Line Pipes
1.10
Service Line Pipes for Minitec
Machines (SS and CS Pipes) 1,080,100.00
1.20
Service Line Pipes for Miditec
1T Machines (SS and CS Pipes) 1,322,100.00
1.30
2T Machines (SS and CS Pipes) 1,066,150.00
1.40
3T Machines (SS and CS Pipes) 779,775.00
2 Fittings and other Accessories for Service Lines
2.10
Fittings and Accessories for
Service Lines - Minitec
Machines 3,868,431.00
2.20
Service Lines - Miditec 1T
Machines 3,906,606.00
2.30
Service Lines - Miditc 2T
Machines 3,499,640.00
2.40
Service Lines - Miditc 3T
Machines 2,727,720.00
3
Material for Service line Laying, Bracketing,
Insulation & Jacketting
3.10
Service line Laying, Bracketing,
Insulation & Jacketting- Minitec
Machine 408,800.00
3.20
Insulation & Jacketting-Miditec
1T Machines 429,570.00
3.30
Insulation & Jacketting-Miditec
3.40
Insulation & Jacketing-Miditec
4
Consumable
and

Workmanship
4.10
Consumable and Installation -
Minitec Machines 497,000.00
4.20
Miditec 1T Machines 633,000.00
4.30
4.40
5 Contingency (5% from total) 1,081,361.60
Total For Mechanical with 5%
contingency 22,708,593.60
4 Machinery
1.00 MINITEC3-1T X 7 Units (CIF) 73,902,080.00 577,360.00
2.00 MIDITECC3-1T X 6 Units (CIF) 73,620,480.00 575,160.00
TOTAL COST FOR THE NEW
DYEING MACHINES 276,035,840.00 2,156,530.00
Total for the project Phase I 41,405,376.00 48,622,265.48

Three Chamber High Temperature Dye Machine

High Temperature Drain arrangement

Post-Project Time Management Analysis
ID Name Duration Start Finish
0 DYE HOUSE PROJECT - ACTIVITY - (PHASE 02) 154.13 days 5/4/14 8:00 AM 9/29/14 3:00 PM
1 REMOVE THE GN-28,GN-29 10 days 5/4/14 8:00 AM 5/13/14 2:00 PM
2
FLOOR PREPARATION & OLD MACHINE
CONCRETE PLINTH REMOVING 5 days 5/18/14 8:00 AM 5/22/14 4:00 PM
3
FLOOR CONCRETING & POWER TROWELING
WORK GN-28,GN-29 AREA 1 day 5/23/14 8:00 AM 5/23/14 5:00 PM
4 CONCRETE CURING PERIOD 7 days 5/24/14 8:00 AM 5/30/14 3:00 PM
5
WORK TSF 17,18,19 AREA 1 day 5/26/14 8:00 AM 5/26/14 5:00 PM
7 MACHINE UNLOADING 6 days 5/30/14 8:00 AM 6/4/14 3:00 PM
8 INSTALLATION OF MD3-05 6 days 6/5/14 8:00 AM 6/10/14 3:00 PM
9
MD3-05 MACHINE WIRING WORK & PIPING
WORK 7 days 6/11/14 8:00 AM 6/17/14 3:00 PM
10
MD3-05 MACHINE COMISSIONING & HAND
OVER TO PRODUCTION 5 days 6/18/14 8:00 AM 6/22/14 3:00 PM
11 REMOVE THE ECO - 34 5 days 6/23/14 8:00 AM 6/27/14 5:00 PM
12
FLOOR PREPARATION & OLD ECO -34 AREA
MACHINE CONCRETE PLINTH REMOVING 3 days 6/28/14 8:00 AM 6/30/14 3:00 PM
13
WORK ECO - 34 AREA 1 day 7/1/14 8:00 AM 7/1/14 5:00 PM
16
MD6 - 01 MACHINE WIRING WORK & PIPING
WORK 10 days 6/13/14 8:00 AM 6/22/14 1:00 PM
17
MD6 - 01 MACHINE COMISSIONING & HAND
18 REMOVE THE ECO - 30 5 days 6/30/14 8:00 AM 7/4/14 5:00 PM
20
WORK 7 days 6/16/14 8:00 AM 6/22/14 3:00 PM
21
23
WORK 7 days 6/18/14 8:00 AM 6/24/14 3:00 PM
24
25 REMOVE THE TSF-12,TSF -13,TSF-14 15 days 7/10/14 8:00 AM 7/24/14 12:00 PM
26
27
30
WORK
10 days 7/7/14 8:00 AM 7/16/14 3:00 PM

31
32 INSTALLATION OF MD4-02 7 days 7/8/14 3:00 PM 7/15/14 12:00 PM
33
WORK 8 days 7/15/14 8:00 AM 7/22/14 3:00 PM
34
35 REMOVE THE ECO-31,ECO-36,ECO-37 13 days 7/30/14 8:00 AM 8/11/14 12:00 PM
36
37
39 INSTALLATION OF MD2-05 5 days 8/8/14 3:00 PM 8/13/14 12:00 PM
40
WORK 7 days 8/13/14 8:00 AM 8/19/14 3:00 PM
41
43
WORK 7 days 8/14/14 8:00 AM 8/20/14 3:00 PM
44
46
WORK 8 days 9/3/14 8:00 AM 9/10/14 3:00 PM
47
49
MD1-08MACHINE WIRING WORK & PIPING
WORK 6 days 9/1/14 8:00 AM 9/6/14 4:00 PM
50
52
WORK 6 days 9/6/14 8:00 AM 9/11/14 3:00 PM
53
55
WORK 6 days 9/9/14 8:00 AM 9/14/14 3:00 PM
56

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