Industrial attachment of MM KNITWEAR Ltd

SOUTHEAST UNIVERSITY
Department of Textile Engineering
Report on 2 months Industrial Attachment
As a curriculum in Wet Processing Technology
(From 05th February to 06th April, 2011)
At
M M Knitwear Ltd.
Konabari,Nilnagar, Gazipur.
Supervising Teacher:
Prof. Syed Fakhrul Hassan Murad
Chairman
Department of Textile Engineering
Southeast University
Submitted By :
Kazi Mamun Hossain
ID No: 2007100400024
Md.Azijul Haque
ID No: 2007100400045
Dhaka, 16.05.2011

ACKNOWLEDGEMENT
At first my gratefulness goes to Almighty Allah to give me strength and ability to
complete the industrial training and this report. You have made my life more bountiful.
May you name be exalted, honored and glorified.
Now I wish to take this excellent opportunity to thank a lot of people who have
assisted and inspired me in the completion of my training period:
I express my gratitude to Prof. Syed Fakhrul Hassan Murad, Head, Department
of Textile Engineering, and my supervisor, to whom I am extremely indebted for his
tremendous support and guidance throughout my training period. Being working with
him I have not only earned valuable knowledge but was also inspired by his
innovativeness which helped enrich my experience to a greater extent. His ideas and way
of working was truly remarkable.
I would like to thank the management of the M M Knitwear Ltd. for giving me the
opportunity to do the industrial training successfully and also their valuable suggestions.
My deepest appreciation goes to Mr. Nurul Islam, General Manager, M M Knitwear Ltd.
for his permission to conduct my industrial training without which it would be
uncompleted. The generous support is greatly appreciated.
I would also like to thank executives, senior executives and other officials of M
M Knitwear Ltd. for helping me to complete industrial training successfully. My
gratitude also goes to all the employees of M M Knitwear Ltd. for their sincere co-operation,
support and valuable advices.
Last but not least, thanks go to my precious family for their never ending love and
inspire at every stages of my life. Without their continuous support I realize that I would
not be a person I am right now.

TABLE OF CONTENTS
CHAPTER – 1..................................................................................................3
1 Project Description............................................................................................5
1.1 COMPANY PROFILE....................................................................................................6
1.2 location:......................................................................................................................7
1.3 Basic lay-out of the factory .......................................................................................8
1.4 Vision and Mission...................................................................................................10
1.5 Different Departments.............................................................................................11
1.6 Remarks....................................................................................................................11
CHAPTER – II......................................................................................................13
2 Man power management.................................................................................14
2.1 Dyeing & Finishing Section.......................................................................................15
2.2 Knitting section.........................................................................................................16
2.3 Management System...............................................................................................17
2.4 Duties & Responsibilities of Production Officer.......................................................17
2.5 Duties & Responsibilities of Senior Production Officer...........................................18
2.6 Duties & Responsibilities of GM (Production).........................................................18
2.7 Remarks....................................................................................................................18
CHAPTER – III.....................................................................................................19
3 Machine Description........................................................................................20
3.1 Lay-out Of Dyeing & Finishing Section.....................................................................20
3.2 Dyeing Machinery....................................................................................................22
3.3 Finishing Machinery.................................................................................................27
3.4 Description of Machinery.........................................................................................28
3.4.1 Working principle of dyeing machinery............................................................28
3.4.2 Working principle of finishing machinery.........................................................29
3.5 Remarks....................................................................................................................41
CHAPTER – IV....................................................................................................42
4 Raw material.....................................................................................................43
4.1 Grey Fabrics..............................................................................................................43
4.2 Dyes..........................................................................................................................43

4.3 Chemicals.................................................................................................................45
4.4 Remarks....................................................................................................................45
CHAPTER-V........................................................................................................46
5 PRODUCTION PLANNING,SEQUENCES & OPERATION.............................47
5.1 Process flow chart of knit dyeing.............................................................................47
5.2 Dyeing work flow chart............................................................................................48
5.3 Dyeing Parameters...................................................................................................49
5.4 Description of production process...........................................................................50
5.5 Dyeing Recipe...........................................................................................................53
5.6 Finishing...................................................................................................................56
5.7 Finishing machine setting.........................................................................................57
5.8 Daily Production Report...........................................................................................59
5.9 Monthly Average Production...................................................................................59
5.10 Remarks..................................................................................................................59
CHAPTER – VI....................................................................................................60
6 QUALITY ASSURANCE SYSTEM...................................................................61
6.1 Quality Policy............................................................................................................61
6.2 Quality Assurance Procedure...................................................................................61
6.3 Inspection area.........................................................................................................62
6.4 PROBLEMs ENCOUNTERED IN DYEING....................................................................63
6.5 Process of Shade Matching......................................................................................65
6.6 List of Equipments....................................................................................................65
6.7 Quality Standard.......................................................................................................66
6.8 Remarks....................................................................................................................67
CHAPTER- VII.....................................................................................................68
7 Maintenance.....................................................................................................69
7.1 Maintenance of Machinery .....................................................................................69
7.2 Routine ....................................................................................................................69
7.3 Manpower Setup for Maintenance..........................................................................70
7.4 Maintenance Procedure...........................................................................................70
7.5 Maintenance Tools and Equipments.......................................................................73

7.6 Remarks....................................................................................................................74
CHAPTER- VIII....................................................................................................75
8 UTILITY SERVICES..........................................................................................76
8.1 Utility Facilities Available ........................................................................................76
8.2 Source of Utility........................................................................................................76
8.3 Capacity and Other Technical Details......................................................................76
8.4 Cost of different Utilities .........................................................................................79
8.5 Remarks....................................................................................................................79
CHAPTER – IX....................................................................................................80
9 STORES & INVENTORY CONTROL................................................................81
9.1 Scope of Inventory Control......................................................................................81
9.2 Frequency of Inventory Update...............................................................................81
9.3 Inventory Control System for Raw Materials...........................................................81
9.4 Inventory Control System for Finished fabric..........................................................82
9.5 Inventory Control System for Spare Parts................................................................82
9.6 Remarks....................................................................................................................82
CHAPTER-X........................................................................................................83
10 COST ANALYSIS............................................................................................84
10.1 INTRODUCTION......................................................................................................84
10.2 Costing elements....................................................................................................84
10.3 Knitting Charge of Different Fabrics.......................................................................84
10.4 Dyeing Charge of Different Fabrics........................................................................85
10.5 Finishing Charge of Different Fabrics.....................................................................85
10.6 COSTING OF THE PRODUCT....................................................................................86
10.7 Remarks..................................................................................................................86
CHAPTER – XI....................................................................................................87
11 MARKETING ACTIVITIES..............................................................................88
11.1 Consumer of Products............................................................................................88
11.2 Country of Export...................................................................................................88
11.3 Local Market...........................................................................................................88
11.4 Marketing Strategy.................................................................................................88
11.5 Duties & Responsibilities of Marketing Officer......................................................89

11.6 Remarks..................................................................................................................89
CHAPTER –XII....................................................................................................90
12 Effluent Treatment Plant (ETP).....................................................................91
12.1 Process Flow chart of Biological Effluent Treatment Plant....................................91
12.2 Function of different Unit of Biological Effluent Treatment Plant (E T P).............92
12.3 Product Quality Checked........................................................................................93
12.4 Remarks..................................................................................................................93
CHAPTER –XIII...................................................................................................95
13 Conclusion......................................................................................................96
13.1 SOME SUGGESTIONS..............................................................................................96
13.2 Limitations of the report........................................................................................97

Industrial Attachment Introduction
Introduction :
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 M M Knitwear Ltd , which is a 100%
export, oriented composite Knit Dyeing Industry. It has well planned & equipped fabric
and Knit dyeing-finishing units in addition to facilitate Knitting and Knit wear
manufacturing.
The rationale behind the existing structure and future expansion of M M Knitwear
Ltd is to capture value-added at each stage of the textile manufacturing process.
Despite Bangladesh’s lack of indigenous cotton production capacity, M M Knitwear Ltd
has leveraged Bangladesh’s labor cost advantage and export competitiveness to the
Maximum.
Southeast University Page | 1

Industrial Attachment Objectives
Objectives :
Þ To familiarize with the factory and production.
Þ To set the sequential work and factory layout
Þ To keep a motel on the deviation between theory and industrial bulk
production
Þ To correlate between institutional and industrial working techniques
and procedures
Þ To observe the management system
Þ To have a concept on production planning, costing, marketing
techniques etc
Þ To know about waste reduction and utilization
Þ To know about how a technical person developed quality of products
at various steps (knitting, dyeing, finishing and garments making)
Þ To have a proper knowledge on the product development to customer
handling

CHAPTER – 1
PROJECT
DESCRIPTION

Industrial Attachment Project Description
M M Knitwear LTD

1 PROJECT DESCRIPTION
M M Knitwear Ltd has started manufacture and export of garments since 2001.
The beginning M M Knitwear Ltd has a very good reputation as a financially sound and
ethical business house. It has a long term association with selected factories, some of
them are certified in terms of social and quality compliance by world’s highest rating
bodies, and outstanding sourcing capabilities. Thus M M Knitwear Ltd has been able to
prove itself to be a reliable supplier for knit item in any style and design
Specializing in all kinds of knitted items. It is housed in its own building surrounding an
area of 310,000 sq. ft. And 4,300 workers and stuff.
The determination to achieve superior customer service and on time delivery has earned
M M Knitwear Ltd recognition as an invaluable player and the desire to succeed in
customer satisfaction with every order makes the M M Knitwear Ltd team even stronger
it’s these fundamental that keep this unit in the game and wining every time.
Buyers:
Sl. buyers
1 NEW YOURKE
2 MERCURY
3 ROWA
4 VISAGE
5 WHITE STONE
6 LI & FUNG
7 SPRING FIEL
GENEREL INFORMATION ABOUT THE FACTORY

1.1 COMPANY PROFILE
Name of the project : M M knitwear LTD.
Type of the project : 100% Export oriented Knitwear industries
Year of establishment : It was established in the July2001.
Address : Factory, Ambag road, Konabari , Nilnagar
Gazipur, Bangladesh.
Head office : House #16, Road #10, Sector # 1,Uttara Model Town
Dhaka-1230, Bangladesh
Investors : Md. Mofizul Islam, Managing Director
History of the project : M M Knitwear has started manufacture and export of
garments since 2001.
Project Cost : The project cost of M M Knitwear Ltd is nearly
100.croretaka.
Annual production Capacity: The annual production capacity in MMKL ltd are given
Below-
Dyeing & Finishing Capacity : 7250 Tons. (Around)
Knitting Capacity: 3250Tons. (Around)
Sewing: 50000 pcs/day (Average)
Area : 310,000 sq. ft.

1.2 location:
Gazipur Chowrasta
UR
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Department
of Textile
Engineering
SEU
TANGAIL ROAD
MymeNS
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ighway
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dhaka
GA
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M M
Knitwear
Ltd.
A
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KONABARI
LOCATION OF M M KNITWEAR LTD

1.3 Basic lay-out of the factory
W
S N
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2
4
5
3
6
E
NT
R
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E
X
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7
1
Vision & mission of the project:

1 : Security office.
2 : Administration office
3 : Fabrics Store (Gr.Floor)+Knitting (2ndFloor+3rd floor), . .
Human Resources Department (HRD)(4thFloor), .
Marchanding section (5thFloor), garments(6th Floor – 9th floor)
4 : Yarn store (Gr. Floor)+ +Garment section(1st Floor – 7th floor)
5 : Fabric dyeing & finishing section.
6 : Effluent Treatment Plant (ETP).
7 : Generator house, Water Treatment Plant(WPT), Maintenance building.

1.4 Vision and Mission
The mission and vision of M M Knitwear Ltd. is to manufacture and deliver high
quality readymade garments (RMG) to its customers. The core objective is to attain and
enhance customer satisfaction by providing on time delivery of desired quality
readymade garments and also to increase efficiency of workforce.
To attain these objectives, the management of M M Knitwear Ltd. has decided to
adopt the following-
1. To increase awareness regarding customers requirements throughout the
organization.
2. By providing training to develop efficiency of the employee.
3. To collect customer’s feedback regularly to know about their conception about
their company and to take timely appropriate action.
4. To reduce the percentage of wastage / rejection minimum by 2% per annum’s
implement and monitor ISO 9001:2000 quality management system within the
organization
Main Production : Basic T-Shirt, Tank top, Long Sleeve- Shirt, Polo
Shirt, Shorts, Ladies & Kids Knitwear & all kinds
of knit garments & Knit fabrics.
Fax Number : + 880 – 2 – 8922483
E–mail Address : info@mmknitwear.com
URL : http://www.mmknitwearbd.com
Certification & awards : Oeko Tex Standard 100 Certified by the
concern authority.
Last year Export Turnover : 18.50 Million U.S Dollars
Workers and Stuff : 4,300
The annual Production capacity of M M knitwear Ltd is an approximate idea, it may
vary.

1.5 Different Departments
To ensure smooth running of various activities, some departments are available
they are given bellow:
 KNITTING SECTION:
1.Knitting
2.Inspection
 KNIT DYEING SECTION:
1.Batch section
2.Store house for dyes & chemicals
3.Dye house
4.Dyeing & QC lab
5.Finishing
 GARMENTS SECTION:
1.Merchandising
2.Sample
3.Production
 MAINTENANCE:
1.Electrical
2.Mechanical
 ACCOUNTS & COMMERCIAL SECTION
 ADMIN SECTION
Physical Infrastructure :
Buildings- one ten storied building, one six storied building, and 1 dyeing shade.
Buildings are made by brick.
Total Area of Industry : 3,00,000 Sq.Ft
1.6 Remarks
The company owns 300000 Sq. Ft. of high land property at
Ambag,Konabari,Gazipur,Dhaka; which is 10 km from the Gazipur Chourasta. Charming
sights along with natural beauty of rural areas with no hazards or air pollution attracts the
foreign buyers during their visits. The company has the desire to achieve recognition of
the project as the ‘M M Industrial Park’ and to set up within the park area industries and
health care center in near future. Plans include for Acrylic Yarn manufacturing unit,
Packaging unit, Designing unit and Hospital.

CHAPTER – II
MANPOWER MANAGEMENT

Industrial Attachment Man power Management
2 MAN POWER MANAGEMENT
The company has skilled administration, management and marketing team guided by
proficient, dexterous & experienced leaders of offer right solution for the consumers with the
right eminence & with the shortest lead-time for the export market in Bangladesh. The best
use of continuous development of human resources by providing them standard equal
opportunity is the keys for achieving comprehensive competence in all level of the
organizational hierarchy.
M.M. knitwear ltd the Managing Director/ Chairman who controls the entire factory. And
the others respective department chief controls their department in this factory.
In this below the organ grams of administration and the others department is showing:
Deputy
Chief Egg.
Electrical
Eng.
Sub assistant
Eng.
Foreman
Medical Officer
Nurse
Deputy
Account
Officer
Accounts
Assistant
Accounts
Officer
Officer
Senior
Clark
Junior
Clark
Peon
Managing director
Director, H R Dept.
Mechanical
Egg.
Sub assistant
Eng.
Foreman
Assistant
General
Manager
Marketing
Officer
Store
Manager
Security (ADMIN)
Officer
Assistant
Security
Officer
Security
Havilder
.Security
Guard
Asst. Chief
store Manager
Asst. Officer
Store
officer
Foreman
Assistant
Manager
(ADMIN)
Administration
Officer
Assistant
Administration
Officer
Administration
Assistant
Peon

2.1 Dyeing & Finishing Section
Finishing
In charge
Sewing man
Squeeze
Operator
Dryer
Operator
Lab
In charge
Lab
Technician
GM
PM
APM
SPO Batch
In charge
PO
APO
Supervisor
Sr. Operator
Asst. Operator
Operator
Sewing man
Helper
Turning m/c
Operator
Helper
Compactor
Operator
Helper
Q.C.
Technician

2.2 Knitting section
AGM
PO
Store Incharge Knitting Master Supervisor
Section-wise manpower
Fitter man
Operator
Department Manpower
Fitter man
Operator
Knitting 150
Dyeing & Finishing, Lab & QC 320
ETPs 10
Garments 3590
Power, Boiler, Utility & Maintenance 50
Inventory 10
Administration 77
Security 55
Others 44
Total 4306

Management Medium:
 Intercom telephone
 Fax
 E-mail
 Written letters & Papers
 Oral
2.3 Management System
Þ Buyer sample is send to G.M.
Þ Matching is done by lab in charge.
Þ Sample is prepared by dyeing master.
Þ Sample is send to the buyer for approval.
Þ Approved sample is returned and taken as STD. Sample for bulk production.
Þ Asst. dyeing master gives responsibilities to production officer.
Þ Then production officer, with the supervisors start bulk production.
Þ On line and off line quality check is done by lab in charge and asst. dyeing master.
Þ After dyeing finishing in charge controls the finishing process with the supervision of
production officer.
Þ After finishing, the material is checked by dyeing master.
Þ Finally G.M. checks the result with dyeing master and decision is taken for delivery.
2.4 Duties & Responsibilities of Production Officer
1. To collect the necessary information and instruction from the previous shift for the
smooth running of the section.
2. To make the junior officer understand how to operate the whole production process.
3. To match production sample with target shade.
4. To collect the production sample lot sample matching next production.
5. To observe dyed fabric during finishing running and also after finishing process.
6. To identify disputed fabrics and report to PM/GM for necessary action.
7. To discuss with PM about overall production if necessary.
8. To sign the store requisition and delivery challan in the absence of PM
9. To execute the overall floor work.
10. To maintain loading/ unloading paper.

2.5 Duties & Responsibilities of Senior Production Officer
1. Overall supervision of dyeing and finishing section.
2. Batch preparation and pH check.
3. Dyes and chemicals requisition issue and check.
4. Write loading / unloading time from machine.
5. Program making, sample checking, color measurement.
6. Control the supervisor, operator, asst. operator and helper of dyeing machine.
7. Any other work as and when required
2.6 Duties & Responsibilities of GM (Production)
1. Overall supervision of dyeing and finishing section.
2. Check the sensitive parameters of different machines for smooth dyeing.
3. Check the different log books and report to management.
4. Check the plan to control the best output.
5. To trained and motive the subordinates how to improve the quality
production.
6. Control the supervisor, operator, asst. operator and helper of dyeing m/c.
7. Maintenance the machinery and equipments.
8. Any other work as and when required
2.7 Remarks
The manpower management system of M M Knitwear Ltd. is well arranged. Every
officers & stuffs are responsible for their duty. But there are only three textile engineers in
the industry (General manager, Production manager and Production officer). It is not
sufficient for smooth production. More technical people is required.

CHAPTER – III
MACHINE DESCRIPTION

Industrial Attachment Machine Description
3 MACHINE DESCRIPTION
3.1 Lay-out Of Dyeing & Finishing Section
N
W E
S
13
13
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11
18
ENTRY
12
16 17
16
16
15
15
10 10
7
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3
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13
4
6
5
14
9
8
2
17
17
17

1. Office of PM
ENTRY
2. Offline QC
3. Inspection table
4. Compactor
5. Tube-tex
6. Equalizer Dryer
7. Steenter
8. Calender
9. Slitting m/c
10. Squzzer m/c
11. Office of GM
12. Chemical store
13. Dilmelner high pressure Dyeing m/c
14. Office & Online QC
15. Bangla dyeing m/c
16. Korean dyeing m/c
17. Sample dyeing m/c
18. Turning m/c

3.2 Dyeing Machinery
In dyeing section of M M Knitwear Ltd, there are 22 Dyeing Machines, among of
them 7 m/c’s are for sample dyeing and 15 m/c’s are for bulk production.
Machine no.- 01:
Name : Semi-Automatic Vertical Winch-1 chamber
Brand : Sungmoo
Origin : Korea
Capacity : 120 kg/Batch
Efficiency : 80-90 %
Temperature :950C (maximum)
Pressure : Atmospheric
Material : Liquor : 1:8
Machine no.- 02:
Brand : Sungmoo
Origin : Korea
Capacity : 240 kg/Batch
Machine no.- 03 :
Brand : Sungmoo
Origin : Korea
Capacity :350 kg/Batch
Machine no.- 04 :
Brand : Sungmoo
Origin : Korea

Machine no.- 05 :
Brand : Tongjeng
Origin : Taiwan
Machine no.-06:
Brand : Tongjeng
Origin : Taiwan
Machine no.-07:
Brand : Tongjeng
Origin : Taiwan
Machine no.-08:
Name : Dms Ht Jumbo Jet Flow (HP Winch)
Brand : Dilmenler
Origin : Turkey
Temperature : 135o C(maximum)
Pressure : Water 4 bar and Steam 6 Bar

Machine no.-09:
Brand : Dilmenler
Origin : Turkey
Machine no.-10 :
Brand : Dilmenler
Origin : Turkey
Machine no.-11:
Brand : Dilmenler
Origin : Turkey
Machine no.-12:
Brand : Dilmenler
Origin : Turkey

Machine no.-13:
Brand : Dilmenler
Origin : Turkey
Machine no.-14:
Brand : Dilmenler
Origin : Turkey
Machine no.-15:
Brand : Dilmenler
Origin : Turkey
Machine no.-16&17:
Name : Sample Winch
Brand : Suntex
Origin : Chaina

Machine no.-18&19:
Name : Sample Winch
Brand : Suntex
Origin : Chaina
Machine no.-20:
Name : Sample Winch
Origin : Bangladesh
Machine no.-21:
Name : Sample Winch
Origin : Bangladesh
Machine no.-22:
Name : Sample Winch
Origin : Bangladesh

3.3 Finishing Machinery
In finishing section of M M Knitwear Ltd, the machines which are available are
listed below:
1. Slitter m/c(1 set)
2. Stenter m/c(1 set)
3. Detwisting m/c(2 set)
4. Natural Gas Dryer m/c(1 set)
5. Compacting m/c(4 set)
6. Air Turning m/c(1 set)
7. Calendering m/c(1 set)
Slitting machine:
Brand : Bianco
Origin : Italy
Capacity :12000 kgs/Day
Sun-Supper ‘S’ Tenter(98″ Roller&8Chember) machine:
Brand : IIsung
Origin : Korea
Pin chain compactor machine:
Brand : Laffer
Origin : Italy
Capacity :6000-8000 kgs/Day
Open width compactor machine:
Brand : Laffer
Origin : Italy
Capacity :1200-1800 M/H
Tube compactor calendar machine:
Origin : Korea
Tubular compactor machine:
Brand : Tubetex
Origin : USA

Soft Setting calendar machine :
Origin : Korea
Natural Gas Dryer Machine 3 Chamber machine:
Brand : Dilmenlar
Origin : Turkey
Ait Turning machine:
Brand : Dongnam
Origin : Korea
Auto-detwisting Ballooning Squeezer machine :
Brand : Dongnam
Origin : Korea
Auto-detwisting Ballooning Squeezer machine :
Brand : Merson
Origin : Turkey
3.4 Description of Machinery
3.4.1 Working principle of dyeing machinery
The dyeing m/c’s has a large tank where the fabric is loaded through out the nozzle. It has
a good arrangement of water line (in let & out let), steam line, heat exchanger, liquor
circulating motor and a chemical dosing tank. The loaded fabrics are circulating through
out the nozzle continuously and the dyeing take place by the supplying of dye liquor by
the liquor circulating motor when the fabric is passed over the drawing reel. It has also a
control panel, which automatically control the production parameter. But it should firstly
set manually. In case of low temperature machine it can raise up the temperature only
95oC (maximum) where as a low temperature machine can raise up the temperature up
to140oC . During unloading of fabric drawing out reel is used.

Chemical dosing tank
Fabric
Fig: HTHP winch dyeing machine
3.4.2 Working principle of finishing machinery
3.4.2.1 Slitting machine
The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After dyeing
completed and falling of water from fabric the fabric is fed in slitting m/c. So it is
necessary to remove some water initially for the case of further processing in this m/c.
The initial squeezer does this work. The de-twisting unit removes twists that may present
in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2
feeler rollers with sensors. By these rollers it detects twist in fabric and removes by
rotating rope fabric in opposite direction. Before slitting there is a blower which blows air
to open the tubular fabric & makes it easy to pass over cigger. The cigger can be
extended in circumference and opens the tubular fabric in full circumference. Slitting is
done by using open mark detecting golden eye by around knife. Then the fabric passes

through the padder where washing or chemical treatment is done. Squeezer is used to
remove 60-70% of water. After removing water width is controlled by stretcher and
fabric is delivered by folding device.
Slitting machine contains the following Parts
 Basket
 Slitter
 Photo sensor
 Twist opener
 Padder squeezer
 Squeezing unit
Operational parameter
Set the padder pressure as required (3-7bar)
Set the speed as much as possible (30-80m/min).
Function of the Machine:
 Used to remove excess water after pretreatment and dyeing
 To slit the tube fabric by the knife for opening of the fabric and ready for
stentering
 Delivered fabric in crease free state
 Before squeezing balloon is formed with the help of compressed air
passing by a nozzle or air sprayer
 It can control the diameter of fabric and GSM and shrinkage by over
feeding mechanism

Problem causes by the Machine
 Photo sensor may failure
 For that fabric may be cut to the other line
 It may cause folding problem
 Bowing
 Spirality
3.4.2.2 Squeezing/Dewatering machine
After completing the dyeing process from the dyeing m/c then the fabrics are ready for
de-watering. In de-watering m/c tubular fabrics are mainly processed. There is a magnetic
sensor which scene the twist of the fabric and its direction and turn the fabric in opposite
direction to remove twist automatically. Here dewatering is performed De-watering is
the process to remove the water from the fabric completely by squeezing and it is done by
the padder. A suitable expander is used before the fabric is passed through the nip of the
padders, which expands the fabric flat wise and adjust the width.
The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%, Lacoste-40% wider than
the required width. There is a pair of rubber coated padder, where water is removed from
fabric when passed through the nip of it.
Normally squeezer contain single or double padders where,
- One for removing water and
- Other for applying finishing chemicals such as softener.
But this finishing is done only for the tubular fabric. Open widths knitted fabrics are
applied finishing treatment later in stenter.

Here present the compressor which given compress air to form ballooning before passing
through the padder. This balloon remove crease mark but not form the maximum balloon
otherwise shrinkage increase. In feed & Out feed traverses which present in albatros
control the following functions by over feeding system.
 To control the width (dia) of the fabric.
 To control the spirality of the fabric.
 To control the crease mark of the fabric.
 To control the length of the fabric.
Different parts of dewatering m/c
Tube tex dewatering machine contains two unit & two bath. One is for extraction and
another for processing where softener or other chemical are applied for giving extra
finish.
Maintenance during operation
 Proper balloon form by compressor air other wise crease mark appears.
 Padder contract point a just perfectly according to the fabric construction otherwise
accurate water will not remove.
 Albatros must be clean every one or two hours later.
Function
 Reduce water from fabric
 Fabric open from rope form
 Dia/width control
 Twisting and spirality control by twisting wheel
 Apply chemical
 Softening agent
 Brightening agent
Application of brightening agent / softening agent
 Cationic
 Non / anionic
 Spamin Kl (white)
 Ultra sot QM (dull)
 Paranous Ic (PET)

Controlling parameter
 Maximum pressure : 45 PSI
 For deep shade : 30-35 psi
 For medium shade : 20-25 psi
 For light shade : 10-12 psi
 Squeezer pressure : 4kg (maximum)
 Maximum speed : 80m/min
If pressure is increase, shade will be light.
 Crease mark
 Bowing
 Twisting
 Uneven padder setting causes uneven squeezing
3.4.2.3 Dryer
After de-watering the fabric is passed through the dryer. This machine contains two
chambers. Two mesh endless conveyors are placed lengthwise to the chamber named
conveyor net and filter net, each chamber contain a burner, which supply hot air .This hot
air is guided through the ducting line by suction fan .There are nozzles placed in between
filter net and conveyor net. When the fabric pass on the conveyor net, hot air is supplied
to the wet fabric to dry it. There are exhaust fan which such the wet air and deliver to the
atmosphere through the ducting line.
The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric.
If the m/c temperature is high then m/c speed also high and the m/c temp. is low then m/c
speed also low . The vibration speed of the m/c for heavy fabric is 730 m/min and normal
fabric is 480 m/min.

Special feature of Tube Tex steam dryer
 Steam dryer (two chambers).
 Vibration occurs in heating zone.
 Process air pressure switch present.
 Maximum temperature increase up to 2000C.
 Steam control switch present.
 Two burners present.
 Two conveyor belts are present.
Maintenance during operation
Temperature: Set the temperature between 1200C -1300C for white and 1500C -1700C for
color fabric. If GSM is high then temperature will be high or, moisture content is high
temperature will be high.
Set the over feed up to 10~20% or as required to get finish G.S.M.
Set the speed as much as possible (6~20m/min). if GSM is high then speed will be high.
Function
Dry the fabric
GSM control
Shrinkage control up to 3-3.5%
75% dries at 150oC

Maximum temperature : 2000C
Minimum temperature : 1100C
For colored fabric : 1500C-1850C
White fabric : 1200C-1300C
The temperature of different chambers according to the shade of the fabric
Shade Chamber-1 Chamber-2
Light 1200c 1300c
Medium 1350c 1400c
Deep 1500c 1700c
Drying temperature depends on GSM of the fabric
GSM White Colored
130 1200C 1300C
140 1350C 1400C
150 1400C 1450C
160 145-1500C 1500C
170 1550C 1550C
190-200 1600C 1650C
200-250 1750C 165-1750C
250-350 1850C 1850C
Shade variation due to uncontrolled temperature
More roller speed caused the Wales distortion
For Lycra heat setting is more necessary
If heat is more Lycra fabric can be extended and create low GSM fabric
Light shade due to high temperature
3.4.2.4 Stenter machine
Stenter Machine is generally used to finish the open fabric. This stenter machine consists
of eight chambers; each contains one burner, two blowers, two ducting line, nozzles and
suction fan attach with the suction line. The burner produces hot flue gases which guided

though the ducting line by the help of blower. There are nozzles placed above and bellow
the rail. When the fabric passed through the rail, then hot air is sprayed to the above and
bellows the fabric with the help of nozzle. The hot air is circulating in the chamber and
the moisture in the fabric is evaporated, which leave the chamber with the help of suction
fan through the ducting line. Temperature of each chamber can control automatically by
controlling the intensity of burner. Generally lower temperature is maintained the first
and last chamber then other chambers.
The speed of the fabric is maintained according to the moisture content of the fabric.
After passing the fabrics to all the chambers, the fabric is collected for compaction.
Feed
Fabric
Chemical Tank Softener Tank
Fig: Passes diagram of senter machine
Feed Roller
Weft
Straighter
Walkway
Delivery Roller
Six Chambers Cooling
Chamber
The performance of the stentering range depends on proper introduction of the cloth into
the machine. The finer the fabric is being processed, the greater the significance of the
correct, crease free and fault free fabric introduction. In stenter m/c the fabric first passed
through different rollers including weft straightening device, uncurling device for proper
feeding of the fabric into the machine. Then it passed through the selvedge detector
which detect the selvedge and adjust the rail for proper gripping the fabric in the pin
arrangement. This stenter m/c consists of both pin and clip arrangement. The fabric first
grip by pin and gust before entering the chamber, pin are locked by clip arrangement. To
maintain proper dimension of the fabric, length wise overfeed and width wise tension is
given to the fabric.
Deliver
ed
fabric
Padding
Rollers
Padding
Rollers

Important parts
- Burner (12) - Suction Fan (12)
- Exhaust air fan (6) - Nozzle
- Over feed roller. - Chain arrangement
Different sections & their function of stenter machine
Padder Section: In the padder section the fabric is treated with chemicals specially with
softener and acid in two tanks.
Weft straightner: The main function of Weft Straightner is to control the bowing &
Skewnesss of the fabric.
Width Setting Chamber: This Chamber control the width of the fabric by clip of 10 pin.
Heatting Chamber: This chamber controls the shrinkage and the G.S.M of fabric.
Temperature Range:
Cotton- 1500C~1700C
Polyester-1650C~1850C
With Lycra -1750C~1900C
Cooling Chamber: This chamber cooled the hot fabric before reach to delivery zone.
Exhaust Motor: This specific part used to exit the steam produced in the chambers and
also exit the extra temperature from the machine.
Delivery Zone: This zone delivered the fabric in a folded form. In this zone the fabric
has to
Pass through several rollers in order to prevent the formation of crease mark in the
finished fabric.
No. of chamber : 8 (without cooling chamber)
No. of burner : 8
No. of blower : 16
Padding mangle : 2
Exhaust fan : 8
Type : pin stenter
Maximum production : 5ton/day

Chamber to chamber distance : 3m
Padder pressure : 3-4kg
Temperature setting
 Maximum temperature : 200˚c
 Minimum temperature : 130˚c
 Heat setting range : 175-185˚c
 Lycra heat setting range : 175˚c -180˚c for finishing
: For Dyed fabric is done at 170˚c-175˚c
Temperature setting for different shade
 For light shade : Normal temp
 For deep shade : High temp
 Pigment dyeing : 150˚c -160˚c
Function of stenter machine
1. Apply chemicals
2. Apply softener
3. Drying of fabrics
4. Width control
5. Curing of fabric
6. GSM control
7. Shrinkage control
8. Spirality control
9. Heat setting on cotton/ Lycra
10. Pigment dyeing
11. Bowing effect control
12. Surface coating
13. Heat setting
 Lycra may be decompose due to unbalanced heat
 Elasticity may be loose due to dia extension caused GSM low
 Color spot may be occurred due to lack of proper chemical mixing
 Softener spot
 Foaming spot
 Iron spot

 Running shade may be seen due to difference between speed and heat
 Crease mark may be appeared if expanding of the fabric is not accurate.
3.4.2.5 Compactor machine
The main object of compactor is to make the fabric surface smooth, to control the
residual shrinkage, G.S.M and if required fabric width also. To control the residual
shrinkage the fabric is previously shrinkage artificially by gathering of loops of knitted
fabric and it is set by heat and pressure. In tube & open compactor, the dried knitted
fabric is face to steam when it passed through the Teflon coated conveyor belt. When a
cotton fabric absorbs water, it swells and shrinks (particularly in length direction)
because the absorbed water allows the cellulose chains to move relative stain free
position. Then the fabric is passed through the expander. This m/c contains two
compaction units to compact both side of the tubular fabric. Each unit contains a hot
rotating cylinder, blanket which rotate in contact with the cylinder and Teflon cover
.while passing the expander roller, the fabric is over feeded. The fabric is compacted with
the pressure of blanket and Teflon cover while passing through the hot cylinder .Due to
compaction stitch length is reduced. Then the fabric is passed through the counting
device .Before packing, the fabric is inspected carefully.
Important parts:
· Over feed roller
· Steam sprayers
· Expander
· Cylinder (2)

· Blanket (2)
· Teflon covers
Operational parameter
Set the temperature at 110-1390C (as required)
Set the overfeed % as required; to increase GSM, overfeed need to increase to a certain
limit.
Width control
Length compaction
We know that Compaction Percentage can be calculating as following formula
Feed rollspeed Compaction = -Delivery rollspeed ×100%
Feed rollspeed
 Cheats mark
 Compaction mark
 Fabric folding

 Side loose and tight
Remedies
 Properly compact the fabric
 Properly compact the over feeding
 Perfect pressures apply.

3.5 Remarks
M M Knitwear Ltd is a well-equipped industry. It contains machinery of well known
brands like Thies, Tubetex, Laffer, Bianco etc. The availability of these m/c’s are
helpful to increase the productivity of the industry. The arrangement of machines
is very beautiful and there is enough space for movement of the workers.

CHAPTER – IV
RAW MATERIAL

Industrial Attachment Raw Materials
4 RAW MATERIAL
M M Knitwear Ltd is a knit composite textile industry. In the industry the raw
materials used for production are:
1.Grey Fabrics
2.Dyes
3.Chemicals
4.1 Grey Fabrics
Following types of grey fabrics are processed®
Single jersey Terry & French terry
Single jersey/lycra polar
Interlock Eyelet & mini-eyelet
Rib Mesh (warp knitted fabric)
1X1rib/lycra waffel
Combined rib Collar & cuff
Lacoste Pique
Source® 40% comes from the Knitting Department of Landmark Fabrics Ltd and
other 60% comes from outward as sub-contract.
Daily Fabric Production Capacity®
Item Quantity
Single jersey, Pique 3800kg/day
Lacoste, Interlock 1500 kg/day
Rib 1000 kg/day
Collar & cuff 6000 pcs
4.2 Dyes
In M M Knitwear Ltd. the following types of dyes are used:
· Reactive dyes (cold brand & hot brand)
· Disperse dyes
The commercial name of the dyes with their prices are collected from the dye
stock report®
Sl. No. Name of the Dyes Price in Tk/kg
01 Remazol yellow RR 195
02 Remazol blue RR 520
03 Remazol red RR 420
04 Remazol blue BB New 380

05 Remazol G.yellow RGB 320
06 Remazol blue RGB 350
07 Remazol Ultra red RGB 460
08 Remazol T/blue RGB 600
09 Remazol red-RGB 466
10 Rifa blue RSPL-N 1120
11 Solazol black-B 370
12 Solazol red-SP3B 650
13 Solazol blue R/SPL 1242
14 Solazol black-GRE 210
15 Solacion navy blue-HEXL 800
16 Solacion yellow-HE4RN 1150
17 Solacion red HE3B 800
18 Evercion red-HE7B 950
19 Evercion orange-HER 1050
20 Evercion navy-HER 900
21 Dri. Turqouise 520
22 L/P black-KAP/KNA 315
23 L/P navy-NNA 450
24 Syno white-4BK
25 Sun white BVB
26 San white 4BK
27 Reactobond black-XL
28 Reactobond blue BB
29 Reactobond red BRF 550
30 Reactobond blue H2R
31 Reactobond red CRB
32 Reactobond red F3B
33 Kirazol yellow w 2BRL 480
34 Kirazol blue EMRX
35 Kirazol red EMX
36 Taicron Billian blue SGLT
37 Taicron yellow E3GT 900
38 Taicron orange E3RT 850
39 Taicron black SE-EXNT 620
40 Taicron navy blue SE-EXNT 750
41 Taicron red EF-BNT 950
42 Taicron red WW2RT 880
43 Taicron scarlet

4.3 Chemicals
In M M Knitwear Ltd., the following chemicals are used. The names of the
chemicals with their prices are collected from the dye stock report:
Sl. No. Name of the Chemicals Price in Tk/kg
01 Imarol-PCLF(Detergent) 180
02 Finoscour-OSP(Multi scouring agent) 250
03 Kappasoft BD New(softener) 190
04 Marla ADZ(Sequester) 225
05 Cros colour CHBS(Stabilizer) 65
06 Cros colour FBP
07 Marla KT(Anticreze) 18
08 Kappaquest-A41(leveling) 105
09 Kappasoft SM 205
10 Enzyme VGS 600 130/L
11 Jintex-ALATE SQ 117CA 95
12 Cros colour BFE
13 Antifoam-MX 115
14 Silicon THS-180
15 Optovon-SV
16 Marla HAS
17 Jincosofter-CBA 224
18 Sandofix-EC
19 Jintex-TFA
20 Lyocel powder
21 Egonol-DFT 110
22 Cros colour-ADM
23 Radiclean-AL-80
24 Cros colour PCP
25 Acetic acid 85
26 Caustic soda 35
27 Hydrozen Peroxide 25
28 Soda Ash 20
29 Gluber salt 15
30 Common solt 10
31 Kepatrx R-98
4.4 Remarks
M M Knitwear Ltd is so careful about its raw materials. The raw materials are
always collected from those suppliers who supply the dyes & chemicals of higher quality.

CHAPTER-V
PRODUCTION PLANNING,SEQUENCES &
OPERATION

Industrial Attachment Production Planning
5 PRODUCTION PLANNING,SEQUENCES & OPERATION
5.1 Process flow chart of knit dyeing
Grey fabric Inspection
Batching
Stitching
Loading
Scouring
Bleaching
Dyeing
Finishing

5.2 Dyeing work flow chart
Scouring & bleaching
(Wetting agent, sequestering agent, anti creasing agent, anti foaming agent, alkali,
stabilizing agent, hydrogen per oxide) or multi functional scouring agent.
▼
Per oxide hot with a/acid
▼
Enzymes wash with a/acid
▼
Leveling with sequestering
▼
Salt dosing
▼
Dye dosing
▼
Soda dosing
▼
Sample
▼
Drain
▼
Washing off
▼
A/acid
▼
Softener
▼
Unload

5.3 Dyeing Parameters
a. pH:
- During H2O2 bleaching pH 9.2 – 12
- During reactive dyeing pH 10.5 – 12.5
- During disperse dyeing pH 4.5 – 6.0
b. Temperature:
- For cotton scouring 1050C
- For cotton cold wash 300 – 400C
- For cotton hot wash 700-800C
- For cotton acid wash 450C
- For cotton dyeing 980C (For hot brand)
600C (For cold brand)
- Polyester dyeing: 1350C
- OBA application 980C
c. Time:
Set
- For scouring & bleaching 40 mins
- For reactive dyeing 60-90 mins
- For disperse dyeing 60-90 mins -
d. M:L ratio:
- For reactive dyeing M:L ration maintained between 1 : 6 to 1 : 8

5.4 Description of production process
Process Flow Chart of Scouring and Bleaching:
Machine filling with water
Chemical Dozing at 50 0C
Run time 10 min.
H2O2 Dozing
Heating at 60 0C
NaOH dozing
Heating at 110 0C
Run time 20 min.
Cooling at 95 0C
Rinse at 80 0C
H2O2 - Killer Dozing
Run time 10 min
Run time 10min.
Sample Check
Check H2O2
Cooling for 55 0C
Acid wash 3 min Drain

Process Flow Chart of ENZYME:
Run for 4 min. at 48 0C
Heating at 55 0C
Dozing enzyme
Run time 45 min.
Drain
Process Flow Chart of WHITE DYEING:
Heating at 55 0C
Chemicals dozing
Run time 60 min.
Dyes dozing
Heating at 80 0C
Run time 15 min.
Cooling at 55 0C
Rinse for 5 min.
Drain
PH Check
PH Check

Process Flow Chart of Color Dyeing:
Heating at 60 0C
:
Chemical dozing
Run time 5 min.
Dyes dozing
Run time 1 min.
Salt dozing
Run time 20 min.
Soda dozing
Run time 4 min.
Rinse
Drain
Process Flow Chart of SOFTENING:
Sample Check
Heating at 50 0C
PH Check
PH Check
PH Check
Chemicals dozing
Run time 30 min. Drain

5.5 Dyeing Recipe
Recipe No : 01
Fabric Type: Lacoste Order No: 21172
Fabric GSM: 160 Buyer Name: TEXCO BD
Color: Red Fabrics wt.:604.0kg M:L: 1:8

ITEM RATE QUANTITY(gm)
Imarol PCLF (Detergent) 1% 4800
Jintex 2ud(Sequestering Agent) 0.25% 1200
Marla KT(Anti-creasing Agent) 1% 4800
Cross colour CHBS (Stabilizer) 0.2% 960
Caustic Soda 2% 9600
H2O2 2% 9600
Acetic Acid 1% 4800
Fibsilase HDL-350 (Enzyme) 0.3% 1450
Kappaquest A-41 (Leveling Agent) 0.25% 1200
Kappaquest A-41 0.7% 3300
Jintex-ALATE SQ 117CA(Leveling
Agent)
Acetic Acid 0.1% 400
Ev/red-HE-7B 4.5% 24462
Ev/orange-HE-R 4.12% 22396
S/ N Blue-HE-XL 0.00318% 17
Solt 80% 386000
soda 20% 96000
RS 0.7% 3300
Acetic Acid 1% 4800
DRF 1% 4800
Kappasoft-SM(Softener) 0.2% 1000
Recipe No : 02
1% 4800

Fabric Type: Interlock Order No: PGTD0039
Fabric GSM: 240 Buyer Name: EUROPA
Color: Navy Fabrics wt.: 720.0kg M:L: 1:8
Imarol PCLF 1% 5760
Marla ADZ 0.25% 1440
LSP 1% 5760
Cross colour CHBS 0.2% 1152
Caustic Soda 2% 11520
H2O2 2% 11520
Acetic Acid 1% 5760
Kappaquest A-41 0.25% 1440
So/ Black-B 3% 17280
So/ Red-SP3B 0.8% 4608
So/ Yellow-SP3R 0.9% 5184
Solt 60% 345600
soda 20% 115200
AW 0.7% 4000
Acetic Acid 1% 5760
Kappasoft-SM 0.2% 1152
Recipe No : 03

Fabric Type: 1 X 1 Rib Order No: 1012315
Fabric GSM: 180 Buyer Name: LIZ FSSHION
Color: White Fabrics wt.: 380.0kg M:L: 1:9
Imarol PCLF 0.2% 700
Marla ADZ 0.2% 700
Cross colour CHBS 1% 3400
Caustic Soda 2.5% 8500
H2O2 6% 20000
Syno White- 4BK 0.9% 3400
Imarol PCLF 0.05% 170
Acetic Acid 1% 340
Fibsilase HDL-350 0.2% 700
Kappasoft-SM 0.5% 1700
5.6 Finishing

Open fabric
Hydro-extraction
Dewatering
Drying
Slitting
Stentering
Open compacting
Finishing
5.7 Finishing machine setting
Dewatering M/C Setting ®
Tube Fabric
Hydro-extraction
Dewatering
Drying
Tube compacting

Fabric type Fabric
speed(m/min)
Over feed%
Single jersey(Viscose) 80 30
Single jersey(cotton/lycra) 80 22
Single jersey(cotton) 80 10-11
1X1 Rib 80 11
Interlock 80 14-15
Terry 80 5-9
Gas Burnt Dryer M/C Setting ®
Fabric type Fabric speed
Single jersey(cotton) 6.5 140 15
Single jersey(cotton/lycra) 6.5 140 15
1x1 Rib 6 140 15
Interlock 5 140 15
Terry 5 140 15
Compactor Setting
Fabric Type Fabric
speed
(m/min)
(m/min)
Steam
pressure
(psi)
Temperature Over feed%
Compacting
pressure
(psi)
Temp
°c
Overfeed%
Single jersey (cotton) 25 60 70 120-150 5-7
Single
jersey(cotton/lycra)
20 50 60 120-150 6-7
Single jersey
(viscose)
25 60 70 120-150 8
1x1 Rib 25 60 70 120-150 3-4
Interlock 25 60 70 120-150 3-4
Terry 25 60 65 120-150 8

Stenter Setting ®
FABRIC TYPE FABRIC
SPEED
(m/min)
TEMPERATURE
(0C)
OVER FEED%
Single jersey (Cotton) 30-40 160 Upto 30
Rib/Interlock (cotton) 25-30 160 Upto 30
Single jersey (Viscose) 26 170 Upto 60
Mini-eyelet(Polyester) 20-25 185 Upto 4
Mesh (Polyester) 20-25 185 Upto 4
5.8 Daily Production Report
The daily production report is recorded in the logbook and it contains following
information®
§Machine No. §Quantity
§Date §Loading Time
§Batch No. §Unloading Time
§Order No. §Runtime
§Fabric Type §Shift
§Color §Remark
5.9 Monthly Average Production
The monthly average production of dyeing unit of M M Knitwear Ltd. is 360 tons
5.10Remarks
The production process, followed by the Dye-house of M M Knitwear Ltd. is
impressive. The processes are being carried out very quickly and accurately. Due to the
excellence of process, machineries and lab trials very few cases of re-dyeing is
performed.

CHAPTER – VI
QUALITY ASSURANCE SYSTEM

Industrial Attachment Quality Assurance System
6 QUALITY ASSURANCE SYSTEM
6.1 Quality Policy
It is the policy of M M Knitwear Ltd. to produce quality dyed knit fabrics that
meet the customer’s expectations & needs. To implement this policy the top management
of Landmark Textile Mills Ltd. is committed to provide adequate resources in terms of
good raw materials and trained personnel & continually improve / upgrade its processes
and systems. The quality control policy of Landmark Textile Mills Ltd. is stated below-
 Leadership program from the top.
 In-process quality control during manufacturing operation.
 Evaluation programs in all areas of knitting, dyeing, cutting, sewing and finishing.
 Maintain chain of responsibility.
 Follow strict stuffing, auditing and reporting.
 Use inspection machines in required points.
 Maintain standard AQL.
 Sufficient lighting and sanitation.
 Final inspection prior to packaging.
 Meeting the appropriate expectations of clients.
6.2 Quality Assurance Procedure
M M Knitwear Ltd. assures the quality of their products in the following three steps:
1. In laboratory.
2. In dyeing section
3. In finishing section
The quality as surance procedures are described below:
In laboratory:
 Swatch card from buyer according to their requirement is received.
 Recipe prediction for sample dyeing using CCMS.
 Sample dyeing until matching with the swatch card. Acceptable color difference
is less than 1.
 If matching is OK, then it is sent to the buyer for approval.
In dyeing section:
 After approval form the buyer, sample dyeing is done in dyeing m/c, in dyeing
shed & again matched with the approved sample.
 If result is OK, then balk production is commenced.
 During dyeing process, before the final acid wash, samples are taken and checked
for accurate shade matching.

 After dyeing sample is collected & matching is done.
 Rubbing and wash fastness tests are carried out.
In finishing section:
 Correctly dyed, after treated & matched fabrics are allowed for finishing.
 By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
 Then sampling is done several times to test GSM, Shrinkage & fastness properties.
 Finally fabric is inspected & prepared for delivery.
6.3 Inspection area
 Shade match of fabric
 G.S.M.
 Fabric diameter
 Spirality
 Shrinkage (%)
 Length wise
 Width wise
 Wash fastness
 Rubbing fastness
 Faults
 Dyeing faults
 Knitting faults
 Finishing faults
Knitting Faults ®
 Hole
 Slub
 Needle mark
 Stripe
 Missing yarn
 Contamination
Dyeing Faults ®
 Uneven shade
 Running shade
 Fastness property
 Dye spots and marks
Finishing Faults ®
 GSM variation

 Spirality
 Shrinkage control
 Marks
6.4 PROBLEMs ENCOUNTERED IN DYEING
Uneven Dyeing ®
1. It can be caused due to rapid addition of dyes and chemicals. For this purpose
the dosing of soda ash should be maintained properly.
2. Pressure difference.
3. Over loading in the m/c.
4. Yarn lot mixing.
5. Improper control of temperature.
6. Less amount of leveling agent.
7. Improper pretreatment.
Uneven Shade in Rope to Rope ®
1. Improper rope length in each chamber.
2. Improper fabric flow speed in each nozzle.
Off Shade®
1. Improper M: L ratio.
2. Lower amount of auxiliaries.
3. Improper mixing of dyestuffs.
Dye Spots ®
This is most common fault caused by operator not correctly mixing and
thoroughly dissolving dyestuffs in the right amount of water.
Batch to Batch Shade Variation ®
If any of parameters of dyeing are changed then it will produce problems in batch
to batch consistency. In order to avoid this defect the following steps should be followed-
1. Maintain the same liquor ratio.
2.Check that the fabric has the same dye affinity.
3. Use the same standard program procedures for each batch.
4. Making sure that the operators add the right bach of chemicals at the same time
& temperature in the process.

5. Check the water supply daily especially ph, hardness & Na2CO3 content.
Crease Mark ®
Crease marks are produced due to the lower concentration of anti creasing agent
and improper cooling rate (defective cooling gradient). This is encountered by increasing
the concentration of anti creasing agent and proper adjustment of cooling rate.
Running Marks ®
Running marks are frequently related to the material construction and are caused
by poor opening of the fabric rope.
1. Reducing the machine load and running at a slightly higher nozzle pressure, or
using the next largest available nozzle size, may also help.
2. Either pre setting or pre relaxation of the fabric before dyeing can avoid this
problem.
3. Running and crack marks can also be a result of incorrect process procedures. A
higher fabric speed, combined with slower rates of rinse and cooling will often correct
the problem.
4. Care should be taken to check that bath draining temperatures are not very high
especially viscose blends are involved.
5. Shock cooling of static material will also cause crack marks.
Intensive Foaming ®
In case of intensive foaming, which is caused when, the pumps try to pump a
mixture of air and water. This resets in the loss of nozzle pressure & floating of flake. If
the foaming is severe it is better to drop the bath & restart the process, after adding an
anti foaming agent to the new bath.
Patchy Dyeing ®
It is caused, if dye solution is not correct and also scouring is improper.
Miscellaneous Problems ®

Batch to batch processing may vary due to the improper calculation of dyes and
chemicals and improper strength of salt soda and H2O2 etc. Beside hardness of water and
caustic may lead to an improper shade.
6.5 Process of Shade Matching
The required shade provided by the buyer is reproduced in the lab in lab dyeing
machine after the recipe prediction. The lab in-charge first uses the Computer Color
Matching System, to obtain the closest shade match recipe. Then he consults the shade
card and Pentone book to verify the obtained recipe. If he thinks that certain changes in
the recipe is necessary, he then alters the recipe according to his experience. This recipe
is used to dye a sample of 5 gm fabric in the lab dyeing machine with following
parameters.
a) Temperature and time ®
Cold Brand Reactive Dye - 65° c temp; 60 min
Hot Brand Reactive Dye - 98° c temp; 60 min
Turquoise Color (Cotton) - 85° c temp; 60 min
Polyester - 130° c temp; 30 min
b) M:L ratio ®
The samples are usually dyed using 1:10 ratio.
Pentone Book:
Pentone Textile Color Selector
Total shade – 1701
Color numbering system – 6 digit + suffix
First two digits ® 11 to 19 ( range of lightness)
Middle two digits ® 01 to 64 ( range of hue)
Last two digits ® 01 to 64 ( range of chroma)
6.6 List of Equipments
1. I.C.I. Pilling Box Tester®
Brand Roaches
Operation Time 6 hours
R.P.M. 60
Total Revolution 21600
Scale Range for Pilling 1 to 5

Accepted Level 4 to 5
2. Rubbing Fastness Tester ®
Brand SDL
Instrument Name Crock meter
Measured Elements Wet and Dry Rubbing Fastness
Number of Rubbing 10
Scale Range 1 to 5
Accepted Scale Range For Wet 3 to 4 and For Dry 4
3. Light Box ®
Brand: Verivide
Origin England
Lamp option TL-84 (tube light), D65 (normal daylight), UV
(optical brightener), F (fluorescent).
4.Washing Machine
Origin : U S A
5 Lab Dyeing Machine
Brand: Pyretic-2000
Origin : U. K
6. Tumble Dryer ®
Origin Italy
Lowest Material Loading 1 kg
Time 40 to 45 minutes
Temp 120° c
7 Spectra Photo meter
Brand: Data Color
Origin : U. S. A
8.Electric Balance
Origin U.S.A
6.7 Quality Standard
 Shrinkage: Should not exceed ± 4.
 Wash Fastness:
Fastness to washing DIN EN ISO 20105 C 03: 60°c : at least 4 -5.
Staining on Cotton, Polyester, Polyamide, Wool : at least 4.
 Rubbing Fastness:
Fastness to rubbing DIN EN ISO 105 X 12: Dry at least 4 & Wet at least 3.
 Color Difference, DE: Should not exceed 1.

6.8 Remarks
M M Knitwear Ltd. is always aware about the quality of their product. The
quality of the product is maintained as per requirement of the buyer. M M Knitwaer
Ltd. is well equipped for checking the quality of the product. They send the quality report to
the buyer from time to time/ batch to batch.

CHAPTER- VII
MAINTENANCE

Industrial Attachment Maintenance
7 MAINTENANCE
7.1 Maintenance of Machinery
Maintenance of machinery is very essential mechanical effort for achieving
smooth running of different machines. Maintenance is a process by which equipment is
looked after in such a way that trouble free services and increased machine life can be
ensured and specific product quality required by the customers is sustained. On time
maintenance increase m/c lifetime & ensures trouble free services.
In M M Knitwwar Ltd. 2 types of maintenance are done:
1. Break down maintenance
2. Routine maintenance
Break Down Maintenance
Routine Maintenance
Maintenance
Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance
1. Break down maintenance: Break down maintenance is done instantly when
problem arises in machine. In this case, repairs are made after the equipment is out of order
and it cannot perform its normal functions.
2. Routine maintenance: After a particular period of operation, the machines
are cleaned & reordered, that is routine or schedule maintenance. The maintenance
department does it once in a month. Schedule maintenance varies, time in time &
also depends on situation according to types of machines, because maintenance is
directly related to production.
Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also
done. Workers inform about the problem areas of the machines. Depending on their
information maintenance is done. Maintenance engineer analyze the records and take
steps according to requirement.
7.2 Routine
Maintenance is a necessary task in any industry. But the degree and interval of
maintenance is dependent upon the age of the machineries. Some time routine
maintenance can hamper the production.So, some important machines such as
Stenter,Old Dyeing machine are routinely maintained.

7.3 Manpower Setup for Maintenance
For electrical Maintenance:
Per shift:
♦ B Sc. Engineer - 1
♦ Diploma Engineer - 1
♦ Senior Technician – 2
♦ Junior Technician – 4
For mechanical Maintenance:
Per Shift:
♦ B Sc. Engineering - 2
♦ Diploma Engineering - 3
♦ Senior Technician – 1
♦ Junior Technician – 4
7.4 Maintenance Procedure
Maintenance: Mechanical
Machine: Dyeing Machines
Sl. No. Item needed to be checked & Serviced
1. Greasing of the winch bearing
2. Complete cleaning of machine
3. Cleaning of drain valves, replace seals if required
4. Checking of air supply filter, regulators, and auto drain seals
5. Cleaning of filter elements
6. Greasing of unloading roller bearings
7. Checking and cleaning (if required) of addition tank level indicator
8. Checking the oil level of pump bearing and refill if required
9. Checking the function of heat and cool modulating valves
10. Checking of all belts and belt tension
11. Check circulation, reel and other pumps
12. Checking of all door seals

Machine: Stenter Machine
1. Removal of gas burnt deposits from chains
2. Checking of gas burners
3. Cleaning of softener application unit
5. Checking and cleaning of steam pipe lines
4. Checking and cleaning of gas pipe lines
5. Grinding of fabric gripping pins
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet
8. Checking of motors
Machine: Dewatering Machine
1. Cleaning of softener application unit
2. Checking of rotating device of rotating trolley unit
3. Checking of pneumatic pressure valves
4. Checking and replacement (if necessary) of rubber pads of stretching unit
5. Checking of plaiting device
6. Checking of speed regulating unit

Machine: Dryer
1. Checking of gas pipe lines
2. Checking of gas burners
3. Checking of belt conveyor system
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet
Machine: Compactor Machine
1. Checking of Steam pipe lines
2. Checking of pneumatic pressure valves
3. Checking of belt conveyor system
6. Checking and replacement (if necessary) of compacting shoe
7. Cleaning of compacting shoe

Machine: Boiler
1. Checking of gas pressure and gas supply line
2. Dosing of softening chemicals to supply water
3. Checking of all steam lines
4. Cleaning of burner tank (after six month interval)
5. Checking and replacement of valves
6. Cleaning of feed water tank
7. Checking and replacement of filters
8. Cleaning of sight glass
7.5 Maintenance Tools and Equipments
Sl. No. Maintenance tools/equipments Functions
1. Adjustable wrench Used for setting nut & bolts
2. Pipe Spanner For pipe fitting
3.
Spanner
Fixed Spanner for nut & bolts
fitting
4.
Socket spanner
Handle system for nut & bolt
fitting
5. Hammer To apply load where required
6. Screw driver To release any screw
7. Punch Used to fit any worn out shaft
8. Lock opener To open the clip of bearing
9. Hack saw To cut any metallic thing
10. Outside calipers To measure outside dia
11. Inside calipers To measure inside dia
12. Slide calipers To measure very small dia
13. Vernier scale To measure very small dia

14. Chain ton To lift heavy load
15. Welding machine To join metallic parts
16. Grinding machine To make the smooth fabrics
17. Tester To test electric circuit
18. Pliers To grip anything & cut anything
19. Avometer/Voltmeter To measure voltage
20.
Steel tape
To measure length, width &
height
21. Chisel To cut any metal
22. File To smooth the rough surface
7.6 Remarks
The maintenance department of M M Knitwear Ltd. is well equipped. It
has sufficient maintenance manpower including mechanical and electrical
engineers. They perform maintenance tasks of the machines during the holidays
and vacations. Otherwise, they perform breakdown maintenance, which as
stated earlier is very rare in M M Knitwear Ltd. To increase the lifetime of the
machineries and ensure the proper running of the machines, the task of this
department is very important.

CHAPTER- VIII
UTILITY SERVICES

Industrial Attachment Utility Services
8 UTILITY SERVICES
8.1 Utility Facilities Available
Þ Electricity
Þ Gas
Þ Water
Þ Compressed air
Þ Steam etc.
Government Supply (PDB)
Þ ▪Electricity or Power
Factory's Own Generator
Þ ▪ Air Compressor
Þ ▪ Natural Gas
Þ ▪ Steam Supply
Þ ▪ Water
8.2 Source of Utility
The main Utility, which is used by M M Knitwear Ltd., is Natural gas. From Natural gas
generator produce electricity. From natural gas and electricity in associate with
mechanical and electrical apparatus, M M Knitwear Ltd Produce other Utilities like
water, steam, Compressed air etc.
8.3 Capacity and Other Technical Details
Power (Electricity): Generator house is the main Power Producing Plant of M M
Knitwear Ltd. there are two Generators in Generators house. Specifications of two
Generators are given below:
Generator : 01
Type : Gas Generator
Brand Name : CAT BANGLA
Origin : U S A
Model No : G- 3014
Rated Power : 438KVA
Maximum Current : 350 KV
Frequency : 50 Hz
Engine R P M : 1500
Voltage : 400
Power factor : 0.8
Water Temp. : 94º C
Mobil Pressure : 58 P S I

Gas Pressure : 10 P S I
Generator : 02
Type : Diesel Generator
Brand Name : Perkins
Origin : India
Model No : 350 – E
Rated Power : 350 KV
Maximum Current : 274 KV
Frequency : 50 Hz
Engine R P M : 1500
Volt : 400
Power factor : 0.8
Boiler: Steam generator or boiler is usually a closed vessel made of steel. There is Twq
boiler in M M Knitwear.
Function: Boiler function is to the heat produced by the combustion of fuel (Gas) to
water and ultimately to generator steam. The steam produced may be supplied in wet
processing department for –
►Heating cylinder dryer
►Steaming during dyeing
Objects: For supplying steam.
Types of steam:
1. Wet steam
2. Dry saturated steam, and
3. Superheated steam.
In Divine Knit dyeing Ltd. wet steam is used for the relevant processes.
Boiler Specification:
Brand Name : Cochern
Origin : Scotland
Type : Fire tube boiler
Capacity : 6 ton per hour
Pressure : 5 bar
Temperature : 180º C
Fuel : Natural Gas
Year of Manufacturer: 1997
Water supply for the boiler:
Water required for steam production is supplied by deep tube well.

Pretreatment of the boiler water:
Boiler feed water needs special standard. Any deviation from the required standard may
result in scale formation, which eventually reduces the efficiency of the boiler. This
ultimately affects the cost of steam generation and makes the production cost high. To
maintain the required standard of the water, there should be some means to pretreat that
the boiler feed water. To protect scale formation of boiler, NELCO is used as chemical in
water feed tank. 200 gm NELCO is injected per 12 hrs. In M M Knitwear Ltd. there are
water softeners that act before the water enters the boiler.
Manufacture of the softener: The manufacturer of the softener is cleaver brocks, U
S A.
No of the Softener: There are two water softener to pretreated the boiler feed water
Softener Specification:
Brand Name: Cleaver brooks
Model No: ACC- SMR – 150 – 1- 1/2T
Serial No: CH – 0000 236
Capacity: 1500000000GRS / TANK
Unit NO: HS 008892
Pipe Size: 1.5 inch
Salt Capacity brine marker: 576 lbs
Compressed Air:
The compressed air is supplied from air condition from air compressor. There are two air
compressors in M M Knitwear Ltd.
Compressor No: 01
Brand Name: Atlas Copco
Origin: Belgium
Model No: GA 34 FF
Serial No: TT 254070
Maximum working pressure: 10 bar
Average working pressure: 6-7.5 bar
Free air delivery: 54 liter / second
Normal shaft power: 34 Kw
Rotational Shaft speed: 3000 r pm
Gross weight: 480 kg
Year of Construction: 2000

Compressor No: 02
Brand Name: BOGO
Origin: Japan
Model No: S361694
Serial No: 546206
Maximum working pressure: 10 bar
Average working pressure: 6-7.5 bar
Year of Construction: 2001
Volt: 400
Frequency: 50 Hz
8.4 Cost of different Utilities
Electricity Cost:
Gas generator = 2.70 TK/KW- HR
Diesel generator = 6.50 TK/ KW-HR
Gas Cost: 4.94 TK/m3 for boiler
3.66 TK/m3 for generator
4.6 TK/m3 for domestic Purpose
Steam Cost:
4.20 TK/ m3 Kg fabric
8.5 Remarks
For smooth running of factory main utilities like gas, electricity or steam is very essential.
Sometimes gas pressure is low than required pressure. When the gas pressure is low, then
diesel generators run. Government should have to ensure proper gas supply for Industry.

CHAPTER – IX
STORES & INVENTORY CONTROL

Industrial Attachment Store and Inventory Control
9 STORES & INVENTORY CONTROL
9.1 Scope of Inventory Control
1. Raw materials ®
 Dye store
 Other chemicals
 Gray fabric
2. Finished fabric
3. Spare parts
9.2 Frequency of Inventory Update
1. Monthly inventory control
2. Annual inventory control
9.3 Inventory Control System for Raw Materials
Dye store & other chemicals store ®
 Both of these are received by the store in charge.
 First he sends these to quality in-charge for inspection. If they are found to be of
required quality then they are taken to store by the storekeeper.
 Store in-charge supplies these when required and records the date, type of material,
quantity and section in which supplied, in his register book.
Grey fabric store ®
 Grey fabric is usually stored in another storeroom, which is separate from dyeing
shade.
 Grey fabric is first sent to the QC department for quality assurance and then taken to
the storeroom.
 Grey fabric is received by fabric store in-charge.
 He supplies the fabric as per requirement and records the date, type of material,

Industrial Attachment Store and Inventory Control
9.4 Inventory Control System for Finished fabric
 Finished fabric from the compactor or stenter goes to inspection team. Here
inspection is done by a four points system.
 Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness
etc are tested from the lab before packaging.
 After finishing the fabric is kept in package before their transfer to the garments
department.
 It is controlled by the finishing in-charge who keeps a list of total finished product.
He also keeps a list of delivery products.
 He supplies the fabric as per requirement and records the date, type of material,
9.5 Inventory Control System for Spare Parts
 Spare store officer keeps the spare parts in store and makes a list of spare parts.
 If the spare parts are little in stock he gives requisition to maintenance manager.
 Maintenance manager gives requisition to head office. Head office imports spare
parts or buys from local market as per requirement.
 As new spare parts arrive to store officer, he receives and catalogues them.
 He supplies the spare parts as per requirement and records the date, type of material,
9.6 Remarks
Landmark Textile Mills Ltd. has individual stores for raw materials, finished goods and
spare parts. The store of dyestuff and chemicals are not so clean. There is not enough
space to store the finished goods. It requires increasing the store area.

CHAPTER-X
COST ANALYSIS

Industrial Attachment Cost Analysis
10 COST ANALYSIS
10.1INTRODUCTION
The process by which the setting price of a product is calculated is called
Costing. It is a very important task for a factory which runs for business purposes. And it
is also strictly followed in the M M knitwear Ltd. Costing of the products considering
the raw materials expenditure, salary and wages of officers and workers, distributions
and advertisement expenses etc. all direct and indirect expenses is done in this factory. It
is determined by a top of accountants with advice and consultancy of executive director
Setting Price = Sum. Of the cost + Profit margin.
10.2Costing elements
1. Production Cost
 Direct cost
Raw material cost
Direct labor
 Indirect cost
 Indirect labor
 Factory overhead
 Processing cost
 Administrative cost
2. Marketing & Selling cost
 Transportation cost
 Advertising cost
 Commission of sales executives
Cost of product = (Sum of all Direct & Indirect expenses + Administrative cost
+ Factory Overhead)
10.3Knitting Charge of Different Fabrics
Fabric name Charge per kg(Tk)
1. Single Jersey 10
2. Single Jersey with Lycra 30
3. Single lacost 16
4. Double lacost 16

5. Single PK 16
6. Double PK 16
7. Rib 17
8. Rib with Lycra 30
9. Interlock 25
10. Auto strip 80
11. Auto striper with Lycra 100
12. Fleece 22-25
10.4Dyeing Charge of Different Fabrics
Name of fabric process Charge per kg(Tk)
1. White with Enzyme 35
2. White without Enzyme 30
3. Avg. color with Enzyme 85
4. Avg.color without Enzyme (Light& med.) 75
5. Deep shed with Enzyme (Black) 110
6. Deep shed without Enzyme (Black) 95
7. Only wash (Tubular) 25
8. Only wash (Open) 45
9. Double dyeing (Face & Back) 115
10.5Finishing Charge of Different Fabrics
Name of fabric process Charge per kg(Tk)
1. Slitting only 5
2. Stenter only 25
3. Compacting only 15
4. Stenter + Compacting 35
5. Stenter + Compacting+ wash 50

6. Tube Compacting 10
10.6COSTING OF THE PRODUCT
Let,
Count of yarn = 30/1 Ne
Price of yarn per kg. = 2.80 $
Particulars Cost (Tk.) Total Cost (Tk.)
Cost of raw material / kg. 184.80
Knit charge / kg. 10.00
Process loss (5%) 9.25
Price of Gray Knitted Fabric (S/J) per kg. 204.05
Dyeing cost (Avg. color) 120.00
Process loss (10%) 32.40
Dyed fabric cost 356.45
Packing cost 3.30
Total cost of dyed fabric 359.75
Fabric price (with 25% margin) 449.69
10.7Remarks
The costing of product is a secret matter of the industry. They are not interested to flash
the cost related data. Therefore, we could not gather the actual price of product and
costing of the product.

CHAPTER – XI
MARKETING ACTIVITIES

Industrial Attachment Marketing Activities
11 MARKETING ACTIVITIES
11.1Consumer of Products
1. Textile Pressing Germany (TPG)
2. Ananda fashion (Indian buying house) – U.K.
3. Euro centra
4. Kauf hoff
5. Gulden Pfenning
6. Metro Sandra
11.2Country of Export
 UK
 Germany
 Italy
 Turkey
 USA
 Others
11.3Local Market
M M Knitwear Ltd. is a 100% export oriented industry. But the dye-house of
M M Knitwear Ltd. do take orders from several local companies on sub-contract basis
when they are free. These local companies are following.
 Texco BD.
 Liz Fashion
 Europa
 Probir BD
 Others
11.4Marketing Strategy
Marketing strategy is a very important factor to sale the products to the buyer. If
the marketing strategy is not so developed, it will be very hard to reach the goal. In case
of garments marketing the dealings with the buyer is a very important factor.
In Landmark Textile Mills Ltd. mainly senior marketing officers, merchandiser &
higher officials deal with the buyer. There are some fixed buyers of the industry. These
buyers give their orders continuously all over the year. The marketing officers & the
merchandisers communicate with the buying houses to collect the orders.

Industrial Attachment Marketing Activities
By both side understanding the rate & the order quantity are fixed.
11.5Duties & Responsibilities of Marketing Officer
Dealing with the buyer & convincing the buyer is the main duty of marketing
officer. A marketing officer also has some other duties. The main duties &
responsibilities of a marketing officer are given bellow-
· To prepare cost sheet by dealing with the buyer.
· To take different steps by discussing with the high officials & merchandisers.
· To maintain a regular & good relationship between commercial officers &
merchandisers.
· To maintain communication with the buyers and buying houses.
· Communicate with better knowledge of the products.
Actually the responsibilities & duties of marketing officer begin from getting
order of buyer & ends after receiving payment by the buyer. So, he should be always
smart, energetic & sincere.
11.6Remarks
Landmark Textile Mills Ltd. has an energetic and motivated marketing &
merchandising team. They are always in communication with the buyers. The marketing
section also looks after the quality & quantity requirement of the buyers.

CHAPTER –XII
EFFLUENT TREATMENT PLANT

Industrial Attachment ETP
12 EFFLUENT TREATMENT PLANT (ETP)
The effluent generated from different sections of a textile industry must be treated before
they are discharged to the environment. Various chemicals and physical means are
introduced for this purpose.
Capacity : 80m3/ hr
Cost : Tk. 2.5 / m3
12.1Process Flow chart of Biological Effluent Treatment Plant
Fabric Dyeing
Pumping and Screening
Homogenizing Tank
Distribution Tank
Acid Dosing
Antifoaming
Dosing Biological Oxidation Tank
Sedimentation Tank
Sludge Return Tank
Sludge Thickener
Dry Sludge
Filter Press
De-colorant
Dosing
Dispose to Land Filling
Polyelectrolyte
Dosing

12.2Function of different Unit of Biological Effluent Treatment
Plant (E T P)
♦Screening unit: It works like a filter. By filtering waste water, it removes threads,
pieces of fabrics, small metal pieces etc. In this unit a rotating brush is used for clean the
pores if screen. The brush rotates periodically.
♦ Storage and Homogenization tank:
Different waste water from varies process is stored and makes a homogeneous mixture by
mixing different concentration of waste water.
♦ Neutralization tank:
Neutralization of waste water is performed by dosing 98% H2SO4 as required to control
the PH
Of waste water PH range 6.5 to 7.5.
♦ Distribution tank:
It distributes the water to the biological oxidation tank. Continuous aeration is supplied
here. Antifoam is dosed here to control the foaming in the oxidation tank.
♦ Biological oxidation tank:
It is the heat of E T P. The entire harmful chemicals are damaged here by breaking their
bonds. This is done by bacteria. To ensure the proper function work and growth of
bacteria, few conditions must be maintained.
○Temperature : 35º to 37º C
○ PH (Maximum) : 6.5
○ Dissolved oxygen : 4 PPM
♦ Sedimentation Tank / Biological feeding tank:
Treated water is overflowed here from oxidation tank. Decolourent is used here to
destroy the color of waste water.
♦ Settling tank / Sedimentation Basin:
A tank or basin in which waste water is held for a period of time, during which the
heavier solids settle to the bottom and the lighter material will floats to the water surface.
In this tank sludge is immersed and the harmless water is discharge to ponds, Land, river
etc.
♦ Sludge Thickener:
Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge. After one
hour of
Polyelectrolyte dosing aeration is stopped and fresh water discharge to drain when sludge
is taken. The thickened sludge is transferred to the sludge thickener bed.

♦ Sludge Thickener bed:
Here sludge is dried which is used as good fertilizer as well as fuel of brick field. Sludge
is dried under the sunlight.
Required Chemical of Biological E T P:
Sulphuric Acid:
Function: Neutralize the waste water controlling the PH. It is auto dispensed in the
neutralization tank.
Polyelectrolyte:
Function: Used for sedimentation / sludge coagulation and also killing bacteria.
Antifoaming Agent:
Function: Used for reduction / controlling foam. It is used auto / manually in the
distribution tank.
De-colorant:
Function: Used for removing color. It is used auto / manually in the sedimentation
feeding tank.
Sodium Hypochlorite:
Function: It is used to kill the harmful bacteria. It is used in the biological oxidation tank.
12.3Product Quality Checked
o Biological Oxygen Demand (BOD)
o Chemical Oxygen Demand (COD)
o Total suspended solids
o Total dissolved solids
o Color
o pH etc.
12.4Remarks
Waste water from processing industries e g. Dyeing , Printing , Finishing and washing
causes great harmful effect on our environmental, As a result agricultural land loses its
fertility, natural water becomes polluted aquatic life is destructive and crops are damages.
So, it is important to control ETP plan.

CHAPTER –XIII
CONCLUSION

Industrial attachment of MM KNITWEAR Ltd

Industrial attachment of MM KNITWEAR Ltd

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