This document provides information about an industrial training completed at YASSMA KNITTING & DYEING Ltd., a knitting, yarn dyeing and garment factory in Bangladesh. It includes an introduction to the training, details about the company such as its vision, products and buyers. Production processes like dyeing, washing, drying and quality control are described. Information is also given about the machinery, raw materials, chemicals used and responsibilities of staff in the dyeing section.

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1
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT OF
YASSMA KNITTING & DYEING.

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2
CHAPTER-1
INTRODUCTION

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3
INTRODUCTION
Industrial training is one of the most essential parts of engineering & technical education. This
industrial training is included in our syllabus to acquaint us with the practical implementation of
the technology studied within the industrial environment. Though it is very helpful & lays the
milestone for starting the carrier for fresh Textile graduates.
Wet processing which occupies a vast field in modern Textile technology is undergoing many
stages of processing. Many problems are generally being encountered during each operation
stage starting from desizing to finishing section. Finally from mill training, I learn practical wet
processing under industrial environment. I think it will be helpful in my future carrier life.
Industrial training is an indispensable part to study of practical knowledge of an industrial unit
for student of textile Engineering. YASSMA KNITTING & DYEING Ltd. is the 100% export
oriented industry in Bangladesh. The factory is concerned about knitting, yarn dyeing and knit
garments. Due to the changing environment the textile sector faced with challenge, But the
YASSMA KNITTING & DYEING Ltd. will fully prepare to face the situation.
I have completed my 6 weeks long industrial training in dyeing and finishing section of
YASSMA KNITTING & DYEING Ltd. These training enable me to avoid the gap between
theoretical and practical knowledge. The incumbent is deputed to YASSMA KNITTING &
DYEING Ltd. for practical industrial training program.

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CHAPTER-2
COMPANY
PROFILE

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Company Profile:
Factory Name : YASSMA KNITTING & DYEING Ltd.
Type : 100% Export Oriented Yarn Dyeing Industry.
Year Of Establishment : 01 January 2009
Investors : Md.
Address:
Factory Address : Plot/23-25,Adamjee-EPZ,Siddirgonj, Narayangonj.
Head Office& Corporate Office : Baridhara –DOHS, Banani, Dhaka.
Sponsors : Islami Bank, HSBC Bank.

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Vision:
To establish as a one stop source for the Global knit Apparel market and to satisfy and meet
customers expectation by developing and providing products and services on time, which offer
value in terms of Quality, Price, Safety and Environmental impact.
Assuring complete compliance with the international quality standards and also providing the
employees internationally acceptable working condition and standards. To promote the
development and to use human talent and equal opportunity of employment.
Mission:
YASSMA KNITTING & DYEING Ltd. realizes the need to take out a competitive segment in
the changing global market of today through technological excellence and human expertise.
YASSMA KNITTING & DYEING Ltd. is committed to transpose its local success to the world
scene.
LOCATION:
The Project is located at Adamjee,EPZ,Siddirgonj,Narayangonj. It is about 40
kilometers away from Primeasia University,Banani,Dhaka.
Main Products:
 Dyed cotton yarn
 Viscose yarn
 Acrylic-cotton blend.

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Major Buyers & Fashion Labels:
H & M ESPRIT
C & A DECATHLON
MQ
PUMA

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CHAPTER-3
MANPOWER
MANAGEMENT

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Management System:
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 International
standard equal opportunity is the keys for achieving comprehensive competence in all level of
the organizational hierarchy.
Total Shift :
2 shifts per day.
Shift Duration
General 9.00 am- 6.00 pm
A 8.00 am- 8.00 pm
B 8.00 pm-8.00 am

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Organogram of Dyeing Section:
General Manager

Deputy General Manager

Manager

Deputy Production Manager

Asst. Production Manager

Sr. Production Officer

Production Officer

Supervisor

Asst. Supervisor

Sr. Operator

Operator

Asst. Operator

Helper

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Responsibilities of Production Manager :
1. To plan the production schedule with capacity & volume of order.
2. To observe dyeing finishing.
3. To supervise senior production officer & production officer.
4. To rectify any kinds of problems during dyeing.
Responsibilities of Production Officer :
1. To check recipe.
2. Batch preparation & pH
check.
3. Control of supervisor, operator, astt. Operator & helper of dyeing floor.
4. To match shade as required.
5. To find out dyeing & yarn fault as early as possible.
6. To recover the finished yarn this is rejected from quality department.
7. To register each batch dyeing condition.
8. To check daily production report.
9. To check water level in dyeing stage.
10. To maintain connection with finishing & quality control department.
11. To maintain connection with maintenance department etc.
Remarks :
There are a sufficient number of Efficient Textile Engineers & Technical persons. This is why
they achieved a very good reputation in Knit Dyeing Sector.

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CHAPTER-4
MACHINE
DESCRIPTION

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MACHINE DESCRIPTION
For yarn dyeing process,YASSMA KNITTING & DYEING Ltd. uses state-of-the-art machinery
of SSM Brand from Switzerland, FADIS and DETTIN from Italy, and STRAYFIELD from
England.
Yarn Dyeing Capacity: 20 Tons/day
Machine List:
TYPE BRAND MC. QTY.
TOTAL 86 Nos.
Yarn Dyeing M/C Fongs, China 48 Nos.
Yarn Printing M/C Laip, Italy 01 Nos.
Soft Winding M/C Fadis, Italy 02 Nos.
Soft Winding M/C SSM, Switzerland 13 Nos.
Hard Winding M/C Fadis, Italy 02 Nos.
Hard Winding M/C SSM, Switzerland 10 Nos.
Hydro Dettin, Italy 04 Nos.
Dryer Stryfield, England 02 Nos.
Dryer Stalam, Italy 02 Nos.
Sewing Thread SSM (Hacoba), Switzerland 01 Nos.
Auto Dosing

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CHAPTER-5
RAW MATERIALS
AND CHEMICALS

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Type of Raw Materials :
Grey Yarn:
 Single Ply cotton yarn
 Double Ply cotton yarn
 Tree Ply cotton Yarn
 AC blend yarn.etc
Commonly Used Dyes :
Name of Dyes
Synozol G,Yellow HF 2GR
Synozol Red HF 6BN
Synozol Black B
Synozol Orange SHF RR
Synozol Br,Blue R-SPCL
Synozol Turquise Blue HFG 266%
Synozol Yellow K-3RS
Synozol Red K-3BS
Synozol Navy Blue K-BF
Synozol Yellow 4GL
Synozol Yellow 4GR
Synozol Red SHF GD
Name of Dyes

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Synozol Blue K-BR
Synozol Ultra Black DR
Synozol B/Red BB
Synozol Yellow HB
Synozol Navy Blue HB
Synozol Deep Red HB
Synozol Red K-GD
Synozol Black HF GR
Sun White BVB
Syno White 4BK
Leucophor BBU
Rifazol Orange RN
Rifazol G,Yellow 4GR
Rifazol Turquise Blue G-165%
Rifazol Br,Blue R-SPCL
Rifazol Deep Black ED Conc
Drimaren Navy CLR
Drimaren Yellow HFR
Drimaren Blue HFRL
Remazol Yellow RR
Remazol Blue RR
Remazol Orange RR
Remazol Turquise Blue G
Commonly Used Chemicals & Auxiliaries:

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Agent of- Name of items
Chemicals of KBC Co.(Pvt).
2UD
Eco
Scouring & Bleaching agent
Imerol PCLF
TF-129B
Perlavin NDA
Sabilezer TF-122B
Causic Soda
Hydrozen peroxide
Acetic acid
Peroxide Killer Bactasol Sap
Lavelling agent
Sarabid MIP
TF-210 B
Sequestering Agent
Sirrix 2UD
ladiquest-1097U
TF-510B
Periquest BSV
Antifoaming Agent
Antimussol UFD
Periwet WDP
Salt
Glober Salt
Refined salt
Soda Ash
Soaping Agent
Ladipur RSK
Parlavin SR/SN
Fixing agent
Optifix EC
Perifixan RS
TF-234 B
Color Softner
Cepreton UCP
GTF-445C
Perifil 210 Liq
White Softner
Nass-T ( Local )
GTF-442
Sodium hydrosulfite

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Source of Raw Materials:
Grey yarn is collected from buyers.
Dyes & Chemicals are imported from Germany , Switzerland , Singapore , Turkey , India , China
etc.
Remarks:
Price & Monthly consumption are unavailable.

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CHAPTER-6
PRODUCTION
PLANING, &
OPERATIONS
Operations

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Production Parameters:
PH
:
For Scouring & Bleaching : 10-11
Before Enzyme : 4.2-4.5
Before Leveling : 5.5 (All Color)
6 for Black, Red, Deep Color.
After Leveling : 5.5 (All Color)
6 for Black, Red, Deep Color.
Before Dyes : 5.5 & 0.2
After Salt : 5.5 & 0.2
After Soda : 10.5-11.5
After Acid wash : 5.5-6.5
Before Softener : 5.5
Temperature:
For Scouring & Bleaching : 105°C
For Cold Wash : 40-550
C
For Hot Wash : 80-950
C
For Cotton Dyeing : 80-900
C (For Hot Brand)
600
C (For Cold Brand)
For Polyester Dyeing : 1300
C
Time:
For Scouring & Bleaching : 30-40 minute for Normal color
50 minute for Critical Color
For Reactive Dyeing : 60-90 minute.
Remarks:
Critical colors are Green , Turquoise Blue , Brown , Dark grey .
Material &Liquor ratio:
For Reactive Dyeing Material & Liquor Ratio is maintained in Between 1:8

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Production Flow Chart:
Grey yarn Collection from Grey store
▼
Winding on hard package
▼
Yarn loading to m/c
▼
Scouring & Bleaching
▼
Bio polish ( Enzyme Treament)
▼
Dyeing
▼
Soaping
▼
Fixing
▼
Softening
▼
Unloading from dyeing m/c
▼
Drying
▼
Inspection
▼
Winding on soft package
▼
Final inspection
▼
Packaging.
Grey yarn inspection section:
Object of inspection:
 To check the actual count of yarn
 To identify the yarn faults
 To ensure about the yarn quantity

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Yarn fault:
1. Slub
2. Neps
3. Thick & thin place
4. Patta / Barre
5. Yarn contamination
6. Yarn hairiness
Batch Section
Function or purpose of the batch:
 Order sheet (Received from buyer)
 To receive the grey yarn package from soft section or other source
 To send the grey yarn to the dyeing floor by trolley with batch card
 To prepare the batch of yarn on the carrier
 Dyeing shade (Color or white, Light or Dark)
 M/C capacity
 Yarn structure.
 Yarn type, etc
 To keep records for every previous dyeing.
 Keeping the no. of batch as less as possible for same shade, etc.
 Minimizing the m/c washing time or preparation time.
Batch management:
Primary batch is done by the dyeing manager. Batch section in charge receives this primary
batch plan from dyeing manager. Then the works is adjusting, according to m/c condition.
Remarks:
Proper batch can minimize the batch to batch shade variation. It can near or same dyeing
condition for every batch of same shade. Thus it improves the dyeing quantity & minimizes a lot
of dyeing cost.

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Scouring-Bleaching Process:
Scouring-Bleaching is carried out in the same bath and at the same time simultaneously.
Scouring-Bleaching Chemicals Used in a batch:
Agent Brand Name g/l
Wetting agent TF-129 B 0.70
Sequestering agent TF 510 1.0
Stabilizer TF 122 0.5
Antifoaming agent Alkafoam AF-10 1.0
Alkali Caustic soda 1.8
Bleaching agent H2O2 2.5
Peroxide Killer Bactasol Sap o.85
Acid Acetic Acid 0.6
N.B : Amount of Chemical varies according to yarn consumption .

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Procedure of Scouring-Bleaching :
 At first required amount of water is taken into the m/c.
 Then the yarn is loaded
 Then Wetting, Sequestering, Stabilizer is added by inject at 500
C.
 Then Temperature is raised to 600
C.
 Then Caustic soda is added by linear dosing for 6 minutes.
 Then temp rised to 70°c .Then H2O2 is added by linear dosing for 8 minutes.
 Then. Temp raised to 1050
C. Runtime 60 minutes.
 Then temp.is decreased to 900
C.Rinse at 900
 Then Hot wash at 900
 Then Rinse at 900
-
 Then Bayreduct PRN is added by transfer at 900
C × 10΄
 Then Rinse at 900
 Then Drain out.
 Fill water. Acid treatment for neutralization at 70°c °× 10´ & PH
is checked.
 Then rinse at 55°c× 10΄
 Then Primafast-100 is transferred at 55°c. Run time 20-50 minitues.
 Then Hot wash at 800
 Finally drain out
N.B :
1. In case of critical color after loading water & yarn first hot process is carried out with
sequestering agent & detergent to get better result. Rest of processes are same as usual.

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White dyeing process:
Batch No : 27942 Machine No : 02
Batch Date : 22.04.09 Water : 5600 Lit
Liquor ratio : 1:7 Yarn Weight : 1000.00 kg
Customer : United Count : 32/2
Color : White 10-100
Recipe :
Name of the Chemicals Amount (g/l)
Feloson NOF 0.40
Exstab BRH 0.40
Feloson NOF 0.50
Exstab BRH 0.40
Antisil CONZ 0.60
Caustic soda 2.50
Hydrogen per Oxide 6.00
Singo white-2BX 0.10 %
Singo white-BHV 0.33 %
Invatex-CS 0.10 %

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Procedure:
 At first required amount of water is taken in the m/c.& the yarn is loaded simultaneously.
 Then Wetting agent, Sequestering agent is added for first hot at 600
C × 10´.
 Then Temperature is raised to 800
C × 10´. After then Rinse for 10´ & decrease temp. to
40°c .
 Drain out.
 Filling new water & Wetting agent, Sequestering agent & Stabilizer is added by inject at
40°c × 5΄.
 Then Caustic soda is added by linear dosing for 10΄ .
 Then temp. is raised to 60°c & Then H2O2 is added by linear dosing for 10΄.
 Then temp. raised to 70°c & Invatex-CS, Singo white-BHV, Singo white-2BX are added
by linear dosing for 20΄.
 Then temp is raised to 100°c at 2°gradian for 35΄ (Check sample after each 20΄)
 If white shade is matched then temp is decreased to 90°c at 3°gr with Ringe wash.
 Then to 80°c at 2°gr & Rinse for 10΄ .After then to 70°c at 5°gr.
 Bath drain.
 Fill with new water & temp is set to 80°c × 10´
 Then temp is decrease to 50°c with Rinse wash & continue for 5´-7´.
 Acid is added for neutralization by inject & running for 10´
 Again Rinse wash is performed for 10´ at 55°c.
 Enzyme is added at 570
C × 60´.
 If OK then temp is raise to 70°c & Runtime 10´.
 Down temp. to 500
C. Rinse for 10´
.
 Add Softener at 450
C. Runtime 10´
 Then Unloading.
.

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27
Dyeing Procedure for all color without Turquoise, Brown, Khaki,
Chocolate Color:
 At first required amount of water is taken in the m/c.& the yarn is loaded
simultaneously.
 Then Felosan NOF and ExstabBRH are added by inject at 500
C .
 Then Temperature is rised to 800
C and Runtime 10-15´.
 Then Rinsing at 80°c×10΄
 Then water is drained out and filling new water as required at 50°c
 Then Felosan NOF, ExstabBRH and Antisil CONZ are added by inject at 500
C . For s/j
anticreasing agent is added.
 Then temp. is raised to 60°c and NaOH is added by linear dosing for 6´
 Then temp rised to 70°c .Then H2O2 is added by linear dosing for 8 minutes.
 Then. Temp rised to 1050
C. Runtime 50 minutes.
 Then temp.is decreased to 900
C at rate of 2°gradian /min and Rinse at 900
 Then Bayreduct PRN is added by inject at 900
C and Runtime 10΄
 Then Rinse at 900
C* 10and decreasing Temp. to70°c at a time.
 Then Drain out.
 Filling new water. Acid treatment for neutralization at 70°c °× 10´ & PH
is checked.
 Then rinse at 70°c× 10΄ and decreasing Temp. to55°c at a time.
 Then Primafast-100 is transferred at 55°c For enzyme treatment. Run time 50΄
 Then Hot wash 800
 Finally drain out
 Then filling new water as required and temp. is raised to 60°c.
 Then Seragal CFTR is added by inject and for singal jersey Primasol JET is added.
Runtime 5-6´.
 Then salt is added by inject and Runtime 10΄. In case of deep shade salt is added two
times.
 Then PH
is checked & maintained within 5.5-6. and dye solution is added by linear
dosing for 20΄ and Runtime at 60°c×20΄
 Then Soda is added by progressive dosing for 35΄ and Runtime at 60°c×60΄( After each
10΄ sample is cut and matched to swatch.)
 Then temp. is cooled down to 50°c and Rinse at 50°c×15΄
 After completed rinsing water is drained out and filling new water as required.
 Then temp. is raised to 60°c and Avolan IS is added by inject
 Then temp. is raised to 100°c and Runtime 10΄
 Then temp. is felt down to 95°c with rinsing and Runtime 10΄
 Then temp. is felt down to 80°c with rinsing and Runtime 20΄
 Then sample is cut if ok then temp. is felt down to 50°c with rinsing .
 After completed rinsing zelasal fix is added by inject at 50°c and Runtime 5´. Acetic acid
is used to maintain PH
 Then Alcamine CWS is added by inject and Runtime 10΄
 Then temp. is felt down to 45°c with rinsing and Runtime 6-7΄
 Then unloading

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Dyeing Procedure for Brown, Khaki, Chocolate Color, Grey Series:
 At first required amount of water is taken in the m/c.& the yarn is loaded
simultaneously.
 Then Felosan NOF, Exstab BRH are added by inject at 500
C.
 Then Temperature is raised to 800
C.and Runtime 6 minutes
 Then Rinsing at 80°c×10΄
 Then decreasing temp. to 50°c with rinsing and Drain out
 Then filling new water as required at 50°c and Felosan NOF, Exstab BRH and Antisil
CONZ are added by inject at 500
C. For s/j anticreasing agent is added.
 Then temp raised to 60°c and NaOH is added by linear dosing for 6 minutes.
 Then temp raised to 70°c and H2O2 is added by linear dosing for 8 minutes.
 Then. Temp raised to 1050
C. Runtime 60 minutes.
 Then temp.is decreased to 900
C. at the rate of 2° gradian/min and rinsing at 900
 Then Bayreduct PRN is added by inject at 900
C and Runtime 10΄
 Then Rinse at 900
 Then Drain out.
 Filling new water. Acid treatment is carried out for neutralization at 70°c °× 10΄ & PH
is
checked.
 Then temp.is decreased to55°c with rinsing
 Then Primafast-100 is transferred at 55°c for enzyme treatment and Runtime 50-60
minitues.
 Then Hot wash at 800
C
 Then temp.is decreased to 450
C with rinsing and drain out.
 Then filling new water as required.
 Then Seragal CFTR is added by inject and for singal jersey Primasol JET is added.
Runtime at 45°c×10΄.
 Then PH
is checked which must be 5.5-6 and color is added by linear dosing for 30´ and
Runtime at 45°c×20΄.
 Then half salt is added by progressive dosing for 15´ and Runtime at 45°c×5΄.
 Then rest of salt is added by progressive dosing for 15´ and Runtime at 45°c×5΄.
 Then. Temp raised to 600
C and Runtime at 60°c×25 minutes.
 Then soda ash is added by progressive dosing for 55΄ and Runtime at 60°×60΄ ( After
each 10΄ sample is cut and matched to swatch.)
 Then temp. is decreased to 50°c with rinsing and Runtime at 50°c×40΄
 Then drain out and filling water as required.
 Then. Temp raised to 550
C and Acetic acid is added and run at 55°c× 10 minutes
 After completed rinsing water is drained out and filling new water as required.
 Then temp. is raised to 60°c and Avolan IS is added by inject
 Then temp. is raised to 70°c and Runtime at 70°c×10΄
 Then temp. is felt down to 50°c with rinsing and Runtime at 50°c×10΄
 Then sample is cut if ok then zelasal fix is added by inject at 50°c for deep shade and
Runtime 5΄. Acetic acid is used to maintain PH
 Then Alcamine CWS is added by inject and Runtime 10΄
 Then temp. is felt down to 45°c with rinsing and Runtime 6-7΄
 Then unloading.

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29
Stripping Process :
Recipe:
Full Stripping for Light Colour :
TF-129 B - 0.65 g/I
Soda - 1.0 g/I
Caustic soda - 1.0 g/I
Hydrose - 2.0 g/I
Full Stripping for Deep Colour :
TF-129 B - 0.75 g/I
Soda - 1.0 g/I
Caustic soda - 1.50 g/I
Hydrose - 3.0 g/I
Machine Wash :
Recipe :
Hydrose 4 kg
Caustic soda 4 kg
TF-129 B 2 kg
N.B : Amount of m/c wash chemical depends on m/c size.
Process :
 Required amount of water is taken in the m/c.
 Then temp.is raised to 1300
C.
 Then Relosan NOF, Caustic soda, Hydrose is added.
 Runtime at 130°c×30 minutes.
 Then temp. is decreased to 900
C.
 Decreasing temp. to 450
C with rinsing and Runtime at 45°c×10 minutes.
 Then Drain out.

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30
Dyeing Fault:
Dyeing faults are given below -
1. Patchy dyeing effect:
Reasons:
 Faulty injection of alkali.
 Faulty color.
 Due to hardness of water.
 Due to improper salt addition, etc.
2. Roll to Roll variation or meter to meter variation:
Reasons:
 Yarn lot mix
 Faulty heat setting.
 Hardness of water.
 Faulty m/c speed, etc
3. Dye –stain:
Reasons:
 Un dissolved caustic soda particle in bath.
 Un dissolved salt particle in bath.
4.Rub mark:
Reasons:
 Due to reel cranking.
 Due to sharp delivery.
 Due to sharp delivery roller, etc

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CHAPTER-7
QUALITY
ASSUREANCE
SYSTEM

32. Dec. 9
32
Quality Management System:
The Quality Assurance Department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing.
Objects of quality control:
 Research.
 Selection of raw materials.
 Process control.
 Process development.
 Product testing.
 Specification test
Quality management system:
Off-Line Tests:
All the Off-Line tests for finished fabrics can be grouped as follows:
 Physical tests
 Chemical tests
Physical Tests:
 Count of yarn.
 Abrasion/pilling resistance
 Rubbing test

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33
Chemical Tests:
 Fastness to washing.
 Fastness to light
 Fastness to heat
 Fastness to Chlorinated water
 Fastness to water spotting
 Fastness to perspiration
Online Tests:
 Dyed yarn
 Shade check
 Wash fastness
 Water fastness
 Crocking fastness
Quality standard:
Mainly this mill follows ISO standard for testing. But testing standard depends on buyer
requirements.

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CHAPTER-8
EFFLUENT
TREATEMENT
PLANT

35. Dec. 9
35
Effluent Treatment Plant (ETP)
Effluent Treatment Plant (ETP) is a plant by which waste water is treated in order to make the
waste water environmental friendly. Effluent Treatment makes sure that water releases meet
Bangladesh Environmental Association water quality standard. It is very important and essential
to keep the environment pollution free. Now a day ETP is the most important term to set a textile
industry. Government, Environmental Association and foreign buyers are creating pressure to set
ETP in every textile industry. So to ensure the proper growth of textile sector and pollution free
environment every textile industries have to set up an ETP.
Details on ETP :
There are three effluent treatment plants which are :
 Physico-chemical treatment plant
 Chemical-biological plant
 Biological treatment plant.
Chemical treatment plant :
In this process effluent water are mainly converted into sludge of metal complex by chemical
reaction. Then it is separated from the water and dried and dipped into soil. But the sludge
remain activate which is harmful.
Biological treatment plant:
This process is mainly build up by using micor-organism. This is Bacteria. Amoeba, and
Protozoa. Bacteria are two types, one is Anerobic & Aerobic.. First one is hazardous for our
environment and second one is friendly for our environment. In here Bacteria break the bond of
harmful chemical by enzyme secretion. As a result harmful chemical converted into
environmental friendly. The sludge produces by this process is also used as different functions
such as fertilizer, fuel in the brick field.

36. Dec. 9
36
Micro organism is the main raw material for Biological plant :
 Bacterial
 Amoeba
 Protozoa
Bacteria :
 Bacilli
 Cocci
 Beggiatoa
 Spirillum
 Vitereoeilla
Protozoa :
 Paramecium caudatum
 Euplotes
 Coplidium
Amoeba :
 Rotifiers
 Collities
 Novcotidia

37. Dec. 9
37
Comparisons between Chemical-Physical and Biological ETP
TYPE OF INSTALLATION CHE-PHY BIOLOGICAL
General purifying yield > 90%
COD/BOD Reduction 50-60% 90-95%
Color Elimination Yes Yes > 90%
Ammonia Elimination No Yes >95%
Nitrogen Elimination Total 30% >95%
Phenol Elimination No >90%
Final Salinity With Respect Water To be
purified
Higher then input Same as Input
Sludge produced per m3
of Effluent Treatment 6 kg 0.1-0.2 kg
Sludge produced per Kg of COD 1.8 kg 0.2 kg
Sludge character Toxic Non-Toxic
Sludge disposal Very Difficult Very-Easy
Running cost per m3
of Effluent Treatment TK.25.0-30.0/- TK.3.5-4.0/-
Initial cost (Chemical-Physical Base 100) 100 200/220
Space Occupied For 1000 m3
/day 300-350m3
At least 600 m3
Reliability 30% 80%
Possibility Fish Life Directly In Purified H20 No Yes
Possibility Reuse of Purified Water for
Irrigation
No Yes
Compliance With European Laws (very strict) No Yes all
Produced of bad smell Yes No
Treatment Quality Improper, < Proper,European
Bangladesh
Standard
Standard

38. Dec. 9
38
ETP PROCESS DIAGRAM
Under drain
Under hole
By pump
By over flow
By over flow
By under hole path By pump
Under drain pipe
By pump
Waste water from dyeing machine or incoming
Screening Unit
Storage & Homogenization Tank
Neutralization Unit
Distribution Unit
Biological Oxidation Tank
Sedimentation feeding tank
Sedimentation or clarifiers
Sludge recirculation pit
Sludge thickener tank
Sludge drying naturally at Sludge drying bed
Sludge out as fertilizer used in crops field or burning
at brick field after natural drying
H2O2 tank
H2SO4 by dosing
Manually feeding
Bacteria for proper
living on
Antifoam feeding by
dosing pump
Decolorant dosing for
coloring remove
Treated water used in
irrigation or river or
pond
Poly electrolyte
feeding by dosing
pump

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39
Required Chemicals of Biological ETP :
 98% H2S04.
Function : Neutralize the waster water by controlling ph.
It is auto dispensed in the neutralization tank.
 Polyelectrolyte.
Function : Used for sedimentation/sludge coagulation and also killing bacteria.
[ Coagulation in water treatment, the use of chemicals to make suspended solids gather or
group together into small flocks.]
It is used auto/manually in sludge thickener tank.
 Decolourant.
Function : Used for removing color.
It is used auto/manually in sludge thickener tank.
 Anti foaming agent.
Function : Used for reducing/controlling foam.
It is used auto/manually in the distribution tank.
 Sodium hypochlorite.
Function : It is used to killing harmful bacteria.
It is used in the Biological Oxidation tank.

40. Dec. 9
40
Standard value of effluent by :
USEAPA-United State Environmental Protection Agency
IWRA-International Water Resources Association
GOB-Government of Bangladesh .
Tank Parameter Unit Standard value
Clarifier
(treated effluent)
Phosphate, PO4 Ppm 5 to 14
Ph - 6 to 8
Colour APHA 220 to 250
BOD Ppm 29 to 60
COD Ppm 250 to 300
Ammonia, NH3 Ppm 5 to 10
Nitrate, No3 Ppm 10 to 15
Nitrate, No2 Ppm Less than 1
Sulphate, So4-2 Ppm 1000
Chlorine, C12 Ppm 1
Chloride, CI Ppm 500 to 600
Total suspended dissolve solides Ppm 60 to 80
Total dissolve solides Ppm 2100
Functions of different unit of Effluent Treatment Plant (ETP)
1. Screening unit :
Threads
Pieces of yarns
Small metal pieces etc.
In this unit a rotating brush is used for cleaning the pores of screen. A motor is used
here for rotating the brush. The brush rotates periodically.
2. Storage and Homogenization tank : Different waste water from various processes is
stored and makes a homogeneous mixture by mixing different concentric waste water.

41. Dec. 9
41
3. Neutralization tank : Neutralization of waste water is performed by dosing 98% H2S04 as
required to control the ph
of waste water. PH
range : 6.5 to 7.5.
4. 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.
5. Biological oxidation tank : It is the heart of ETP. The entire harmful chemicals are
damaged here by breaking their bonds. This is done by bacteria. To ensure the proper functional
work & growth of bacteria few conditions must be maintain.
Temperature : 350
to 370
C
PH : Maximum 7.5
Dissolved oxygen : 4 ppm
[Dissolved Oxygen-a measure of the oxygen dissolved in water expressed
in milligrams per liter.]
6. Sedimentation/Biological feeding tank : Treated water is overflowed here from
oxidation tank. Decolourent is used here to destroy the color of waste water.
7. Clarifiers : 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 float to the water surface. In this tank sludge is immersed and the harmless water is
discharged to drain on ponds, land, river, Lake Etc.
8. Sludge thickener tank : Sludge is taken here from clarifier. Polyelectrolyte is dosed to
coagulate the sludge. After one hour of polyelectrolyte dosing aeration is stopped and fresh water
discharge to drain when sludge is thicken. The thickened sludge is transferred to the sludge
thickener bed.
9. Sludge thickener tank : Here sludge is dried which is used as good fertilizer as well as
fuel of brick field. Sludge is dried under the sunlight.
Airation :
The process of adding air to water. In waste water treatment, air is added to freshen waste water
and to keep solids in suspension.
Remarks:
Utility service is sufficient to run this project. More projects can be run by the existing Utility
services.

42. Dec. 9
42
CHAPTER-9
STORE &
INVENTORY
CONTROL

43. Dec. 9
43
Frequently inventory control:
 Monthly inventory control.
 Annual inventory control.
The type of inventory carried in this mill is as follows :
 Grey yarn: Imported/Own factory.
 Dyes and Chemicals: Important.
 Spare parts and Consumables: Local/Imported.
 Packing materials: Local/Imported.
 Finished yarns: Good/Reject.
The prime responsibility for the inventory management function in the company including the
estimation of consumption quantities of raw materials over the forecast period and initiation of a
purchase requisition keeping in view quantities is transit and an order and the adequacy as
otherwise of material coverage during lead time is as follows :
The Procurement Department is responsible primarily for the sourcing of raw material.
Inventory system of Raw materials :
 Grey yarn is stored in the Grey store. The batch is prepared by taking Grey yarns from
Grey store.
 There is a separate store for Dyes & Chemicals. Various types of Dyes &
 Chemicals are stored here according to company's storing criteria. The operator takes
Dyes & Chemicals from this store according to Recipe Sheet.
Remarks:
Inventory management is good & satisfactory.

44. Dec. 9
44
CHAPTER-10
COST ANALYSIS

45. Dec. 9
45
 Costing of the product:
Costing system mainly describes how the cost of the final product is fixed by the
company/beneficial. According to buyer/customers requirement at first the fabric is collected
from local and foreign suppliers. Then it id calculated how much dyestuff and chemical is
required to the end of the processing of that specific fabric .After that, the final cost is fixed
including some profit. Then the unit price is offered to the buyer for approves it.
 Costing of the prodsuct is done by the consideration of the
following factors:
Amount raw materials consumed.
Direct Labour
Indirect Labour
Factory Cost
Officer and administrative cost
Sales and distribution cost
Profit, etc.
Remark:
The costing of product is a secret matter of the industry. They are not interested to flash the cost
related data. So we could not collect the price of product and costing of the product.

46. Dec. 9
46
CHAPTER-11
MARKETING
ACTIVITIES

47. Dec. 9
47
Buyer of the Products :
 H&M
 Puma
 C & A
 G-Star
 Wal-Mart
 Decathlon
 Esprit etc
Importing Countries :
 Germany
 Switzerland
 Turkey
 Singapore
 China
 India
Exporting Countries :
 European Countries.
 USA .
 Canada .

48. Dec. 9
48
CHAPTER-12
UTILITY

49. Dec. 9
49
Utility Services of ATN:
Here the following utility services are available-
1. Water
2. Electricity
3. Compress air
4. Steam
5. Gas
6. other
1.WATER
Water for a textile plant may come from various sources. These include surface water from rivers
and lakes, and subterranean water from wells. In PPC they collect water from Under ground.
Natural and pretreated water may contain a variety of chemical species that can influence textile
wet processing in general, and dyeing in particular.
The various salts present in water depend on the geological formations through which the water
has flowed. These salts are mainly the carbonates (CO3
2-
), hydrogen carbonates or bi-carbonates
( HCO3
-
), Sulphates ( SO4
2-
) and chlorides ( Cl-
) of calcium ( Ca2+
), magnesium (Mg2+
) .
Although calcium and magnesium carbonates in limestone are relatively insoluble in water. So in
this reasons, water hardness can be divided into two ways-
1) Temporary hardness : Ca(HCO3)2 , Mg(HCO3)2 , Fe(HCO3)2 .
2) Permanent hardness : CaCl2 , CaSO4 , Ca (NO3)2 , MgCl2 , MgSO4 ,
Mg(NO3)2 .

50. Dec. 9
50
Standard water quality for dye house:
Parameter Permissible concentration
Color Color less
Smell No bad smell
Water Hardness <5 ppm
PH value 7-8 (Neutral)
Dissolve solid < 1 ppm
Inorganic salt < 500 ppm
Iron(Fe) < 0.1 ppm
Manganese(Mn) < 0.01 ppm
Copper (Cu) <0.005 ppm
Nitrate(NO3) < 50 ppm
Nitrate(NO2) < 5 ppm
2.Electricity:
Sl. No. Name of Machine Capacity Quantity Brand Origin
01 Gas Power 1125 KVA 02 sets Waukesha USA
02 Generator 490 KVA 01 set Caterpiller USA
03 Generator 490 KVA 01 set Cummins UK
04 Generator 150 KVA 01 set Volvo Sweden
05 Generator 250 KVA 01 set Weifeng China
06 Generator 650 KVA 02 sets Caterpiller USA

51. Dec. 9
51
3. Air Compressor:
Sl. No. Name of Machine Capacity Quantity Brand Origin
01 Air Compressor 4.25 m3/hr 03 sets Comp air UK
02 Air Compressor 9.61 m3/hr 03 sets Comp air UK
4. Steam:
Sl. No. Name of Machine Capacity Quantity Brand Origin
01 Boiler 5400 Kgs 01 set Cleaver
Brooks
UK
02 Boiler 9400 Kgs 01set Cleaver
Brooks
UK
5.Gas
DCKIL uses natural gas from Titas Gas Transmission Company. Gas is used as the fuel of
Boiler, Generator and also used for heating dryer, Stenter and compactor m/cs etc.
6.Other Machines:
Sl. No. Name of Machine Capacity Quantity Brand Origin
01 Air Dryer 4.25 m3/hr 03 sets Comp Air UK
02 Air Dryer 9.61 m3/hr 03 sets Comp Air UK
03 Multi grade wall
filter
120 m3/hr 01 sets IECID Ltd. India
04 Activated carbon 120 m3/hr 01 sets IECID Ltd. India
05 Softener 120 m3/hr 01 sets IECID Ltd. India
06 Deep Tube well
pump
0.75 Cusec 02 sets KSB India
07 Deep Tube Well
Pump
1.5 Cusec 02 sets KSB India
08 Cooling Tower 350 RT 01 set Linear Malaysia
09 Cooling Tower 350 RT 01 set Spaco Thailand
10 Cooling Tower 150 RT 01 set Linear Malaysia

52. Dec. 9
52
CHAPTER-13
MAINTENANCE

53. Dec. 9
53
MAINTENANCE:
Maintenance is a procedure by which we can maintain active functioning in operation according
to the behavior and utility of a particular element. In engineering, we use this terminology for
maintaining smooth and uninterrupted performance of machines, tools and metallurgical
characteristics in practical uses.
Objective of maintenance:
 To keep the factory plants, equipments, machine tools in an optimum working condition.
 To ensure specified accuracy to product and time schedule of delivery to customer.
 To keep the downtime of machines to the minimum thuds to have control over the
production program.
 To keep the production cycle within the stipulated range.
 To modify the machine tools to meet the need for production.
Three types of maintenance are performed in ATN:
1. Preventive Maintenance.
2. Routine/ Schedule Maintenance.
3. Breakdown Maintenance.
1. Preventive Maintenance: Actions performed periodically (or continuously) prior to
functional failure to achieve the desired level of safety and reliability for an item.
These actions are performed to prevent or reduce consequences of failures.
2. Schedule maintenance: It is time-based maintenance and pre-planned to perform on
machine and equipments. This plan usually made on monthly basis.
3. Breakdown maintenance: In this type of maintenance when the macine remains stop
that time the maintenance is done.
MANPOWER SET-UP FOR MAINTENANCE:
 A Shift 8 AM 8 PM
 B Shift 8 PM 8 AM
 General Shift 9 AM 6 PM

54. Dec. 9
54
MAINTENANCE TOOLS & EQUIPMENTS:
1. Combination tools / spanner
Function : Tightening & looseng of nuts & bolts.
2. Socket ratchet set
Function : Tightening of nuts & bolts
3. Slide Range
Function : Tightening & loosening of nuts & bolts
4. Monkey pliers
Function : Tightening & loosening of nuts & bolts
5. Pipe threat cutting tools
Function : To cut the threat in pipe.
6. Bearing puller
Function : To assist the opening of bearing from shaft.
7. Pipe range
Function : Tightening & loosening of pipe joint
8. Pipe cutting tools
Function : for pipe cutting.
9. Hole punch
Function : Punching the hole.
10. Divider
Function : For circle making on metal & wood.
11. Easy opener
Function : To open the broken head bolt.
12. External threat die
Function : For external threat cutting.

55. Dec. 9
55
13. Heavy scissor
Function : Cutting of gasket & steel sheet
14. Pipe threat cutting tools
Function: To cut the threat in pipe.
15. Drill machine and drill bit.
Function : for drilling.
16. Grease gun
Function : For greasing of moving parts of M/C.
17. Grinding M/C
Function : For grinding & cutting of mild steel.
18. Welding M/C
Function : For welding & cutting.
19. Spirit leveler
Function : For perfect leveling.
20. File
Function : For smoothing the surface.
21. Harmmer
Function : For scaling & Right angling.
22. Circlip tools
Function : Circlip opening & closing.
REMARKS:
Maintenance of M/C’s are very essential to prolong the M/C life and good maintenance is
important consideration. It is necessary to check that all routine maintenance is being done
regularly and properly otherwise efficiency of each department will be reduced.

56. Dec. 9
56
CHAPTER-14
COMPLAINCE

57. Dec. 9
57
Compliance:
Compliance means comply something i.e. yield to the wishes another. The main aim of
compliance is to ensuring the all labor rights and facilities according to buyer code of conduct.
Different compliance issues which they are obeyed:
 Admin & HR dept.:
 Personnel policies:
 Recruitment policy
 Leave and holiday policy
 Attendance and leave register card:
 Their weekly working hour not more than 66 hours including overtime in a week.
 They have the approved manpower list.
 Health & hygiene:
 First aid ensures.
 Medicine registers.
 Maternity and pregnancy register.
 Pure drinking water
 Towel for hand dry.
 Safety:
 Safety committee
 Fire fighting committee
 Rescue committee
 Broken needle register
 Needle detector
 Fire alarm & switch
 Evacuation plan
 Rubber mats to every iron man.
 Welfare:
 Welfare committee
 Day care centre
 Canteen facility

58. Dec. 9
58
 Salary and wages:
 Fix wages in considering minimum wages which is declared by the government.
 Salary and wages given before 7th
day of month.
 Physical security:
 They have separate cargo entrance area (receiving and unloading) from the front
side.
 They do not keep any partially filled/ completed cartons on the floor at the end of
any working day. They keep it to finished goods store.
 Education and training program:
They arrange security training program on regular basis for all employee of the factory.
Compliance item:
Some example of compliances item are given below:
 First aid box
 Water pot
 Toilet
 Wash basin
 Complain box
 Evacuation plan
 Exhaust fan
 Emergency exit/light/ light set
 Smoke detector
 Fire extinguisher
 Hose cabinet
 Manila rope
 Gas musk.

59. Dec. 9
59
CHAPTER-15
Conclusion

60. Dec. 9
60
Conclusion
I have completed our Industrial Training successfully by the grace of Allah.
Industrial Attachment sends me to the expected destiny of practical life. YASSMA KNITTING
& DYEING Ltd. is a well known factory in the textile field of Bangladesh . The completion of
the two months industrial attachment at YASSMA KNITTING & DYEING Ltd. Textiles Ltd.
Gave me the inspiration that factory is one of the appropriate destiny to implement the
theoretical knowledge. From this industrial attachment we got the details idea about the factory
environment, production process, total management, store & inventory process, maintenance,
utility etc.
YASSMA KNITTING & DYEING Ltd. is well equipped and the working environment is
excellent. The relation between top management to bottom level is so nice.
We are lucky to get the opportunity of having training in this mill.
The factory runs by a number of efficient Textile Engineers, Skilled technical & Non-technical
persons.
All the Textile Engineers, technical & Non-technical persons are very sincere, co-operative and
helpful.
We wish good luck of them and also for this factory.