Presentation on Envoy Textiles Limited

1. Presentation on
Industrial Training in Envoy Textiles Limited
BGMEA University of Fashion
and Technology

2. Supervising Teacher
Prof. Dr. Engr. Abu Bakr Siddique
Faculty of Textile Engineering
BGMEA University of Fashion and Technology (BUFT)
Presented By Presented To
Dept. of TE
BGMEA University of Fashion &
Technology.
Lecturer, Dept. of TE
BGMEA University of Fashion &
Technology.
Name ID Department
Hasan Syead Onike 161-100-0-155 Textile Engineering

3. Introduction
Envoy Textiles Ltd., LEED Certified Platinum, by United States Green Building Council
(USGBC), USA leading denim fabric producer in Bangladesh since 2005, started the commercial
production in early 2008. This industry is professionally managed and technically sound organization
located at Bhaluka, Mymensingh (60 km North of Dhaka City).
The plant is fully integrated with State of the Art technology and machinery from USA, Japan, Korea,
Switzerland, Italy, India& Belgium.
Envoy Textiles Ltd. produces indigo denim fabric with the best and most modern ROPE DYEING
Technology. With ever increasing acceptance of quality fabric and increase in demand the production
capacities were expanded at regular intervals. The target production capacity of Envoy Textiles Ltd. is
20 million meter per year.

4.  Major Buyer of Envoy:
 Google view of Envoy Textiles Limited:

5.  Vision & Mission of the company:
 To achieve a global dominance through
 Consistency in product supply.
 Continuous product innovation.
 Customer orientation and cost effectiveness.
 Decrease the percentage of wastage.
 Safe & hygienic working environment to workers.
 Customer satisfaction by all means.

6. Corporate Social responsibilities (CSR)

7. Denim fabric manufacturing flow chart:
Sample analysis at R & D department
↓
Production planning
↓
Ball Warping
↓
Rope Dyeing
↓
Long Chain Beaming
↓
Sizing
↓
Weaving
↓
Finishing
↓
Inspection
↓
Packing
↓
Dispatch

8.  Raw Materials
1.Cotton fiber
2.Viscose fiber
 Types of yarn used:
1.Rotor yarn
2.Ring yarn
3.Slub yarn
4.Polyester yarn
5.Lycra yarn
Yarn count :
For warp: 6, 7, 9, 10. 12, 20, 26 ( Normal + Slub)
For weft : 6, 7, 9, 10. 12, 20, 26 ( Normal + Slub)
Polyester: 150D, 300D, 450D, 600D

9.  Ball Warping
Ball warping is the process of warping in which log is
prepared for the rope dyeing. Here magazine type of creels
is used for the creeling of yarns in the form of cheese.

10.  Description of ball
warping machine:
Unit-01
Unit-02
M/C No Brand Name Country of Origin Creel Capacity Speed(mpm)
1 GRIFFIN USA 456 300
2 GRIFFIN USA 456 300
3 GRIFFIN USA 456 300
4 MORRISON USA 528 300
M/C No Brand Name Country of Origin Creel Capacity Speed(mpm)
1 Karl Mayer China 456 300
2 Karl Mayer China 456 300
3 Karl Mayer China 456 300
4 Karl Mayer China 456 300
5 Karl Mayer China 456 300

11. Rope dyeing consists of twisting the yarns into a rope that is then quickly
dipped into indigo baths. This dyyeing is considered a superior dyeing
technology where the dyeing uniformity achieved is better than other Indigo
Dyeing technologies like Slasher Dyeing.
Rope dyeing
 Shades that are processed at Envoy Textiles Ltd
1. Indigo
2. Black
3. Topping
4. Bottoming

12. Long Chain Beamer (LCB)
 Long Chain Beamer:
In Long Chain Beamer, the yarn alignment in the dyed rope is change from a rope form to a sheet form.
The basic purpose of long chain beamer is to open the rope into a sheet form of yarn and wind onto a
sizing beam which in transferred to the sizing machine.
 Function of LCB:
I. Individualization of dyed rope with
the help of reed
II. To make quality full beam of warp
III. To make the yarn suitable for sizing
process

13.  Working Procedure:
1 Receive rope from dyeing section
2.Set up the load under accumulator
3.Do the reed denting
4.Set up reed width
5.Load empty beam on the machine
 Description of machine in LCB SECTION:
M/c No Brand Name Origin
1,4-10 GRIFFIN USA
2,3 MORRISION USA
11,12 KARL MAYER CHINA
Section 1
Section 2
M/c No Brand Name Origin
1-12 KARL MAYER CHINA

14. Sizing
The process of applying a protective adhesive coating upon the yarns
surface is called sizing.This is the most important operation to attain
maximum weaving efficiency especially for blended and filament yarns.
Chemicals used in sizing section
 Starch
 Temsize
 Softener
 Wax
 Size tex-5
 Kollo tex-5
 Kollo tex-750
 Quick solan SPR
 Binder

15. Size Pick % =
Sized Yarn Count = Count of Unsized Yarn×
 Sizing Defect:
 Loose
 Tight
 Beam stain
 Size spot
 Less width
 Slack end
 Sizing Equation
× 100%

16. Weaving
 Weaving:
Weaving is a process of interlacement of two sets of threads
namely the warp and weft threads in lengthwise and crosswise
respectively to form a fabric.

17.  Production Calculation
Let,
Machine rpm =750
PPI= 49
Efficiency =92%
We know,
Production / shift = (RPM / PPI) *Efficiency
= (750 /49 /39.37) * 60 * 8 * 92%
= 171.69 m /shift

18. Toyota Air jet loom
Picanol Optimax Rapier loom Tsudakama Air jet loom
Picanol GT-Max Rapier loom
Weaving Machines

19. Finishing Section

20.  Objectives
 To improve the appearance of the fabric.
 To improve the feel of the fabric by softening, stiffening etc.
 To impart special properties to the fabric for specific end uses.
 Finishing Faults
Crease mark
Unsinged
Width variation
Finishing m/c stop
Waviness
Finishing oil spot
Burn selvedge
Back staining
Low stretch
Low shrinkage & Chemical spot

21. Quality Assurance & Lab

22.  Quality Assurance
Quality assurance (QA) is a way of preventing mistakes and defects in
manufactured products and avoiding problems when delivering solutions or
services to customers.
The following job is doing by quality assurance:
 Inspection
 Laboratory (Physical & Chemical)
 Clearance
 Fabric Inspection Method
There is various fabric inspection systems such as follows:
 4 Point System
 10 Point System

23.  Research and Development
 Process flow chart of R& D:

24.  About R & D
Research & Development department is an important
department for any textile industry. ETL has also a Research
& Development (R&D) with modern amenities which
correlates very well with the upcoming new product. The
main goal of R&D department is finding good thing that are
convenience for the company and they try to implement it in
production to improve the quality of fabric.
It is divided into three sub-divisions such as:
 Washing Section
 Sewing & Sample Section
 Fabric Analysis & Development

25.  UTILITY FACILITIES
Introduction
Production and profit are closely related. In order to get a quality final product it needed fresh
raw materials as well as effective manpower and machinery in good working condition. Utility in
conjugation with the three M‟s pays a vital role to maximize the production as well as profit.
Utility Ensure
 Power supply
 Water supply
 Steam supply (By boiler)
 Compressed air supply (By Air compressor)
 Exhaust air handing (By vacuum planning system) Gas supply
 Workshop facility
 Civil work
 Waste water treatment (By effluent project)

26.  Effluent Treatment Plant
In a textile industry water is polluted by dye house effluent. Dye house effluent means
waste water from dye house which discharges into surface water and contains various
types of wastage which is very harmful to environment. These hazard chemicals are
treated in ETP plant through some process by using chemicals.
Capacity: 200 m3/Hr and around 3400 m3/Day

27. THANK
YOU