Givensee Group of Industries Ltd.

1. 1
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT OF Givensee Group of Industries Ltd.

2. 2
INTRODUCTION
By achieving practical knowledge it is possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equality necessary in association with the theoretical knowledge.
The industrial attachment is the most effective process of achieving practical experience. University education provides us vast theoretical knowledge as well more practical knowledge, despite of all these Industrial Attachment helps us to be familiar with technical support of modern technology, suitability about various processing/operation stages.
It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, production cost analysis, inventory management, purchasing, utility and maintenance of machinery and their operation technique etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. Industrial attachment makes us reliable and improves courage and inspiration to take self-responsibility.
We had the opportunity to perform the industrial attachment with Givensee Group of Industries Ltd. During 42days (6-Weaks) long attachment, We studies the man, Machine, material expects of the Batching, Dyeing section (Knit fabric), Finishing section, Quality Control, Lab, Knitting section, store & inventory control of the mill. According to my studies there we have prepared the following report and would like to present.
We have prepared this report according to the guideline given by the University authority, which will lead to a strong guideline and milestone for our future career.

3. 3
Object of Industrial Attachment
B. Sc. in Textile Technology is the combination of Theoretical knowledge along with the practical experience. We as the Graduates of Textile Technology must acquire adequate practical knowledge to combat with the challenge that we will face in future. This is why 'the mid-course' industrial training has been included in our academic curriculum.
The main objective of this training is to comprehend our theoretical knowledge along with the practical knowledge. It also enables us to orient ourselves with the practical environment that we will work in future. We systematically learned about various steps of wet processing.
Moreover we know about the man management technique. We also learned about dyeing techniques and quality assurance system.

4. 4
CHAPTER-1
PROJECT
DESCRIPTION

5. 5
Company Profile
Introduction:
Hotapara Garments LTD.was established in late 2005 and is currently one of the largest
knitwear manufacturing factories in Bangladesh. It has been exporting automatic circular
knitted items to North American and European retailers. Its operations are spread over a floor
space of more than 180000 sq. Ft. With a net export of over USD 12 Million in 2011, we are
ready to support our customer with their new knitwear collections for the upcoming seasons.
Hotapara Garments LTD. can produce various types of fabrication such as Single Jersey, Rib,
Interlock, Pique, and Drop Needle, 2-Thread / 3-Thread Fleece and feeder stripe repeats.
Ourdyeing section has capabilities of dyeing under atmospheric pressure in case of cotton fabric
andalso it can dye viscose, nylon and polyester fabrics under pressure dyeing conditions. Some
ofour common product lines are T-shirt, Polo shirt, Knitted Jackets and bottoms.

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Hotapara Garments LTD. has a successful record of customer satisfaction. It is also a highly
Compliant unit in terms of social standard. It has a very strong quality management team,
whoare continually reporting their finding to the board of directors. This ensures our
commitment tothe customers on their quality requirement.
Hotapara Garments LTD. has a daily production capacity of 40,000 pieces of T-shirts, Polo shirts
and other knitted items and its major raw materials such as yarn and accessories are sourced
fromother group sister concerns such as Givensee Spinning Mills LTD. and GivenseeGarment,
Accessories LTD.
Our Spirit:
Our Market base experience, research techniques and razor- sharp analytical skills have
enabled us to leverage opportunities in our existing and emerging markets.
Our Vision:
To become the largest multinational embellishment corporate in garments Industry

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Infrastructure:
Being one of the earliest composite units in Bangladesh, HGL has a very robust infrastructure in
Terms of machinery, floor layout and space distribution. The factory is well equipped with top
of.The line machinery along with adequate a pares in order to ensure smooth operation and
efficient performance
COMPANY NAME HOTAPARA GARMENTS LTD.
Factory Address BOKRAN, MONIPUR GAZIPUR.
Head Office Givensee Group of Industries
House # 06, Road # 13
Sector # 03, Uttara Model Town
Uttara, Dhaka, Bangladesh.
Tel: 8932813, 8913802
8961936jkj
Mail: rubel@givenseegroup.com
Establishment Year 2005
Banker MERCHANTILE BANK LTD
Production Capacity 1.2 MILLIONE PER MONTH
Dyeing capacity 12000KGS PER DAY
Knitting Capacity 8000KGS PER DAY
Sewing Capacity
Basic T- Shirt 40000
Polo shirt 32000
Fancy Item 25000
Floor space 120000 SFT.
Yearly Turnover US$14.50 MILLIONE PER ANNUM(APRX)
Total Workers 1850
Minimum Order Quantity 5000 PCS
Shipment lead time
associated with
60 DAYS

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Different Departments:
To ensuring smooth running of various activities, some departments are available they are
given below:
Knitting Section:
 Knitting
 Grey Fabric Inspection
 Batch Section
Knit Dyeing Section:
Store house for Dyeing & Chemicals
 Dyeing Section
 Lab & QC
 Finishing
 Single Jersey(S/J)
 S/J with Lycra Alt/Full Feeder
 Heavy Jersey
 Honeycomb Pique
 Diamond Pique
 Lycra Pique
 Single Lacoste
 Double Lacoste
 Interlock
 1x1 Rib
 2x2 Rib
 1x1 Rib
 2x2 Rib with Lycra with Lycra
 French Terry
 Yarn Dyed
 Polo Shirt (Basic/Fancy)
 T-Shirt(Basic/Fancy)
 Sweat Shirt
 Tank- tops
 Skirts & Dresses
 Ladies Wear
 Children’s Wear
 Sports Wear
 Under Garments

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Garments Section:
 Merchandising
 Sample
 Production
 Packaging
Maintenance
 Electrical
 Mechanical
 Utility Section
 Accounts & Commercial Departments
 Planning Department
 HR Section
 Admin Section
Product Mix:
YARN-
100% Carded; count 20, 22 24, 26, 28, 30, 32, 34, and 40
100% Combed: count 2-. 22, 24, 24, 28, 30, 32, 34, 40
100% O.E Yarn: count 10, 12, 14, 16, 18, and 20
CVC (65% Cotton + 25% Polyester)
Lycra (40d, 80d)

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FABRIC:
1.Single jersey with or without Lycra 2.Ribs -1x1; 2x1; 2x2; plain or with Lycra
3.Polo Pique with or without Lycra 4.Interlock- plain or with needle drop
5.Single or Double Lacoste with or
without Lycra
6.Waffle or Thermal Fabric
7.Terry Fabrics - blended or 100%
Cotton
8.Four track fancy design fabric
Strip fabric
9.Three thread fleece 10.Heavy Jersey
Annual Raw Materials Requirement:
Dyes chemical Yarn Fabric
69600 kg 100000 kg 2640000 kg 2400000 kg
Production Capacity:
GARMENTS
Woven Items : 300,000 pcs per month
Knit Items : 800.000 pcs per month
Sweaters : 1,400,000 pcs permonth
TEXTILE
Yarn : 900,000 lbs.
Knitting : 240,000 kg
Dyeing : 300,000 kg

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Joint Venture:
ZAHINTEX INDUSTRIES 1
Soydana, Board Bazar
Gazipur.
3. ZAHINTEX INDUSTRIES 3
ZAHINTEX INDUSTRIES 4
Bokran, Monipur,
Gazipur.
5. ZAHINTEX INDUSTRIES 7
ZAHINTEX INDUSTRIES 8
Araishaprashad, Kaultia,
Gazipur.
7. MASUMA KHATUN TEXTILE
Bokran, Monipur,Gazipur.
9. GIVENSEE GARMENTS LIMITED
Hotapara,Gazipur.
11. GIVENSEE GARMENTS ACCESSORIES LTD
Araishaprshad, Kaualtia,
Vaoul, Mirzapur,Gazipur.
2. ZAHINTEX INDUSTRIES 2
74/A ,Konabari,
Gazipur.
4. ZAHINTEX INDUSTRIES 5
ZAHINTEX INDUSTRIES 6
Araishaprashad, Kaultia,
Gazipur.
6. ZAHINTEX INDUSTRIES 9
Bishia, Kuribari,
Gazipur.
8. HOTAPARA GARMENTS LIMITED
Bokran, Monipur,
Gazipur.
10. GIVENSEE WASHING LIMITED
Bokran, Monipur,
Gazipur.

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CHAPTER-2
MANPOWER
MANAGEMENT

13. 13
MANPOWER MANAGEMENT
Management System:
 Buyer sample is send to Responsible Management.
 Matching is done by lab in charge.
 Sample is prepared by Ass. Dyeing Manager.
 Sample is send to the buyer for approval.
 Approved sample is returned and taken as std. Sampleforbulk production.
 Asst. Dyeing Manager gives responsibilities to production officer.
 Then production officer, with the supervisors start bulk production.
 On line and off line quality check is dome by Lab in charge and A. D.M.
 After dyeing finishing in charge controls the finishing process with the supervision of
production officer.
 After finishing the material is checked by Ass. Dyeing Manager.
 Finally D.M checks the results with A.D.M and decision is taken for delivery.
Shift Schedule:
Per shift is 12 hrs.
1st shifts 8 am -8 pm
2nd shifts 8pm -8am

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DEPERTMENT NO.OF EMPLOYEE
G.M (PRODUCTION) 01
P.M 01
QC. Manager 02
H.R officer 01
Trainer 10
Senior H.R officer 01
Mercendiser 03
Well fair officer 01
Flore in charge 01
Line chef 05
Production reporter 01
pion 01
supervisor 15
input man 18
Line quality 08
Sewing operator 490
cutting 06
Sewing helper 320
Sewing mechanical 10

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security 13
Office stuff 02
Line quality 10
sample 15
Finishing 260
Quality 63
utility 28
Designation
No of employee
director 01
Group fire officer 01
Side engineer 01
Assistant officer 01
Mechanical engineer/dyeing 01
Store assistant 04

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DYEING SECTION No of employee
Dyeing manager 01
Dyeing assistant manager 01
Assistant production officer 04
Shift in charge 03
supervisor 02
Assistant supervisor 04
Dyeing operator 52
Dyeing helper 21
fitter 01
total 88

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LAB SECTION
:
LAB in charge 01
Assistant in charge 01
LAB technician 04
LAB assistant 03
TOTAL 09
BATCH SECTION
Batch in charge 01
Batch supervisor 02
Batch supervisor 13
TOTAL 16
Finishing manager
01
Q.C. in charge 01
Assistant q.c. in charge 01
Compactor technician 01
supervisor 08
Q.C. 07
Q.I. 05

18. 18
Operator 20
helper 47
Sample man 05
Total 96

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KNITTING SECTION:
Knitting manager 01
Mechanical engineer 01
Shift in charge 02
Q.C. in charge 01
Filter 05
mechanics 03
Q.C. 06
Operator 40
Helper 12
TOTAL 78
OTHERS
WORKSHOP 01
Ometer 01
Leath supervisor 01
Security guard 10
Drive 06
Office pion 12
loader 14
Stuff 08

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CHAPTER-3
LAY OUT PLAN

21. 21

22. 22
CHAPTER-4
MACHINE
DESCRIPTION

23. 23
DYEING SECTION
• Total Dyeing Machine: 27
• No. of sample Dyeing Machine: 12
• No. of Bulk Production Dyeing Machine: 15
Dyeing Machine:
AIR TURNING MACHINE
No. of machine
Machine Name (Functional)
Manufacturer
Manufacturing Country
Model
Brand
Capacity
Function
:02
: AIR TURNING MACHINE
: DONG NUM INDUSTRIAL CO.LTD.
:KOREA
: DNAT-400
: DONG NUM
: 20000
: To reverse the fabric front side to back side.
Machine Name Brand Model Origin Capacity /
M/c
No.of
kg M/C
ED-8-250 2000 1
ED-4-250 1000 1
Overflow winch Tungshing ED-8-250 Honkong 600 4
(Soft Flow) ED-2-250 400 5
ED-1-250 200 2
ED-5-100 70 2
High Pressure Tungshing ERD-2-250 Honkong 400 1
Sample (High
Pressure)
Tungshing ERD-5-15 Honkong 15 1
30 2
Sample Local Banglade
sh
50 1
20 2
10 5
Total M/C 27

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Benefits of overflow winch machine:
1. Efficient washing effect.
2. Less water consumption.
3. Less temperature shocks when filling with cold water.
4. Precise calculation of water consumption.
Fully automatic function:
1. Automatic salt & soda dosing system
2. Automatic chemical injection system
3. Automatic heat exchanging process
Components of M/c:
1. Mixing tank:There is a tank in this machine. Every chemical are used to put here. Here all
the chemicals, dyes & salt are mixing for delivery into machine.
2. Unloading reel: The fabric is used to unload from the machine by this part. The number
of unloading reel is equal to the number of nozzle in the machine. It is rubber coated which
helps to unload fabric easily.
3.Monitor:It is situated at the right side of the machine. The commands are shown in the
monitor & the operators can work from these commands. There are also some buttons for
working properly & to obey these commands.
4. Alarm Box: There is an alarm box on the upper side of the machine. There are also some
buttons to operate the machine & to stop the alarm.

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5. Three detectors:There are 3 detectors on the above of the nozzle are as follows:
a. Temperature detector: It is at the left side between these 3 detectors which can detect
the temperature of the main tank.
b. Fabric turning pressure detector: It is at the middle of these 3 detectors. It can detect
the pressure at which the fabric turning.
c. Atmospheric pressure detector: It can detect the atmospheric pressure of the main
tank.
6. Plain board:It is situated at the right side of the machine.
7. Waterlevel:There is a water level to know the amount of water in the main tank.
It does not give correct result but it can give an approximate result.
Process Requirement:
Software used:
In this factory for total dyeing management usedSETEX – GERMANY.
Key accessories used in this factory for pretreatment to complete dyeing are:
-Salt tank.
-Mixing tank.
-Machine tank.
-PH meter.
-Eye protecting glass.
-Hand gloves.
-Sewing machine.
-Gum boot.
-Hand lifter for carrying the batch.

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N.B:Fixing process is done during dark or deep shade.
N.B: SAS: If shade% is more than salt is added before dyes add. Sometimes salt is adding two
times in deep shade.
DAS:If shade% is less then salt is added after dyes adding
Work instruction of Bulk dyeing Machine:
 At first should to clean the machine.
 Should to check electrical connection of the machine.
 Should to take the working description of daily work from shift operator,
 Senior production officer or production officer.
 To take the fabric from supervisor of batch section according to
 Production plan +Batch lot No. for coloration.
 By observing the indicated program of the machine described abovethe fabric dyeing
program sheet, should to set the program no. kept @ computer memory attached with
the dyeing machine.
 Should to be kept/write down the batch no./program no./party
 Name/order ref./color name/into dyeing m/c/ comp memory.
 Should to use the color into m/c.
 M/c should to run /set by program no.
 Dyes/chemical should to mix from the given chart /chart got from m/c
 During the running of program.
 Coloration running according to the computer program of m/c.
 Sample should to collect from the coloring processed fabric into m/c
 When computer panel program show sample.
 To check shade, collected sample is sent to the lab,
 Water inside m/c is drained out if the sample is "ok" by lab.
 Hot wash is done by filling the water inside m/c of the colored fabric.
 After the drain out of water soft wash of the fabric is done using soft
 Wash chemical by filling water into m/c.
 Then dyed /colored fabric is dropped from the m/c if s sent to the
 Dewatering section with batch card by trolley.

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Checklist before operation:
 Checking the program
 Machine set-up.
 Fabric weight.
 Fabric quality.
 Yarn quality.
 Collar design (Tipping/ solid).
 Rib designs (Normal/Lycra).
 Chemical availability,
 Power availability.
 Steam availability.
 Water availability.
 Compressed air.
 Manpower availability.
 Fabric stitch is done properly.

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Finishing Section
Finishing Machine:
Machine
Name
Brand Model Origin Serial
No.
No.
of
Machine
Capacity
M/C (kg)
Ball
owningSqueeze
r
Corino Italy 1 7000
Ball
owningSqueeze
r
Dongnam DNBS-1600 Korea DN-053, DN-
054
2 8000
Tensionless
Dryer
Dongnam DNTD-2400 Korea 0527, 0653 2 1200
0
Soft Setting Dongnam 1400 Korea 0553, 0830 2 1200
0
Tube Tex
Compactor
Tube Tex BM-
10043(SP)
USA 10043, 10187 2 1400
0
Tumble Dryer GuangzhouPa
yne
China 3 30
Air Turning Dongnam DNAT-400 Korea DN-0829,
DN-0532
2 2400
0
Wet Calendar Dongnam DNW - 1400 Korea DN - 0531 1 6000
Fabric
Inspection
SAFOT JD 6A- 40S China JD 1 A - 40 1
Total = 16

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Lab Section
Wet Lab Machine
Machine name Brand Origin Model Serial no. Test Name
Capacity
(pot)
Qty
.
Spectrophotometer
DATA
COLOR USA 600TM Recipe Analysis 1
Light Box VERIVIDE UK CAC-120 Lab Dip Shade Check 1
Electronic Balance
Meter SHIMADZU JAPAN AUY-120 Weight Measuring 1
Lab Dip Dyeing
M/C-1 Taiwan IR 12SM 8102 12 1
Lab Dip Dyeing
M/C-2 IRDYER IR 12SM 8085 12 1
Lab Dip Dyeing
M/C-3 IR 24SM 6337 Lab Dip Dyeing 24 1
Lab Dip Dyeing
M/C-4 China HB-12SF 11163 12 1
Lab Dip Dyeing
M/C-5 RAPID L-24C 5620 24 1
Dryer Taiwan R-3 92706 Lab Dip Drying 1
Total = 9

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Physical & Chemical Lab Machine
Machine
name Brand Origin Model Serial no. Test Name
Test
method
Qty
.
Crock meter
CROCK
MASTER UK
67
0 670/07/2060 Color Fastness to Rubbing
ISO 105-
X12 1
Q-SUN XENON USA
0SU11B0
2
09.3815.32.
B02 Color Fastness to Light
ISO 105-
B05 1
Wascator ELETROLUX Sweden
FOM71-
CLS
98670116
3 Dimensional Stability ISO 6330 1
Tumble Dryer SIEMENS Poland WDT 2 Shrinkage Test 1
Tumble Dryer WDT 45 1
Rotter wash RAPID China HB 125F Dimensional wash
ISO 105-
C06 1
Pilling Test M/C FYICHINA
YG511-
IV ..0106 Pilling Test ISO 12945-1 1
Precision Woven Y902 ..0906
Color Fastness to
Perspiration
ISO 105-
E04 1
pH meter HANNA
HI.98129,
30 pH & EC/TDS test ISO-3071 2
Total = 10

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Knitting Machine Profile
S/L
No. Brand Origin M/C Grade Dia. Gauge Capacity Qty.
1 17 24 250 1
2 18 24 250 1
3 19 24 250 2
4 20 24 250 2
5 21 24 250 2
6 22 24 250 3
7 23 24 250 4
8 FUKAHAMA TIWAN S/J-SH-2BFA 24 24 250 4
9 25 24 250 3
10 26 24 250 3
11 27 24 250 1
12 S/J-SH-2XFA 28 24 250 2
13 30 24 233 1
14 RIB-SH-2BIR-2 30 18 233 1
15 32 18 200 1
16 34 18 200 2
17 36 18 235235 22
18 30 24 200 1
19 Interlock SH-BIR-2 32 24 200 1
20 34 24 233 1
21
SHIMA
SEIKI GERMANY
FLAT KNIT SFF-
152T 60 14 1200 PCS 2
22 LOCAL
BANGLADES
H
FABRIC
INSPECTION M/C 2
Total = 42

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Utility Section
Utilities & Supporting Equipment
Machine Name Origin Capacity Unit
Gas generator Austria 1064 Kw 3
Diesel generator UK 400 Kw 3
Gas boiler LC - 11
Taiwan
8.4 Ton 4
Air compressor USA 13 m3/hrs 11
Air dryer USA 13 m3/hrs 15

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CHAPTER- 5
RAW
MATERIALS

34. 34
RAW MATERIAL
Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in case of continuous production & for high quality fabric. The EKCL always try to use high
quality raw material to export high quality and world class product.

35. 35
Types of Raw material:
1. Yarn
2. Fabric
3. Dyes
4. Chemical & Auxiliaries
1. Yarn:
• Cotton
• Polyester
• Lycra
• Viscose
2. Fabric:
• Single Jersey(S/J)
• Heavy Jersey
• Honeycomb Pique
• Diamond Pique
• Single Lacoste
• Double Lacoste
• Interlock
• 1x1 Rib
• 2x2 Rib
• 2x2 Rib with Lycra with Lycra
• French Terry
• Terry Fleece

36. 36
3.Dyes:
Serial
No.
Trade Name
Type of
Dyestuffs
Origin
1 COLVAZOL YELLOW-3RS
Reactive
China
2 COLVAZOL YELLOW 4GL (150%)
3 COLVAZOL.RED 3BSN
4 COLVAZOL BLACK-B
5 COLVAZOL YELLOW-4GL
6 COLVAZOLYELLOW-RR
7 COLVAZOL RED-RR
8 COLVAZOL BLUE-RR
1 Shulofix Yellow 3RS(Y 145)
Reactive
2 Shulofix Red 3BS (R 195) China
3 Shulofix Black B
1 Sumifix Brilliant Blue R special gran.
Reactive
Singapore
2 Sumifix Supra Blue BRF 150% gran.
1 STARFIX YELLOW 3RFN 150%
2 STARFIX YELLOW 4GL 150%
3 STARFIX RED 3BFN 150%
4 STARFIX BLACK B 150%
5 STARFIX BRILL BLUE R(SPL) 150%

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6 STARFIX T.BLUE G 150%
7 STARFIX BLUE BRN 150%
1 NOVACRON® YELLOW FN-2R
Reactive
Switzerland
2 NOVACRON® BRILLIANT RED FN-3GL
3 NOVACRON® YELLOW S-3R
4 NOVACRON® RED FN-R
5 NOVACRON® BLUE FN-R
6 NOVACRON® TURQUISE H-GN
7 NOVACRON® SUPER BLACK G
8 NOVACRON® BRILLIANT BLUE FN-G
1 TERASIL® GOLDEN YELLOW W-3R
Disperse
Switzerland
2 TERASIL® YELLOW W-6GS
3 TERASIL® RED FBN CONC
4 TERASIL® RED WW-FS
5 TERASIL® RED W-RS
6 TERASIL® RED W-4BS/W-4BS-01 150%
7 TERASIL® NAVY W-RS
8 TERASIL® BLUE W-BLS
9 TERASIL® BLACK W-NS

38. 38
Chemicals& Auxiliaries
S/L Trade Name Technical Name Origin
1 CETATEX PC H2O2 killer England
2 Avosperse AD Sequestering Agent
3 STABILISER A pdr Stabilizer for H2O2
4 CETALUBE NFL Anti-creasing Agent
5 CETAFIX R Fixing Agent
6 Texsanscour CS Detergent Korea
7 Texsantifoam AF Antifoaming Agent
8 ALBAFIX® ECO Fixing Agent Switzerland
9 ERIOPON® R LIQ. Washing Agent
10 UNIVADINE® DP Leveling& Dispersing
Agent
11 ALBATEX® AB-45 pH-Regulating Agent
12 Alba fixFRD
13 Optifix EC Liq Fixing Agent Thailand
14 HostapalDTC Detergent
15 Leucophor BBU 300
powder
Optical Brightening
Agent
16 Ultrafab ARW Plus Optical Brightening
Agent
Thailand
17 Flake Super TLF Softener
18 ASTROLEVEL CO Levelling Agent Italy
19 Sunhite - 4 B K Optical Brightening
Agent
Taiwan
20 Rossacid N liquid Acid India
21 Hydrogen Per-Oxide
(H2O2)50%
Bleaching agent Bangladesh
22 IogenFibrilase® HDL
350
Enzyme
23 IogenFibrilase® GXM
Ultra
Enzyme Canada
24 KAPPATEX R 98 Strong Reducing
Agent
25 HK J218 Alkali China
26 Acetic Acid Acid Taiwan
27 Caustic Soda Strong Alkali China
28 Soda ASH Light Mild Alkali China

39. 39
29 Glauber Salt Electrolytes Singapore
30 Bleaching Powder Reducing Agent
31 Hydrose Reducing Agent

40. 40
CHAPTER-6
PRODUCTION PLANNING &
SEQUENCE & OPERATION

41. 41
PRODUCTION PLANNING, SEQUENCES & OPERATION
Introduction and Basic Procedure of Planning and Control:
A planned work brings success. Without planning nothing is completed within the required
time. So planning has its own importance which is intolerable. "Planning" gives a scheduled task
and 'control' completes it successfully. But production planning and control is not an easy task.
So Esquire Knit Composite Limited’s has a high-performance department called "Production
Planning & Control". Its Basic working procedure is as follows –
 Taking orders from marketing division.
 Analyzing the orders.
 Planning for knitting the fabric.
 Planning for dyeing the fabric.
 Planning for finishing the fabric.
It is only a basic procedure. It may change according to the type of order. Sometimes, order is
places only for finishing the material or only for dyeing the white goods. Then some steps are
omitted for planning procedure.
Taking orders from marketing division:
EKCL marking division supplies Fabric Orders to the EKCL Planning and control division by a
special format.
Analyzing the orders:
This section analyzes the orders according to buyers, Order Quantity, type of orders (i.e. type of
fabric, color to be dyed etc.), delivery date etc. Then it selects which M/C. to use, no of M/C. to
use, time required for production etc. This section plans for required quantity of fabric to be
knitted

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(Order quantity + 6% of Order Quantity), knitting balance, fabric need to be dyed. Dyeing
balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery balance.
Planning for knitting:
This section plans for knitting production. It selects machine for knit the fabric for specific type
of fabric, type of yarn used, required GSM, width etc. It also gives delivery data for knitted
fabric. It also places orders for buying of yarn from spinning mills by a specific schedule.
Planning for dyeing the fabric:
Production planning for dyeing is called 'Batch Plan'. According to the batch no. And color,
width, style and construction the batch plan is made. For easy understand this section gives
some 'ROUTE CARD.' cards. "ROUTE CARD' cards are serialized according to the priority of
delivery. The batches and "ROUTE CARD ' cards also serialized as to dye light shade at first and
lastly the dark shades, since faulty shades can be converted to dark color later.
Planning for finishing the fabric:
Finishing schedule is same as the dyeing. After dyeing the material goes to the finishing section
with the batch plan. Finished data is written to the batch card and is informed to the planning
section.
However, this section always enforces to all the departments to finish all the works within the
delivery time given by the buyers. This section delivers materials by truck, micro, air etc to the
customer within the meantime. Thus it plays a very important role in the success of the
company.

43. 43

44. 44
KNITTING
SECTION

45. 45
PROCESS FLOW CHART OF KNITTING
Yarn in
cone
form
Feeding
the yarn
cone in the
creel
Feeding the
yarn in the
feeder via
trip-tape
positive
feeding
arrangement
and
Tension
devices
Knitting

46. 46
PRODUCTION FLOW CHART OF KNITTING SECTION
Sample fabric
Design analysis
Machine selection
Setting the Machine forthe Specific Design
Sample Knitting
Sample approval
Bulk Production
Grey fabric inspection

47. 47
DESCRIPTION OF PRODUCTION PROCESS:
1. Firstly, knitting manager gets a production shit from the merchandiser as accordance
as consumer requirements then he informs or orders production officer about it.
2. Production officer informs technical in charge and knows about machine in which the
production will be running.
3. Technical in charge calls for leader of mechanical fitter troops, they two take decision
about machine for production considering machine condition, production capacity,
maintenance complexity, etc.
4. Production officer with experienced mechanical fitter adjusts required stitch length
and grey GSM for required final GSM.
5. Supervisor checks daily production regularity and make operator conscious about
finishing tin due time.
6. Operators operate machine in high attention as if there were no faults in the fabrics. If
he thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty.
Mechanical fitter then fixes it if he can or he informs technical in charge. Then he
comes in spot.
7. After required production and final inspection in 4-point system, they sent in dyeing
section.
PRODUCTION PARAMETER:
 Machine Diameter;
 Machine rpm (revolution per minute);
 No. of feeds or feeders in use;
 Machine Gauge;
 Count of yarn;
 Required time (M/C running time);
 Machine running efficiency

48. 48
YARN PATH OF CIRCULAR KNITTING M/C
Creel
Tube
Knot
Catcher
Tension
Disc
Senser
Ceramic
Eye pot
Yarn
Wheel
Guide
Senser
Guide
Ceramic
Eye pot
(Feeder
Ring)
Feeder
Needle

49. 49
Method of Increasing Production
1. By increasing m/c speed:
Higher the m/c speed faster the movement of needle and ultimately production will be
increased.
2. By increasing the number of feeder:
If the number of feeder is increased in the circumference of cylinder, then the number of
courses will be increased in one revolution at a time.
3. By using machine of higher gauge:
The more the machine gauge, the more the production is. So by using machine of higher gauge
production can be increased.
4. By imposing automation in the m/c:
a) Quick starting & stopping for efficient driving system.
b) Automatic m/c lubrication system for smoother operation.
c) Photo electric fabric fault detector.
5. By imposing other developments:
• Using creel-feeding system.
• Applying yarn supply through plastic tube that eliminates the possibilities of yarn
damage.
• Using yarn feed control device.
• Using auto lint removal.

50. 50
Description of Knitting Parts With Figure:
Name of the
parts
Picture Function
Creel
Creel is a part of knitting machine. Here yarn
packages are stored for yarn feeding in the
machine.
MPF Wheel
Its control the speed of the MPF. Pulley belt
gives motion to the wheel.
MPF
It’s mean Mamminger positive feed. It gives
equal length yarn distribution in the knitting
cycle.
VDQ Pulley
It is a very important part of the machine. It
controls the quality of the product. Altering the
position of the tension pulley changes the G.S.M
of the fabric. If pulley moves towards the
positive directive then G.S.M decreases and
reverse direction G.S.M will increase
Pulley belt
It controls the rotation of the MPF wheel.

51. 51
Yarn guide
pipe
It helps the yarn to feed in the feeder & also
reduce ply.
Inlet & outlet
stop motion
It is an important part of the machine. It stops
the machine instantly when a yarn breaks.
Feeder ring
It is a ring where all feeders are place together.
Feeder
Feeder is a device where yarn passes through the
knitting section.
Brush
It cleans the pulley belt.
Sinker
It is most important element of the machine. It
helps to loop formation, hold down the loop,
knocking over the loop.

52. 52
Sinker ring
It is a ring where all sinkers are placed together.
Cam
Cam is a device which converts rotary machine
drive into a suitable reciprocating action for the
needles and other elements. The cams are
carefully profiled to produce precisely-time
movement and dwell periods and are two types,
engineering and knitting cams.
Cam box
Where cam are placed horizontally in the box.
Needle
Needle is a primary knitting elements. It gives
movement according to the cam arrangement.
Cylinder
Needle track are situated here.

53. 53
Needle trick
Where all needles are placed in a decent design.
Lycra
attachment
Lycra is placed here and feeding to the machine.
Lycra stop
motion
When lycra is broken it stops the machine.
Screen
It is a digital screen. Which show the all machine
information and we can get command to the
machine.
Automatic
oiler
It gives the machine oil all the time properly and
automatically.

54. 54
Production Calculation:
Production per hour = kg
yarncount
R PM N F N N S L mm M E
10 2.54 36 840 2.2046
. . . . . ( ) . 60
    
    
Here,
R.P.M = Machine speed (Revolution per minute)
N.F = Number of feeder
N.N = Number of needle
S.L = Stitch length
M.E = Efficiency of machine

55. 55
Cam Arrangement of some Design
Single Jersey Single Pique
▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲
▲ T
T ▲
Double Pique
Single Lacoste
▲ ▲ T T
T T ▲ ▲
▲ ▲ T ▲
T ▲ ▲ ▲
Two Thread Fleece / F. Terry
Twill Fleece
▲ T ▲ M
▲ M ▲ M
▲ M ▲ T
▲ ▲ ▲ M ▲ M
▲ M ▲ ▲ ▲ M
▲ M ▲ M ▲ ▲
Single Jersey woffle
Thermal / Miss Woffle
T T ▲ ▲
▲ ▲ ▲ ▲
D ▲ ▲ ▲ M M
C M M ▲ ▲ ▲
Woffle mini
Flat Back Rib
D ▲ ▲ T T
C ▲ ▲ ▲ ▲
▲ M M
D ▲ ▲ M
C M T ▲
Separation Rib
▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲
D ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲
C T ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M ▲ M
M ▲ M ▲ ▲ M ▲ M ▲ M ▲ M ▲ M
Small Mash
▲ M ▲ M ▲ M ▲ M ▲ M
D ▲ M ▲ M ▲ M ▲ M ▲ M
C T ▲ T ▲ T ▲ M ▲ M ▲
M ▲ M ▲ M ▲ T ▲ T ▲
1 × 1 Rib
Interlock
▲ ▲
D ▲ ▲
C ▲ ▲
▲ ▲
▲ M
D M ▲
C ▲ M
M ▲

56. 56
No. Faults Response
1. Wrong ply Reject
2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7. Fly & contamination Acceptable for color but not for white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
15. Wrong tube Reject

57. 57
Faults and response taken by grey inspection section:
Rejection criteria for body & Rib:
No. Faults Response
1. Needle marks Major needle line is rejected.
2. Stripe Major needle line is rejected.
3. Barre marks Rejected
4. Slubs 1 point
5. Wrong design Rejected
6. Pin holes 1 point
7. Fly &contamination Acceptable for color but not for white
8. Sinker marks Do
9. Uneven tension Discuss with manager
10. Missing yarn Use 4 point
11. Crease line Do
12. Uneven tension Discuss with manager
13. Oil stripe/line Do
14. Thick-thin place Rejected
15. Mixed yarn Discuss with manager

58. 58
DYEING SECTION

59. 59
Production parameters for dyeing
a.pH-
 During H2O2bleaching pH - 9-11
 During reactive dyeing pH - 10.5-12
 Durinng ebzime pH – 4.5-5
 During salt pH – 4.5-6
 During fixing pH – 6
 Softener using pH – 6-6.5
 During acid wash – 2-3
b. Temperature-
 For cotton scouring - (90-95)0c
 For enzyme wash 55-0c
 For cotton cold wash –( 30-40) 0c
 For cotton hot wash –(70-80) 0c
 For cotton acid wash –(60-70) 0c
 For cotton dyeing with reactive dye –
 (80-90) 0c for hot brand.
 (40-60) 0c for cold brand.
c. Time -
 For scouring 60-70 mins.
 For cotton with reactive dyeing 60-90 mins
 For Enzyme wash 60 mins.
 For hot wash 20 mins.
 For acid wash 20 mins.
d. M: L -
 For reactive dyeing M:L ratio maintain between – 1:9

60. 60
Function of different process:
a. Pre-bleaching – To remove impurities, oil, wax from fiber, fabric / yarn. Also to make fabric
bleached white by removing natural color.
b. Anti-pilling – To remove protruding fiber from fabric.
c. Dyeing – To get desire shade by applying requires chemical.
d. Soaping – To remove unfix color.
e. Fixing – To fix the color strictly.
f. Softening – To make the fabric soft.
Description of production process:
Washing for colored fabrics:
 The colored fabrics to be washed are loaded in the machine.
 Required amount of water is taken.
 PCLF (detergents) added & washing continued at 80°C for 20 min.
 Cold washing.
Scouring-bleaching:
 Fabric to be scoured is loaded in the machine.
 Required amount of water is loaded
 Washing agent/ detergent is added.
 Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when
the temperature reaches at 50 C.
 When the temperature reaches at 60°C then stabilizer is added.
 Then H2O2 is added.
 Temperature is then raised to 90°C and the process is then carried out for 60-90
min. depending on the requirements.
 The liquors are then drained. Then cold wash at 30°-40°C, hot wash at 70°-80°C
and acid wash at 60°-70°C is done.

61. 61
Dyeing:
 After acid wash all liquors are drained out
 Required amount of water is taken
 Then leveling agents, anti-creasing agents, de-foaming agents are added according to
the requirement
 Steam pipes are on & after 10-15 min. dyes are added Salts are added after another 30
min.
 Then soda ash after another 30 min.
 Then the temperature is raised slowly up to the mark
 The process is carried on and samples are taken after every 30-40 min. to match with
the target shade. It continues until shade matching.
 If the sample is matched, then the liquors drained out
 Then cold wash at 30°-40°C, hot wash at 70°-80°C, acid wash at 60°-70°C is done
 Then softener is added at 40°C for 20-30 min.
 Fixer is applied for deep shade only before adding softener
Re-dyeing:
When shade is not matched then fabric is treated again in dyeing machine for shade matching
is known as re-dyeing.
Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur when the
fabrics absorb one or two colors more or less. One re-dyeing process is described below.
 Drain the let off solution.
 Hotwashat70°-80°C.
 Acid wash at 60°-70°C(600 for light shade & 70° for deep shade).
 Soda ash washes at 90°-100°C for 60mins to reduce the depth of shade.
 Acid wash at 60°C.
 Addition to required dyestuffs.
 Salt addition.
 Soda ash addition.
 Other operations are same as previous described dyeing operations.

62. 62
LAB SECTION

63. 63
Process flow chart of Lab:
Swatch from merchandiser or Buyer
Storage
Selection swatch by priority
Recipe Formulation
Spectrophotometer Previous Lab Dip
Record
Carefully Fabric Dyeing
Matching Visually
Recipe correction
Exact matching with swatch
Two or more option of Lab dip sends to buyer
Approved Not Approved
Go for Production Matching Re-Lab dip

64. 64
Procedure for Lab Dip:
 Fabric weight measured by electric balance
 Calculate the recipe
 Keep the fabric in the pot
 Then required amount of water, salt, soda and other chemicals are taken to the pot by
pipetting.
 Start the program for dyeing. The dyeing time and temperature depend on types of dyes
& color being used.
Example:
Process For Reactive Dye Temperature Time
Turquoise , Green& Hospital
color
60°C then migrate it
80°C
30min.
30min.
Any Light & Deep Color 60°C 60min.
 After finished the dyeing time then cold wash two times.
 Acid wash for neutralization.
 Then soaping by required soap solution for 10 min. at 900C.
 Cold wash then drying the lab dip and compare with the standard.

65. 65
Calculation:
Usually following calculations are followed –
Recipe% × Sample Weight
Dye Solution = (cc)
Stock Solution %
Total liquor × g/l×100
Salt, Soda, Chemicals = (cc)
Stock Solution ×1000
Samples send to Buyer:
Now for every separate sample dyeing with separate recipe are send to buyer for approval. The
buyer approves one sample and the recipe of that approved sample is now sending to dyeing
section.

66. 66
BULK
PRODUCTION

67. 67
Bulk Production:
Batching:
Batching means the preparation of the fabric for dyeing according to the capacity of the dyeing
machine. It has done under instruction of planning department and time Schedule of the
dyeing department.
Function or purpose of batch section:
a. To receive the grey fabric roll from knitting section or other source.
b. Turn the grey fabric if require.
c. To prepare the batch of fabric for dyeing according to the following criteria -
• Order sheet (Received from buyer)
• Dyeing shade (color or white, light or dark)
• M/C capacity
• M/C available
• Type of fabrics (100% cotton, PC, CVC)
• Emergency
d. Send the grey fabric to the dyeing floor with batch card.
e. To keep records for every previous dyeing.

68. 68
Batching of a product depends on some factors such as:
 Fabric type
 Yarn count
 Fabric width & GSM
 Machine load capacity etc.
 Ratio of collar cuff with body fabric.
Preparation of batch:
Make the priority as per dyeing plan
•
Check the availability of fabric
•
Take required quantity of body fabric from the store
•
Take collar/cuff as per size
•
Distribution of collar/cuff or rib in each rope equally to ensure equal length
•
Stitch the fabric to make equal weight
•
Prepare batch card
•
Send fabric to the dyeing floor.

69. 69
Production flowchart:
Production flow chart for 100% cotton
Grey fabric loading
Scouring & bleaching at 980C for 1 hour
H2O2 Killer
Acetic Acid
Enzyme [pH 4-4.5, temp.550C, Time 50’-60’]
Hot Wash
Leveling
Dyeing Salt
Acetic Acid
Hot Wash

70. 70
Fixing
Softener
Unload

71. 71
White Dyeing Recipe for (100% Cotton)
Fabric Type: S/J Color: White
Process Chemical, Dyes Name Dosing (g/l
or %)
Consumption (kg)
Pretreatment Texsanscour CS (PCLF) 0.8 1.842
Pretreatment CETALUBE NFL 0.8 1.842
Pretreatment Lianeg– 710 0.2 0.461
Pretreatment STABILIZER A pdr. 0.7 1.612
Pretreatment Caustic Soda 3 6.909
Pretreatment Hydrogen Per-Oxide (H2O2)50% 6 13.818
Pretreatment Texsantifoam AF (JET) 0.2 0.461
Pretreatment Rossacid N Liquid (Green Acid) 1 2.303
Enzyme GXM Ultra 0.28 0.645
Enzyme Rossacid N Liquid (Green Acid) 0.5 1.152
Leveling Lianeg– 710 0.3 0.691
Dyeing .
DYES Leucophorr BBU 300 powder 0.167 0.392450
DYES Sun white - 4 BK 0.05 0.117500
After treatment Lianeg– 710 0.1 0.230
After treatment Ultra Fab Con 4 2 4.606
pH Control Ross acid N Liquid (Green Acid) 0.1 0.230
M : L Scouring Dyeing Enzyme + Softener
Fabric Weight 235 235 235
Liquored Ratio 9.8 9.8 9.8
TOTAL LIQURE 2303 2303 2303

72. 72
Sequence:
At first Scouring bleaching chemicals are added to the bath & they are treated at 980C for 60
min.
Temperature is lowered at 800C, Leucophorr BBU 300 powder&4BK is added Run time is 1hr.
Temp. Is raised to980C & Run time is 20min.
Then Enzyme treatment is applied & then softening
Pretreatment Curve: °

73. 73
Normal Hot:
Dyeing Curve:

74. 74
After treatment Curve:
Sample:

75. 75
Scouring & bleaching process:
Process flow chart:
Machine filling with water at normal Temperature
Fabric loaded at normal temperature (35-40°c)
Scouring & Bleaching chemical is added.
First liq. Chemical &then solid chemical.
Run time 98°C×60'
Absorbency test is done
Rinse & Drain
Per oxide killer is added at 90°C × 20'
Rinse & Drain
Acetic acid is added at 60°×20'
PH is Checked (pH=4.5-5.5)
Rinse & Drain

76. 76
Ant pilling:
Fill Water
Enzyme (Cell soft Combi9800L) at 55°C×55'
PH is Checked (pH=4.5-5)
Rinse & Drain

77. 77
Turquoise Color Dyeing Recipe(100% Cotton)
With Reactive Dye
Fabric Type: S/J
Color: Turquoise
G.S.M: 145
Pretreatment Process: Scouring, Bleaching & Enzyme
Process Chemical, Dyes Name Dosing
(g/l or %)
Consumption
(kg)
Pretreatment Texsanscour CS (PCLF) 0.8 2.074
Pretreatment CETALUBE NFL 0.8 2.074
Pretreatment Lianeg– 710 0.2 0.518
Pretreatment Caustic Soda 2.5 6.480
Pretreatment Hydrogen Per-Oxide (H2O2)50% 2.5 6.480
Pretreatment Texsantifoam AF (JET) 0.2 0.518
Pretreatment CETATEX PC 0.5 1.296
Pretreatment Rossacid N Liquid (Green Acid) 1 2.592
Enzyme GXM ULTRA 0.5 1.134
M : L Scouring Dyeing Enzyme +
Softener
Fabric Weight 324 324 324
Liquor Ratio 8 9 7
TOTAL LIQURE 2592 2916 2268

78. 78
Dyeing Process:
Chemical ASTROLEVEL CO 1.5 4.374
Anti-Creasing CETALUBE NFL 0.8 2.333
Leveling Lianeg - 710 0.3 0.875
DYES DYCHUFIX YELLOW 3R-XF (150%) 0.0012 0.003888
DYES DYCHUFIX TURQUISE BLUE G (H/C) 0.954 3.090960
DYES Sum fixes Supra Blue BRF 150%
gram.
0.036 0.116640
Salt & Soda Glauber’s salt 40 116.640
Salt & Soda Soda Ash Light 10 29.160
After Treatment Process:
Wash Off Rossacid N Liquid (Green Acid) 1 2.916
Wash Off Avorseperse AD 0.5 1.458
Leveling Lianeg– 710 0.1 0.227
Fixing Texsanfix FX 0.5 1.458
Softener Ultra Fab Con 4 1 2.268
pH Control Rossacid N Liquid (Green Acid) 0.1 0.227
Dyeing Curve:

79. 79
Sample:
Again Dyeing MACHINE WASH RECIPE
Sequence:
Bleaching Deter. +Soda add into the machine
At room temp, for 20 min
Increase temp, at 98°for 40 min Drain water
Add PCLF+Castic+Hydross at 98°for 1 hr.
Drain Total m/c cleaning
Serial No Name Dosing (g/1)
01 Bleaching powder 0.5
02 Detergent 0.1
03 Soda ash 1.0
04 Caustic 1.0
05 Hydrous 1.0

80. 80

81. 81
FINISHING

82. 82
Finishing Section:

83. 83
Objective of finishing:
 Improving the appearance, luster, whiteness etc.
 Improving the feel, which depends on the handle of the material & its softness,
 Suppleness, fullness etc.
 Wearing qualities, non- soiling, antic ease, ant shrink, comfort etc.
 Special properties required for particular uses -water -proofing flame proofing etc.
 Covering of the faults in the original cloth.
 Increasing the weight of the cloth.
Finishing effects:
 Easy care.
 Crease recovery.
 Dimensional stability
 Good abrasion resistance.
 Unproved tear strength.
 Good sew ability.
 Soft or stiff handle.
 Shine or luster.

84. 84
CHAPTER –07
QUALITY ASSURANCE
SYSTEM

85. 85
Q. C. Department
Machines:
 Wash Fastness Tester
 Light fastness tester
 Rubbing fastness tester
 Electronic balance
 G.S.M. cutter
 Fabric inspection table
 Light box
 Shrinkage (%) meter
Inspection area:
 Shade match of fabric
 G.S.M.
 Fabric diameter
 Shrinkage (%)
 S Lengthwise S Width wise
 Fiber type
 Wash fastness
 Light fastness
 Rubbing fastness
 Faults

86. 86
Faults are found in Q.C department:
a. Dyeing faults
b. Knitting faults
Knitting faults:
 Hole
 Needle Mark
 Sinker Mark
 Patta
 Slub
 Thick place
 Thin place
 Naps
 Stripe
 Missing yarn
 Contamination
 Light
 Medium
 Deep
Dyeing faults:
Uneven shade
Running shade
In fastness property
Finishing faults:
 GSM variation
 Spirality
 Shrinkage control

87. 87
Quality assurance sysstem
Quality assurance procedure:
The Delta Composite Knitting Industries Ltd. assures the quality of their products in the
following three steps:
 In laboratory
 In Dyeing section &
 In finishing section Procedures are described below:
In laboratory:
 Swatch card from buyer according to their requirement
 Recipe prediction for sample dyeing
 Sample dyeing until matching with swatch card
 If matching is OK, then it is sent to the buyer for approval.
 If buyer approves the sample then bulk production.
In dyeing section:
 After approval from the buyer, sample dyeing is done in dyeing m/c in dyeing shed &
again matched with the approved sample
 If result is OK. Then balk production,
 During dyeing, samples are taken until accurate shade matching. The interval may be
30-40 minutes
 After dyeing sample is collected after softening matching is done
 Last of all, sample is collected after fixation & matched
 Then allowed the fabrics to be finished in finishing section
 Correctly dyed, after treated & matched fabrics are allowed for finishing
 By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements
 Then sampling is done for several times to test GSM, Shrinkage & fastness properties.
 Finally fabric is inspected & prepared for delivery

88. 88
List of Equipment’s:
Machineries & equipment used-
• Spectrophotometer with software (Data color)
• Color light box
• Sample dyeing machine (2)
• Lab. Dip
• Iron
• Electric Balance
• Crock meter
• Washing m/c
• GSM Tester
• PH meter
Quality Standard:
Textile Testing Methods of HGL
1. Dimensional Stability : ISO - 6330
2. Color Fastness to Rubbing : ISO-105X12
3. Color Fastness to Wash : ISO-105C06
4. Color Fastness to
Perspiration
: ISO-105E04
5. Color Fastness to Light : ISO-105B02
6. Pilling Resistance : ISO-12945-1
7. pH test : ISO-3071

89. 89
Problemencountered in dyeing
Uneven Dyeing
a) It can be caused due to rapid addition of dyes and chemicals. For this purpose the
dosing of soda ash should be maintained properly.
b) Pressure difference.
c) Over loading in the m/c.
d) Yarn lot mixing.
e) Improper control of temperature.
f) Less amount of leveling agent.
g) Improper pretreatment.
Uneven Shade in Rope to Rope:
a) Improper rope length in each chamber.
b) Improper fabric flow speed in each nozzle.
Off Shades:
a) Improper M: L ratio.
b) Lower amount of auxiliaries.
c) Improper mixing of dyestuffs.
Dye Spots:
This is most common fault caused by operator not correctly mixing and thoroughly dissolving
dyestuffs in the right amount of water.

90. 90
Batch to batch shade variation:
If any of parameters of dyeing are changed then it will produce problems in batch to batch
consistency. In order to avoid this defect the following steps should be followed-a)
Maintain the same liquor ratio.
b) 2. Check that the fabric has the same dye affinity.
c) Use the same standard program procedures for each batch.
d) Making sure that the operators add the right Bach of chemicals at the same time &
temperature in the process.
e) Check the water supply daily especially ph, hardness & Na2COs content.
Crease Mark:
Crease marks are produced due to the lower concentration of anti-creasing agent and improper
cooling rate (defective cooling gradient). This is encountered by increasing the concentration of
anti-creasing agent and proper adjustment of cooling rate.
Patchy Dyeing:
It is caused, if dye solution is not correct and also scouring is improper.
Process of Shade Matching:
The required shade provided by the buyer is reproduced in the lab in lab dyeing machine after
the recipe prediction. The lab in-charge first uses the Computer Color Matching System, to
obtain the closest shade match recipe. Then he consults the shade card and Pantone book to
verify the obtained recipe. If he thinks that certain changes in the recipe are necessary, he then
alters the recipe according to his experience. This recipe is used to dye a sample of 5 gm fabric
in the lab dyeing machine with following parameters.

91. 91
a) Temperature and time
Cold Brand Reactive Dye - 65° c temp; 60 min
Hot Brand Reactive Dye - 98° c temp; 60 min
Turquoise Color (Cotton) - 80° c temp; 60 min
Polyester -130° c temp; 30 min
b) M: L ratio
The samples are usually dyed using 1:9 ratio.
Pantone Book:
Pantone Textile Color Selector
Total shade-1701
Color numbering system - 6 digit + suffix
First two digits 11 to 19 (range of lightness)
Middle two digits 01 to 64 (range of hue)
Last two digits01 to 64 (range of Chroma)

92. 92
CHAPTER -08
MAINTENANCE

93. 93
Maintenance

94. 94
Maintenance procedure
During maintenance procedure following points should be checked.
Checklist of different parts:
Maintenance: Mechanical
Machine:Dyeing Machines
Item need to be checked & Serviced
Crease the winch bearing.
Complete cleaning of machine
Cleaning of drain valves, replace seals if required
Check air supply filter, regulators, and auto drain seals
Clean filters element and blow out
Greasing of Unloading Roller Bearings.
Checking of oil level and bolts of Unloading Roller Gearbox.
Checking of unloading roller coupling and packing.
Checking and cleaning (if required) of Min Vessel Level Indicator
Check the oil level of pump bearing and refill if required.
Check the function of heat and cool modulating valves
Check all belts and belt tension
Check all door seals
Maintenance:Mechanical

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Machine: Lab dyeing m/c.
SI. No. Item need to be checked & Serviced
1 Check rotating main shaft bearing.
2 Check cooling water inlet and outlet nose and nose clips.
3 Check cooling fans
4 Check driving belts and pulleys.
SL No. Item needed to be checked & Serviced
1. Checking of Steam pipe lines
2. Checking of pneumatic pressure valves
3. Checking of belt conveyor system
4. Checking of plaiting device
5. Checking of speed regulating unit

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CHAPTER-09

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Utility service
Production and profit are closely related. In order to get quality final product it needs fresh raw
materials as well as effective manpower and machinery in good condition. Utility in conjugation
with the three M's plays an important role to maximize the production as well as the profit.
Utility ensures the followings:
1. Power supply (By Generator)
2. Soft Water supply (By Pump)
3. Steam supply (By Boiler)
4. Compressed air (By A/C plant)
5. Exhaust air handling (By vacuum planning system)
6. Fuel & gas supply
7. Effluent Treatment plant (ETP).
Power supply:
Hotapara Garments Ltd. has two generators for power supply to ensure continuous knitting,
dyeing & GMT operation and help to fulfill their target production. Gas generator is widely used
because of lower production cost.
Electricity:The main electricity is supplied by generator & REB
No. of Gas Generator: O2
Capacity: Generator 1-SSOKW
Generator 2-ssoKw
Own Power: Capacity: 4 Mw
REB Power: Capacity: 1 Mw

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Specification of Gas generator: Synchronous Alternator
Types: Gas generator
Company: GE Jenbacher
Made In: Germany
Model: JGS-320
Capacity: 850 kw.
KW: 1064
PF: 0.8
Volts: 415/240
Rotation: CCW
Frequency: 50Hz
RPM: 1500.
Pressure of gas: s-20Pa
Year Built: 2009, Temp rise: 105°C, Weight: 4763Kg.
Total power is then distributed as per requirements of different section like Knitting,
Dyeing (Yarn/Fabric), Finishing, Maintenance, WTP, ETP etc.
Gas: Gas is mainly supplied from TITAS. It is mainly used for steam production.
Water supply:
There are two deep tubes well for supplying water in the factory. This unit collects water from
the underground and here for hardness testing common test i.e. shop testis followed. For
dyeing section 5-10 ppm is maintain. This collecting water is reserve in reserve tank and then
supply everywhere in the factory. On the other hand, there is water treatment plant use to
oxidize water before supply .Soft water is supplied in different section continuously by using
submersible & centrifugal pumps
Source of water: Underground water
No. Of Submersible Pump: 02

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Steam:
Pure steam with required temperature must be produced to meet the continuous demand of
steam in different sections. There are four running boilers & one is remaining to be run used for
steam generation, to meet the requirement of different sections.
Main parts of the boiler:
1. Gas Chamber
2. Blower
3. Gauge glass
4. Safely valve
5. Burner
Boiler 1:
Company: long chuan
Made In: Taiwan
Fuel: Natural Gas
Capacity: 10ton
Connected Load: 20 Kw
Function: To Produce Steam
Compressed Air:
The requirement of compressed air is fulfilled by air compressor m/c. In this m/c, natural gas is
drawn by pipe through the filter 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. While doing so, the cold water becomes slightly hot & it is transferred through
outlet pipe to the overhead reservoir. There the vapors are condensed and outlets drop by
drop. Then the water is set to fall slowly through the reservoir to the compressed air to obtain
moist compressed air.

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Source of Utility:
 Electricity: Generator & REB Power
 Gas: TITAS
 Water: Pumps
 Compressed Air: Compressor
 Steam: Boiler
Function of different ingredients used in E.T.P plant:
Lime:
Lime is used to change the color of effluent & to increase the transparency of color
Ferrous Sulphate:
Ferrous Sulphate is used for the agglomeration of the colloidal matters present in the
effluentPoly Electrolyte:
Poly electrolyte is used to flocculate the precipitation for easy deposition at the
bottomHydrochloric Acid:
Hydrochloric acid is used to sustain the required PH of the biological

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Experimental procedure of ETP:

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CHAPTER-10
MARKETING
ACTIVITIES

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Marketing activities
Hotapara Garments LTD. (HGL) is a 100% export oriented industry. All the goods produced in
this industry are expected into various foreign countries.
Name of the buyers of the products of the industry are-
1) TERRANOVA
2) TAG Int.
3) COLLEZIONE
4) OBS
5) WAVES
6) TURNKEY
7) SATURN Textile.
8) Unitex Knit (Bangladesh)
9) C & A
10) Defecto
11) Style tex.
12) TEX-EBO
a) TEX-EBO J.S
b) TEX-EBO Donny
c) TEX-EBO Raia
d) TEX-EBO Descimas
e) TEX-EBO Lee cooper
13.TEX-EBO Teddy smith

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Buyers of Givensee Group:
Price Quotation
There are some systems for price quotation as given below -
1. FOB (Free on board)
2. C&F (Cost& Freight)
3. GIF (Cost, Insurance & Freight)

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The factory is full compliance with ILO and Bangladesh Labor Law.
Their company policy is as follows:
 No child labor.
 No forced labor.
 Transport facilities for worker.
 Hours of work.
 Voluntary over time.
 Intervals for rest.
 Weekly holidays.
 Annual leave.
 Festival holidays & leaves with bonus.
 Maternity protection.
 Worker's welfare committee.
 Mineral drinking water.
 Sanitary facilities.
 First aid box.
 Canteen services.
 Day care center.
 Health care activities for the worker & employ company doctor.
 Fire extinguisher each & every floor & conduct fire drill at least 12 times a year. We are
giving a top priority on prevention of fire and eventual evacuation.
 Other safety department (no discrimination).
 Compensation cases department.
 The development of compliance programmer.
 Environmental developer.
 Smoking free zone.

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CHAPTER-11

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Recommendation
The working condition of HGL Garments Ltd is much better than most of the textile
manufacturing industry in Bangladesh. But there are few points that might be considered for
improving the current quality and productivity.
Dyeing
i. Operators should be warned to be careful about maintaining proper time of dyeing.
ii. Wastage of water should be reduced.
iii. During the transportation of the fabric in the dyeing floor & also during the loading of
the machine, fabrics are soiled for the contact with floor. This makes the fabric/part of
the fabric dirty. It may require more scouring/bleaching agent or may create stain.
Finishing
I. Use of vacuum cleaner to reduce dust during cleaning machines.
II. Online quality control system should be introduced for greater performance.
III. Removing of unused machine or machine part from finishing and inspection floor.
IV. Workers and staffs of finishing and inspection should be compelled to wear mask during work.
Common suggestions:
I. Drainage system should be improved to displace the rain water efficiently in front of dyeing
floor.
II. Color of ribbon of ID card must be different for executives, interns, staffs & operators so that
everyone can identify themselves easily.

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CONCLUSION:
Industrial training is an essential part for textile education because it minimizes the gap
between theoretical and practical knowledge. Undoubtedly, this industrial training helped us a
lot about textile technology, production process, machineries, and industrial management and
made us comfortable with industrial life. Besides it hive is the first opportunity to work in
industry.
During our two month long industrial training at HGL We got the impression that this factory is
a modern export oriented composite knit including industry. Though it was established9 years
ago, it has earned a very good reputation in foreign market for its best quality product over
many other export oriented textile mills. They are very much concerned about the quality
control of each product. They have well equipped & modern textile testing laboratory. They do
all the chemical & physical tests of dyed good and the results are very good and within the
buyer’s acceptance limit. Moreover they use good quality yarn, dyes, & chemicals in
production. The administration, management and chain of command are well organized.
Mill is settled with utility to give all convenient supports to the productions for twenty- four
hours. It had self-power generator system to satisfy total power consumptions of the mill.
We are enough fortunate that we have got an opportunity of having a training in this mill. This
mill owner home district in Pabna & here 85% workers & officer’s home district also in Pabna.
We got many help from workers& officers.Md. Ibrahim H0ssain, Assistant Dyeing Manager of
Hotapara Garments LTD. always helped us very sincerely and carefully, So many thanks for
him.During the training period we received co-operation and association from the authority full
& found all man, machines & materials on appreciable working condition. All worker & officers
were very sincere & denoted their duties to achieve their goal.