Paramount textile ltd

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Paramount textile ltd

  1. 1. Southeast University Industrial Attachment 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Paramount Textile Ltd Southeast University Southeast University Industrial Attachment 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Paramount Textile Ltd Southeast University Southeast University Industrial Attachment 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Paramount Textile Ltd Southeast University
  2. 2. Southeast University Industrial Attachment 2 Department of textile engineering Industrial Attachment Supervising teacher Prof. Syed Fakhrul Hassan Murad Chairman Department of textile engineering Southeast University Banani, Dhaka. Submitted By: Name Id. No. Contact Remarks Anup Kumar Biswas 2009000400120 01923862487 anup_seu@yahoo.com MohimenurRhaman 2009000400032 01673909394 sumon032@gmail.com M. SadayatHossain 2009000400036 01675652545 sadayathossain@gmail.com
  3. 3. Southeast University Industrial Attachment 3 Abstract The aim of industrial practice is to make us familiar with any kind of industry, the whole process going on the industry, its environment and also with the management system of the industry. As a student Textile engineering department, the target of any student should be to know the production process and the management system. It is because of the fact that to run any industry not only production department is obvious but also the capability of managing the whole system is an obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a better system to cope with the present competition. Thus a diversified challenge emerges in front of the manufacturer and other organizations. With a view to overcome this consequence a new generation of engineering graduates with leadership skills and management capabilities altogether are in demand. We the students of Textile Engineering Department were sent to different industries and assigned to different tasks. We were assigned to Paramount Textile Ltd. (Paramount group Ltd.). This report is a presentation of our experience in the garments and also a details presentation of our works in that industry. Southeast University Industrial Attachment 3 Abstract The aim of industrial practice is to make us familiar with any kind of industry, the whole process going on the industry, its environment and also with the management system of the industry. As a student Textile engineering department, the target of any student should be to know the production process and the management system. It is because of the fact that to run any industry not only production department is obvious but also the capability of managing the whole system is an obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a better system to cope with the present competition. Thus a diversified challenge emerges in front of the manufacturer and other organizations. With a view to overcome this consequence a new generation of engineering graduates with leadership skills and management capabilities altogether are in demand. We the students of Textile Engineering Department were sent to different industries and assigned to different tasks. We were assigned to Paramount Textile Ltd. (Paramount group Ltd.). This report is a presentation of our experience in the garments and also a details presentation of our works in that industry. Southeast University Industrial Attachment 3 Abstract The aim of industrial practice is to make us familiar with any kind of industry, the whole process going on the industry, its environment and also with the management system of the industry. As a student Textile engineering department, the target of any student should be to know the production process and the management system. It is because of the fact that to run any industry not only production department is obvious but also the capability of managing the whole system is an obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a better system to cope with the present competition. Thus a diversified challenge emerges in front of the manufacturer and other organizations. With a view to overcome this consequence a new generation of engineering graduates with leadership skills and management capabilities altogether are in demand. We the students of Textile Engineering Department were sent to different industries and assigned to different tasks. We were assigned to Paramount Textile Ltd. (Paramount group Ltd.). This report is a presentation of our experience in the garments and also a details presentation of our works in that industry.
  4. 4. Southeast University Industrial Attachment 4 Acknowledgement All praises to Almighty Allah alone, the Most merciful and the most compassionate and His Holy prophet “ Muhammad “ (Peace be Upon Him) the most perfect and exalted one among and of ever born on the surface of earth, who is forever touch of guidance and knowledge for the humanity. The work presented in this manuscript was accomplished under the guidance generous assistance, constructive criticism and enlightened supervision of Lecturer Md. Mahamudul Islam. His efforts towards the inculcation of spirit of constant work and the maintenance of professional integrity besides other invaluable words of advice will always serve as beacon of light throughout the course. We take this humblest opportunity to our deepest sense of gratitude and thankfulness to him. This internship report is not the result of individual effort. It is a result of wonderful team- work. We are really thankful on HoripodoDev who is the General Manager of Admin & HR, of Paramount Textile Ltd. who gave us the approval for making of that regard. We are also really thankful on Mohammad ShahdathHossen who is the Deputy General Manager (Weaving) of Paramount Textile Ltd. who helped us for getting information about our internship. We are thankful to all those who supported us and provide us great help for completion of this task. We have tried our level best to prepare this event with high level of accuracy but no one claim to perfect other than Almighty Allah. Executive summary
  5. 5. Southeast University Industrial Attachment 5 This report is the result of two months internship. During the internship it was required to study the organization, department of the organization and critically relate the theoretical aspects of the Textile to the practical situation. Paramount Textile Ltd. operates throughout the world with over 2287employees as part of PARAMOUNT team. Paramount collection has a wide selection of quality 100% cotton, CVC, Cotton-polyester, competent professional staff, a team of talented merchandisers, excellent supplies & support services, and state-of-the-art technology is the driving force behind Paramount’s phenomenal growth in the past years. Paramount has expanded its operations to include the Internet, and has taken advantage of the variety of international trade facilitated by the Web. Now Paramountuses state-of-the-art client/server technology for its market information processes to coordinate its network of global buyers and agents around the world. Environmental Organizational and the individual challenges which are to face by the department of “Paramount Textile Ltd.”. The motive of joining the Paramount is to have an exposure of textile sector and potential to avail a sound and promising career. There are noformal union in Paramount Group. Methodology of internship
  6. 6. Southeast University Industrial Attachment 6 Every research program should follow some basic form of procedures. However mainly this report is written on the basis of experience gathered during the period of Internship. We carefully observed the various activities of different department, especially fabric section of Paramount Textile Ltd. A qualitative research is used to conduct this study. In order to make the report more meaningful and presentable two sources of data and information have been used widely. Both primary and secondary data have been used to prepare the report Content
  7. 7. Southeast University Industrial Attachment 7 Topics Page no. Introduction 9 Objectives of Internship 10 PARAMOUNT TEXTILE LIMITED AT A GLANCE 11-12 PARAMOUNT TEXTILE LIMITED AT A GLANCE 13 Head office (marketing) CAD/Swatch Fisibilitycheck Preparation of dispo Store Soft winding Yarn dyeing Hard winding
  8. 8. Southeast University Industrial Attachment 8 Warping Sizing Draw-in Weaving Gray inspection Singing Washing Stantaring Sanforing Quality assrunce Conclusion Reference
  9. 9. Southeast University Industrial Attachment 9 Initial Conversation Industrial attachment is the first step to professional life of student, especially of technical Side. It’s an indispensable part of study a practically running processing technology of an industrial unit for a student .In our university , processing machines are not in continuous running condition, so it would only provide demonstration of mechanical features & processing technology of the material in accomplishment of the theory there of but not of the situational variables to achieve practical knowledge. So two months industrial attachment program in a dyeing mill was arranged for us. Textile education can’t be completed without industrial training. Because this industrial attachment program minimizes the gap between theoretical and practical knowledge and make me accustomed to industrial environment. I got an opportunity to complete two month long industrial training in PARAMOUNT TEXTILE Ltd, which is a 100% export, oriented Weaving Industry. It has well planned & equipped fabric and Yarn dyeing-finishing units in addition to facilitate weaving & woven fabric manufacturing. The rationale behind the existing structure and future expansion of PARAMOUNT TEXTILE Ltd is to capture value-added at each stage of the textile manufacturing process. Despite Bangladesh’s lack of indigenous cotton production capacity. PARAMOUNT TEXTILE Ltd has leveragedBangladesh’s labor cost advantage and export competitiveness to the Maximum.
  10. 10. Southeast University Industrial Attachment 10 Objectives of Internship Objective: The objective of the report is to learn about the overall activities of different departments in Paramount Textile Ltd. A primary textile industry Academic knowledge is not perfect without practical knowledge. Specific Objectives: This intern paper has been prepared for fulfilling the following specific objectives:  To enlarge the dimension of knowledge regarding fabric manufacturing as well as others.  To define and evaluate the performance of fabric manufacturing Department as well as others.  To observe the effectiveness of fabric manufacturing as well as others.  To get the additional knowledge in different sections of the organization.  To interchange opinions of the officials regarding their organization.  To know the economic condition of Bangladesh through Paramount Textile Ltd. of Bangladesh.  To identify the difference between theory (what we have learned from the text) and practice (what is really happened).  To compare the improvement of the present condition of the Paramount Textile Ltd. with the previous years.  To mention the problems that the Paramount Textile Ltd. face in the process of production and delivery of garments & give some suggestions.  To identify the strengths, weaknesses, opportunities and threats of the Paramount Textile Ltd.
  11. 11. Southeast University Industrial Attachment 11 PARAMOUNT TEXTILE LIMITED AT A GLANCE Name of the factory PARAMOUNT TEXTILE LTD. Chair person Md. ShakhawatHossain Head Office Chaklader House (Level-5&6), House # 22, Road #113/A, Gulshan-2,Dhaka-1212, Banladesh Factory Village: GilarChala, P.O: 1 No C&B Bazar, Thana: Sreepur, Dist: Gazipur, Bangladesh. Phone No. (+8802) +8809890618,9890467 (H) 880-6825 52555(F) E-mail ptexltd@gmail.com Website www.paramountgroupbd.com Bank 1. National Credit and Commerce Bank Limited. Dilkusha Branch, Hossain Chamber, 43 Dilkusha C/A, Dhaka-1000. 2. ShahjalalIslami Bank Limited. Gulshan Branch, Dhaka.
  12. 12. Southeast University Industrial Attachment 12 Space 24 Bigas Manpower 2287 Fabrics quantity 50,000 m /day Dying capacity 60 ton / Day. Fabrics a. In Tappet loom. i. Plain. ii. Twill. iii. Sateen. iv. Some combination weaves which are possible in tappet. v. Oxford. (Warp rib and weft rib). vi. Queen’s Oxford. vii. Matt. viii. Double cloth b. In Dobby loom: i. Various types of weave. ii. Diamond. iii. Diaper. iv. Herring bone. v. Honey comb. vi. The designs which are possible
  13. 13. Southeast University Industrial Attachment 13 in 16 healed frames. Main Customers H&M, C&A, TEMA, NEXT, NORWEST, STUDIO TE, OLYMP, DAVID, CHERRY, MONDIAL, LEVIS, MAYARA, MARKS & SPENCER , CYAN FASHION, VF- ASIA, S-OLIVER Southeast University Industrial Attachment 13 in 16 healed frames. Main Customers H&M, C&A, TEMA, NEXT, NORWEST, STUDIO TE, OLYMP, DAVID, CHERRY, MONDIAL, LEVIS, MAYARA, MARKS & SPENCER , CYAN FASHION, VF- ASIA, S-OLIVER Southeast University Industrial Attachment 13 in 16 healed frames. Main Customers H&M, C&A, TEMA, NEXT, NORWEST, STUDIO TE, OLYMP, DAVID, CHERRY, MONDIAL, LEVIS, MAYARA, MARKS & SPENCER , CYAN FASHION, VF- ASIA, S-OLIVER
  14. 14. Southeast University Industrial Attachment 14 HISTORY OF PARAMOUNT TEXTILE LIMITED Paramount Textile limited was incorporated under the companies Act (Act-8) of 1994 inJune 12, 2006 and went into commercial production in November 2008. One of the leading manufacturers of fabric in Bangladesh. Having started the journey in 2006. We commenced commercial production in 2008.Paramount textile produces high quality yarn dyed woven fabric for fashion brands and retailers across the world. PARAMOUNT TEXTILE is anOeko-Tex certified (Class#1) 100% export oriented woven fabric manufacturer equipped with state of the art machineries sourced from LeadingEuropean and Asian manufacturers, producing 15 million yards of fabric annually. The Factory is located in Sreepur, Gazipur an hour drive from the Dhaka International Airport, Sprawled across 35 acre of factory premise and 2287 numbers of skilled worker and employees. Paramount Textile today is a name to be reckoned with both nationally and globally.  Factory area : Approx. 180acres. (Including ETP)  Type of the factory : Horizontally integrated  No. of employees : Approx. 2287.  Project cost : Approx. 350 Core taka Southeast University Industrial Attachment 14 HISTORY OF PARAMOUNT TEXTILE LIMITED Paramount Textile limited was incorporated under the companies Act (Act-8) of 1994 inJune 12, 2006 and went into commercial production in November 2008. One of the leading manufacturers of fabric in Bangladesh. Having started the journey in 2006. We commenced commercial production in 2008.Paramount textile produces high quality yarn dyed woven fabric for fashion brands and retailers across the world. PARAMOUNT TEXTILE is anOeko-Tex certified (Class#1) 100% export oriented woven fabric manufacturer equipped with state of the art machineries sourced from LeadingEuropean and Asian manufacturers, producing 15 million yards of fabric annually. The Factory is located in Sreepur, Gazipur an hour drive from the Dhaka International Airport, Sprawled across 35 acre of factory premise and 2287 numbers of skilled worker and employees. Paramount Textile today is a name to be reckoned with both nationally and globally.  Factory area : Approx. 180acres. (Including ETP)  Type of the factory : Horizontally integrated  No. of employees : Approx. 2287.  Project cost : Approx. 350 Core taka Southeast University Industrial Attachment 14 HISTORY OF PARAMOUNT TEXTILE LIMITED Paramount Textile limited was incorporated under the companies Act (Act-8) of 1994 inJune 12, 2006 and went into commercial production in November 2008. One of the leading manufacturers of fabric in Bangladesh. Having started the journey in 2006. We commenced commercial production in 2008.Paramount textile produces high quality yarn dyed woven fabric for fashion brands and retailers across the world. PARAMOUNT TEXTILE is anOeko-Tex certified (Class#1) 100% export oriented woven fabric manufacturer equipped with state of the art machineries sourced from LeadingEuropean and Asian manufacturers, producing 15 million yards of fabric annually. The Factory is located in Sreepur, Gazipur an hour drive from the Dhaka International Airport, Sprawled across 35 acre of factory premise and 2287 numbers of skilled worker and employees. Paramount Textile today is a name to be reckoned with both nationally and globally.  Factory area : Approx. 180acres. (Including ETP)  Type of the factory : Horizontally integrated  No. of employees : Approx. 2287.  Project cost : Approx. 350 Core taka
  15. 15. Southeast University Industrial Attachment 15 Organogram of PARAMOUNT TEXTILE Ltd,
  16. 16. Southeast University Industrial Attachment 16 Management system  Intercom telephone  Fax  E-mail  Written letters  Oral Product name: Woven yarn dyed, solid dyed, 100% Cotton & TC Product Mix : A. Gray fabric: 1. Solid dyed 2. Yarn dyed. i. Stripe. ii. Check. B. Design. 1. In Tappet loom. i. Plain. ii. Twill. iii. Sateen. iv. Some combinations weave which are possible in tappet. v. Oxford. (Warp rib and weft rib). vi. Queen’s Oxford. vii. Matt.
  17. 17. Southeast University Industrial Attachment 17 2. 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. Annual production capacity: 18millions per year. Different Departments A. Administration. B. Human Resource and Development Dept. C. Weaving Preparatory D. Weaving. E. R & D(Research & Development) F. Woven finishing. G. Yarn dyeing Dept. H. Store. I. Planning Dept. J. Utility Dept. K. Procurement & Purchasing
  18. 18. Southeast University Industrial Attachment 18 L. Marketing M. QA Dept. N. Inspection Dept. O. Mechanical Dept. P. Electrical Dept. Job description AS A 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, 6) Utilization of manpower.
  19. 19. Southeast University Industrial Attachment 19 PRODUCTION OFFICER: 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. 8) Daily production calculation. 9) Daily production report submitted to higher authority. 10) Sub ordinate worker facility. 11) Fabric fault analysis. 12) Maintain environment of the weaving floor.
  20. 20. Southeast University Industrial Attachment 20 Shift Change Schedule 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 – 06.00 PM General shift, which is applicable for some officers. Man power in different section 1. Weaving a) Stuff & Officer-65 b) Worker-772 2. Dye House a) ) Stuff & Officer -35 b) Worker -124 3. Yarn Dyeing a) Stuff & Officer -78 b) Worker -589 4. Administration a) ) Stuff & Officer -117
  21. 21. Southeast University Industrial Attachment 21 5. Compliance a) ) Stuff & Officer -3 6. Utility a) Stuff & Officer -16 b) Worker-48 7. Security-86 Total Manpower of the factory -2287 Some Buyer of Paramount Textile  H&M  C&A  TEMA  NEXT  NORWEST  STUDIO TEX  OLYMP  DAVID  CHERRY  MONDIAL  LEVIS  MAYARAL  MARKS & SPENCER  CYAN FASHION  VF-ASIA  S-OLIVER
  22. 22. Southeast University Industrial Attachment 22  PVH  DAVID HAWERD  MARUBENI  VERTEX Input & Output Sequence of the factory Yarn ↓ Store ↓ Soft Winding ↓ Yarn Dyeing ↓ Hard Winding ↓ Warping ↓ Sizing ↓ Drawing & Denting ↓ Weaving ↓ Finishing ↓ Inspection ↓ Delivery
  23. 23. Southeast University Industrial Attachment 23 Raw Materials Southeast University Industrial Attachment 23 Raw Materials Southeast University Industrial Attachment 23 Raw Materials
  24. 24. Southeast University Industrial Attachment 24 Some of the manufacturing companies from where Paramount procures there yarn are 1. Zaber Spinning Mill (Bangladesh) 2. GTM (India) 3. Nahar spinning mill (India) 4. Vardaman(India) 5. Jiangsu (China) 6. Winsome 7. Gulshan spinning mill (Bangladesh) 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 Card
  25. 25. Southeast University Industrial Attachment 25 20/1 Open end 30/1 Comb 40/1 Comb,Compact,Organic,BCI 50/1 Comb 60/1 Comb 40/2 Comb 80/2 Comb 100/2 Comb 24/1 Slub 30/1 Slub 16/1 Card 45 TC,PC,CVC 32/2 20/2
  26. 26. Southeast University Industrial Attachment 26 Winding Section Southeast University Industrial Attachment 26 Winding Section Southeast University Industrial Attachment 26 Winding Section
  27. 27. Southeast University Industrial Attachment 27 Winding Section 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 winding Soft Winding Section Soft Winding: where the grey yarn is wound 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. Dye Spring Plastic bobbin Southeast University Industrial Attachment 27 Winding Section 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 winding Soft Winding Section Soft Winding: where the grey yarn is wound 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. Dye Spring Plastic bobbin Southeast University Industrial Attachment 27 Winding Section 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 winding Soft Winding Section Soft Winding: where the grey yarn is wound 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. Dye Spring Plastic bobbin
  28. 28. Southeast University Industrial Attachment 28 Flow Chart of winding DISPO ↓ Store Requisition ↓ Receive the yarn ↓ Setting & Running ↓ Winding ↓ Checking (dia) ↓ Stop winding ↓ Quality assurance ↓ Root card making Delivery for dyeing There are used two types of winding M/C M/c Name CORAL TEXTILE Manufacturer Shanghai Coral Textile machinery Co. Ltd MFD 2008 R.P.M. of Motor 750 No. of Head 54 No. of Drum /head Grooved drum Traversing system Individual
  29. 29. Southeast University Industrial Attachment 29 Stop motion Automatic No. of m/c 01 Production per m/c 10,858 km /day [Assuming 80% efficiency] M/c Name CORAL TEXTILE Manufacturer Taizhrljingwi Textile, China MFD Oct’2008 R.P.M. of Motor 750 No. of Head 54 No. of Drum /head Grooved drum Traversing system Individual Stop motion Automatic No. of m/c 15 Production per m/c 1,62,876 km /day[Assuming 80% efficiency] Southeast University Industrial Attachment 29 Stop motion Automatic No. of m/c 01 Production per m/c 10,858 km /day [Assuming 80% efficiency] M/c Name CORAL TEXTILE Manufacturer Taizhrljingwi Textile, China MFD Oct’2008 R.P.M. of Motor 750 No. of Head 54 No. of Drum /head Grooved drum Traversing system Individual Stop motion Automatic No. of m/c 15 Production per m/c 1,62,876 km /day[Assuming 80% efficiency] Southeast University Industrial Attachment 29 Stop motion Automatic No. of m/c 01 Production per m/c 10,858 km /day [Assuming 80% efficiency] M/c Name CORAL TEXTILE Manufacturer Taizhrljingwi Textile, China MFD Oct’2008 R.P.M. of Motor 750 No. of Head 54 No. of Drum /head Grooved drum Traversing system Individual Stop motion Automatic No. of m/c 15 Production per m/c 1,62,876 km /day[Assuming 80% efficiency]
  30. 30. Southeast University Industrial Attachment 30 Package density Calculation 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 package h= height of package 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 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
  31. 31. Southeast University Industrial Attachment 31 Dyeing Southeast University Industrial Attachment 31 Dyeing Southeast University Industrial Attachment 31 Dyeing
  32. 32. Southeast University Industrial Attachment 32 Dyeing OBJECT: To dye grey yarn for producingthe check and stripe fabric. Flowchart of dyeing Demineralization ↓ Bleaching ↓ Hot wash ↓ Dye run ↓ Neutralization ↓ Finishing ↓ Hydro extracting ↓ Drying
  33. 33. Southeast University Industrial Attachment 33 Dyeing Curve 400 c Dyeing recipe: Process Recipes Demineralization Ladiquest 0.5g/l Acetic acid 0.1g/l 70°-15min Chemicals Dosing Dyes Dosing Salt Dosing Dosing Soda ash Progressive 70% Shade check 550 c Southeast University Industrial Attachment 33 Dyeing Curve 400 c Dyeing recipe: Process Recipes Demineralization Ladiquest 0.5g/l Acetic acid 0.1g/l 70°-15min Chemicals Dosing Dyes Dosing Salt Dosing Dosing Soda ash Progressive 70% Shade check 550 c Southeast University Industrial Attachment 33 Dyeing Curve 400 c Dyeing recipe: Process Recipes Demineralization Ladiquest 0.5g/l Acetic acid 0.1g/l 70°-15min Chemicals Dosing Dyes Dosing Salt Dosing Dosing Soda ash Progressive 70% Shade check 550 c
  34. 34. Southeast University Industrial Attachment 34 In dyeing section three types of dyeing M/c are used. Those are_ Yarn Dyeing (Fong’s) Model ALLWIN-85 Serial No 36028258 MFD(Manufacturing Date) 2011 Country of Origin China Temperature 140C Safety valve test 520 MPa Design Pressure 520 MPa Function Dyeing Manufacturing Company Fong’s national engineering Co. Yarn Dyeing (Go Front) Model GRO-08 Serial No 112 MFD(Manufacturing Date) July’2011 Country of Origin Chang Cheng Temperature 160C Safety valve test 520 MPa Design Pressure 520 MPa 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 Navy Blue 0.5663% Soda ash 10g/l Washing off Ladiphore RSK 0.4g/l Finishing Permafix RDX 0.7% Acetic acid 0.2g/l
  35. 35. Southeast University Industrial Attachment 35 Function Dyeing Manufacturing Company Go Front Holding Ltd. Yarn Dyeing (Scdo Mat) Model 1800 Serial No Y-802-4 MFD(Manufacturing Date) Aug’08 Country of Origin China Temperature 140C Safety valve test 520 MPa DESIGN Pressure 520 MPa Function Dyeing Manufacturing Company Xinlong Electricity Co. Ltd Dryer M/c specification: Dryer M/C 02 Model SP-02170 Serial No 90815 MFD(Manufacturing Date) Sep’2009 Country of Origin China Speed 17 Function Dry the Yarn Manufacturing Company STALAM Dyeing & Printing Co Ltd. Southeast University Industrial Attachment 35 Function Dyeing Manufacturing Company Go Front Holding Ltd. Yarn Dyeing (Scdo Mat) Model 1800 Serial No Y-802-4 MFD(Manufacturing Date) Aug’08 Country of Origin China Temperature 140C Safety valve test 520 MPa DESIGN Pressure 520 MPa Function Dyeing Manufacturing Company Xinlong Electricity Co. Ltd Dryer M/c specification: Dryer M/C 02 Model SP-02170 Serial No 90815 MFD(Manufacturing Date) Sep’2009 Country of Origin China Speed 17 Function Dry the Yarn Manufacturing Company STALAM Dyeing & Printing Co Ltd. Southeast University Industrial Attachment 35 Function Dyeing Manufacturing Company Go Front Holding Ltd. Yarn Dyeing (Scdo Mat) Model 1800 Serial No Y-802-4 MFD(Manufacturing Date) Aug’08 Country of Origin China Temperature 140C Safety valve test 520 MPa DESIGN Pressure 520 MPa Function Dyeing Manufacturing Company Xinlong Electricity Co. Ltd Dryer M/c specification: Dryer M/C 02 Model SP-02170 Serial No 90815 MFD(Manufacturing Date) Sep’2009 Country of Origin China Speed 17 Function Dry the Yarn Manufacturing Company STALAM Dyeing & Printing Co Ltd.
  36. 36. Southeast University Industrial Attachment 36 Observing Hydro Extracting Cycle & production calculation Hydro extracting cycle is with time required Lowering (30sec) ↓ Circulation (12 sec) ↓ Operation (5min, 40sec) ↓ Lifting (21sec) Hydro M/C 03 Model RZT 60 Serial No 217 MFD(Manufacturing Date) Sep’2011 Country of Origin China Power Supply 16 KW,50 HZ+2%,32 A Net Wt. 2500 Kg Max Rotation (Drum) 1530 Function Dehydration Manufacturing Company STALAM Dyeing & Printing Co Ltd. Southeast University Industrial Attachment 36 Observing Hydro Extracting Cycle & production calculation Hydro extracting cycle is with time required Lowering (30sec) ↓ Circulation (12 sec) ↓ Operation (5min, 40sec) ↓ Lifting (21sec) Hydro M/C 03 Model RZT 60 Serial No 217 MFD(Manufacturing Date) Sep’2011 Country of Origin China Power Supply 16 KW,50 HZ+2%,32 A Net Wt. 2500 Kg Max Rotation (Drum) 1530 Function Dehydration Manufacturing Company STALAM Dyeing & Printing Co Ltd. Southeast University Industrial Attachment 36 Observing Hydro Extracting Cycle & production calculation Hydro extracting cycle is with time required Lowering (30sec) ↓ Circulation (12 sec) ↓ Operation (5min, 40sec) ↓ Lifting (21sec) Hydro M/C 03 Model RZT 60 Serial No 217 MFD(Manufacturing Date) Sep’2011 Country of Origin China Power Supply 16 KW,50 HZ+2%,32 A Net Wt. 2500 Kg Max Rotation (Drum) 1530 Function Dehydration Manufacturing Company STALAM Dyeing & Printing Co Ltd.
  37. 37. Southeast University Industrial Attachment 37 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% 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 package 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
  38. 38. Southeast University Industrial Attachment 38 Hard Winding Southeast University Industrial Attachment 38 Hard Winding Southeast University Industrial Attachment 38 Hard Winding
  39. 39. Southeast University Industrial Attachment 39 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. Flow Chart of hard winding Root card ↓ Checking ↓ Receiving ↓ Prepare batch card ↓ Start Hard Winding ↓ Measuring weight 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 package h= height of package Now we consider a sample of 40/1 cotton yarn whose R=3.99cm r= 1.60cm
  40. 40. Southeast University Industrial Attachment 40 h=15.24cm Mass m=1000gm So package density ρ=1000/π (3.992 -1.602 )15.24 gm. /cc =1.563 gm. /cc 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 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
  41. 41. Southeast University Industrial Attachment 41 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. 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.
  42. 42. Southeast University Industrial Attachment 42 Material Handling Equipment for Winding Section: 1. Creel. 2. Trolley. 1. Creel: 2. Trolley
  43. 43. Southeast University Industrial Attachment 43 Warping Southeast University Industrial Attachment 43 Warping Southeast University Industrial Attachment 43 Warping
  44. 44. Southeast University Industrial Attachment 44 Warping In general terms, Warping is transpiring many yarns from a creel of single ends packages forming a parallel sheet of yarn wound onto a beam a section a beam. Today’s warping m/c can process many kinds of materials including course and fine filament & staple yarns, mono filament, texture yarn & smooth yarns, silks & other synthetics yarn. Usually a static eliminator device isrecommended for yarns that can generate static electricity. The warp beam that is installed on a weaving m/c is called a weaver’s beam. A weaver’s beam can contain several thousand ends & different reasons it is rarely produce in on operation. Warping is aimed at preparing the weaver’s beam to be set up on the weaving m/c. Warping carries out following operation:  Creation, out of a limited number of warp threads (Creel load), of a warp composed of any number of threads with desire length;  Arrangement of above-mentioned threads according to the desire sequence;  Manufacturing of a warp beam with said characteristics;  If the creel capacity is equal or higher number of warp threads, the warping would simply entail the direct winding on the warp beam of the threads coming from the creel. Generally, this condition does not take place & even with creels of high capacity the number of creel position never corresponds to the number of threads, which is always by far higher than the number of bobbins, which is creel can contain.  This problem has been solved by dividing the warping operation into two phases: o 1st phase: Unwinding the threads from the bobbins & their winding on intermediate carriers, till attainment of the required total number of warp threads; o 2nd phase: Simultaneous rewinding of all these threads & subsequent winding on weaver’s beam; the contemporaneity of these two operations is prerequisite to produce a beam where all the treads show same tension & the length.
  45. 45. Southeast University Industrial Attachment 45 Types of warping: Warping Sectional (Conical drum or dresser) Direct (Preparatory beam) Flow Chart of warping: Cree ling Knotting (Optional) Drawing Denting Reed Measurement Roller Evener roller Drum Beaming
  46. 46. Southeast University Industrial Attachment 46 Layout plan of preparatory section
  47. 47. Southeast University Industrial Attachment 47 Operation Procedure Direct Warping: 1. As per production program given by assistant manager, preparation through the yarn warp record register, the supervising 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.
  48. 48. Southeast University Industrial Attachment 48 The m/c feature of sectional warping: There are four sectional & one direct warping m/c using in PARAMOUNT Textile. Between the machines two are UK IL & another two are Rabatex. Warping M/C (UK IL) 02 Model UI-501 SI Serial No 5-359 MFD(Manufacturing Date) Aug’08 Country of Origin Korean Creel Capacity 720 M/C Motor RPM 400-500 Function Sectional warping Manufacturing Company UK IL m/c Co. Ltd Warping M/C (Rabatex) 02 Model VM 108 Serial No 46/6 MFD(Manufacturing Date) Feb’10 Country of Origin India Creel Capacity 800 M/C Motor RPM 450-550 Function Sectional Warping Manufacturing Company Rabatex Industries Co. Ltd Warping M/C (TSUDAKOMA) 01 Model TWS-E Serial No 999 MFD(Manufacturing Date) Apr’08 Country of Origin Japan Creel Capacity 644 M/C Motor RPM 600-700 Function Direct Warping Manufacturing Company Tsudakoma Corporation .
  49. 49. Southeast University Industrial Attachment 49 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. 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
  50. 50. Southeast University Industrial Attachment 50 Monitor Display Sectional warping: Drum Diameter: 3.35 Tension Device: Electromagnetic type (Auto controller) If Stripe is, big shape or size then not necessary to cross lease, shape is small then used to cross lease. Reed Movement: Sectional warping motor type:  3 phase induction motor  Rotation by Encoder  RPM : 350-400 (Drum)  AMB : 40C  Rating : Count Wise  Serve Factor : 100% Patrol wash is used to cleaning the guide bar. Jog –To maintain the yarn tension for loose yarn after creel. TPM 500 Section 15 Speed 350 Width 70” P-Roll 1.5 Total ends 5100 Count 20 Revolution 37.9 Type Cotton S-Width 118.63 Density 28.68 Feed 1.4276
  51. 51. Southeast University Industrial Attachment 51 Sizing Southeast University Industrial Attachment 51 Sizing Southeast University Industrial Attachment 51 Sizing
  52. 52. Southeast University Industrial Attachment 52 Sizing Although thequality and the characteristics of the warp yarns coming out of the winding and warping processes are quite good, they are still not good enough for the weaving process for most of the yarns. The weaving process requires the warp yarn to be strong, smooth and elastic or extensible to a certain degree. To achieve these properties of the warp yarns, a protective coating of a polymeric film-forming agent(size) is applied to the warp yarns prior to weaving; this process is called sizing or slashing. Sizing is not a value added process inwoven fabric manufacturing. This is because, after the fabric is woven, the size materials will be removed from the fabric during the finishing operation, which is called desiring. Purposes of sizing  To increase the strength of the yarn.  To reduce the yarn hairiness that would cause problems in weaving process.  To increase the abrasion resistance of the yarns against other yarns and various weaving machine elements.  To reduce fluff and fly during the waving process for the high speed weaving machine.  To increase the weave ability of the warp yarn, this is the main goal of sizing. Southeast University Industrial Attachment 52 Sizing Although thequality and the characteristics of the warp yarns coming out of the winding and warping processes are quite good, they are still not good enough for the weaving process for most of the yarns. The weaving process requires the warp yarn to be strong, smooth and elastic or extensible to a certain degree. To achieve these properties of the warp yarns, a protective coating of a polymeric film-forming agent(size) is applied to the warp yarns prior to weaving; this process is called sizing or slashing. Sizing is not a value added process inwoven fabric manufacturing. This is because, after the fabric is woven, the size materials will be removed from the fabric during the finishing operation, which is called desiring. Purposes of sizing  To increase the strength of the yarn.  To reduce the yarn hairiness that would cause problems in weaving process.  To increase the abrasion resistance of the yarns against other yarns and various weaving machine elements.  To reduce fluff and fly during the waving process for the high speed weaving machine.  To increase the weave ability of the warp yarn, this is the main goal of sizing. Southeast University Industrial Attachment 52 Sizing Although thequality and the characteristics of the warp yarns coming out of the winding and warping processes are quite good, they are still not good enough for the weaving process for most of the yarns. The weaving process requires the warp yarn to be strong, smooth and elastic or extensible to a certain degree. To achieve these properties of the warp yarns, a protective coating of a polymeric film-forming agent(size) is applied to the warp yarns prior to weaving; this process is called sizing or slashing. Sizing is not a value added process inwoven fabric manufacturing. This is because, after the fabric is woven, the size materials will be removed from the fabric during the finishing operation, which is called desiring. Purposes of sizing  To increase the strength of the yarn.  To reduce the yarn hairiness that would cause problems in weaving process.  To increase the abrasion resistance of the yarns against other yarns and various weaving machine elements.  To reduce fluff and fly during the waving process for the high speed weaving machine.  To increase the weave ability of the warp yarn, this is the main goal of sizing.
  53. 53. Southeast University Industrial Attachment 53 Sizing quality: Flowchart of sizing Flange Beam Beam Stand Feeding Guide roller Immersion Roller Squeezing Roller Paddler Roller SIZING SIZING RECIPE SIZING PICK-UP OPERATOR HANDLING SIZING MACHINE DESIGN ADJUSTMENT YARN MATERIAL TYPE QUALITY
  54. 54. Southeast University Industrial Attachment 54 Saw Box Cavity box Dryer Water tank Cooking tank Reservoir tank Mahalu Lease Rod Reed Dropper Pressure Roller Guide Roller Sized Yarn Sizing agent  True starch  Modified starch  Carboxyl methylcellulose (CMC)  Polyvinyl alcohol (PVA)  Polyacrelate
  55. 55. Southeast University Industrial Attachment 55  Polytex-460  Polytex BI  Wax In PARAMOUNT textile, Polytex-460 &Polytex-BI are used as the sizing comical. Polytex- 460 &polytex BI is the combination of all others sizing agent except Wax. Sizing Calculation: Total required chemical = (total length* total ends*30%)/(1.6933*count*1000)+200L Sizing M/C: There are two types of sizing M/C Sizing M/C (TSUDAKOMA) 01 Model HS-40 Serial No 254 MFD(Manufacturing Date) Apr’2008 Country of Origin Japan Beam Capacity 16 M/C Motor RPM 80 m/min (Max) Function Sizing Manufacturing Company ITOCHU Textile M/C Ltd. Sizing M/C (Jupiter) 01 Model MP0000.2195 Serial No 03 MFD(Manufacturing Date) Apr’2008 Country of Origin India Beam Capacity 1 M/C Motor RPM 80 m/min (Max) Function Sizing Manufacturing Company Jupiter Industries Southeast University Industrial Attachment 55  Polytex-460  Polytex BI  Wax In PARAMOUNT textile, Polytex-460 &Polytex-BI are used as the sizing comical. Polytex- 460 &polytex BI is the combination of all others sizing agent except Wax. Sizing Calculation: Total required chemical = (total length* total ends*30%)/(1.6933*count*1000)+200L Sizing M/C: There are two types of sizing M/C Sizing M/C (TSUDAKOMA) 01 Model HS-40 Serial No 254 MFD(Manufacturing Date) Apr’2008 Country of Origin Japan Beam Capacity 16 M/C Motor RPM 80 m/min (Max) Function Sizing Manufacturing Company ITOCHU Textile M/C Ltd. Sizing M/C (Jupiter) 01 Model MP0000.2195 Serial No 03 MFD(Manufacturing Date) Apr’2008 Country of Origin India Beam Capacity 1 M/C Motor RPM 80 m/min (Max) Function Sizing Manufacturing Company Jupiter Industries Southeast University Industrial Attachment 55  Polytex-460  Polytex BI  Wax In PARAMOUNT textile, Polytex-460 &Polytex-BI are used as the sizing comical. Polytex- 460 &polytex BI is the combination of all others sizing agent except Wax. Sizing Calculation: Total required chemical = (total length* total ends*30%)/(1.6933*count*1000)+200L Sizing M/C: There are two types of sizing M/C Sizing M/C (TSUDAKOMA) 01 Model HS-40 Serial No 254 MFD(Manufacturing Date) Apr’2008 Country of Origin Japan Beam Capacity 16 M/C Motor RPM 80 m/min (Max) Function Sizing Manufacturing Company ITOCHU Textile M/C Ltd. Sizing M/C (Jupiter) 01 Model MP0000.2195 Serial No 03 MFD(Manufacturing Date) Apr’2008 Country of Origin India Beam Capacity 1 M/C Motor RPM 80 m/min (Max) Function Sizing Manufacturing Company Jupiter Industries
  56. 56. Southeast University Industrial Attachment 56 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. 3. Squeezing Pressure: A typical roller pressure for wide variety of cotton yarn is given below. First Squeeze: 0.12MPa Secondsqueeze:0.2MPa Immersion roller:0.1MPa 4.Separation Unit: Distances between the lease rods are to be carefully 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 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 Southeast University Industrial Attachment 56 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. 3. Squeezing Pressure: A typical roller pressure for wide variety of cotton yarn is given below. First Squeeze: 0.12MPa Secondsqueeze:0.2MPa Immersion roller:0.1MPa 4.Separation Unit: Distances between the lease rods are to be carefully 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 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 Southeast University Industrial Attachment 56 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. 3. Squeezing Pressure: A typical roller pressure for wide variety of cotton yarn is given below. First Squeeze: 0.12MPa Secondsqueeze:0.2MPa Immersion roller:0.1MPa 4.Separation Unit: Distances between the lease rods are to be carefully 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 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
  57. 57. Southeast University Industrial Attachment 57 308= SIZE BOX 307= SECOND SQUEEZE ROLL 310= LEVEL ADJUSTER 311= STEAM PIPE 312= COVER 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 fibers with yarn. 6. Wax: It acts as a lubricating agent.
  58. 58. Southeast University Industrial Attachment 58 Costing of Size Ingredients Ingredients Cost taka/kg Sure bond 43-53 Starch 29 CMC 139 PVA 267 Size CA 70 Wax 255 Measuring of size take up% of a particular sample Yarn count 40/1 Total ends 7420. Recipes: Water: 600 Lt Sure bond: 60kg Starch: 20kg CMC: 20kg Size CA: 15kg 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%
  59. 59. Southeast University Industrial Attachment 59 Drawing, Denting Southeast University Industrial Attachment 59 Drawing, Denting Southeast University Industrial Attachment 59 Drawing, Denting
  60. 60. Southeast University Industrial Attachment 60 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. 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. 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.
  61. 61. Southeast University Industrial Attachment 61 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. 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.
  62. 62. Southeast University Industrial Attachment 62 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 healed frame and reed count, draw width etc. 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.
  63. 63. Southeast University Industrial Attachment 63 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 yarn with the old piece of cloth wrapped around the surface roller with a number of small knots. Knotting M/c: Knotting (STAUBLI) 02 Model TPM-201-PC Serial No GI 514344 MFD(Manufacturing Date) 2008 Country of Origin Switzerland Volt. 48 V Amp. 2.5 A Function Knotting Manufacturing Company TOPMATIC M/C Co Ltd. Equipment used in Drawing denting and pinning Section: Denting plate (Patti):
  64. 64. Southeast University Industrial Attachment 64 Drawing Hook: Drop Wire: Southeast University Industrial Attachment 64 Drawing Hook: Drop Wire: Southeast University Industrial Attachment 64 Drawing Hook: Drop Wire:
  65. 65. Southeast University Industrial Attachment 65 R&D Southeast University Industrial Attachment 65 R&D Southeast University Industrial Attachment 65 R&D
  66. 66. Southeast University Industrial Attachment 66 R&D Design Cell is one of the most important departments of PARAMOUNT TEXTILE LTD.(weaving). When an 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 production and create an Article code and send this article code the marketing or merchandizing officer and input data to the Data tax 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-DESK DOBBY” From India & KOPPERMANN from 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. Flowchart of R&D: Head office (marketing) CAD /Swatch Feasibility Check Create Dispo number Create CAD (Koppermann&Textronic) Color Analysis Dispo Dispatching Yarn Dyeing Lab/Lab Dip Planning CCI Warping
  67. 67. Southeast University Industrial Attachment 67 CCI Sizing CCI Loom Sample sends in Marketing Dept. Buyer Approval Bulk Order Feasibility check 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. 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. 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. WhenOrder 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
  68. 68. Southeast University Industrial Attachment 68 possible in PARAMOUNT. They Send an Article Request paper. After reaching the Article Request paper Design cell produce Article Code and send mail to the planning and marketing section. Dispo paper contains following types of information: 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. Grey width. 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.
  69. 69. Southeast University Industrial Attachment 69 P.O No: 2012/902 Line No : 01 Count ( Warp x Weft) 40X40 Customer: C & A Yarn Composition (Warp x Weft) 100 % Cotton Finished Fabric Details Dispo No: F205896 Ref : Swatch Ends × Pick (Finished) 84×80 Fabric Type Check Finish fabric width (inch) 57/58” Design Plain Required finished length (meter) 6913 Finish Regular Soft Delivery Date (Finish) 10/12/2012 Grey fabric Details Dispo No: W205896 Request No: P25695 Ends × Pick (Grey) 78×80 Buyer Ref DH# 16634B Grey Width (inch) 62.11 Color Navy/Mint check Require Grey(meter) 7514.13 Reed No 74.25/2 Required loom Production(meter) 7667.48 Reed Width (inch) 65.45 Required warp length (meter) 8519.42 Delivery Date 08/12/2012 Ground inch 4860 R & D Selvedge inch
  70. 70. Southeast University Industrial Attachment 70 Comments Color break down Color Breakdown: Count Shade Color Code Quantity ( kg) Length (Mtr) Cones Warp 40/1 Cream BE11760 308.72 77447.30 270 40/1 Navy NV45321 308.72 77447.30 270 Warp Total 617.44 Section : 9 Weft 40/1 Cream BE11760 308.52 40/1 Navy NV45321 308.52 Weft Total 617.04 Dyed Yarn Details Dispo No: Y205896 Delivery Date: 18/11/2012 SL no Count Shade ALD No Grey yarn (Kg) Dyed yarn (Kg) Yarn Type 1 40/1 Cream BE11760 633.07 617.24 Combed 2 40/1 Navy NV45321 633.07 617.24 Combed Total 1266.13 1234.48
  71. 71. Southeast University Industrial Attachment 71 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
  72. 72. Southeast University Industrial Attachment 72 WEAVING Southeast University Industrial Attachment 72 WEAVING Southeast University Industrial Attachment 72 WEAVING
  73. 73. Southeast University Industrial Attachment 73 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. Process equipment: Air jet loom Loom shed – 1: Total no of loom - 178 Loom shed – 2: Total no of loom - 40
  74. 74. Southeast University Industrial Attachment 74 Lay out plan of weaving Shed 1: Shed 2: Southeast University Industrial Attachment 74 Lay out plan of weaving Shed 1: Shed 2: Southeast University Industrial Attachment 74 Lay out plan of weaving Shed 1: Shed 2:
  75. 75. Southeast University Industrial Attachment 75 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 Picanolomniplus 800 Tappet 06 600-700 10 Picanolomniplus Tappet Dobby 04 450-550 52 Toyota JAT 710 Cam 06 700-950 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 Tsudakoma ZAX 205,205i Cam 02,06 450-600 81 Total 218
  76. 76. Southeast University Industrial Attachment 76 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 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 Model : PS Manufacturer : Sankin engineering Co. Ltd.
  77. 77. Southeast University Industrial Attachment 77 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) Setiakiji 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 Maker : Marubeni Corp 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
  78. 78. Southeast University Industrial Attachment 78 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° How to release or wind a weft: This screen always appears when the machine Stops.Each drum number is displayed. Releasing a weft: Release Single, Turn switch. This switch releases a single turn of wefton the drum. Southeast University Industrial Attachment 78 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° How to release or wind a weft: This screen always appears when the machine Stops.Each drum number is displayed. Releasing a weft: Release Single, Turn switch. This switch releases a single turn of wefton the drum. Southeast University Industrial Attachment 78 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° How to release or wind a weft: This screen always appears when the machine Stops.Each drum number is displayed. Releasing a weft: Release Single, Turn switch. This switch releases a single turn of wefton the drum.
  79. 79. Southeast University Industrial Attachment 79 Release Turns Release Turns switch. This switch releases turns of weft on thedrum. Forward inching switch: This switch should be pressed with INTER-LOCK switch a held down.Holding down FORWARD inching switch runs the machine in the forward direction at allow speed; releasing it stops the machineoperation. Air jet weaving machines run at a speed several times higher than in the conventional ones. Therefore, adjusting them requires instruments suitable for measurement of fast revolution motions, such as pressure gauges, stroboscopes, tension meters, and others as listed below. Southeast University Industrial Attachment 79 Release Turns Release Turns switch. This switch releases turns of weft on thedrum. Forward inching switch: This switch should be pressed with INTER-LOCK switch a held down.Holding down FORWARD inching switch runs the machine in the forward direction at allow speed; releasing it stops the machineoperation. Air jet weaving machines run at a speed several times higher than in the conventional ones. Therefore, adjusting them requires instruments suitable for measurement of fast revolution motions, such as pressure gauges, stroboscopes, tension meters, and others as listed below. Southeast University Industrial Attachment 79 Release Turns Release Turns switch. This switch releases turns of weft on thedrum. Forward inching switch: This switch should be pressed with INTER-LOCK switch a held down.Holding down FORWARD inching switch runs the machine in the forward direction at allow speed; releasing it stops the machineoperation. Air jet weaving machines run at a speed several times higher than in the conventional ones. Therefore, adjusting them requires instruments suitable for measurement of fast revolution motions, such as pressure gauges, stroboscopes, tension meters, and others as listed below.
  80. 80. Southeast University Industrial Attachment 80 Production Procedure 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. 12. Weft cutter. 13. Drop wire and bar. 14. Leno selvedge attachment. 15. Main nozzle. 16. Sub nozzle.
  81. 81. Southeast University Industrial Attachment 81 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 Temple to reed: 3mm EDP pins 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° Shed depth: 2.5cm →Twill: Shed angle: 25° Shed depth: 3.5cm
  82. 82. Southeast University Industrial Attachment 82 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) Key Accessories: Nipper, Pointer, Cutter, Comb etc. 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 are 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.
  83. 83. Southeast University Industrial Attachment 83 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.). 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.
  84. 84. Southeast University Industrial Attachment 84 FINISHING Southeast University Industrial Attachment 84 FINISHING Southeast University Industrial Attachment 84 FINISHING
  85. 85. Southeast University Industrial Attachment 85 Finishing Section Finishing Machineries 1. Singeing De-sizing 1 set 2. Washing machine 1 set 3. Stenter 1 set 4. Peach Finishing 1 set 5. Sanforizing 1 set 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 luster in the finished fabric and to prepare the fabric for next process. De-sizing 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. Southeast University Industrial Attachment 85 Finishing Section Finishing Machineries 1. Singeing De-sizing 1 set 2. Washing machine 1 set 3. Stenter 1 set 4. Peach Finishing 1 set 5. Sanforizing 1 set 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 luster in the finished fabric and to prepare the fabric for next process. De-sizing 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. Southeast University Industrial Attachment 85 Finishing Section Finishing Machineries 1. Singeing De-sizing 1 set 2. Washing machine 1 set 3. Stenter 1 set 4. Peach Finishing 1 set 5. Sanforizing 1 set 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 luster in the finished fabric and to prepare the fabric for next process. De-sizing 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.
  86. 86. Southeast University Industrial Attachment 86 Scouring and Bleaching Scouring is the process by which all natural and adventitious impurities such as well as oil, wax, fat etc. are removed to produced hydrophilic and clean textile material. It is vital process of wet processing. It is done to make the fabric highly hydrophilic and to remove impurities such as oils, 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. Scouring & Bleaching M/C 01 Model LMHO-022 Serial No 200R MFD(Manufacturing Date) Aug’08 Country of Origin China M/C Temp. (60-90)C Function Scouring & Bleaching Manufacturing Company Jiangsu Redflag Printing & Dyeing Co Ltd. Southeast University Industrial Attachment 86 Scouring and Bleaching Scouring is the process by which all natural and adventitious impurities such as well as oil, wax, fat etc. are removed to produced hydrophilic and clean textile material. It is vital process of wet processing. It is done to make the fabric highly hydrophilic and to remove impurities such as oils, 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. Scouring & Bleaching M/C 01 Model LMHO-022 Serial No 200R MFD(Manufacturing Date) Aug’08 Country of Origin China M/C Temp. (60-90)C Function Scouring & Bleaching Manufacturing Company Jiangsu Redflag Printing & Dyeing Co Ltd. Southeast University Industrial Attachment 86 Scouring and Bleaching Scouring is the process by which all natural and adventitious impurities such as well as oil, wax, fat etc. are removed to produced hydrophilic and clean textile material. It is vital process of wet processing. It is done to make the fabric highly hydrophilic and to remove impurities such as oils, 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. Scouring & Bleaching M/C 01 Model LMHO-022 Serial No 200R MFD(Manufacturing Date) Aug’08 Country of Origin China M/C Temp. (60-90)C Function Scouring & Bleaching Manufacturing Company Jiangsu Redflag Printing & Dyeing Co Ltd.
  87. 87. Southeast University Industrial Attachment 87 Stentatering Stentering is done to soften and to control width of the fabric. It is done to give the required finish to the fabric. Stentering (VIROCK) M/C 01 Model LV K4000-200×8 Serial No 0807 MFD(Manufacturing Date) 28th Aug’2008 Country of Origin China Power Supply 30V ,<16A M/C rpm 60m/min Function Soft & Width Controlling Manufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd. Some finishes: 1. Soft/regular finish 2. ETI (Easy to Iron)/wrinkle free finish/resin finish 3. Easy care 4. Paper touch finish 5. Peach finish Southeast University Industrial Attachment 87 Stentatering Stentering is done to soften and to control width of the fabric. It is done to give the required finish to the fabric. Stentering (VIROCK) M/C 01 Model LV K4000-200×8 Serial No 0807 MFD(Manufacturing Date) 28th Aug’2008 Country of Origin China Power Supply 30V ,<16A M/C rpm 60m/min Function Soft & Width Controlling Manufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd. Some finishes: 1. Soft/regular finish 2. ETI (Easy to Iron)/wrinkle free finish/resin finish 3. Easy care 4. Paper touch finish 5. Peach finish Southeast University Industrial Attachment 87 Stentatering Stentering is done to soften and to control width of the fabric. It is done to give the required finish to the fabric. Stentering (VIROCK) M/C 01 Model LV K4000-200×8 Serial No 0807 MFD(Manufacturing Date) 28th Aug’2008 Country of Origin China Power Supply 30V ,<16A M/C rpm 60m/min Function Soft & Width Controlling Manufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd. Some finishes: 1. Soft/regular finish 2. ETI (Easy to Iron)/wrinkle free finish/resin finish 3. Easy care 4. Paper touch finish 5. Peach finish
  88. 88. Southeast University Industrial Attachment 88 Typical recipe: Soft finish: Construction: 40x40/120x80 Tubingal 11/2: 8 gm/L Jinssofter AS852: 20 gm/L Terasil NNO: 10 gm/L Acetic acid: 0.5 gm/L Resin finish: Construction: 50x50/144x90 Fixapreat eco: 50 gm/L CondensolFm: 10 gm/L (Catalyst) Siligenpcp: 20 gm/L (Softening agent) Aniston EPD: 20 gm/L (Softening agent) Jinsofter AS822: 20 gm/L (Softening agent) Acetic acid: 0.5 gm/L Karoline jet B: 1gm/L (Wetting agent) Southeast University Industrial Attachment 88 Typical recipe: Soft finish: Construction: 40x40/120x80 Tubingal 11/2: 8 gm/L Jinssofter AS852: 20 gm/L Terasil NNO: 10 gm/L Acetic acid: 0.5 gm/L Resin finish: Construction: 50x50/144x90 Fixapreat eco: 50 gm/L CondensolFm: 10 gm/L (Catalyst) Siligenpcp: 20 gm/L (Softening agent) Aniston EPD: 20 gm/L (Softening agent) Jinsofter AS822: 20 gm/L (Softening agent) Acetic acid: 0.5 gm/L Karoline jet B: 1gm/L (Wetting agent) Southeast University Industrial Attachment 88 Typical recipe: Soft finish: Construction: 40x40/120x80 Tubingal 11/2: 8 gm/L Jinssofter AS852: 20 gm/L Terasil NNO: 10 gm/L Acetic acid: 0.5 gm/L Resin finish: Construction: 50x50/144x90 Fixapreat eco: 50 gm/L CondensolFm: 10 gm/L (Catalyst) Siligenpcp: 20 gm/L (Softening agent) Aniston EPD: 20 gm/L (Softening agent) Jinsofter AS822: 20 gm/L (Softening agent) Acetic acid: 0.5 gm/L Karoline jet B: 1gm/L (Wetting agent)
  89. 89. Southeast University Industrial Attachment 89 4. Peach finish: Peach finishing is done to give soft, hairy and smooth surface effect to the fabric. For this emery rollers used. Peach Finish M/C (Xetma) 01 Model DE-08280-Aue Serial No 160-008/NW 2200 MFD(Manufacturing Date) 2008 Country of Origin Germany Compressed Air 6 bar Power Supply B/PE/NAC-4000/+10%,50 Hz,200 A Function Finishing Manufacturing Company XetmaVollenweider GmbH Co Ltd. 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) Sunforising M/C 01 Model LMH-442-200 Serial No 804 MFD(Manufacturing Date) 2008 Country of Origin China Steam 2.5 Kgf/cm2 Pressure 2.8KN Function Calendaring Manufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd.
  90. 90. Southeast University Industrial Attachment 90 Finishing To ensure safe and consumer friendly fabric PARAMOUNT has its own high- tech laboratoryand 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. Testingequipments are sourced from renowned companies, such as- JAMES H HEAL-UK SDL ATLAS-UK DATA COLOR SpectroPhotometer-USA
  91. 91. Southeast University Industrial Attachment 91 QA Southeast University Industrial Attachment 91 QA Southeast University Industrial Attachment 91 QA
  92. 92. Southeast University Industrial Attachment 92 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 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
  93. 93. Southeast University Industrial Attachment 93 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 fibers 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 tighter than another warp Mandible Reject 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
  94. 94. Southeast University Industrial Attachment 94 Quality Assurance Dept Finished Fabric Test Report Date: Order No. : Test Std. : P.T .L Customer : Construction : Shade : Fiber Comp. : 100% Cotton Recipe No. : Finish Type : Test Parameters Test Method Requirement Results Remark Threads Per Inch Ends Picks Yarn Count ISO 7211-5 Warp Weft FabricWidth(Inch) Overall Useable Fabric Weight (gm/m 2 ) EN ISO 12127 Max deviation 5% Dimensional Stability To Washing EN ISO 6330/4A:2000 Shirt/Dress Crepes. Voiles Warp +/-3.0% Max. 5% Weft +/-3.0% Max. 5% Tensile Strength ISO 13934-2:1999 Warp 140 N 100 N Weft 140 N 100 N Tear Strength ISO 13937-1:2000 Warp 7 N 6 N Weft 7N 6 N Seam Slippage ISO 13936-1:2004 (6 mm) Warp 80 N 60 N Weft 80 N 60 N Abrasion Resistance (Martindale) EN ISO 12947-2:1998 Lt. Shade Dk. Shade 4c @ 10’000revs 3c @ 10000 revs Pilling Resistance ISO 12945-2:2000 ¾ @ 2’000 Revs. Color Fastness To Crocking ISO 105 x 10 Lt. Shade Dk. Shade Dry- 4s 3s Wet- 3/4s 2s Color Fastness To Wash ISO 105 C06, 60℃ Change- 4c Change- 3/4 Staining- 3/4 Staining- 2/3 Color Fastness To Water ISO 105 E01 Change- 4c Change- 3/4 Staining- 3/4s Staining- 2/3 Color Fastness To Perspiration ISO 105 E04 (Acid) Change- 4c Change- 3/4 Staining- 3/4 Staining- 2/3 ISO 105 E04 (Alkali) Change- 4c Change- 3/4 Staining- 3/4 Staining- 2/3 Color Fastness To Light ISO 105 B02 Change- 5c, White & Pastels- 4c ………………….. ………………………. Tasted by Approved by
  95. 95. Southeast University Industrial Attachment 95 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 Pilling resistance ICI pilling box James. H. Heal & Company, Halifax,
  96. 96. Southeast University Industrial Attachment 96 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& Carbolite James. H. Heal & Company, Halifax, England Light Fastness Light fastness Tester(Mercury vapor lamp) James. H. Heal & Company, Halifax, England Crocking Fastness Crocometer James. H. Heal &
  97. 97. Southeast University Industrial Attachment 97 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
  98. 98. Southeast University Industrial Attachment 98 Utility Southeast University Industrial Attachment 98 Utility Southeast University Industrial Attachment 98 Utility
  99. 99. Southeast University Industrial Attachment 99 It is one of the important sectors of a textile factory. Generator, Air compressor, Boiler, Chiller, Water treatment plant (WTP), Effluent treatment plant (ETP), Humidification plant, Dryer Southeast University Industrial Attachment 99 It is one of the important sectors of a textile factory. Generator, Air compressor, Boiler, Chiller, Water treatment plant (WTP), Effluent treatment plant (ETP), Humidification plant, Dryer Southeast University Industrial Attachment 99 It is one of the important sectors of a textile factory. Generator, Air compressor, Boiler, Chiller, Water treatment plant (WTP), Effluent treatment plant (ETP), Humidification plant, Dryer
  100. 100. Southeast University Industrial Attachment 100 ETP The effluent generated from different sections of a textile mill must be treated before they are discharged to environment. Various chemicals & physical means are introduced for this purpose. The effluent treatment plant in PARAMOUNT TEXTILE LTD. is biochemical combination process developed by India. Objects: This process is provided for treating the effluents of dyeing, finishing, weaving & thus allow discharging it s per norms given by World Bank dept of environment of Bangladesh. This process comprises of collecting, pumping, clarification, Characteristics of raw effluents: Volume : 140 cubic meter / day Peak flow : 148 cub met / hr pH : 7.6-7.8 BOD : 250-800 PPM COD : 500 PPM TDS : 2000 PPM TSS : 200 PPM D.O :0.50- 0.60 PPM Color : Reddish- Black
  101. 101. Southeast University Industrial Attachment 101 Requirement of discharge effluent as per World Bank: pH : 7- 7.5 BOD : < 50 COD : < 198 TSS : < 100 TDS : 602 DO : 5-5.5 Color : No. Chemicals used & their colors: Chemicals used Appearance Ferrous sulphate Granular solid, greenish color Lime White granular solid Poly acrylate White granular solid Sulphuric acid Clear liquid
  102. 102. Southeast University Industrial Attachment 102 Product Quality Check: Following chemical tests are carried out to check the quality: - BOD - COD - Total suspended solids - Total dissolved solids - Color - pH Flow Chart of Effluent Treatment: Raw effluent ↓ Equalization ↓ Collection Sump ↓ Pump station ↓ Clarifier ↓ Aeration tank ↓ Setting tank ↓ Clear water, pH check ↓ Drain
  103. 103. Southeast University Industrial Attachment 103 Sludge Separation: Sludge of DAF ↓ Sludge thickening plant ↓ Sludge drying be
  104. 104. Southeast University Industrial Attachment 104 Typical Output of the Plant: This information we collect from the regular ETP operation chart Raw effluent treated 15000 LPH Raw effluent color Reddish Black Raw effluent pH 7.8 Raw effluent TDS 1998 Raw effluent TSS 200 Raw effluent DO 0.52 Raw effluent BOD 250 Raw effluent COD 500 Treated effluent color Nil Treated Effluent Temp 380 C Treated Effluent PH 7.2 Treated Effluent TDS 600 Treated Effluent TSS 100 Treated Effluent DO 5 Treated Effluent BOD 45 Treated Effluent COD 198
  105. 105. Southeast University Industrial Attachment 105 WTP WTP means water treatment plant. In normal water there are including many type of organic compound such as Mg, Ca, Zn, K, Fe etc. To remove this compound WTP are used in textile industries. Otherwise after dyeing some mark are found in woven fabric. Another many problems are found in a fabric such as shade matching problem, dyes problem. To minimize this type of problems WTP are used. So it is very useful for textile industries. In paramount textile there are 2 water treatment plants. Objective  To make suitable water for Dyeing, Sizing, Finishing etc.  To minimize various type of marks. Effect  Various type of mark in fabric, dyeing problem etc. Working process of WTP There are 3 tanks in WTP, which are: 1. Multi Grad Filter 2. Braine Solution Tank 3. Softener Tank (Resin are include in Softener tank) Flow diagram of WTP: Ground water Pump Multi grad filter Braine solution Softener Yarn dyeing section Sizing Finis
  106. 106. Southeast University Industrial Attachment 106
  107. 107. Southeast University Industrial Attachment 107 Aeration In between the aeration tank, the Fe is removed mainly. Basically Fe is not removed in general way. So it is very match tough to remove. By oxidation Fe is remove easily. Multi Grad Filter It is a7 layers tank where the bacteria remove. These 7 layers are made by sand which work as filter. Softener Tank In softener tank, Mg, Ca, Zn, K is removed. Actually all these metal parts are formed in “ion” and reacts with resign and water made metal free. Brine solution When capacity of ionization power of resign is discriminately low then brine solution is helped to recover the power. Capacity Three plants are working here. A. 150 m3/hr B. 100 m3/hr C. 60 m3/hr Different M/c which are used in Utility section: Diesel Engine 01 Model GSW 275 Serial No 0237044/006 MFD(Manufacturing Date) Jan’08 Country of Origin UK WDG 311 Frame Core UCD 274K RPM 500 Power 50 Hz, 400 V Function Power Generate Manufacturing Company PRAMAC Co. Ltd Chiller 01 Model YSX 437 (3)-174 Serial No 011 MFD(Manufacturing Date) Nov’11 Country of Origin China Chilled water Temp 7C
  108. 108. Southeast University Industrial Attachment 108 Chilled water Flux 273 M3 /Hr Cooling water Inlet 32C Cooling water Flux 425 M3 /Hr Fuel Gas Inlet Temp 195C Fuel Gas Flux 16729 Kg/Hr Steam Pressure 8 MPa Steam Consumption 1860 Kg/Hr Power Supply 3 , 400V,50 Hz Electric Power 72 KW Working Wt. 24.1 Ton Ex Work No SXHL 1331 Function To Cool the water Company Name Jiangsu Shungliang Air Conditioning Equipment Co. Ltd Pump 15 Model Y 160 ML 2 Serial No 080429079 MFD(Manufacturing Date) Country of Origin China Cos  0.88 Power 15 Hp RPM 2930 Power Supply 50 Hz, 380 V, 21.8 A Function Water Supply Manufacturing Company Generator 05 Model JGS 320 GSNL Serial No 5849181 MFD(Manufacturing Date) 2008 Country of Origin Austria Rated Power 1415 KW Rated Voltage 400/231 V Current 2042 A Mass 15500 Kg Max Temp 30 C Function Current Generate Manufacturing Company GE Jenbacher GmbH & Co. Ltd Boiler (Danlim Royal) 02 Model ZL-Z Serial No 014A MFD(Manufacturing Date) Jun’08 Country of Origin Korea Actual Evaporation 8000 Kg/Hr
  109. 109. Southeast University Industrial Attachment 109 Design Pressure 1 Mpa Heat Efficiency 90 % Fuel Consumption 42 Nm3 /Hr Heating Surface 97 M2 Capacity 100 M3 /Min Power 15 KW Normal Size 40 A Manufacturing Company DanelimRoyel Boiler Co. Ltd Boiler (Weihupt) 01 Model G 70/2-A Serial No 0085Q 0723 MFD(Manufacturing Date) 2010 Country of Origin Germany Gas Type Natural (N) Rating (Min 800-Max 8500) KW Supply Pressure (Min 15-Max 500) mbar Electric Rating 2389 KW Power 400 V, 1-50 Hz, 10 A Manufacturing Company Max WeishauptGmpHCo.Ltd Air Compressor 06 Model ZT 250 VSD Serial No APF 154024 MFD(Manufacturing Date) 2010 Country of Origin Belgium Working Pressure 8.6 Bar Input Power 240 KW Rotational Shaft speed 2370 r/min Manufacturing Company Atlas Copco Air Power Co. Ltd Air Dryer 06 Model FD 1250 A FS Serial No 8573-1 MFD(Manufacturing Date) 08 Country of Origin Belgium Working Air 13 Bar Weight 860 Kg, Power Supply 400 V, 50 Hz, 8.3 KW Ambient Max 45C Manufacturing Company Atlas Copco Air Power Co. Ltd Cooling Tower 08 Model ZONZLG 760
  110. 110. Southeast University Industrial Attachment 110 Serial No 200-0-11-920 MFD(Manufacturing Date) Nov’08 Country of Origin China Power 11 KW RPM 180 Model Of Blower Fan JTLZ 58 Output Temp 32C Input Temp 38C Water Pressure 44 KPa Frame Wt 3820 Kg Manufacturing Company SHUANGLIANG FRP COOLING MACHINARY CO.
  111. 111. Southeast University Industrial Attachment 111 Maintenance Southeast University Industrial Attachment 111 Maintenance Southeast University Industrial Attachment 111 Maintenance
  112. 112. Southeast University Industrial Attachment 112 Maintenance 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 Maintenance 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.
  113. 113. Southeast University Industrial Attachment 113 Maintenance of sizing machine Periodical Inspection Daily Inspection 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. →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; →Exhausting drain in the air filter equipment.
  114. 114. Southeast University Industrial Attachment 114 Weekly inspection →Exhaust drain from the air compressor and the pressure reducing valve with the filter; →Remove lint from the static electricity eliminator. 1. Roll chain tension 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. Checkingpoint’s are- a.Size circulation pump b.Winding motor 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 replaces it. 3. Pressuredrop after passing the air filter in the pneumatic piping When the pressure difference between the primary and secondary side reaches 0.1MParepace the element.

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