Industrial attachment of newtex composite textiles ltd.

Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 1
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT OF Newtex Composite Textiles Ltd.

ABSTRACT:
By means of the practical knowledge it’s possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge.
In this report describe about our entire internship period. By this industrial attachment we can know about Impress-Newtex composite Textiles Ltd basic information. The internship paper provides knowledge about Knitting, planning, wet processing lab, dyeing, finishing, quality & dry lab. It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to accustomed with the industrial atmosphere & improve courage & inspiration to take self-responsibility.

CONTENT
Topics name Page No.
1.CHAPTER -I....................................................................................................7-9
COMPANY PROFILE
1.1 General information About the Mill
1.2 Buyers of Impress-Newtex Composites Textile Ltd.
1.3 Site Location
2.CHAPTER -II.............................................................................................10-11
STRUCTURE OF THE ORGANIZATION
2.1 Organ gram of Impress-Newtex Composite Textiles Ltd
2.2 Shift Classification
2.3 Responsibilities of the officer
3.CHAPTER -III………………………………………………………………...12-26
KNITTING DEPARTMENT
3.1 Knitting
3.2 Raw materials
3.3 Lay-out of knitting section
3.4 Specification of knitting department
3.5 Production flow chart of knitting section
3.6 Description of production process in Impress-newtex
composite textiles ltd
3.7 Production parameter
3.8 DESCRIPTION OF IMPORTANT MACHINE PARTS
3.9 Types of fabrics produce in Impress-Newtex Composite
Textiles Ltd.
3.10 Production Calculation
3.11 Knitting faults, causes & their remedies

4.CHAPTER -IV………………………………………………………………...27-29
PLANNING DEPARTMENT
4.1 Planning department
4.2 Batch section
4.3 machines used in batch section
5.CHAPTER -V……………………………………………………………….....30-31
WET PROCESSING LAB
5.1 Dyeing laboratory
5.2 Lab Dip
6.CHAPTER -VI…………………………………………………………….......32-47
Dyeing
6.1 Raw-materials
6.2 Production planning, sequence & operations
6.3 sequence of operation for knit dyeing
6.4 Dyeing process
6.5 Process sequence of stripping
6.6 Lay out plan of Dyeing Shed
6.7 Specification
7.CHAPTER -VII……………………………………………………………….48-54
FINISHING
7.1Finishing
7.2Process flow chart of knitting finishing
7.3 Lay out Plan of Finishing Shed
7.4Specification of Finishing Section
7.5Objects of finishing machine used in Impress-Newtex
composite Textiles Ltd.
7.6Data for Tumble machine
8.CHAPTER -VIII……………………………………………………………....55-58
QUALITY CONTROL
8.1 Quality Management System
8.2 Objectives of quality control
8.3 Quality Management system in Impress-Newtex Composite

Textiles Ltd.
8.4 Analysis of different types of faults
8.5 Four (4) point system
9.CHAPTER -IX…………………………………………………………………59-63
DRY LAB
9.1 Different types of machine used in finishing lab
9.2 Short note on some tests
10.CHAPTER -X………………………………………………………………64-69
WTP & ETP
10.1 Water treatment plant
10.2 Standard water quality for dye house
10.3 Flow chart of ETP
10.4 Step wise function of different unit of E.T.P
11.CHAPTER -XI……………………………………………………………….70-73
MAINTENACE & UTILITY SERVICES
11.1 Maintenance
11.2 Utility servicess
12.CHAPTER -XII……………………………………………………………..........74
CONCLUSION
12.1Comments
12.2Some suggestions

CHAPTER-I
COMPANY PROFILE
1.1 General information About the Mill
Name of the Company : Impress-Newtex Composite Textiles Ltd.
Type : 100% Export oriented Knit Dyeing Factory.
Year of Establishment : 1996.
Location : Gorai, Mirzapur, Tangail.
Address:
Factory : Gorai industrial area, Mirzapur, Tangail.
Head Office : “Evergreen Plaza”(6th Floor) 260/B, Tejgaon Industrial Area, Dhaka-1208
Project Cost : 100crores taka.
Capacity : Knit Dyeing 22-24 tons per day Annual Turnover :Around 10 Lac U.S Dollar/year.
Physical Infrastructure:
Physical infrastructure of Impress-Newtex Composite Textiles Ltd. is simple one. It is constructed by steel structure; outside is brick wall, somewhere it is R.C.C. & brick wall structure.
Vision:
1. To be one of the best leading composite mill in Bangladesh
2. To build a true marketing led enterprise with motivated workforce, innovative vision & more value added product portfolio, customer satisfaction & understanding of global market.
Mission:
Each of our activities must benefit and add value to the common wealth of our society. We firmly believe that, in the final analysis we are accountable to each of the

constituents with whom we interact; namely, our employees, our customers, our business associates, our fellow, citizens.
Medical facility:
Trained team of medical are formed in case of any emergency.
Working environment:
An excellent working environment exits in the factory with proper ventilation & light. No child labor work in the factory
Certification & Award: ISO 9001:2008 certified Company.
1.2 Buyers of Impress-Newtex Composites Textile Ltd.
Name/logo
Country
SWEDEN
NETHERLAND
Germany
AUSTRALIA

1.3 Site Location
Mirzapur Cadet College Impress-
Newtex
Group
Karnafully
Knit-Industries
Ltd.
Nabinagor Chandra
West
South
North
East
Dhaka-M anikgonjRoad
Dhaka- Tangail Road

CHAPTER-II
STRUCTURE OF THE ORGANIZATION
2.1 Organ gram of Impress-Newtex Composite Textiles Ltd.
Impress-Newtex Composite Textiles Ltd. is well equipped with highly efficient team of management, which is very essential for smooth running of a factory.
Chairman
Managing Director
Director
Executive Director
Senior General Manager
General Manager
Deputy General Manager
Manager
Deputy Manager
Assistant Manager
Senior Executive
Executive
Junior Executive
Supervisor
Operator
Assistant operator
Helper

2.2 Shift Classification
There are three shifts per day in Impress-Newtex Composite Textiles Ltd. So each shift contain eight hour. Shift Start End A
6:00 A.M. 2.00 P.M. B 2.00 P.M. 10:00 P.M. C
10:00 P.M. 6:00 A.M. General 9.00 AM 5.00 PM
The factory runs 24 hours a day & 365 days a year. It maintains a strong working schedule which is shown in the chart below-
Section
No. of shift
Duration
Dyeing
3 shifts
8 hours each
Knitting
3 shifts
8 hours each
Finishing
3 shifts
8 hours each
Inspection
3 shifts
8 hours each
Staff & Commercial
General shift(9am to 5pm)
8 hours
Top management
General shift(9am to 5pm)
8 hours
2.3 Responsibilities of the officer
 General Manager (G.M):
 Deals with the buyers & merchandiser.
 Setting up price for the product
 Planning, applying & controlling all administrative functions.
 Following up the instructions of the Managing Direction & Chairman.
 Arranging necessary facilities for the buyer’s demand.
 Manager:
 Planning for the sequence of operation.
 Organizing necessary raw materials for the production
 To follow the production & provide solution to the production problems.
 Indicating reasons which are liable for less production.
 Executive:
 Follows the worker’s movement
 Discuss with the manager what is going on the floor
 Maintain production sequence
 Check the sample at a certain time interval.
 Setting program for the supervisor

CHAPTER: III
KNITTING DEPARTMENT
Fig: Knitting machine
3.1 Knitting
Knitting is considered to be the second most frequently used method of fabric construction, after weaving. It is one of the several ways to turn thread or yarn into cloth. It is similar to crochet in the sense that it consists of loops pulled through other loops. In other words, knitting is the process of construction of a fabric made of interlocking loops of yarn by means of needles. The loops may be either loosely or closely constructed, according to the purpose of the fabric. The loops or stitches are interlocked using a needle which holds the existing loop and a new loop is formed in front of the old loop. The old loop is then brought over the new loop to form the knitted fabric. Knitting is different from weaving in the sense that a single piece of yarn can be used to create fabric. The knitted fabric consists of horizontal rows known as courses and vertical columns of loops known as wales.

3.2 Raw materials
3.2.1 Types of raw material
1. Yarn
2. Lycra
Yarn:
Natural and synthetic, Cellulosic and non-cellulosic all kind of yarn are used as raw materials in this mill. Generally, Cotton, Polyester, Viscose are mostly used in knitting departments.
Fiber composition
Count
Yarn type
Cotton
7, 10, 12, 13, 16, 20, 30
Carded
16, 20, 30, 40, 50, 60, 80, 100/2, 80/2, 20/2, 30/2, 40/2, 50/2, 60/2
Combed
PC
16, 20, 30, 45
Carded or Combed
CVC
12.5, 20, 30, 38, 40, 45, 26/2
Combed
Viscose
16, 20, 30, 40
Combed
Spandex
20D, 40D
Polyester
70D, 75D, 100D, 120D, 150D
Fig: Yarn

3.3 Lay out of knitting section
Fig: Lay out of knitting section
3.4 Specification of knitting department
1.
 Machine no: 1
 Brand: PRECISION FUKUHARA WORKS LTD.
 Origin: Japan
 Model: DXC-35
 Size: 20

2.
 Machine no: 2
 Brand : PRECISION FUKUHARA WORKS LTD.
 Origin: Japan
 Model: DXC-35
 Size: 20
3.
 Machine no: 3
 Brand : ORIZIO PAOLO S.p.A
 Origin: ITALY
 Power: 45V
 No. of phases: 3
 Frequency: 50-60 Hz
4.
 Machine no: 4
 Brand : ORIZIO PAOLO S.p.A
 Origin: ITALY
 Power: 45V
5.
 Machine no: 5
 Brand: ORIZIO PAOLO S.p.A
 Origin: ITALY
 Power: 45V
6.
 Machine no: 6
 Brand: ORIZIO PAOLO S.p.A
 Origin: ITALY
 Power: 45V
7.
 Machine no: 7
 Brand: JIUNN LONG MACHINE CO. LTD.
 Origin: TAIWAN
 Model no: JLS-4
 No. of needles: 1740T
 Diameter: 23’’
 Feeder: 69F

 Gauge: 24G
8.
 Machine no: 8
 Origin: TAIWAN
 Model no: JLS-4
 Feeder: 96F
 Gauge: 24G
9.
 Machine no: 9
 Origin: TAIWAN
 Model no: JLS-4
 Feeder: 108F
 Gauge: 24G
10.
 Machine no: 10
 Origin: TAIWAN
 Model no: JLS-4
 Feeder: 69F
 Gauge: 24G
11.
 Machine no: 11
 Origin: TAIWAN
 Model no: JLS-4
 Feeder: 63F
 Gauge: 24G
12.
 Machine no: 12
 Origin: TAIWAN
 Model no: JLS-4

 Feeder: 57F
 Gauge: 24G
3.5 Production flow chart of knitting section
Sample fabric
Design analysis
Machine selection
Setting machine for the specific design
Sample knitting
Sample approval
Bulk production
Grey fabric inspection
3.6 Description of production process in Impress-newtex composite textiles ltd.
In every mill, there maintains a sequence in production processing. It is also followed in this mill where I was in industrial attachment. The process sequences are in list below:
1. Firstly, knitting manager gets a production sheet from merchandisers as accordance as consumer requirements. Then he informs or orders senior production officer about it.
2. Senior production officer informs technical in charge and knows about m/c in which the production will be running.
3. Technical in charge calls for leader of mechanical fitter troops, they two take decision about m/c for production considering m/c condition, production capacity, maintenance complexity etc.
4. Production officer with experienced mechanical fitter adjusts required stitch length and grey GSM (gram per square meter) for required final GSM.

5. Supervisor check daily production regularity and make operators conscious about finishing in due time.
6. Operators operate machine in highly attention as if there were no faults in the fabrics. If he is sure about any fabric fault, then he call for mechanical fitter in duty. Mechanical fitter then fixes it if he can or he informs technical in-charge. He then comes in spot.
7. After required production and final inspection in 4-point system, they are sent in dyeing section
3.7 Production parameter:
During production of fabric in circular knitting machine following parameters must be maintain:
1. Machine Diameter;
2. Machine RPM (Revolution/Minute);
3. Number of feeds or feeders in use;
4. Machine Gauge;
5. Count of yarn;
6. Required time (Machine running time);
7. Machine running efficiency.
3.8 DESCRIPTION OF IMPORTANT MACHINE PARTS
Creel:
Creel is a part of a knitting machine. Hear yarn package are store and ready to feed in the machine
VDQ pulley:
It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley moves towards the positive directive then the G.S.M. is decrease. And in the reverse direction G.S.M will increase.

Pulley belt:
It controls the rotation of the MPF wheel.
Brush:
Its clean the pulley belt.
Tension disk:
It confront the tension of the supply yarn
Inlet and outlet stop motion:
It is a important parts of the machine. It stops the machine instantly
when a yarn is break.
Yarn guide:
Its help the yarn to feed in the feeder.
MPF Wheel:
Its control the speed of the MPF. Pulley belt gives motion to the
wheel.
MPF:
Its isMamenger positive feed. Is is also an important parts of the
machine. It’s give positive feed to the machine.

Feeder ring:
It is a ring. Where all feeders are pleased together.
Feeder:
Feeder is help yarn to feed in to the machine.
Needle:
It is a principal element of the knitting machine. Its help the yarn to
create a loop. And by this way fabric are produce. Prior to yarn
feeding the needle is raised to clear the old loop from the hook, and
received the new loop above it on needle stem. The new loop is then
enclosed in the needle hook as the needle starts to descend.
Needle track:
Where all needle is placed together in a decent design.
Sinker:
It is most important element of the machine. Its help to loop forming,
knocking over and holding down the loop.
Sinker ring:
Sinker ring is a ring. Where all sinkers are pleased together.
Cam box:
Where the cam are set horizontally
Cam:
Cam is device s which converts the rotary machine drive in to a
suitable reciprocating action for the needles and other elements.

Lycra Attachment: Lycra is placed hear. And feeding to the machine.
Sensors:
It is one kind of stop motion to stop the machine when the lycra is
break.
Cylinder:
Needle track are situated hear.
Cylinder Balancer: It helps the cylinder to set in a proper alignment.
Screen:
it is a digital screen. Which show the all machine information and we
can give command to the machine.
Automatic oiler:
Its give the machine oil all the time properly and automatically.
Inverter:
Its is the heart of the circular knitting machine. Its control the speed of
the machine.
Power Switch:
To give the power to the machine.

3.9 Types of fabrics produce in Impress-Newtex Composite Textiles
Ltd.
 single Jersey
 Single Lacost
 Double Lacost
 P/C Lycra Baby Tery
ON/OFF Switch:
It help the m/c to start and stop.
Manual drive:
To drive the machine manually.
Machine motherboard:
All the Electronic parts are placed hear.

 Fleece fabric
 Terry Fleece
 Pique
 Lycra single jersey
 Stripe fabric
 Grey Mélange (5%,10%,15% viscose)
3.10 Production Calculation:
A. Production/shift in kg at 100% efficiency :( formula)
Yarncount
RPM No of Feeder No of Needle SL mm
    
    

10 2.54 36 840 2.2046
. . ( ) 60 12
Yarncount
RPM No of Feeder No of Needle SL mm

  

3527.80
. . ( )
B. Production/shift in meter: (formula)
/ 100
. 60 12
/
/min.

   


Course cm
RPM No of Feeder Efficiency
Course cm
Course
C. Fabric width in meter: (formula)
/ 100
.
/ 100
.




Wales cm
Total no of Needlesused in knitting
Wales cm
Total no of wales
D.
Let,
Fabric Type: Single Jersey Plain
Number of Feeder: 90
R.P.M. of Machine: 30
Machine Diameter: 30
Machine Gauge: 24
Count of Yarn: 24/1 Ne

Stitch Length: 2.74
Efficiency: 85 %
Production/8 hours shift = (90*30*60*8*0.85*3.14*30*24*2.74)/ (10*2.54 *36 *840*24*2.2046)
= 168 Kg
Actual production
Efficiency = × 100%
Calculated production
=138/168×100
= 82 %
E) G.S.M calculation [G.S.M gm/m2]:
GSM means grams per square meter. In knitting fabric it is the main parameter. It is
controlled by loop length. If loop length increases GSM will decrease and vice versa. It is
measured by GSM cutter & electric balance. It may also be calculated as below.
GSM =
100
s  l  tex
GSM =
Ne
s l  590
Industrial Calculation of Impress-Newtex Composite textiles ltd:
Collect sample (s/j) by G.S.M cutter and weighted from the weighting balance.
e.g.;  form balance we get 1.838g grey fabric
so, Gray G,S.M=1.838 2 100g /m
=183.8gm/m2
Calculate Finish G.S.M as like procedure
By calculation finish G.S.M =235g/m 2
From finish G.S.M calculating grey GSM, SL, count:
 Suppose a fabric involve 180 finishes G.S.M
So, gray G.S.M=
1.3
FinishG.S.M
= 138
1.3
180

So, count=
F.G.S.M
4320
= 
180
4320
24/s
Where,
S = wale per cm course per cm.
= wpc  cpc.
l = loop length in mm.

So, S.L = 28.78
24 138
95351.5
.
95351.5



countGGSM
cm=2.9 mm
3.11. Knitting faults, causes & their remedies
Faults Causes Remedies
Hole Mark  Holes are results of yarn breakage or
yarn cracks.
 During loop formation the yarn breaks in
the rejoin of the needle hook
 If the yarn count is not correct on
regarding structure, gauge, course &
density.
 Badly knot or splicing
 Yarn feeder badly set
 Yarn strength must be
sufficient to withstand
the stretch as well as
uniform.
 Use proper yarn count.
 Correctly set of yarn
feeder.
 Knot should be given
properly.
Needle Mark  When a needle breaks down then needle
mark comes along with the fabrics.
 If a needle or needle hook is slightly
bends then mark can be obtained.
 Needle should be
straight.
Sinker mark  When sinker corrode due to abrasion
then sometimes can’t hold a new loop as
a result sinker mark comes
 If sinker head bend the sinker mark can
be obtained.
 Sinker should be
changed
Star Mark  Yarn tension variation during production
 Buckling of needle latch.
 Low GSM
 Maintain same yarn
tension during
production
 Use good conditioned
needle
Drop Stitch  Defective needle
 If yarn is not properly fed during loop
formation then causes drop stitch.
 Too loose take down mechanism
 Insufficient yarn tension
 Badly set yarn feeder
 Needle should be
straight & well
 Proper feeding of yarn
during loop formation
 Yarn tension should be
proper
Oil Mark  When oil lick through the needle trick
then it pass on the fabrics & makes a line
 Ensure that oil does not
pass on the fabric.
Well maintenance as well as
Proper oiling.

Pin Hole  Due to break down or bend of the latch,
pin hole may come in the fabric
 Change the needle
Grease Mark  Improper greasing
 Excess greasing
 Proper greasing as well
as proper maintenance
 
Yarn
Contamination
 If yarn contains foreign fiber then it
remains in the fabric even after finishing
 Count mixing can causes this fault
 By avoiding lot count
mixing

CHAPTER –IV
PLANNING DEPARTMENT
4.1 Planning department
Mainly planning department of the factory divided into 2 sections
1. Store section
2. Batch section
Fig: Planning department
Objective of Store section:
 To receive the grey fabric from knitting department or other sources.
 To store the grey fabric according to order number & fabric type
 To update the daily grey fabric store report
4.2 Batch section
Production planning for dyeing is called batch plan. According to the batch no, color,
width, style & construction the batch plan is made.
Batch preparation sequences:
Receive batch card from grey in charge
Made the priority as per dyeing plan
Take one specific batch card
Read the batch card for own understanding
Check the availability of fabric

Take require quantity of the body fabric from ware house
Make required no. of rape maintaining equal length
Take collar as per size, keep the total weight
Distribute the collar/ cuff or rib in each rope equally ensure equal length
Stitch the fabric
Write down the weight against roll no. in the back side of the batch card
Write the total weight in the batch card
Put signature & data
Fill up the production report form.
Information checks point:
 Order no
 Color
 Yarn count
 Yarn lot
 Yarn brand
 Machine no
 Roll no

4.3 machines used in batch section
1.
 Machine name: Fabric inspection machine
 Brand: Uzu
Fig: Fabric inspection machine
2.
 Machine name: Air turning machine
 Model no: DNAT-400
 Brand: DONG NAM INDUSTRIAL CO., LTD
 Origin: Korea
Fig: Air turning machine

CHAPTER -V
WET PROCESSING LAB
5.1 Dyeing laboratory
Lab is the most important section of a dyeing industry. Higher precision lab
can aid easily to achieve the goal of the organization. Before bulk
production a sample for the approval from industry is sent to buyer. As per
requirement of the buyer the shade is prepared in a lab considering the
economic aspects.
5.2 Lab Dip
A lab dip is a swatch of fabric test dyed to hit a color standard. It is a process by which
buyer’s supplied swatch is matched with the varying dyes percentage in the laboratory
with or without help of spectrophotometer. Lab dip plays an important role in shade
matching & this is an important task before bulk production. In previous article of this
author we have to learn on flow chart on dyeing lab.
5.2.1 Object of Lab Dip:
The main objectives in lab dip are as follows:
1. To calculate the recipe for sample dyeing.
2. To compare dyed sample with swatch by light Box or Spectrophotometer.
3. To calculate revise recipe for sample dyeing.
4. Finally approved Lab Dip (Grade: A, B, C & D)
5.2.2 Process Sequence of Lab Dip:
Lab dip plays an important role in dyeing process. Bulk dyeing process completely
depends on the lab dip development work. Lab dip is completely managed as the
following sequence.
Lab Dip Requisition from buyer
↓
Entry in the computer
↓
First recipe is given by swatch/pantone number
↓
First correction

↓
Second correction
↓
Grading of sample (A, B, C, D)
↓
Yarn and knit sample send to buyer
↓
Approved by buyer
↓
Order for bulk production
↓
Production card with approved sample and recipe send to production section.

CHAPTER -VI
DYEING
6.1 Raw-materials:
In impress-Newtex Composite Textiles Ltd., the raw materials used for production are –
 Grey Fabric
 Dyes
 Chemicals
6.1.1 Grey Fabric:
The following type of Grey Fabric are dyed-
 single Jersey
 Lycra single Jersey
 Interlock
 Lacoste
 Rib
 Lycra Rib
 1x1 Rib& others
 collar & cuff
 polyester Fabrics
Source: The required single jersey grey Fabrics &it’s derivatives are produced in this
industry & double jersey & it’s derivatives are bought from others factory.

6.1.2 Dyes & Chemicals Used in Impress- Newtex Composite Textiles
Ltd:
Aids Chemicals name
General Chemicals
Soda ash
Caustic
H2O2
Hydrose
Antifoam-39
Gluber salt(anhydrose)
Acid H2SO4
Acetic Acid
Formic Acid
Invatex AC
Oxalic Acid
Cat-ionic softener
Aikamine CWS
Sun Soflon FK-21
Non-ionic (white) Sun SofterA300
SupamineFPS
Anticrease TexportD-900
Ciba Fluid C
Texport GL-500
Wetting Agent Invadine DA
Sun Morl CK-1
SandocleanPCLF
Fixing Agent Neofix R-250(FDR)
cibatex ECO
Buffer AmoniumSulphide
cibatex AB-45
Soaping Agent Alcosper Ad
Lipotol PS-60
SadopurRSk
Sequestering Agent Invatex CS
Neocrystal BGS
Sirrix 2Ud
Leveling Agent Cibacel DBC
Neocrystal 200B
Drimagin E2R
Lyoprint RG
setamal BL

Per-oxide killer Invatex PC
Croaks N
Enzyme Bio-polish EC
Bio-polish AL
Tinozyme 44L
Stabilizer Stabilizer Sifa
Neorate pH-100
Brightener Siba white
Uvitex BHV
UvitexBBT
Naka white
Leucopher BMB
6.1.3 Dyes used in Impress- Newtex Composite Textiles Ltd
Dyes
Solazol Black sp GRI
Reactofix Red ME 4BL
Cottofix Red ME 4BL
Reactofix orange ME 4RL
ReactofixN.ME2GL
Reactive yellow H4GL
Reactive Deep Black N
Cottofix Black B
Reactive Blue R (SP)
Remazol Red RR
Remazol yellow RR
Remazol Blue RR
Remazol Blue BB NEW
Remazol T. Blue G
Remazol B. yellow 3GL
Remazol Red RGB
Cibacron Red FN2BL
Cibacron Red FB
Cibacron RedFN3G
Cibacron Red WB
Cibacron Blue FNR
Cibacron Blue FGFN
Cibacron Navy WB
Drimarin yellow CL2RL
Drimarin Red CL5B
Drimarin VIOLET K2RL
Drimarin Navy CLB

Drimarin Blue CT2R
Bezaktrive yellow S3R
Bezaktrive yellow SLE
Bezaktrive yellow VGL
Diss yellow F5GL
Diss Red BF
Diss Blue FRL
Diss Navy 2GL
Diss Black EXNSF
Terasil Black WNS
Terasil Red FB
Terasil Red WFS
Terasil Red W4BS
Sunfix Supra Scarlet 2GL
SunfixSupraT/ Blue G
Sunfix Supra Blue EXF
Sunfix Supra Navy Blue EXF
Sunfix Supra Red EXF
Sunfix Supra yellow EXF
Sunfix Br. Blue R
Sunfix Br. yellow4GL
Sunfix HF yellow 3R
Sunfix HF RedG
Sunfix HF Red 2B
Sunfix HF Navy 2G
Sunfix HF Blue 2R
Sunfix HF Brown RL
Sunfix Supra Marine EXF
Sunfix Supra Navy Blue BF
Sunfix Supra yellow 3RF
Sunfix Supra Br. Red 3BF
Sunfix Red 4BNF
Sunfix orange 3R
Sunfix Br. yellow 3GF
Sunfix Supra BlueBRF
Sunfix Supra Red GF
Sunfix Dark Brown BRS
Sunfix Br. violet B.SPI
Taifix Red SF3BT
Taifix yellow SF3RT
Taifix Black SFBSDT
Taifix Black SFBT
Taifix Br. Blue RTSPC
Taifix Br. BlueR special
Taifix Navy Blue BRNT
Taifix Black GRNT

6.2 Production planning, sequence & operations
6.2.1 Production parameters:
A. pH:
- During H2O2 bleaching pH 9-11
- During reactive dyeing pH 10.5-12
- During disperse dyeing 4.5-5.5
B. Temperature:
- For cotton scouring 900 -950C
- For cotton cold wash 300-400C
- For cotton hot wash 700-80C
- For cotton acid wash 600-700C
- For cotton dyeing at 800-900C ( For hot brand )
400-600C (For cold brand)
- Polyester dyeing: 1000-1300C
C. Time:
- For scouring 60-90 mins
- For reactive dyeing 60-90 mins
-for disperse dyeing 30-60 mins
D. M:L ratio
-for reactive dyeing M:L ratio maintained 1:8
Description of production process:
Washing for colored fabrics:
- The colored fabrics to be washed is loaded in the machine
- Required amount of water is taken
- PCLF ( detergents ) added and washing continued at 800C for 20 mins
- Cold washing

Scouring – bleaching:
- Fabric to be scoured is loaded in the machine .
- Required amount of water is loaded .
- Washing agent / detergent is added.
- Steam pipes are on and scouring agent ( i.e caustic soda/ soda ash ) added when
the temperature reaches at 500C.
- When the temperature reaches at 600C then stabilizer is added .
- Then H2 O2 is added.
- Temperature is then raised to 950 C and the process is then carried out for 60-90
mins depending on the requirements.
- The liquors are then drained .
- Then cold wash at 300-400 C, hot wash at 80-950 C and acid wash at 40-500 C is
done.
Dyeing:
- After acid wash all liquors are drained out.
- Required amount of water is taken.
- Then leveling agents, anti – creasing agents, de-foaming agents are added
according to the requirement.
- then the temp. is raised up to mark and after 10-15 mins dyes added.
- Salts are added after another 30 mins.
- Then soda ash after another 30 mins.
- Then the temperature is raised slowly up to the mark.
- The process is carried on and sample are taken after every 10-20 mins to match
with the target shade. It continues until shade matching.
- If the sample is matched then the liquors drained out.
- Then cold wash at 300-400 C, hot wash at 700-800 C, acid wash at 40-500 C is
done.
- Then softener is added at 450 C for 20-30 mins.
- Fixer is applied for deep shade only before adding softener.

Re-dyeing:
When shade is not matched then fabric is treated again in dyeing machine for shade
matching is known as re-dyeing.
Generally re-dyeing is done if the shade is deeper or lighter than the target shade. It may
occur when the fabrics absorb one or two colors more or less. One re-dyeing process is
described below.
- Drain the let off solution.
- Hot wash at 700-800 C.
- Acid wash at 40-500 C ( 400 for light shade and 500 C for deep shade )
- Soda ash washes at 900-1000 C for 60 mins to reduce the depth of shade.
- Acid wash at 600 C
- Addition to required dyestuffs.
- Salt addition.
- Soda ash addition.
- Other operations are same as previous described dyeing operations.

6.3 SEQUENCE OF OPERATION FOR KNIT DYEING:
Batching
Fabric turning
Loading to the machine
Pre-treatment (Scouring &Bleaching )
Dyeing
Dewatering
Drying
Compacting & Calendaring
Final inspection & packing

6.4 Dyeing process
 Maple process: Every chemical are applied at low temperature such as at 400c &
color steam in between 40 to 60oc.
Scouring temperature= 98oc & scouring time 30 minutes
 Turquoise process: Every chemical are applied at 600c & migration is done
from 60 to 90oc & cooling temperature is 60oc.
 Taupe process: Every chemical are applied at low temperature such as at 600c &
color steam 60oc.
6.4.1 Dyeing flow chart for 100% cotton:
Leveling: 60 for 10 min.
Color (600C X20min)
Salt, Soda, Caustic:
(600C X 20 min)
Color Steam: 20 min.
Color wash: 10 min.
Normal hot (80 0C X 20’)
Ringe: 15’
Add
Acetic Acid------1%
(Run time 10’)

Hot wash
(800C X10’)
Add softener
(900C X25’)
Unload
6.4.2 Process sequence of polyester dyeing
Fabric load
Water level as required
Rise temp. to 600C
Addacidat 600C
Rise temp. to 950C
(Run time 10’)
Drain
Rise temp. to 450C
Hot wash With PS-60------1%

(980C X 10’)
AdddyesDosing(45 0C x 10’)(Run time15’)
Rise temp. to 1300C (Run time 30’)
Cooling to 700C if shade ok then BD
Drain
Add Hydrose + caustic (800C x 10’)
Hot wash(800C X10’)
AddAcetic Acid&softener(450C X 10’)
COLD wash(300C X10’)
Unload
6.5 Process sequence of stripping

Fabric loading
Loading hot – 900C for 10 min
Washing at 40OC for 10 min
Drain & filling
Leveling run at 400C for 10 min
Caustic dosing for 400 C for 10 min
Steam up at 400C to 1000C
Steam up at 1000C to 1300C
Run time 70 min
Cooling
Normal hot at 900C for 10 min
Drain & filling
Acid run at 400C for 10 min
Washing at 400C for 10 min
Drain & filling
Lab test & unloading
6.6 Lay out plan of Dyeing Shed

:
6.7 Specification
1
2
3
14
15 13
16
17
12
5
6
7
S-8
S-9
S-
10
S-
11
4
Diesel
Genera
tor
Fire Tube Boiler
B B
Gas Generator
7
Godown

Dyeing Machine type Machine Quantity
Winch dyeing Machine 13
Winch dyeing Machine(SAMPLE) 4
Winch dyeing Machine(Atmospheric)
Machine no. 01 02 03 04
Name of the
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Brand name Sclavos
Tong gene
Tong gene
Tong gene
Origin Greece
Taiwan
Taiwan
Taiwan
Capacity 1200kg
800kg 1200kg 250kg
Year of
manufacturing
2008 1995 1995 1995
No. of Nozzle 4
4 6 4
Temp. range Up to 1420C
Up to 980C Up to 980C Up to 980C
Model Tgru-Half 1-5 Tgru-Half 1-15 Tgru-Half 1-25 Tgru-Half 1-50
Machine no. 05 06 07 12
Name of the
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Brand name Sclavos
Fong’s Fong’s Fong’s
Origin Greece
Honkong Honkong Honkong
Capacity 1500kg
450kg 650kg 600kg
Year of
manufacturing
2008 1995 1995 1995
No. of Nozzle 6
4 4 4
Model DIN-EN-729-3
BS-5500 BS-5500 BS-5500

Machine no. 9 10 11 8
Name of the
Machine
Winch dyeing
Machine(Sample)
Winch dyeing
Machine(Sample)
Winch dyeing
Machine(Sample)
Winch dyeing
Machine(Sample)
Brand name Dilmenler Fong’s
Tong Gene Tong Gene
Origin Turkiye
Honkong
Taiwan
Taiwan
Capacity 35kg 25kg
20kg 10kg
Year of
manufacturing
1999 1999 1995 1993
No. of Nozzle 1 1
1 1
Machine no. 13 14 15 16
Name of the
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Winch dyeing
Machine
Brand name Tong gene Fong’s
Tong gene Tong gene
Origin Taiwan
Honkong
Taiwan
Taiwan
Capacity 600kg 800kg
1000kg 600kg
Year of
manufacturing
1998 2001 2001 2001
No. of Nozzle 3 4
6 3
Machine no. 17
Name of the
Machine
Winch dyeing
Machine
Brand name Tong gene
Origin Taiwan
Capacity 1000kg
Year of
manufacturing
1998

No. of Nozzle 6

CHAPTER –VII
FINISHING
7.1 FINISHING
Any operation (other than preparation and coloring) that improves the appearance
and/or usefulness of fabric after it leaves the loom or knitting machine. Finishing is the
final series of operations that produces finished textile fabric from grey goods.
The word "finish" means all the different treatments applied to a fabric to change such
things as its
• Appearance,
• Feel or hand,
• Wear ability or care requirements.
7.2 Process flow chart of knitting finishing
 For Tubular form:
Hydro-extractor
De-watering
Dryer
Tubular compactor
 For open form:
Hydro-extractor
De-watering
Dryer
Slitter
Stenter
Compactor

7.3 Lay out Plan of Finishing Shed
Notation
A Open compactor I Physical test Lab.
B Platinum
Stenter m/c
J Supervisor’s room
C bianco Slitter K Hydro-extractor
D De-watering m/c L Information desk
E Dryer M Chemical Lab.
F Tube compactor
G Finishing table

7.4Specification of Finishing Section
Machine
name
Hydro-extractor
De-watering
m/c
Sutter
Slitter
Dryer
(tube)
Dryer
(open)
m/c no. 02
Model no. DMS 07
(centifuge)
R 02 940727
Serial no. DMS07
KC1250 2003-
02
DMS053k2G
2400 2003-
09
Year of Mfg 2003 2005 1995 2003
Brand name Dilmenler Bianco Bianco RUCKH Dilmenler
Manufacturing
country
Turkey Italy Italy Germany Turkey
Total power 16.12kW
Capacity 125kg 8 tons/day 8 tons/day
R.p.m 60m/min 4-30
m/min.
4-30
m/min.
No. of motor 03
No of
chamber
2 3
Application
Open
width&
tube fabric
Open
width& tube
fabric
Temp. 1100C -
2200C

Machine name Open compactor Open
compactor(new)
Tubecompactor
m/c no. 1 1 1
Model no. compacta_ck/240-a comptex/Fv 200 comptex/Fv
Machine name Platinum
Stenter m/c
m/c no. 1
Model no.
Serial no. 72276-0463
Year of Mfg 1995
Brand name BRUCKNER
Mfg country Germany
Temp. 50-2500C
Capacity 8 tons/day
R.p.m 15-30m/min.(knit)
15-80m/min.(woven)
Used Utilities Electricity, Water,gas,Compact air
No of chamber 3
Application Open width fabric
Max. width 102”
Min. width 30”
Steam Pressure 2 Bar
Air Pressure 10 Bar
Extra attachment Mahlo attachment for Bowing control

Brand name SperottoRimer Ferraro Ferraro
Manufacturing
country
Italy
Italy Italy
Temp. 110-1400C 110-1400C 110-1450C
Capacity 4 tons/day 4 tons/day 8 tons/day
R.p.m 13-22m/min. 13-22m/min. 16-35m/min.
Used Utilities Electricity, steam, gas,
Compact air
Electricity, steam, gas,
Compact air
Electricity, steam,
gas, Compact air
No of chamber
Application Open width fabric Open width fabric Tube fabric
Max. width 86” 86” 52”
Min. width 36” 36” 16”
Machine name Tube compactor
Brand name Tubetex
Mfg country Italy
Temp. 60-1000C
Capacity 4 tons/day
R.p.m 20-30m/min.
Used Utilities Electricity
No. of cylinder/drum 1
no.of pin roller 24 (pile -18,c pile-6)
cylinder rpm 100
Tension 3kg
pin type Both pile & counter pile fabric

7.5 Objects of finishing machine used in Impress-Newtex
composite Textiles Ltd.
 Ferraro machine:
 Compacting machine for tubular fabric.
 To iron the fabric. This machine used before packaging.
 DILMENLER (Tube Dryer):
 To dry the wet the fabric.
 To control GSM
 Tubetex:
 To compact the fabric
 CALATOR:
 To squeeze the water from fabric (dewatering)
 To apply softener
 To increase the diameter as well as control the diameter.
 CORINO machine:
 To squeeze the water from fabric (dewatering)
 To apply softener
 To increase the diameter as well as control the diameter.
 Hydro machine:
 To squeeze water from fabric.
*** Softener can’t be used by this machine & the machine works by using anti-centrifugal
force.
 Tumble machine:
 To dry the fabric at relax situation
 To increase the GSM
 To decrease shrinkage
 Slitting machine:
 To cut tubular fabric
 To remove excess water from the fabric

 Stenter machine:
 To control the diameter
 To dry the fabric
 To control GSM of fabric
 This machine used for heat setting
*** This machine is used for CVC, 100% cotton & Lycra fabric in open form.Chain-pin
present in this machine, so this machine used only for open fabric.
7.6Data for Tumble machine
Fabric type Before GSM Final GSM Steam Time
(min)
Heat time
(min)
Cool time
(min)
Single jersey 105 115-120 3 5 2
Waffle
(white)
160 180-190 25-26 8-10 5
Waffle (red) 160 180-190 5 6-7 3
Rib 160 180-190 5 6-7 3

CHAPTER -VIII
QUALITY CONTROL
8.1 Quality Management System
The quality assurance department is assigned to maintain consistently uniform quality
of the material in process & various stages of its manufacturing.
8.2 Objectives of quality control
 Research
 Selection of raw materials
 Process control
 Process development
 Product testing
 Specification test
8.3 Quality Management system in Impress-Newtex Composite
Textiles Ltd.
Quality Assurance
On-line Off-line
8.3.1 Online quality Control:
There are two types of online quality control. These are as follows-
 Raw material control:
Raw material control means control the quality of raw materials (grey fabric, dyes,
chemicals & auxiliary)
 Process control:
Process control means the selection of right process & controlling of some
parameters such as pH, water hardness, water volume, temperature, reel speed,
pump pressure.

8.3. Flow chart for quality assurance
Yarn test sample inspection
Recorded on yarn test report
Recorded on grey fabric 4 point inspection report
Finished fabric inspection
Recorded on finished fabric inspection report
If passed if failed non correctional Rejected
Send for lab test Correction able
Send for corrective action as required
If passed if failed
Delivery to finished store send for corrective action as required
8.4 Analysis of different types of faults

Types of fault Source Remedy
1 Broken needle From knitting More attention & preparation requires
during production
2 Hole Mostly from knitting More attention & preparation requires
during production
3 Color spot From dyeing More attention & preparation requires
during production
4 Softener spot Mostly from dyeing Need to control wet process correctly
5 Lycra out Lycra missing or
breakage during knitting
To be more careful during knitting
6 Poly propline
present
From yarn Need to select contamination free yarn
selection.
7 Stripe/thick &
thin
Mostly from yarn More attention & preparation requires
during production
8 Mixed Mostly from knitting More attention & preparation requires
during Knitting
9 Dirty spot Mostly from dyeing &
finishing
More attention & preparation requires
during production
10 Fly color spot From dyeing More attention & preparation requires
during production
11 Dead cotton From yarn Need to be more careful during yarn
selection
12 Contamination From yarn Need to contamination free yarn
13 Crease mark From improper storage
or wet process
More attention in storage & wet process
14 Oil spot Mostly from knitting More attention & preparation requires
during production

8.5 Four (4) point system
This inspection is pointed by 4 point system:
4 point parameter Point Acceptable limit
0-3 1 <20: A grade fabric
>3-6 2 20-30: B grade fabric
>6-9 3 30<: Unacceptable fabric
>9 4
Hole<1 2
Hole>1 4
Total point = (Total fault*36*100)/(Roll length in yards* Actual width)

CHAPTER –IX
DRY LAB
9.1 Different types of machine used in finishing lab
Name of the
machine
Objectives Brand/
Manufacturer
Origin
Light fastness test
machine, Xenotest
150S+
To determine the fastness against
light of dyed & printed fabrics
ATLAS GERMANY
Auto Burst To determine the bursting strength
of textile fabrics
- -
ICI pilling & Snagging
Tester
To determine the resistance to
pilling & surface change of textile
fabric
Wrap reel electronic
machine
To prepare specific length for
measuring yarn count
Incubator To determine the color fastness of
perspiration, water, saliva of the
dyed & printed fabrics
Microprocessor pH
meter
To measure the pH value of the
aqueous extract of textiles
HANNA
INSTRUMENTS
Crock master To determine the dry & wet rub of
all textiles fabric & yarn
James Heal &
co ltd.
England
9.2 Short note on some tests
1. Color fastness to wash test:
Required materials:
1. Sample size(40mm x100 mm)
2. Multifibre (40mm x100 mm)
3. ECE Detergent—4gpl
4. Sodium perborate----1gpl
5. Distilled water
6. Steel balls
Required instrument:
 Rota wash
 Scissor
 Stitch m/c

Procedure:
1. Cut Sample &Multifibre then Stitch.
2. 50ml ECE &50ml Sodium per borate are taken with the sample .
3. The sample is kept in 600C for 30 min in Rota wash
4. m/c
5. Rinse the sample with cold water.
6. Dry at 600C by hanging.
Report:
Dry the sample &the change of shade &degree of staining is measured by grey scale &
staining scale.
2. Color Fastness to perspiration Test:
Test Specimen:
 Sample size(50mm x50 mm)
 Multifibre (50 mmx50 mm)
 Cut the Multifibre into two piece
 Sandwich the test specimen between two piece of Multifibre.
Testing Solution:
1. Alkaline Solution:
Histidinemonohydrochoridemonohydrate(C2H10CIN3O2.H2O)---5gpl
NaCl--------5gpl
Di sodium hydrogen Orthophosphate (Na2HPO4.2H2O)-------2.5gpl
pH-----8(adjust by 0.1N NaOH)
2. Acidic Solution:
Histidinemonohydrochoridemonohydrate(C2H10CIN3O2.H2O)---5gpl
NaCl--------5gpl
sodium Di hydrogen Orthophosphate (NaH2PO4.2H2O)-------2.5gpl
pH-----5.5(adjust by 0.1N NaOH)
Method:
 The composite sample is put in a peri dish
 Solution (Alkaline& Acidic)is taken into 2 dish (M:L=1:20)
 Bubble is made out from the specimen by tapping
 A glass is placed in the composite specimen for 15 min. at room temp.
 Excess Solution is poured out .

 Peri dish with composite specimen &glass plate is placeed into the incobator at
(37=/-2) 0 C for 4 hours
 The specimen is dried (temp.<60 0 c)
Report:
The change of shade &degree of staining is measured by grey scale & staining scale.
3.Color Fastness to water test:
Test Specimen:
 Sample size(50mm x50 mm)
 Multifibre (50 mmx100 mm)
 Cut the Multifibre into two piece
 Sandwich the test specimen between two pieces of Multifibre.
Testing Solution: Water is taken as required.
Method:
 The composite sample is put in a peri dish
 Water is taken in the peri dish as required.
 Bubble is made out from the specimen by tapping .
 The specimen is put for 30 min.
 A glass is placed in the composite specimen for 15 min. at room temp.
 Excess Solution is poured out .
 Peri dish with composite specimen &glass plate is placeed into the incobator at
(37=/-2) 0 C for 4 hours
 The specimen is dried (temp.<60 0 c).
Report:
4.Color Fastness to Rubbing(dry & wet):
Sample:
 Dyed sample(15cm x5cm)
 White sample(5cm x5cm)

Procedure:
 White test fabric is put on to the grating & stag by steel wire .
 The sample is run 20 times manually for 10s.& the rubbing fastness of the
sample cloth &degree of staining is accessed.
 For rubbing fastness (wet) , the rubbing cloth is placed in the water
&socked & squeeze .
 wet rubbing test fabric is put on to the grating & stag by steel wire .
 The sample is run 20 times manually for 10s.& the rubbing fastness of the
sample cloth &degree of staining is accessed.
Report:
5.Dimensional Stability (Shrinkage/Spirality) Test:
Sample : Two piece of 50cm x50cm sample
Procedure:
 Conditioning: The sample is put in a table for 4 hours .
 Cut the sample & benchmark should be 35 cm X35 cm. Stitch the sample in 3
sides by over lock sewing m/c
 Put the sample in washing m/c & run according to buyer requirement.
 Drying: All buyers requirement is tumble Dry except ECO SCOURING is flat
dry.
Shrinkage calculation:
Shrinkage %=( before wash- after wash)/ before wash X 100
Spirality calculation:
S=(S1+S2)/2
Spirality=(S=S X L)/100
Where,
S1=the right side distance of the specimen from the stitch line after wash
S2=the left side distance of the specimen from the stitch line after wash
L= Length before wash.
6.pH test of the dyed fabric :

Test specimen :
 2gm of dyed fabric is taken.
 Cut the fabric into 2 piece of (5mm X 5mm)
Procedure:
 The sample is taken into conical flax.
 100ml distill water (slightly warm) is taken into conical flax.
 The conical flax is put on to the magnetic stirrer for 30 min.
Report:
The pH of the conical flax is measured by digital pH meter.
Salt &Soda is taken on basis of the shade%. They are:
shade%. Salt (gpl) Soda(gpl)
0.001-0.100 20 6
0.101-0.500 24 8
0.501-1.000 30 10
1.001-2.000 40 12
2.001-3.000 50 14
3.001-4.000 60 16
4.000 & above 80 20
CHAPTER -X

WTP & ETP
10.1 Water treatment plant
There are two deep tubeweel by the two side of the treatment plant. There are also two
submersible pumps in the deep tubeweel one is 100 ft deep and another is 140 ft deep. The
submersible pump transfer raw water in the water tank by creates force. The formation of
oxidation of the water by showering with the help of another two pimps in the water tank.
Iron content removes by the oxidation.
Two circular transfer raw water in the (vessel no-1) Multigrade filter unit. The large size
plastic, iron that means solid content are removed in the multigrade filter unit. The water is
transferred to the (vessel No-2) Activated carbon filter unit. In the (vessel No-2) Activated
carbon unit to remove chlorine that means bad smell. The water then transfer in to the (vessel
No-3) softener unit from the activated carbon unit at the presence of cationic resin (Zeolite) is
reacted with water to remove the hardness of water.
The water is transferred in to the reserve tank from the softener unit. The soft water is
supplied from the reserve tank by the 7 Boosting pump in the different section of the factory.
The back wash & regeneration process:
The back wash process to clean the vessel no-1,2& 3. The back wash process should
be done after 8-12hrs. After 40-48 hrs later the regeneration process should be done. It should
be done after back wash process. After back wash the common salt dissolved with water in to
the STT (salt saturated tank) the solution of common salt is ringing the resin by the injector.
The use of 18% salt in the total solution.(Suppose, 5000 lit of solution the amount of salt
600kg). The resin is activated by the salt rising. Hereused cationic resin (NaHSO3). If the PH
of the water increase or decrease it should be control by the dosing chemical (Sodium
Hypochlorite) from the chemical tank.
Figure: Water treatment plant
Where,
A=Hard water storage tank
B=Stone filter
C=Carbon filter
D=Resin filter
E=Soft water storage tank
A
B
C
D
E

F= Pump
10.2 Standard water quality for dye house:
Minimum standard Permissible concentration
Color Colorless
Smell No bad smell
Water hardness < 50
PH Value 7-8 Neutral
Dissolved solid < 1 mg/1
Inorganic salt < 500 mg/1
Iron (Fe) < 0.1 mg/1
Manganese (mn) < 0.01 mg/1
Copper (Cu) < 0.005 mg/1
Nitrate (NO3) < 50 mg/1
Nitrite (No2) < 5 mg/1
Hardness check:
The hardness should be checked after every 6 hrs. It should be checked by the
hardness test kits. The using hardness test kits are Hanna Instrument. Made in Italy.If the
hardness is going to be 0.5 on the syringe scale. Then have to do the regeneration process.
The capacity of the vessel 115m3/ hr or 115 ton/hr.
10.3 Flow chart of ETP:

Effluent treatment plant (ETP)
Process: Biological.
Capacity: 110 m3 / hour.
The major sources of liquid discharge are
- Scouring.
- Bleaching.
- Dyeing.
- Washing.
Dye wastes content:
- Carbon, nitrogen, phosphorus.
Bleaching:
- Dilute hypochlorite solution.
Effluent
Water from
Dyeing
Equalizer
Tank
Reaction
Tank
Floccula-tion
Tank
Aeration
Tank
Secondary
clarifier
PHControl
Tank
Prmary
clarifier
Chlorintion
Tank
Multifilter
Discharge
Effluent

- H2O2
Raw materials:
- Main raw material:
- Cotton yarn.
- Mixed yarn
- Dyes
- Chemical
1. dye include:
- Reactive.
- Disperse.
2. Chemical includes:
- Detergent
- Soda ash
- Caustic soda.
- H2O2
- Stabilizer.
- Acetic acid.
10.4 Step wise function of different unit of E.T.P
Equalizer Tank:
Use chemical: Acid solution.
Function: To neutralize raw waste water by dozing smaller particle.
PH Control Tank:
Use chemical: Fe2SO4, Fitcary.
Function: To control PH.
Reaction Tank:
Use chemical: Lime.
Function: To agglomerate smaller particle.
Flocculation Tank
Use chemical: Polyelectrolyte & alum.
Function: To produce flock.
Primary Clarifier:
Function: To monitor performance of flocculation clarifier & separate solid waste.

Sludge Bed:
Function: Solid waste dried & send to outside for burial
Aeration Tank::
Use chemical: Bacteria, Urea, Cow dung.
Function: Bio logical oxygen demand & Chemical oxygen demand reduced here &
diffused aeration system ensures high oxidation efficiency.
Secondary Clarifier:
Function: Remaining solid waste separate here. Reduced total solid.
Chlorination Tank::
Used chemical: Sodium hypochloride
Function: Disinfection done here.
Multi filter:
Function: Extra suspended impurities separation by passing into the sand.
Here removed suspended solution and correction the water color.
BSTI’S standard:
- pH = 6-9
- BOD = 50 mg/L
- COD= 200 mg/L
- Suspended solid = 150 mg/L
- Color = Light brownish.

Fig: E.T.P Plant

CHAPTER -XI
MAINTENACE & UTILITY SERVICES
11.1 MAINTENANCE
11.1.1OBJECTIVES OF MAINTENACE.
1. To keep the factory plants, equipment, machine, tools, in an optimum condition.
2. To ensure specified accuracy to product and time schedule of delivery to customer.
3. To keep the downtime of machines miniumthes to have control over the production
program.
4. To keep the production cycle within the stipulated range to modify the machine tools
to meet the need for production.
Maintenance Tools, Equipments& their function:
Name of Tools Functions
Hammaer To give shape
Slide Wrench Tightening & opening bolt
Spanner Tightening & opening bolt
PliarCutting,Holding, Joining Wire
Hacksaw Cutting.
Pipe WrenceTightening ,opening,gripping pipe.
Chisel Shaping, Cutting.
File Shaping.
Clamp Gripping.
Name of EquipmentsFunctions
Grinding m/c Grinding.
Cutting m/c Cutting.
Drill m/c Drilling.
Shaping m/c Shaping.
Lathe m/c To make something.
Bending m/c Bending.
11.1.2 MAINTENACE PROCEDURE:
Normally preventive maintenance is used. During maintenance period following points
should be checked.

11.1.3 CHECK LIST OF DIFFERENT PARTS
Maintenance : Mechanical
Machine : Dyeing
SL.Items need to be checked &serviced
1. Grease the m/c bearing.
2. Complete cleaning of m/c.
3. Cleaning of drain valves, replace seals if required.
4. Check air supply filters ,regulators auto drain seals.
5. Clean filters element & blow out
6. Greasing of unloading roller bearing .
7. Checking of oil level and bolts of unloading roller gearbox.
8. Checking of unloading roller coupling and packing.
9. Checking and cleaning (if required )of main vessel level indicator.
10. Check the oil level of pump bearing and refill if required .
11. Check the function of heat and cool modulating valves.
12. Check all door seals.
MAINTENANCE : ELECTRICAL
MACHINE : DYEING MACHINE
SL. ITEMES NEED TO BE CHECKED & SERVICED
1. Check & clean fluff & dirt at dirt at all motor fan covers.
2. Check all motors terminals.
3. Check main panels ( by using compressed air ).
4. Check panel cooling fan and clean its filter.
5. Clean main pump inverter and its cooling fan.
6. Check all circuit breaker, magnetic conductors and relays.
7. Check current setting of all circuit preacher and motor over load.
8. Visual checking of all power and control cables.
9. Check all pressure switches.
10. Check calibration of main vessel and all addition tank.
11. Check all pneumatic solenoids.
12. Check calibration of heating or cooling modulating valve.
13. Check setting of tangle sector.
14. Check setting and operation of lid safely switches.
15. Check all emergency switches.
16. Check all indicating lamps.
17. Check all on/off switches.
18. Check all signal isolators.

11.2 UTILITY SERVICESS
Power & utilities Section:
Description of m/c no.of m/c Capacity
Generated Power:
Prime power generation ,
Cruascar Gas Generator
Model: FGLD 480
Origin: Spain
1Unit 636kW
Stand by: Diesel Generator,
puma, Origin: England
1Unit 140 kW
A. Sub station 1000kVA
Total connected load 1776 kW
Air Compressor:
Kaeser Screw Compressor,
Model: AS44, 30 kW,4M3
/MIN. each
2 Units 8M3 /MIN
Omgersp:-Rand
Reciprocating Compressor,
Model: SSR ML-5057.5kW
CAPACITY of air disharge
1Unit 8M3 /MIN
Ingersol- Rand
Reciprocating Compressor,
Model: 3000.22 kW
2 Units 4.40 M3 /MIN
SWAN Reciprocating
Compressor, Model: C4080,
10 kW
1 M3 /MIN
Total air discharge capacity 21.4M3 /MIN
Description of WATER
pump
no.of m/c Capacity
Centrifugal pump for water
supply to dyeing & others
Section
1 100m3/h
20HP Pedrollo pump each
pump , 1, 000L/min flow
rate
4Unit 4,000 L/min
10HP Pedrollo pump each
pump , 600L/min flow rate
1Unit 600 L/min
5.5HP Pedrollo pump each
pump , 350L/min flow rate
1Unit 350 L/min

Spare pump motor Pedrollo
20HP
1Unit 1,000 L/min
Boiler:
Ciever Brooks Boiler 10
tons /hr
1 set
11.2.2 Prime power Generator:
 Brand name :GUASCOR
 ORIGIN:Spain
 Model: FGLD 480
 Stand by voltage: 380 Kw,795kVA
 Prime voltage: 636 Kw,1208kVA
 Phase: 3
 Weight:1845kg
11.2.3 Diesel Generator:
 Brand name :KOMATSU
 Origin: SINGAPORE
 Model: EGS 630-3
 Stand by voltage: 440Kw,550kVA
 Prime voltage: 440Kw,550kVA
 Phase: 3
 Weight: 3800kg
11.2.4Boiler:
 Brand name :Cleaver Brooks
 ORIGIN: U.S.A
 Model: CB 700-650
 Slno.:L 94002
 Max. pressure:200psi

CHAPTER -XII
CONCLUSION
12.1COMMENTS:
Industrial training is an essential part for textile education because it minimizes
the gap between theoretical and practical knowledge. Undoubtedly, this industrial
training give us a lot about textile technology, production process, machineries,
industrial management and made us comfortable with industrial life. Besides it give
me the first opportunity to work in industry.
During our six weeks long industrial training at Impress-newtex Composite textile
ltd., we got the impression that this factory is a modern export oriented composite
knit including industry. Though it was established 18 years ago, it has earned a very
good reputation in foreign market for its best quality product over many other
export oriented textile mills. They are very much concerned about the quality of
their product. That’s why they establish on-line and off-line quality control of each
product. They have well equipped and modern textile testing laboratory. They do
all the chemical & physical tests of dyed good and the results are very good and
within the buyer’s acceptance limit. We have also understood Impress-newtex
Composite textile ltd., cares a lot about then quality. If there was any problem it was
quickly removed with the help of experienced and skilled production manager.
Moreover they use good quality yarn, dyes, and chemicals in production. The
administration, management and chain of command are well organized.
12.2Some suggestions:
 The knitting m/c stoppage time should be analyzed & minimized. The
maintenance should be carried out when the machine is out of action.
 The dyeing floor is watery most of the time; it should be cleaned all the time
 The illumination of the dyeing shade should be enhanced. It may exert the
fatigue of worker.
Last of all we again give great thanks to ALLMIGHTY for successful completion of our
industrial attachment & we want to give thanks all the officers & workers who helped us
by cooperating & giving reliable information to us.
END

Industrial attachment of newtex composite textiles ltd.

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