3. 3
PARAMOUNT TEXTILE LIMITED AT A GLANCE
PARAMOUNT TEXTILE LIMITED
1. Name of the project : Paramount Textile Limited
2.Location : Gilar Chala,Sreepur, Gazipur.
3. Address : About 60 kms north of Dhaka city.
Factory :
Village:Gilar Chala, P.O: 1 No C&B Bazar
Thana:Sreepur,Dist:Gazipur, Bangladesh.
Tele-Fax: 880-6825 52555
4. 4
Office:
Chaklader House (Level-6), House # 22,Road #113/A,
Gulshan-2,Dhaka-1212,Banladesh
Ph:(+8802) +8809890618,9890467 Fax:(8802)9890783
E-mail:ptexltd@gmail.com Web;www.paramountgroupbd.com
5. Board of directors :
Chairman& Managing Director.
Md. Shakhawat Hossain
7. Communication :The project is easily accessible by road.
8. Product name :Woven yarn dyed ,solid dyed .
100% Cotton & TC
9. Product Mix :
A) Gray fabric:
1. Solid dyed
2. yarn dyed.
a. Stripe.
b. Check.
5. 5
B) Design.
a. In Tappet loom.
i. Plain.
ii. Twill.
iii. Sateen.
iv. Some combination weave which are posible in tappet.
v. Oxford. (Warp rib and weft rib).
vi. Queen’s Oxford.
vii. Matt.
b. In Dobby loom:
i. Various types of weave.
ii. Diamond.
iii. Diaper.
iv. Herring bone.
v. Honey comb.
vi. The design which are possible in 16 heald frames.
10.Annual production capacity : 18millions per year.
11.Factory area :Approx. 180acres.(including ETP)
12.Type of the factory :Horizontally integrated
13.No. of employees :Approx. 100.
14.Project cost :Approx. 2000million taka
15.Different Departments :
a) Adminstration.
6. 6
b) Human Resource and Develoment
Dept.
c) Weaving Preperatory
d) Weaving.
e) Woven finishing.
f) Yarn dyeing Dept.
g) Store.
h) Planning Dept.
i) Utility Dept.
j) Procurement
k) Merketing
Location description: Paramount Textile Limited is located in Sreepur, Gazipur
about 60 kms North from Dhaka while it takes about 90 minutes by bus.There
are available bus services from Mohakhali Bus Terminal and also from Gulistan
Bus Terminal.
Transport:
For the Paramount officer’s there are two micro bus and one private car which
carry them on to the factory from Dhaka.
Cost of Transport:
About 100Taka per head from Gulistan
HISTORY OF PARAMOUNT TEXTILE LIMITED:
Paramount Textile limited was incorporated under the companies Act(Act-8) of
1994 in june 12, 2006 and went into commercial production in November 2008
8. 8
Oraganogram
Chariman
Deputy Managing Director
Executive Director (Operation) Executive Director
(Finance & Accounts)
G. M. (Admin, H. R., Compliance) DGM (A/F)
Manager (Admin / HR) Manager (Compliance) Manager (Purchase)
Executive Executive Executive
Jr. Executive Jr. Executive Jr. Executive
Officer - 1 Officer - 1 Officer - 1
Peon Peon Peon
SHIFT CHANGE:
There are three shifts per day in P.T.L. So each shift
contain eight hour.
Shift Duration
A 06.00 AM – 02.00 PM
B 02.00 PM – 10.00 PM
C 10.00 PM – 06.00 AM
General shift 09.00 AM – 05.00 PM
9. 9
General shift, which is applicable for some officers.
Man power in different section (weaving) of PTL
10. 10
JOB DESCRIPTION:
SENIOR PRODUCTION OFFICER:
In a weaving factory a senior production officer plays a great role in
production and man power management who are production related. Here we
enlist the duties of senior production officer:
1) Follow up weaving production,
2) Regular observation of weaving floor,
3) Prepare weaving order status regularly,
4) Maintain the quality of the product,
5) To help the senior prod. Officer & co-operate with others for fulfilling
the required destination.
PRODUCTION OFFICER:
11. 11
Production officer is the right hand of senior production officer and
he is directly related with production manpower and informs senior production
officer time to time. Here are his listed duties:-
1) Follow up overall weaving production,
2) Decide every m/c utilization during production,
3) Recruit new labor,
4) To inform the authority on the overall weaving prod. and make it
financial profitable,
5) Regular m/c maintenance,
6) Maintain sub-contract orders,
7) Help weaving manager & also guide the junior officers of the section,
etc.
Function area:
Setting the different parameters of machines, using correct
yarn for order, controlling machine store, controlling process quality
system.
Remarks:
The organization and management system are good for mill
environment and as the job description is classified, so duties are done
honestly and sincerely.
13. 13
Machine Description
There are two ways woven fabric produced:
1. Solid dyed
2. Yarn dyed
Generally yarn dyed fabrics are costly item. Because dyed yarn are
costly and in case of yarn dyed fabric Sectional warping is necessary
which is also costly and time consuming process.
Weaving
Solid dyed Yarn dyed
14. 14
↓ ↓
Store Store
↓ ↓
Direct Winding Soft Winding
↓ ↓
Sizing Yarn Dyeing
↓ ↓
Drawing & Denting Hard Winding
↓ ↓
Weaving Sectional Waarping
↓
Sizing
↓
Drawing & Denting
↓
Weaving
Now the machines used in every stage are described below-
Soft winding:
Machine Type: A (HS 101C)
No. of M/cs:07
Name Of m/cs: Soft winding machine
Brand name: CORAL TEXTILE
Origin: China
15. 15
No of head: (54×2)/machine
M/c rpm:2800
Machine Type: B (TH-8A)
No. of M/cs:06
Name of M/ca: Soft winding machine
Brand Name: TAIZHOU JINWEL TEXTILE
Origin: China
No. of head: (54x2)/mahine
M/cs rpm: 2800
YARN DYEING
A Dyeing machine
M/c model No. of
m/c
Capacity
Kg
Power Kw Steam
Kg/hr
Water
hrm /3
Labwin-3 1 4 2.1 2 .12
Labwin-6 2 8 3.5 34 .40
Labwin-12 4 12 8.5 62 .80
Allwin-53 3 48 11.5 214 1.9
17. 17
C.RF DRYER
No. of machine:2
Brand Name:STALAM(Shanghai) DYET
Origin:China
Capacity:12tons
Power consumtion:170kw/machine
Steam Consumtion:450kg
Hard Winding
M/c Type:A(HS 101C)
No. of machine:7
Name of m/c: Hard winding machine
Brand Name:CORAL TEXTILE
Origin:China
No of head: (54×2)/machine
M/c rpm:2800
M/c Type:B(TH-8A)
No. of machine:3
Name of m/c: Hard winding machine
Brand Name:TAIZHOU JINWEL TEXTILE
Origin:China
No of head: (54×2)/machine
M/c rpm:2800
18. 18
M/c Type: C (SHA)
No. of machine: 1
Name of m/c: Hard winding machine
Brand Name: STLM (shanghai) DYET
Origin: China
No. of head: 108
Installed Power: 14kW
WARPING
A.High Speed Warping m/c
No. of machine: 1
Brand Name:TSUDAKOMA
Origin:JAPAN
Creel capacity:644
Creel Type: V type
Max beam width: 1780mm
B. Sectional warping m/c
Type 1
No. of machine: 2
Brand Name: UKIL MACHINARY
Origin: KOREA
Creel capacity: 720
Creel Type: V type
Max beam width: 1780mm
19. 19
Type 2
No. of machine: 2
Brand Name: RABATEX
Origin: INDIA
Creel capacity:800
Creel Type: V type
Max beam width: 1780mm
Sizing:
Type 1
No. of machine:1
Brand Name: Tsudakoma
Origin: Japan
Back beam capacity: 16
No of drying cylinder: 12
No of size box: 02
No of wax box: 01
Power consumption: 76kw
Type 2
No. of machine: 1
Brand Name: JUPITAR
Origin: INDIA
Back beam capacity: 1
No of drying cylinder: 8
20. 20
No of size box: 02
No of wax box: 01
Power consumption: 76kw
Loom
Total no of looms: 218
Brand name
of the Loom
Shedding
Device
Weft
Insertion
RPM No. of
Looms
Picanol
omniplus 800
Tappet 06 700-850 10
Picanol
omniplus
Tappet
Dobby
04 650-900 52
Toyota JAT
710
Cam 06 725-950 15
Toyota JAT
710
Dobby 06 600-700 01
Toyota JA
600/610
Tappet
Dobby
2+4+6 525-650 34
Tsudakoma
ZAX 9100
Cam 06 750-850 12
Tsudakoma
ZAX
Dobby
Tappet
04 500-650 13
Tsudakom
ZAX 205,205i
Cam 02,06 450-600 81
21. 21
Total 218
Finishing machines
1. Singeing and Desizing m/c
No. of m/c: 01
Company Name: Jaingsu Redflag Printing & Dyeing machinery Co. Ltd.
Origin: China
Speed: 80-85 m/min (Standard: 70 m/min)
Power Consumption: 60-70 kW
2. Scouring & Bleaching m/c
No. of m/c: 01
Origin: China
3 baths for hot wash (90 -100 degree celcius) where the first 2 are
chemical bath.
One steamer (Steaming temperature: 100 degree celcius)
Again 4 baths for hot wash
Drying cylinder No. 24
Power Consumption: 70 kW
3. Stentering m/c:
Company name: HUNAN VIROCK TEXTILE PRINTING AND DYEING
MACHINERY CO. LTD.
22. 22
No. of m/c: 01
Origin: China
Model: LVK4 000 – 200X8
Drying chamber: 08
Temperature: 120- 170 degree celcius
Fan Speed: 1480 rpm
Fabric dry: 43 m/min
Power Consumption: 140 kW
4. Peach Finishing M/c:
Company name: Xetma Vollenweider GmbH
No. of m/c: 01
Origin: Germany
Model: DE- 08280
Number: 160.008/NW 2200
Year of manufacturing : 2008
Power Consumption: 76 kW
5. Sanforizing m/c:
Company name: WuXi Dakai Printing and dyeing machinery Co. LTD.
No. of m/c: 01
Origin: China
Model: LMH 4P2 – 200
Number: 0804
Year of manufacturing : 2008
23. 23
Power Consumption: 70 kW
Remarks:
Maximum m/cs are made of China& Japan. Looms are of old
model. If technology would have better and new version m/cs been used
productivity would have been greatly increased.
25. 25
Main raw Material is yarn.
Yarn used mainly 100% cotton, PC, CVC, 100% Polyester, Lurax, lycra
core spun yarn.
Some common type of yarns are tabulated below with local price
Count Type
10/1 Autocone
16/1 Autocone
16/1 Comb
20/1 Autocone
20/1 Comb
20/1 Kard
20/1 Open end
30/1 Comb
40/1 Comb
50/1 Comb
60/1 Comb
40/2 Comb
80/2 Comb
100/2 Comb
24/1 Slub
30/1 Slub
16/1 Kard
26. 26
Some of the manufacturing companies from where Paramount procure
there yarn are
1 Zaber Spinning Mill
2.GTN (India)
28. 28
There are two ways Woven fabric produced:
1. Solid dyed.
2. Yarn dyed.
Generally yarn dyed fabrics are costly item. Because dyed yarn are
costly and, In case of yarn dyed fabric Sectional warping is necessary
which is also costly and time consuming process.
Weaving
↓ ↓
Store Store
↓ ↓
Direct Winding Soft Winding
↓ ↓
Sizing Yarn Dyeing
↓ ↓
Drawing & Denting Hard Winding
↓ ↓
Weaving Sectional Waarping
↓
Sizing
↓
Drawing & Denting
↓
Weaving
Solid dyed Yarn dyed
29. 29
When Order Comes to the Marketing Section, then they contact
with the Product development (in case of new product) or Design cell (in
case of available product) that, is it possible or not possible in
PARAMOUNT. They Send a Article Request paper. After reaching the
Article Request paper Design cell produce Article Code and send mail to
the planning and marketing section.
Planning print a Dispo paper and send to 10 sections with related
production of that fabric.
Dispo Paper:
Dispo Paper is a paper which contain All necessary information for the
production of a specific item of fabric. A typical Dispo Paper is attached
below:
Buyer Merchandiser Marketing
Design CellPlanning
1. Design Cell
2. Yarn Requisition
3. yarn store
4. winding
5. yarn dyeing
6. warping
7. Sizing
8. Drawing, denting
9. Weaving
10. Finishing.
Send Dispo Paper
30. 30
Paramount Textiles Ltd.
Y/D GREIGE FABRIC SPECIFICATION.
PI No: T40824 Line No : 01 Conut ( Warp x Weft) 40X40
Costomer :Paramoun Textiles
………..C & A
Yarn Composition (Warp x
Weft)
100 % Cotton
FINISHED FABRIC DETAILS
Dispo No :
F90001
Ends x Picks ( Finished ) 120X90
Fabrice Code : Blue Stripe Finished Fabric width ( inch 58/59"
Design : Plain
Required Finished Length (
Mater
9,076.00
Finish SOFT Delivery Date ( Finished 27/02/2009
GREIGE FABRIC DETAILS
Dispo
No:W90001
Req No : Ends x Picks ( Greige ) 112X90
Article Code Greige Width ( Inch 63"
Reed No 108/2 Required Greige ( Mater ) 9,711.32
Reed Width (
Inch
65.55
Required Loom Production (
Mtr)
9809.41
Flow
Code:TYD0412
R.P.M : 525 Required Warp Length ( Mtr) 11,630.04
Delivery Date 20/02/2009 Ground Ends 7080
D.C Comments
D:4,
G:1234,S:1234
Selvedge Ends 120
31. 31
Color
Breakdown
Count Shade Color Code
Quantity (
kg)
Length
(Mtr)
Warp
40/1 White 797 94874.90
40/1 Blue 443 47477.95
Warp Total 1240
Weft
40/1 White 920
Weft Total 920
DYED YARN DETAILS
Dispo No : W90001 Delivery Date : 28/02/2009
BREAKDOWN OF YARN FOR DYEING
Dispo
Line
Count Shade ALD NO
Greige
Yarn ( kg)
Dyed
Yarn ( kg)
Yarn
Type
1 40/1 White 1850 1805
2 40/1 Blue 478 466
Total 2328 2271
Design Cell:
Design Cell is one of the most important department of PARAMOUNT
TEXTILE LTD.(weaving). When a order comes to the marketing or
merchandizing officer he/she send the fabric to the design cell that is it
possible or not possible in PARAMOUNT. They send a Article request
paper. Design cell analyze the fabric design and test the feasibility of
32. 32
produciton and create a Article code and send this article code the
marketing or marchandizing officer and input data to the Data tex which
is a software used in PARAMOUNT for all types of information by
networking.
PARAMOUNT’s Design department is equipped with hand loom
and sophisticated software”TEX-DESIGN CLASSIC” by
KOPPERMANN of GERMANY.
After getting Article code planning discuss with marketing officer
about costing. Then marketing officer send mail or discuss directly to the
buyer about pricing of the product.
If buyer agree with the price then marketing officer send mail to
the central planning section with Article code.
Planning take a print of dispo paper for the article code from the
system data tex. After printing dispo paper they send it to the design cell
to check or verify. Design cell check and give drawing and denting plan
and send it to the planning section again.
Planning then send it to the various section where these
information required and at a time requisition all necessary raw
materials or other materials.
Organ gram of Design cell:
Assistant Manager
↓
Data Entry +
Design Analyzer (3 person)
↓
Peon (1 person)
33. 33
Dispo paper goes to the following sections:
1. Design cell.
2. Store.
3. Winding.
4. yarn dyeing.
5. warping.
6. sizing.
7. Drawing and denting.
8. Loom.
9. Finishing
Dispo paper contains following types of informations:
1. Fabric Specification.
2. Yarn composition
3. Finished type.
4. Finished fabric’s EPI x PPI
5. Finished fabric’s width.
6. Required length.
7. Reed count.
8. Grey EPI and PPI.
9. Greige width.
34. 34
10.Reed width.
11.Reed EPI
12.Required greige length.
13.Required warp length.
14.Ground Ends.
15.Selvedge Ends.
16.Cover Factor.
17.Numerical Plan (Warp & Weft)
18.Drawing & Denting Plan.
Possible Ends per inch by using Available Reed in Inventory in
PARAMOUNT by denting 2,3 and 4 in a dent For yarn dyed fabric.
a) Read available for air jet Looms Jat-600-ZAX(Tsudakoma)
Si
No
Read
No
1/1-2
Ends/EPI
2/1-3
Ends/EPI
3/1-4
Ends/EPI
Present Required Short Remark
1 144 160 4 15 -11
2 131 146 218 291 3 3 0 Local
3 130 144 217 289 66 66 0 New 25
4 128 142 213 284 1 0 1
5 126 140 210 280 23 25 -2 10 New
6 122 136 203 271 41 41 0
7 120 133 200 267 36 36 0 37
Available
8 118 131 197 162 36 30 0 36
39. 39
There are major departments are :
2. Winding.
Section Cumulative Section Cumulative
Yarn Dyeing 2.50 24.59 2.50 27.24
Winding 1.00 21.48 1.00 24.06
Warping 3.50 20.26 - 22.81
Sizing 0.50 16.05 - 22.81
Weaving (Crimp) 8.00 15.47 13.50 22.81
Greige (Reject) 1.00 6.23 1.00 6.23
Process Loss 1.50 5.17 1.50 5.17
Shrinkage 1.5 3.59 1.50 3.59
Inspection (Rejection 2.00 2.04 2.00 2.04
Total 24.59% 27.24%
40. 40
3. Warping.
4. Sizing.
5. Drawing, Denting.
6. Weaving.
7. Inspection.
These departments are described below:
Winding Section
Definition: In fabric manufacturing (weaving) process this is the first
stage where rewinding of supplied yarn is done on to a desired package
suitable for use in the next process.
Types of Winding:
1. Soft Winding.
2. Hard widing
41. 41
Soft Winding Section
Soft Winding: where the grey yarn is wond on to a special dye spring or
plastic bobbin and the package(spool) is made softer and bulkier to
make it suitable for dye penetration in the(package) dyeing machine.
42. 42
Dye Spring Plastic bobbin
Organogram:
The organogram of this section is given below:
Section in charge
↓
Senior Operator
↓
Operator
↓
Helper
↓
Cleaner
Skill Level Man power
Section-in charge 3
Senior Operator.
36
Operator
Helper 27
Cleaner. 12
Total 72
43. 43
M/c Name : CORAL TEXTILE
Manufacturer : Shanghai Coral Textile machinery Co.
Ltd
Manuf. Year : 2008
R.P.M. of Motor : 1430
No. of Head : 2
No. of Drum /head : 54
Traversing system : Grooved drum
Motor : Individual
Stop motion : Automatic
No. of m/c : 07
Production per m/c : 86867 km /day [Assuming 80%
efficiency]
44. 44
Flow Chart: DISPO
↓
Store Requisition
↓
Recieve the yarn
↓
Setting & Running
↓
Winding
↓
Checking(dia)
↓
Stop winding
↓
Quality assurance
↓
Root card making Delivery for dyeing
Assignment in soft winding :
1. Finding out package density
2. Production calculation
45. 45
1.Finding out package density
We know package density ρ =mass(m)/volume(v) gm/cc
Volume= π( R2
-r 2
)h
R= outer radius of package
R= inner radius of pkg
h= height of pkg
Now we consider a sample of 40/1 cotton yarn whose
R=4.138
r= 1.59
h=15.24
mass m=1000gm
So package density ρ=1000/π(4.1382
-1.592
)15.24 gm/cc
=1.433 gm/cc
2.Production calculation
We know production= speed(m/min)×60×24 ×1.09/(840×40×2.2045)
kg/day/head
When speed is 800m/min at 80% efficiency
Production=800×60×24×1.09/(840×40×2.2045)kg/day/head
=10.5976kg/day/head
Total production=10.5976×54×12kg/day
=6867.2448kg/day
47. 47
OBJECT:
To dye grey yarn to produce check and stripe fabric.
Dyeing procedure:
Deminerelization
↓
Bleaching
↓
Hot wash
↓
Dye run
↓
Neutralization
↓
Finishing
↓
Hydro extracting
↓
Drying
Dyeing process:
Process Recipies
48. 48
Demineralization Ladiquest 0.5g/l
Acetic acid 0.1g/l
70°-15min
Bleaching Caustic 1g/l
Per- oxide 4g/l
115°-20min
Dyeing Ladiquest 0.80g/l
Salt 40g/l
Suffix Yellow SPD 4%
Suffix Red SPD 0.2325%
Suffix Nevy Blue 0.5663%
Soda ash 10g/l
Washing off Ladiphore RSK 0.4g/l
Finishing Permafix RDX 0.7%
Acetic acid 0.2g/l
Assignments
1.Observing Hydro Extracting Cycle & production calculation
2.Production calculation
2.Observing Hydro Extracting Cycle & production calculation
49. 49
Hydro extracting cycle is with time required
Lowering(30sec)
↓
Circulation( 12 sec)
↓
Operation(5min,40sec)
↓
Lifting(21sec)
Water removing Efficiency:
Weight of cone after dyeing: 2.38kg
Weight of cone after drying: 1.11kg
Water removing Efficiency=(2.38-1.11)/2.38%
= 53.36%
3.Production calculation of RF Dryer
Length of RF Dryer=13m
At 28rpm it takes 21 min 9 sec to pass this length
Along this length it can accommodate 416 pkgs i.e 416kgs
So at 21 min9sec or 1269sec it can dry 416kgs
So in 1hr or 3600sec it can dry=416×3600/1269 kg/hr
=1180.14 kg/hr
so Production per day=1180.14×24kg
=22658.688 kg
=22.66 tons
Hard Winding Section
51. 51
Hard Winding: Where the grey yarn dyeing machine is converted
from spool to paper cone, to make the yarn easily be fed to the sectional
warping machine.
The organogram of this section is given below:
Section in charge
↓
Senior Operator
↓
Operator
↓
Helper
↓
Cleaner
Manpower
Skill Level Man power
Section-in charge 3
Senior Operator.
36
Operator
Helper 27
Cleaner. 12
Total 72
52. 52
M/c Name : CORAL TEXTILE
Manufacturer : Shanghai Coral Textile machinery Co.
Ltd
Manuf. Year : 2008
R.P.M. of Motor : 1430
No. of Head : 2
No. of Drum /head : 54
Traversing system : Grooved drum
Motor : Individual
Stop motion : Automatic
No. of m/c : 07
Production per m/c : 6867 km /day [Assuming 80%
efficiency]
Flow Chart:
Root card
↓
Checking
↓
Recieving
↓
Prepare batch card
↓
Start Hard Winding
↓
Measuring weight
53. 53
Assignment in Hard winding :
3. Finding out package density
4. Production calculation
1.Finding out package density
We know package density ρ =mass(m)/volume(v) gm/cc
Volume= π( R2
-r2
)h
R= outer dia of package
r = inner dia of pkg
h= height of pkg
Now we consider a sample of 40/1 cotton yarn whose
R=3.99cm
r= 1.60cm
h=15.24cm
mass m=1000gm
So package density ρ=1000/π(3.992
-1.602
)15.24 gm/cc
=1.563 gm/cc
2.Production calculation
We know production= speed(m/min)×60×24 ×1.09/(840×40×2.2045)
kg/day/head
When speed is 800m/min at80% efficiency
Production=800×60×24×1.09/(840×40×2.2045)kg/day/head
=10.5976kg/day/head
Total production=10.5976×54×12kg/day
=6862.32kg/day
54. 54
Faults in winding section:
Faults Causes
1. Excessive Hard package Excess tension
2. Excessive Loose package Less tension
3. Ring Faulty drum
4. Stitching Vibration of Package
5. Ribbon Ribbon breaker problem.
6. Bulging Improper alignment of Package
7. Entanglement Jerking package
8. Bunch Improper store and handling
9. Cut cone Package drop
10.Reverse winding Low pressure
Types of Maintenance:
1. Schedule maintenance
2. Break down maintenance.
Spare item types:
1. Readymade / purchase:
2. Fabrication tool in work shop / other side
3. Import item.
Quality Control in winding Section:
The following quality is maintained in preparatory stage.
55. 55
Shade matching:
The dyed yarn compared with lab drip sample or swatch card.
Level Checking:
During package dyeing dyes chemical enter in to package by pressure.
So there is a possibility to differ level in inner and outer side. It is
checked and allow up to (5 -6)%
Fastness:
Water and color fastness is checked.
Strength:
CSP, tenacity, CV% of tenacity, elongation are tested.
Package hardness:
Soft wound package is checked by hand if it is hard improper dyeing
will occur, the hard wound package also checked if it is less hard or too
hard it will create problem in subsequent process.
Material Handling Equipment For Winding Section:
1. Creel.
2. Trolley.
1. Creel: 2. Trolley
57. 57
Operational Staff: Section in charge
↓
Senior Operator
↓
Operator
↓
Helper
Direct Warping
Process Flow:
Dispo
↓
Yarn from store
↓
Creeling
↓
Warping
58. 58
A. High Speed Warping m/c
No of m/c: 1
Brand name : TSUDAKOMA
Origin:JAPAN
Creel capacity : 644
Creel type : V type
Maximum beamwidth: 1780mm
High Speed Warping m/c Setting:
Set up parameters Range Set value
Cone no. of Creel 400-600 As required
Warping Speed 1-1200 m/min
Warping length 1-999999 m
Shift selection 1-5 3
Beaming drum
pressure
1-11 mm scale 5 mm scale
Beam barrel dia 315 mm Fixed
Beam flange dia. 987 mm Fixed
Beam width 1800 mm As required
Operation Procedure Direct Warping:
1. As per production program given by assistant manager,
preparation through the yarn warp record register, the supervising
59. 59
officer collects griege yarn from store as per required count, lot
number and quantity.
2. The machine operates and helpers open / break the yarn cartoon
and place the cones in the creel head as per program and draw the
head end of the cone through pretension rods, feeler guides, yarn
guides and then through expanded comb of beaming unit.
3. The basic creel data setting and machine data setting are done
according to the requirement as per m/c manufacturer operating
instruction.
4. An empty beam is set in between driving clutch and engaged by
means of electric switch.
5. All the ends from the creel is wrapped around the beam manually
one round.
6. The press roller is moved towards the beam by means of electric
switch.
7. The m/c is then run slowly and checked for yarn alignment with
beam flange on both sides. To ensure alignment the expanded
comb may be moved either to the right or left as required by
switch.
8. Thus the m/c is ready and the operational switch is to be turned
on.
9. As the present length is achieved the m/c will stop automatically.
The beam is doffed by switch and another beam is mounted.
10.In this way a set of beams are made to feed the subsequent sizing
process.
61. 61
B Sectional Warping m/c (Type 1):
No of m/c: 2
Brand name : UK IL MACHINARY
Origin: KOREA
Creel capacity : 720
Creel type : H type
Maximum beamwidth: 1780mm
Warp width:
Total Ends Warp Width
Below 7200 1800 mm
7200 2000 mm
Above 7200 2100 mm
. Causes of yarn breakage in warping:
1. Weak yarn.
2. Sloughing off.
3. Over lapping.
4. Knots/ bad splice.
5. Slubs.
6. Loose yarn.
7. Pig tail.
8. Cut yarn.
9. Bad tip cone.
10.Short cone.
62. 62
Assignment: Observing the end breakage.
Serial no Position of breakage Time consumed
1 Between reed& drum 12sec
2 Near package 1min 4sec
3 Far package 1min 44sec
4 Between reed& drum 13sec
5 Missing end on Drum 2min 21sec
6 Between reed& drum 25 sec
7 Breakage from pkg 1min 33 sec
8 Missing end on Drum 2 min 33 sec
9 Missing end on Drum 2min 25 sec
10 Missing end on Drum 2 min
63. 63
Sizing
Sizing is the processof applying an adhesive coating on the yarn
surface. it is done mainly to protect the yarn knot to get hairy while on
weaving.Paramount has a sizing machine which facilites the sizing need
of the whole factory.
Machine Specification (Type 1):
No.of m/c: 1
BrandName: Tsudakoma
Origin:Japan.
Back beem Capacity: 16
No. Of size Box: 2
No of Drying cylinder:12
No of Wax box:1
Power Consumption:76kw
64. 64
Units of the m/c:
1.Back Beam unit
2.Sizing Unit
3.Drying Unit
4.Leasing Unit
5.Beaming or Take up unit
Controlling Points:
1.Speed of the Yarn Passing
2.Drying Unit-Cylinder temperature must not exceed 150˚C to maintain
R.H. less than 6% which is a requisite for cotton yarn.
65. 65
3. Squeezing Pressure: A typical roller pressure for wide variteyof
cotton yarn is given below.
First Squeezee: 0.12MPa
Secondsquzee:0.2MPa
Immersion roller:0.1MPa
4.Separation Unit: Distances between the lease rods are to be care fully
set up for solid dyed & yarn dyed fabrics
5.Headstock : All the settings are done from here.
Size Box:
There are two size boxes and one hot wash box.
66. 66
Main parts of size box are
301= TENSION DETECTION ROLL
302= IMMERSION ROLL
303= FIRST SIZING ROLL
304= FIRST SQUEEZE ROLL
306= SECOND SIZING ROLL
308= SIZE BOX
307= SECOND SQUEEZE ROLL
310= LEVEL ADJUSTER
311= STEAM PIPE
312= COVER
67. 67
Some typical size recipes used in PARAMOUNT given below with
their function-
Construction: 30x30/120x70
Total ends:6876
Recipes:
Recipes: Yarn count 30/1
Total ends:6876
Yarn count 30/1
Total ends:6876
Water 600 Lt 600 Lt
Sure Bond 60 kg 60 kg
CMC 20 kg 18kg
Size CA 15 kg 18 kg
Wax 2 kg 3 kg
Polytex. 460 20 kg 20 kg
Function:
1. Sure Bond: It work’s as adhesive to increase solidity percentage in
the size recipes.
2. Starch : It also works as adhesive. As its price is of low it is mainly
used to reduce the size cost when yarn count is coarser
3. CMC: It is a synthetic adhesive used mainly to help in penetrating
other chemicals into yarn.
4. PVC :This adhesive is only used on finer count yarn.
5. Size CA:Its mainfunction is to bind protruding fibres with yarn.
6. wax: It acts as a lubricating agent.
68. 68
Costing of Size Ingredients
Ingredients Cost tk/kg
Sure bond 43-53
Starch 29
CMC 139
PVA 267
Size CA 70
Wax 255
Assignment: Measuring of size take up% of a particular sample
Yarn count 40/1
Total ends 7420.
Recipes:
Water: 600 Lt
Sure bond: 60kg
Startch: 20kg
CMC: 20kg
Size CA: 15kg Sized yarn Unsized yarn
Wax: 2kg
Wt of 1m of total yarn before sizing = 0.12kg
Wt of 1m of total yarn before sizing=0.1340kg
So, Size take up %=(0.134-0.12)/0.12%
=11.67%
69. 69
Drawing, Denting Section
Process definition:
After a sized beam or weaver’s beam is made, it is time to mount this
beam over the loom. There are two methods used to prepare this beam
for mounting on a loom.
1. Warp tying or knotting (Quick style) change process.
2. Reaching – in /Drawing – in and beam gaiting.
70. 70
Warp tying:
This method is limited to use where and exactly same article or quality
of fabric is to be made that is already running in the loom. The following
points are considered-
1. The total number of warp ends should be the same as that of
running.
2. The count of yarn and weave design should be same.
Before tying a new beam with an older one, the new beam is to
undergo a process called leasing, whereby the adjacent yarns are kept
separated by placing a yarn in between them. This is very essential in
case of tying a yarn dyed beam; otherwise the warp pattern scheme
will be disturbed and lost.
For monocular beam (solid dyed beam), tying is performed without
leasing.
Drawing – in:
The method of mounting weaver’s beam on to the loom, which is
adopted for the same style of working of adjacent warp yarns or yarn
interlacement, compared to that of running in looms.
In this method warp yarns are separated individually as per count or
color pattern from the adjacent yarn and hooked to the access of
drawer’s hook called reaching – in.
71. 71
The yarn as it comes to “reach” or drawer’s hook is then drawn
through dropper (or drop wire) and then passed through the split of the
reed dent called denting.
Operation procedure:
Warp tying:
1. According to that plan, knotting – in – charge & Drawing – in –
charge jointly arrange leasing of beams, the respective beams
being identified from the sizing data sticker.
2. As leasing is completed the beam is transported to a specific loom
and mounted on loom beam bracket. The tying frame is set on
proper position.
3. The ends of old beam and the ends of the new beam are accurately
brushed and gripped by the frame sothat older and newer ends,
make and upper & lower set of yarn placed in proper tension.
4. The warp tying head is mounted over the tying frame. In case of
STAUBLI machine, number of knots per repeat of color pattern is
entered in to machine.
5. Then the machine is started. After the programmed number of
knots per color is reached, knotting will stop. Operator will check
the correctness of the knot and start again by switch.
6. Thus knotting will be completed up to the end of set, tying up per
set of older yarn with lower set of new warp.
72. 72
7. As knotting is completed, the knotting operator make a quality
card mentioning customer name, work number, beam number
beam length, knotting operator’s name and date and time of
knotting.
8. The sizing date sticker is set over the quality (of doffing) card, and
the card is set over the loom.
9. The knotting operator also makes a work record in his register
book.
10.As knotting is completed, tying head and frame are removed, the
old piece odd knotted yarn is pulled through the machine, i.e.
through heald wire and reeds and thus new warp set is allowed to
pass and made ready to run.
Drawing – in and reaching – in:
1. The customers fabric swatch is sent to the weaving section,
generally after warping is done, either by enclosed to the order
sheet to form or separately. Assistant manager (weaving) then
analyzes the swatch for reproduction. In this stage the determines
–
a. The design of sample i.e. whether dobby or tappet or
combination of two.
b. The drawing – in, denting and lifting or tappet/ cam setting
plan.
c. The required number of heald frame and reed count, draw
width etc.
73. 73
2. Then whenever the sized beam is ready, the worked out drawing
– in plan, reed count etc. against an order number is given to the
drawing – in – charge for production. Drawing – in – charge for
production. Drawing – in – charge makes a work program
considering the following:
a. The availability of the run out loom for beam.
b. The availability or required number of reed count.
3. Drawing – in – charge and senior drawer find out the desired sized
beam number from the sizing production record, check against the
specific work order number and from transport these to the
drawing – in – section by trolley and start working there.
4. According to the work order number each design/ drawing – in
plan is recorded in the register book, the produced sample being
attached thereafter.
5. After drawing – in/ denting is completed each beam is set with a
quality/ doffing card, the sizing data sticker is being attached on
the card.
6. During deciding the loom number the drawing – in – charge takes
into consideration designing scope and color insertion scope of the
respective loom.
7. Finally beam gaiters carry this beam along with dropper, healds
and reed with trolley onto the specified loom and mount.
8. They will pull the new yarn from the beam and set in the loom
with dropper, healds and reed properly positioned and tie the new
74. 74
yarn with the old piece of cloth wrapped around the surface
roller with a number of small knots.
Equipment used in Drawing denting and pinning Section:
Denting plate (Patti):
Drawing Hook:
Drop Wire:
75. 75
WEAVING SECTION
Process Definition:
The act of inter lacing Warp yarn(of a beam) with the inserted weft yarn
in a definite order to form a fabric suitable for use as a dress material,
domestic or industrial purpose is called weaving. The machine used for
this purpose is called loom.
Weaving Floor of PARAMOUNT
76. 76
Process equipment:
Air jet loom
Loom shed – 1:
Total no of loom - 178
Loom shed – 2:
Total no of loom - 40
EQUIPMENTS OF LOOM SECTION
The machine used for the purpose of weaving can be categorized as
follows:
Brand name
of the Loom
Shedding
Device
Weft
Insertion
RPM No. of
Looms
Picanol
omniplus 800
Tappet 06 700-850 10
Picanol
omniplus
Tappet
Dobby
04 650-900 52
Toyota JAT
710
Cam 06 725-950 15
Toyota JAT
710
Dobby 06 600-700 01
Toyota JA
600/610
Tappet
Dobby
2+4+6 525-650 34
77. 77
Tsudakoma
ZAX 9100
Cam 06 750-850 12
Tsudakoma
ZAX
Dobby
Tappet
04 500-650 13
Tsudakoma
ZAX 205,205i
Cam 02,06 450-600 81
Total 218
SPECIFICATIONS OF AIR JET LOOM:
GENERAL SPECIFICATION
Motor R.P.M : 1410
M/C speed : 625 PPM
Motor pulley dia : 100mm
M/C pulley dia : 225mm
Reed : Profiled reed
Shedding : Cam, Electric Dobby
Take up motion : Electronic
Let off motion : Electronic
Warp stop : Electrical
Weft stop : Electronic
78. 78
HEALD SHAFT SPECIFICATION
Brand Name : New light
Manufacturer : Nankai industrial Co. Ltd.
Origin : Japan
PHOTO ELECTRIC SENSOR
Model : CY-21P-SK
Manufacturer : Sunx Ltd.
Origin : Taiwan
LENO BOBBIN WINDER
Brand Name : Precision spooler
79. 79
Model : PS
Manufacturer : Sankin engineering Co. Ltd.
Origin : Japan
SIGNAL LAMP
Manufacturer : Hayashi feeler Co. Ltd.
Origin : Japan
CABLE
Manufacturer : Mitsubishi Cable Industries
Ltd.
Origin : Japan
REED SPECIFICATION
Brand Name : (i) RTOS (ii) Setia kiji reed
Origin : Japan
Type : Profile reed
Reed Count : 129, 121, 116, 106, 99, 92, 88/2,
74/4, 72/4 etc.
Reed Width 172.50cm
WARP BEEM CARRIER
Brand Name : TODO
Model : S-1500
Manker : Marubeni Corp
80. 80
Origin : Japan
OVER ALL CLEANER
Brand Name : LUWA
Type : Suction
LOOM MOTOR SPECIFICATION (3 Phase Inductor Motor)
R.P.M : 1410
Maker : Meidensha Corp
H.P : 3KW
SIGNAL LAMP:
COLOR INDICATION
Red : Warp breakage
Green : Weft breakage
White : Loom stop
Yellow : Selvedge leno bobbin breakage
LENO SETTING:
Right side : 10°
Left side : 280°
PRODUCTION PROCEDURE:
81. 81
Operation stuff:
Assistant Manager – section in charge
Production officer – shift in charge
Loom Technicians – shift wise running loom checking/ tuning/
setting & gauging
Senior loom operator – as a line jobber, for production & Q.C.
Loom Operator
Helpers & movers – for supplying yarn and yarn cartoons
Casual worker – For keeping the machine & section clean
Different parts of Air Jet loom:
1. EDP(Electronic Drum Prewinder).
2. Tappet(Cam).
3. Lever and Puller.
4. Reed.
5. Dobby.
6. Easing roller.
7. Back rest.
8. Take up roller.
9. Cloth roller.
10.Weft Feeler.
11.Dummy selvedge stop.
82. 82
12.Weft cutter.
13.Drop wire and bar.
14.Leno selvedge attachment.
15.Main nozzle.
16.Sub nozzle.
17.Tample.
18.Dummy selvedge system.
19.Monitor and Mother board
20.Pressure control Switch.
21.Grease tank.
Adjustment of setting:
Cutter to reed distance: 1mm
Tample to reed: 3mm
EDP pin to bend: 0.5mm.
Sub nozzle to sub nozzle: 88mm.
Two pick gear: 0.23m
Shed Size:
→Plain:
Shed angle: 30°
Shed depth: 3 – 3.5cm
→Plain + Shateen:
Shed angle: 20°
83. 83
Shed depth: 2.5cm
→Twill:
Shed angle: 25°
Shed depth: 3.5cm
A= WARP BEAM
B= BACK REST
C= DROPPER
D=HEALD FRAME
E= REED
F= FRONT REST
G= TAKE UP ROLLER
H= CLOTH ROLLER
88. 88
Hand Loom Section
In PARAMOUNT Textile Ltd there is a hand loom section. There
are several hand loom section with combined section, such as treadle,
treadle pad dobby, treadle and jacquard. There is also hank winding
frame, sample high speed warping machine, sectional warping machine
also.
When PARAMOUNT gets a new order without any swatch, then a cad
is prepared and sends it to the Hand loom section. There a small size of
sample is prepared. If the sample is prepared successfully according to
specification, then the planning department took necessary step for bulk
production.
90. 90
Grease inspection:
Two persons can do the job-
1. loom checker
2. grease inspection checker
First meter checking procedure:
Approved sheet by executive
Checking point:
For solid dyed:
1. construction
2. width(standard+/- 1”)
3. weave design as std
4. selvedge
5. reed number
6. denting order
7. design/color/pattern
For yarn dyed:
1. construction
2. width(standard+/- 1”)
3. weave design as std
4. selvedge
5. reed number
6. denting order
7. design/color/pattern
91. 91
All check points are checked by first meter checker and executive will
confirm that ok or not ok. By comparing with the first meter of first loom
and approved sample.
Loom checkers job:
Any type of fault like
1. stop mark
2. miss pick
3. double pick
4. wrong knotting etc found then this sample is not approved
List of equipments:
1. scissor
2. pick counter
3. measuring tape
Quality Standard : Given on the dispo paper
FABRIC INSPECTION
PROCESS DEFINATION:
Fabric inspection is the process of identifying weaving faults in the
fabric just after the grey fabric production in the loom.
EQUIPMENT:
1. Inspection table
2. Fabric inspection machine(Nazer, L 90p, Pakistan)
93. 93
MACHINE SET-UP:
M/C Set Value & Parameter
Check
: M/C Set Value &
Functionality
Check
1. Guide roller speed : 40 meter/min
2. Light : Artificial day light
3.Length measuring meter : Attached with the fabric &
the m/c
4. Automatic cutter(knife) : Functionality check
5. Slippage measuring roller : Functionality observe
6. Batcher : Check batcher setting with
motor
Operation Procedure:
The steps involved in the Inspection Process is as follows:
1. Inspector connects the batcher with motor and feeds the fabric by
the guide roller. The fabric goes through a special table where
there are arrangements for special lighting to detect faults in the
fabric visually.
2. Fabric is inspected as per inspection procedure of 4-point system.
After the inspection, the fabric is rolled or folded without any
crease and is packed by polythene paper. The inspector puts the
Identification Sticker on the fabric roll with details of the fabric (i.e.
order no, customer, batch no, shade, roll no, usable width
composition etc.).
94. 94
Type of fabric : Maximum Roll size
(meter)
1. Poplin : 250
2. Yarn dyed : 250
3. T.C Fabric : 300
4. Twill : 150
3. The good as well as reject quantities are entered in the MASH
module of Datatex system with respective quality codes and then
they are transferred to the finished goods stores.
Four Point Inspection System:
Generally any piece of fabric with less than 40 points fault per 100
square yard is allowed to pass however for a roll; the average value
should not exceed 28 points per 100 square yards. More than 40 points
fault per 100 square yards is recorded as reject. Normally fabric faults
are recorded using the 4-point system given below:
4-Point Grading System
Fault length Points to be assigned
(0 to 7.5) cm or less than
3”
1 points
(7.5 to 15) cm or (3” to
6”)
2 points
(15 to 22.5) cm or (6” to
9”)
3 points
More than 22.5 cm or 9” 4 points
95. 95
Assessing Fabric Fault
Faults name Definition Faults area Points
Double pick In full width an extra pick 0 to 9 inch
over
4
Miss pick Missing of one or more picks 0 to 9 inch
over
4
Reverse pick After arriving reverse back and
causes double pick
0 to 3 inch
over
1
Broken or half
pick
Pick less than full length 0 to 9 inch
over
4
Crack More than three pick missing 0 to 9 inch
over
4
Snarling Bunch of weft yarn woven in one
place
1 inch 2
Pressure loose Loop formed in the fabric Between 1
yards
4
Let-off mark Weft way mark for irregular pick
dense
0 to 9 inch
over
4
Wrong pattern Design broken on warp way 0 to 9 inch
over
Starting mark Weft way mark while starting the
loom
Full width 4
Reed mark Reed having more gap than the
normal way.So warp way line visible
Reject
Temple mark Along the temple one or more pin
mark visible
Reject
Count mixing Mixing of various count Reject
Slubs Bunch fibres in yarn 0 to 1 inch 1
Double yarn One extra warp yarn woven along
with regular warp
Reject
Loose warp One or more warp yarn having more
looser than another warp
Mandible Reject
Tight warp One or more warp yarn having more Mandible Reject
96. 96
tighter than another warp
Stitch/warp float One or more warp yarn not properly
interlaced with weft for some
distance
0 to 3 inch
over
1
Oil spot Oil drop in the fabric
Zala Bunch of warp yarn breakage 0 to 9 inch
over
4
Bad selvedge Narrow or higher width of selvedge Informed
weaving
FINISHING SECTION
Finishing Machineries
1. Singeing-Desizing 1 set
2. Washing machine 1 set
3. Stenter 1 set
4. Peach Finishing 1 set
5. Sanforizing 1 set
1. Singeing – Desizing:
Singeing is a process by which projecting or floating fibers stand
out on the surface of the fabric are burned off. Singeing is done to
remove hairy fibers projecting from surface of cloth and given a
smoothen face. It is also done to increase lusture in the finished fabric
and to prepare the fabric for next process.
97. 97
Desizing is the first wet processing textile finishing technology
employed to remove the sizing material from the fabric. It depends on
the solubility of the film forming polymer, on the effects of numerous
subsequent wet processing steps, on the interactions with added
chemicals. It is done to remove starch from the fabric and to increase
absorbency of the fabric.
2. Scouring and Bleaching:
Scouring is the process by which all natural and adventilious
impurities such as well as oil, wax, fat etc. are removed to produced
hydrophilic and clean textile material. It is vital precess of wet
processing. It is done to make the fabric highly hydrophilic and to
remove impurities such as olis, waxes, gum, husks as completely as
possible.
Bleaching of textile material is chemical or commercial process
which can be defined as destruction of natural coloring matters to
impart a pure permanent and basic white effects suitable for the
production of white finishes, level dyeing and desired printed shade
with the minimum or on tendering or without diminishing the tensile
strength. It is done to ensure a pure and permanent basic white color
fabric and to destruction of natural coloring matters from the fabric.
3. Stentering:
Stentering is done to soften and to control width of the fabric. It is
done to give the required finish to the fabric.
99. 99
4. Peach finish:
Peach finishing is done to give soft, hairy and smooth surface
effect to the fabric. For this emery rollers used.
5. Sanforizing:
Sanforizing is mainly done to control shrinkage of the fabric. It is
also done to give a better softening effect and controlling width of the
fabric.
Step wise process:
Spraying Unit Steam Roller Rubber Belt Cylinder Steam Roller
Blanket Cylinder (Ironing for permanent shrinkage control)
Common Fabrics Produced In PARAMOUNT
Fabric name: Plain
Construction:130×80/40×40,60”
Composition: 100% Cotton
109. 109
To ensure safe and consumer friendly fabric PARAMOUNT has its own
high- tech laboratory and computer data processing system.The
laboratory is fully equipped with modern testing equipments enabling
them to check the fabrics in all the stages of required testing criteria and
performances.Testing equipments are sourced from renowned
companies,such as-
JAMES H HEAL-UK
SDL ATLAS-UK
DATA COLOR Spectro Photometer-USA
QUALITY ASSURANCE & LAB TESTING SECTION
110. 110
PHYSICAL TESTS:
Test Name Equipments Manufacturer
Thread per inch Thread counter James. H. Heal &
Company, Halifax,
England
Gram per square
meter
G.S.M tester James. H. Heal &
Company, Halifax,
England
Width test Measuring tape N/A
Tensile strength Elmendorf tearing
tester
1653
James. H. Heal &
Company, Halifax,
England
Seam slippage Alphatens James. H. Heal &
Company, Halifax,
England
Abrasion resistance Nu-Martindale
Abrasion & Pilling
tester
James. H. Heal &
Company, Halifax,
England
111. 111
Pilling resistance ICI pilling box James. H. Heal &
Company, Halifax,
England
Thermal stability Roaches Roaches engineering
limited
Crease resistance Shirley crease
recovery tester
James. H. Heal &
Company, Halifax,
England
CHEMICAL TEST:
Test Name Equipments Manufacturer
Wash Fastness Gyro wash James. H. Heal &
Company, Halifax,
England
Water Fastness Perspirometer &
Carbolite
James. H. Heal &
Company, Halifax,
England
Sweat Fastness Perspirometer & James. H. Heal &
112. 112
Carbolite Company, Halifax,
England
Light Fastness Light fastness
Tester(Mercury vapor
lamp)
James. H. Heal &
Company, Halifax,
England
Crocking Fastness Crocometer James. H. Heal &
Company, Halifax,
England
Washing stability Wascator James. H. Heal &
Company, Halifax,
England
ANALYSIS:
Test Name Equipments Manufacturer
Fiber analysis Electronic microscope James swift U.K.
Fabric analysis Balance, Thread
counter
N/A
Design analysis N/A N/A
113. 113
DAILY WEAVING PERFORMANCE REPORT
QUALITY ASSURANCE DEPARTMENT
PARAMOUNT TEXTILES LIMITED
Date: ………
Order
#
Customer Construction Quality Shade Starting
time
Loom
#
Sample
Rcv
Time
Sign Remark
115. 115
Maintenance is one of the main concerning points for any production
oriented organization. PARAMOUNT having its own maintenance department
is a strong section. It has a skilled group of maintenance manpower.
Manpower:
Section Name of No of Description
Man
Required
Coverage for off
day, Total
Machine/Job Machine per Shift
leave &
absenteeism
In charge 0 0 1
Asst Engineer 0 0 1
Maintenc Mechanical 218 Forman 0 0 1
loom Senior Fitter 2 2 8
Fitter 2 2 8
Asst Fitter 2 3 9
Helper 3 3+General shift6 18
Total=46
In a weaving factory, Maintenance is done mainly on Sizing machine and on
looms.
Maintenance of sizing machine
Periodical Inspection
Daily Inspec tion
Remove any lint on the suction filter for the cooling fan for the driving motors
in each section. Check any trouble and the following points:
→Abnormal noise,
→surface condition, vibration, rotation irregularity of each roll;
→Tension in each section;
→Steam, air size and oil leakage;
→Steam pressure:
a. Main supply pressure
b. Supply pressure to the drying cylinder
c. Supply pressure to the sizing section.
116. 116
→Air pressure:
a. Main supply pressure,
b. Pressure during power failure-at the beam stand and the middle
section,
c. pressure due to the cut mark device-standard 0.3MPa.
→Steam drain exhaust;
→Squeeze roll pressuring condition;
drain in the air filter equipment.
Weekly inspection
→Exhaust drain from the air compressor and the pressure reducing valve with
the filter;
1.Roll chain tention
Adjust tension with tension wheel.If the chain has slack replace it.Some check
points are-
a.Sizing section: Sizing roll driving
b.Drying Section: Pre-cylinder drying and main cylinder drying.
c.Take-up section:Warp beam and doffing driving,
Taking-up roll driving.
2.V-Belt Tension
Slide the motor base and the V-belt tension.Checking points are-
a.Size circulation pump
b.Winding motor
117. 117
Every three month inspection
1.Steam strainer cleaning:
Clean the strainer two or three days after starting operation for the first
time.Clean it every three months after that.
2.Take up box frame and hydraulic unit:
Check the oil amount in the take up box frame and hydraulic unit. Supply if it is
necessary.If oil is dirty replace it.
3.Pressuredrop after passing the air filter in the pneumatic piping
When the pressure difference between the primary and secondary side
reaches 0.1MPa repace the element.
4.Cleaning of the steam trap
Clean the steam trap two or three days after starting operation for the first
time.Clean it every three months after that.
Every six month inspection
Polish the rubber rolls in the sizing section every six months.
Check the bearings.
#Tools for assembly
1. 1-ton chain block: Four sets
2. 1-ton forklift: 1-2 sets
3. Transit and stepladder
# Man power
A staff of four to six required to unpack, install and wire the machine.
Lubrication
1. Lubrication position and required amount
Model Oil or grease Application Q’ty/unit
HS40 Oil Take-up gear box 6.5 litres
118. 118
Sizing gear motor 6.0 litres
Heatproof Oil Centralized
lubrication oil
3.0 litres
Hydraulic
actuation oil
Oil tank 15.0 litres
Grease Sliding section,
bearing
1.0 liters
2. Recommended Oil
Manufacturer Oil Grease Hydraulic
actuation oil
Centralized
lubrication
Nippon oil
Corporation
FBK OIL
RO150
MULTINOC
GREASE 2
FAIRCOL A46
ESSO Teresso 150 Beacon EP2 Teresso32
MOBIL Mobil DTE
Extra heavy
Mobilux
Grease 2
Mobil Rarus
425
119. 119
Maintenance of loom
Periodical Inspection and Maintenance
#Routine Inspection and Maintenance
Inspection Position Check points Maintenance
Brake Check for abnormally
highly temperature
ASdjust
Selvedge Check for abnormal noise Adjust to 0.2mm
Feeler Head Check for dirt on the lens Clean the lens
Cutter Check the weft is well Replace damaged edges
Selvedge formation Check that the selvedge
yarn is threaded properly
and in uniform tension
Correctly threading and
adjust tension
Temple Check that the temple
marks do not appear
Adjust
Catch cord Check that the tuft is not
wound on the take up roll
Remove the tuft and clean
Inspection and Maintenance After weaving
Inspection Position Check points Maintenance
Whole loom Check driving and
lubrication section
Remove lint and waste
yarns
lubricate
Temple Check the temple ring
rotates easily and are
not worn out
Remove lint and
dirt,when neede replace
FDP Check that lint has not
adhered to the hook pin,
main drum or pin drum
Clean
Heald frame Check that the heald
frame height difference
is 2mm or less compared
Adjust the heald frame
height
120. 120
with specific value
Air filter Check if the drain is filled
up
Drain
Let off Check that yarn has not
adhered to the easing
shaft
Remove waste yarn
Lubrication Grease nipples, teeth of
open gears
Apply grease with brush
Every Six Month Inspection and Maintenance
Inspection Position Check points Maintenance
Thread guide Check for dirt Clean
Hook pin assembly of
FDP
Check inside for dirt Clean
Sensors Check that they function
normally
Replace
Gear box of take-up and
let-off Section
Check for dirt of oil Replace
Air Filter Check that the filter
element is not clogged
Clean ,replace
Reed Check for adhesive
monomer and abrasions
Clean, replace
Main nozzle Check that the pipe is
not bent
Replace
Sub nozzle Check for bent on the
tips
Replace
Yearly Inspection and Maintenance
Inspection Position Check points Maintenance
Warp beam Check that abrasion of
journal section is 0.3mm
or less
Shock absorber Check the function Replace
121. 121
Cutter on the LH Check the edge for
sharpness
Grind or replace
Hook pin assembly Check that abrasion is
0.5mm or less
Remove burr
Cloth roll metal bush Check that bush
abrasion is 0.8mm or
less
Replace
Every Three yearly Inspection and Maintenance
Inspection Position Check points Maintenance
Cloth roll Check that the roll
rotates smoothly and
cloth is wound
Replace the brake lining
Sub nozzle Check for dirt Clean
Every Seven year Inspection and Maintenance
Inspection Position Check points Maintenance
Overhaul Loom, Bearings, Gear
,Cams, Hook pins, Main
motor Shedding section,
Let-off and take-up
section,FDP section
Lubrication Points
Position Period Lubricant type
Driving Section Gear box- 6 months
Main motor-3 months
Oil A
Grease C
Shedding Section Heald Frame Guide-1
week
Gtrease A
Let off Section Gear box-6 months
Gears-After weaving
Oil B
Grease A
Take-up Section Gear box-6 months
Gears-6 months
Oil B
Oil A
Selvedge Section Slide Gear-After weaving Grease A
122. 122
Bobbin Shaft-After
weaving
Cutter Section Cutter lever pin-After
weaving
Cutter cam-After
weaving
Grease A
Automation Support Bracket-After
weaving
Grease A
Recommended Lubricants
Manufacturer Name
NIPPON OIL CORPORATION FBK Oil RO100
SHELL Tellus Oil C100
JOMO Ratus 100
MOBIL Mobil DTE Oil Heavy
EXXON Teresso 100
Tools and Their Functions
Name Functions
Pulley Puller
Adapter
For removing the motor pulley from the main motor shaft
G6 type puller For pulling out the loom pulley from the crank shaft
Turnbuckle For opening the split of the motor base
Tube Cutter When cutting the synthetic flexible tube
Torque
wrench
When mounting the reed on the reed holder
Adjusting
Bracket
When adjusting the vertical position of the tension metal
supporter
G3 type puller For disassembling the FDP drum to remove the drum holder
Lifting rod bar Moving up the press roll in gaiting
124. 124
Utility Services
There are following utility services are available in Paramount:
1. Gas.
2. Water.
3. Electricity.
4. A/c Plant (Chiller).
5. Compressed Air.
6. Steam.
7. Efluent treatment plant.
125. 125
Power generation
Facility:
The main utility electricity is generated by generators which are
operated by Gas and Diesel engine. The diesel engine works as standby
engine.
There are 5 gas engine operated generators
Engine Name: JENBACHER GAS ENGINE
Manufacturing Country: AUSTRIA
Capacity:
Total Capacity: 3543KW.
0.3 – 0.4 m3 Gas is required per KW electricity generation
Gas is supplied from Titas Gas.
Specification:
1. Gas engine used.
2. 20cylinders per engine
3. Overall efficiency – 90%
4. Heat recovery possible from 4 engines
5. Stroke of engine – 185 mm
6. Cylinder capacity – 71.6 dm3
7. Ignition pressure – 90 bar
8. Piston speed – 9m/s
9. Air flow of full load = 1.65 kg /hour.
10. Exhaust flow of full load= 1.7 kg /hour.
11. Exhaust gas temperature =500ºC
126. 126
12. Pressure of gas = 60 -62 millibar
13. Air pressure =10 bar
14. Engine rpm=1500
15. Engine temperature= 85º C – 90ºC
16. Cylinder Temperature = 550º C – 650ºC
17. Oil change after 750 hours
18. Oil required /engine = 180 lt.
Distribution:
Different Section of PTL
WEAVING 1299KW
YARN DYEING 1623KW
OTHERS 620KW
Steam generation
Facility:
Pure steam with required temperature must be produced to meet the
conditions demand of steam in different sections.
Fire tube type boiler is used to steam generation.
No. of boiler: 2 twine boiler
Capacity:
Total : 8+6=14 ton /hr.
Steam flow 9 ton/hr each (approximately)
Specification:
1) 3 phase heating system
2) The lower drum is 100% water filled and the top drum is
60% water & 40% steam filled.
127. 127
3) Measuring meter for water supply.
4) 4” depth greasol insulation so no heat at outside.
5) Steam pressure 8.2 kg/cm2
6) Water pressure 10.3 kg/cm2
7) Origin: Korea
8) Steam temperature: 185ºC
9) Boiler temperature (inner): 225 -275ºC
Chemicals used for boiler feed water:
NaCl solution for regeneration.
NALCO-4654 (Scale removal)
Distribution:
1. The major portion of the steam is supplied to the PTL dye house.
To heating the drying Cylinder.
To heating the calendar rollers.
Heating the chemicals liqor.
2. Sizing section of PTL
For Size cooking
Size box to keep required viscosity
Compressed Air
Facility:
Natural gas is drawn by pipe through the filters above the
compressor & the air is compressed. In such a case the air becomes
slightly hot. Hence cold water is drawn to reduce the temperature of
compressed air. Thus the cold water becomes slightly hot & goes
through outlet pipe to the overhead deserver. Then the water falls
128. 128
slowly through a sieve and becomes cool & feed to the compressor. At
the other hand the cooled compressed air along with some vapors are
transferred to the reservoir where the vapors are condensed and outlets
drop by drop.
The moist compressed air is transferred to the dryer & a slight warm
compresses air is delivered to required sections of PARAMOUNT
TEXTILE LIMITED.
Capacity:
Total number of
Compressor
: 2+4 =6
Capacity : 41.4 * 6= 248.4
Pressure of deliver air : 8.5 bars (designed)
6.5 – 7.0 bars (actually produced)
The compressors deliver oil and moisture free compressed air.
Specification:
a) Name: Air compressor (Cop co).
b) Brand name: Electronikon-ZR5
c) Manufacturer: ATLAS COPCO AIR POWER n.v. WILRIJK,
BELGIUM.
d) Model: 2T-250V SD
e) Type: Rotary screw type.
f) Year of manufacture: 2007-2009
Parameters Set value
Unloading pressure 7 bar
Pressure difference 0.6 bar
Oil pressure 7 bar
Motor running time 15 sec
Distribution:
1. The major consumption of compressed air is in weaving section.
min
3m
129. 129
2. To the looms for pick insertion (for Air jet loom).
3. To clean different section and machinery
4. To the sensors where pneumatic pressure required (computerized
control machines).
5. For the compensator movement.
6. Pneumatically controlled loading and unloading of yarn dyeing
machinery
7. Pneumatically controlled loading and unloading of different
machinery.
Air conditioning
Facility:
Water is cooled down below its normal temperature (i.e. 9 – 9.5ºC)
through A/C plant. A/C plant to maintain required amount of relative
humidity and temp.
Capacity:
Number of A/C plant: 2
Refrigerant specification:
1. Lower shell pressure = 6.2 mm Hg (Absorbed +Evaporator)
2. Upper shell pressure = 49.8 mm Hg (Low temp. generator)
3. High temp. generator pressure = 671.5 mm Hg.
4. Dilute solution concentration = 58.6%
5. Medium solution concentration = 61.0%
6. Strong / concentrated solution concentration=63.4%
130. 130
Distribution:
The maintenance of relative humidity and temp is very important
for weaving to reduce yarn breakage and produce quality fabric. A/C
plant maintain required amount of relative humidity (80 – 85%) and
temp (22 – 26ºC) in weaving 1,2,3 section. warping, winding and Final
inspection section.
Water
Facility:
Continuous supply of iron and hardness free water for PTL, PYDL
must be ensured by pump.
Capacity:
Mainly two pumps are used for water pick up.
Pump Capacity Setup
Submersible pump – I 160m3/hr Discharge value: 100% open
Submersible pump –
II
150 m3/hr Discharge value: 100% open
Depth of pump: 140 ft.
Also pump for chemical dosing & centrifugal pump for yarn dyeing.
Chemicals used:
Soda Ash.
Manganese – di – Oxide.
Grease or lubricant.
Distribution:
The major distributions of water are:
1. PTL dye house.
2. PTL weaving preparetoryhouse.
3. Boiler house for steam generation.
131. 131
Gas
The gas is supplied from Titas Gas.
Gas is used for steam production.
Gas is used for power generation.
Generally 36 m3 gases are required to produce 1 ton steam.
0.3 – 0.4 m3 Gas is required per KW electricity generation.
Cost:
Utility Cost
Electricity 2.75 Tk/ KW
Air 0.30-0.35 Tk/m3
Water 17Tk/m3.
Waste water 13 Tk/m3
Steam 500 Tk/ton.
Effluent Treatment Plant
ETP is used to treat the water used in various purposes in textile
processing in PARAMOUNT TEXTILE LTD.to make the water
environment friendly.
Number of plant: 1
Area of Plant :30 acres
Type of ETP : Chemi-Biological Plant
Capacity /day : 150 tons ( 150m3)
132. 132
Aeration Tank
Biological Tank-2
Biological Tank-1
Clearifier-1
Clearifier2
2222222222
Clear water tank
Clear water tank
Blowing
Tank
Chemical mixing Tank
Biological tank 3
Sludge
Tank
E.T.P
COLORED WATER
133. 133
Number of treatment plant and their names:
1. Tank 1:Blowing tank
2. Tank 2:Chemical mixing tank
3. Tank 3:Clarifier 1
4. Tank 4:Clarifier 2
5. Tank 5: Boilogical tank 1
6. Tank 6: Boilogical tank 2
7. Tank 7: Boilogical tank 3
8. Tank 8:Clear water tank
Chemicals used in ETP
Name Amount Price tk./kg
Lime 200 kg 8.5-9
Ferrous Sulphate 250 kg 17
Polyelctrolyte 2 kg 300
Biological Organ : Bacteria produced naturally
PH Controlling:
PH in ETP is less than 9.
If PH is decreases in the ETP, the amount of lime is increased.
If PH is increases in the ETP, the amount of Ferrous sulphate is increased.
Costing
Total treating capacity per day is 150 tons( 150m3)
Total cost per month is 1.5 lacs
So,water treating cost =150000/(150000×30)
=0.03 tk/kg of water
Remarks:
Most utility are made of own machines. So the continuous supply is
possible. The costs of utilities are also less than government supply. For
large project it consumes more utilities.
135. 135
STORE & INVENTORY CONTROL
INTRODUCTION:
Inventory is planning and execution involves participation by
most of the fundamental segment of business sales, production,
purchase, finance and accounting. Inventory is a wider sense is defined
as any idle resource of an enterprise how ever it is semi-finished packing
spares and other stocked in order to meet an expected demand or
distribution.
OBJECTIVES OF INVENTORY CONTROL:
1) Financial activities:
a) To save amount of investment
b) To know the cash position
2) Property Protection:
a) Preventable waste
b) Insurable damage
c) Unauthorized use
3) Operating:
a) To obtain the best overall balance between
production and inventory carrying cost.
b) To minimize losses
c) To avoid stock out and to keep inventory
holding costs in costs in balance.
136. 136
INVENTORY SYSTEMS:
For Raw Materials:
In this factory, Paramount Textiles Limited, raw
materials are yarn of different type, different of count . As according to
Weaving section demand yarn is produced in different spinning mills,
some times from foreign country and they are kept in the store for raw
materials in accordance with type and count. As like as polyester, cotton,
lycra are kept separately and also to their count variation. Inventory
office keeps record of this raw materials amount, their usage and
storage.
Raw material partially received from production planning & directly
from head office.
Material receiving & inspection report (MRIR) is prepared. Receive
quantity is mentioned & noted down.
Department gives store requisition to warehouse.
As per requisition materials supplied & this record is noted down.
There is a software which is networking with various section where
these information are required. The software is Data tex.
For Spares:
Different spare parts of Weaving machines and
other equipments are kept in store as inventory so that there are no time
and money losses while it is being used. Here also Data tex software is
used.
For Finished Goods:
Finished goods in Paramount Textiles are the
Finished Fabric. Finished fabrics are delivered to the garments section or
to the buyer. Here also Data tex software is used.
137. 137
STORE ROOM:
There are four type store room in PARAMOUNT TEXTILE
Limited.
a) Yarn Store.
a. Grey.
b. Dyed.
b) Fabric Store.
a. Greige.
b. Finished.
c) Main Store.
The main store room contain this following goods-
a) Size Chemicals.
b) Packing materials.
c) Stationary books.
d) Electrical & Mechanical parts.
e) All kinds of weaving parts.
FREQUENCY ON INVENTORY UPDATE:
Monthly inventory control
Annual inventory control
SCOPE OF INVENTROY CONTROL:
Raw materials : Yarn (Grey & Dyed)
Finished fabric
Spare parts
General store (Capital equipment, Accessories, Stationary,
Maintenance parts)
REMARKS:
The space is noticed to be insufficient considerably.
An expansion of space is thus desired for sound inventory.
The department is computer oriented .
139. 139
Costing is the most important tools in any business. In the weaving process,
all the functions may go right but if the costing is wrong, the total process will
go on loss in spite of profit.
PARAMOUNT has its own technique of costing. Though it is a matter of secrete
for the company welfare, PARAMOUNT has given us idea about costing.
Some important costing parameters of PARAMOUNT are given below
Average ppm of loom 600
Efficiency 80%
Total running hour/day 24
Average PPI 60
Fixed cost/loom/day (Considering facility and overheads) tk.6000
Production cost /picks tk.0.030
Some typical calculation
#Total production =(PPM/PPI)×24×60×Efficiency
= (600/60)×24×60×0.80
= 292 meters/day
#Costing on picks
Production cost /pick tk.0.025
Production cost /min ( Production cost /pick)×PPM
= 0.030×600= 18 tk
Production cost /DAY ( Production cost /min)×60×24
=18×60×24
=25920 TK.
Total Production Cost /day = Production cost /DAY + Fixed cost/loom/day
=(25920+6000) tk.
=31920 tk.
Production cost /meters = (Total Production Cost /day )/( Total
production /day)
= 31920/292 tk
=109.31 tk
#selling price
Considering profit 20% tk.(109.31+109.31*20%)
=tk.131
140. 140
Some important data regarding costing
#Costs of raw materials
Count Type Price$
10/1 Autocone 1.6
16/1 Autocone 1.8
16/1 Comb 2.1
20/1 Autocone 2.15
20/1 Comb 2.15
20/1 Kard 2.0
20/1 Open end 1.85
30/1 Comb 2.25
40/1 Comb 3.5
50/1 Comb 3.7
60/1 Comb 4.5
40/2 Comb 3.1
80/2 Comb 6.5
100/2 Comb 7.00
24/1 Slub 3.3
30/1 Slub 3.4
16/1 Kard 1.95
#Some typical process costing
Construction: 40X40/120X90, 58/59” Soft
Warp yarn cost: 0.367
Weft yarn cost: 0.260
Warp dye cost: 0.231
Weft dye cost: 0.111
Weaving cost: 0.509
Finishing cost: 0.176
Total cost/mtr: 1.71
143. 143
PARAMOUNT has a strong marketing policy including a strong marketing
managent.It has a group of skilled manpower that looks after the strong
marketing strategy.
Man power of markeking
Deputy Managing Director
↓
Executive Director
↓
General Manager
↓
Deputy General Manager
↓
Assistant General Manager
↓
Manager
↓
Deputy Manager
↓
Assistant Manager
↓
Senior executive
↓
Executive
↓
Junior Executive
CONSUMER OF THE PRODUCTS:
The mill has a great number of renowned and international consumers. The
main consumers of this factory are European country such as Germany, France,
Netherlands, Denmark, Italy & England. Following are some regular consumers:
1) C&A
2) H&M
3) M&S
4) TEMA
144. 144
5) MONDIAL
6) RADHAMONI
7) DEKKO
8) CELLIO
9) VISION APPAREL
10) SHIRT MAKER
11) DEFACTO
12) CHERRY FIELD
13) NEW YORAER
14) NAK FASHION
15) ULLA POPKEN
16) PROMINENT
17) DAVID HAWARD
Importing Countries
Yarn Size materials Dyes and
chemicals
Machineries
INDIA INDIA INDIA JAPAN
THAILAND KOREA INDIA
CHINA
KOREA
Duties & Responsibilities of Marketing Officer:
Dealing with the buyer & convince the buyer is the main duty of the
marketing officer. A marketing officer also has some other duties. The main duties
responsibilities of a marketing officer are given below :-
To prepare cost sheet by dealing with the buyer.
To take different steps by discussing with the high officials & merchandisers.
To maintain a regular & good relationship between commercial officer &
merchandisers.
To maintain a regular communication with the buyer & buying houses.
Communicate with the new buyers.
Display the better criteria of the products.
145. 145
Remarks :- The marketing activities of this mill is so good. The marketing &
merchandising section is well organized
CONCLUSION
146. 146
The industrial training gives us the opportunity to work in mills. It is an
experience of normal academic learning,
This training gives us actual picture about man, machine, material,
methods and market. We have earned the direct knowledge about the raw
materials, actual running condition of the m/c’s. Works technologist and
administration.
This mill is a well planed with enough expansion facilities. Their exist are
wonderful employer and worker relation. Working environment for the labors
is also good.
During our training we visited administration section, store, boiler
section, generator room, compressor section etc. Everywhere we got cordial
behavior from all employees
Above all this training for 46 days in the Paramount Textile Ltd. has given us a
new experience for practical life.
College of Textile Technology has given me the field to perform the
industrial attachment with Paramount Textile Ltd. This attachment seems to
me as a bridge to minimize the gap between theoretical and practical
knowledge. Undoubtedly, this attachment paved us the way to learn more
147. 147
about Textile Technology, industrial practices, and industrial management
and production process.
Besides this attachment gave us the first opportunity to work in an
Industry and acquainted us with the internal sight and sound of Textile
Industries. I believe with all these, the experience of the industrial attachment
will help our future life as a Textile Technologist.
