A presentation on machines maintenance of Wet processing department in textile engineering. It has details on many machines used in the department.

1. Topic: Maintenance of Wet Processing
Industry Machineries
Syed Ferdous Mahmud
Department: Textile Engineering
BGMEA University of Fashion &
Technology
BGMEA University of
Fashion & Technology
Presenter Name/ID:

2. Contents
• Wet Processing Industry
• Machineries of Wet Processing Industry
• Current Challenges Maintenance
• Maintenance Objective
• Common problems and possible solutions
• Types of Cost of Maintenance
• Maintenance Types
• Maintenance Strategies
• Maintenance Terminology
• Conclusion

3. Wet Processing Industry
• Wet processing is the process of adding color or
different finishes to textile products like fibers,
yarns, and fabrics.
• There are different sectors under wet processing
as Pre-treatment, Dyeing, Printing and Finishing
are the major sectors.
• From every sector there are many machineries.

4. Machineries of Wet
Processing Industry
• In case of Pre-Treatment:
Singeing machine Kier boiling machine

5. Machineries of Wet
Processing Industry
J-boxbleaching
machine
Padding mangle
DesizingInJ-box

6. Machineries of Wet
Processing Industry
Winchdyeing
machine
Beam dyeing machine
Hankdyeing
machine
In case of Dyeing:

7. Machineries of Wet
Processing Industry
Rotaryscreen
printingmachine
Roller printing machine
Flatbedscreen
printingmachine
In case of Printing:

8. Embossing calendaring
machine
Pad chain type mercerizing machine
In case of Finishing:
Teasel
raising
machine
Sanforizing machine

9. Maintenance
• Maintenance is defined as that function of production
management concerned with the day to day problem of
keeping the physical plant in good operating condition.

10. Current Challenges
Maintenance
• People not trained
• Production time loss
• Product liability concerns
• Cost of downtime unknown
• Cause and effects not fully understood
• Obsolete configurations get mistakenly loaded or reloaded
• Configuration and changes to it, not documented or not
controlled

11. Maintenance Objective
• Prevent breakdown or failures
• Maximize useful life of equipment
• Minimize production loss from failures
• Increase reliability of all operating systems
• Minimize frequency and severity of interruptions
• Maximize performance of production equipment
• Keep equipment safe and prevent safety hazards
• Maximize production capacity

12. Common problems and
possible solutions
Problem: Motor Damage
Cause: Motor not giving enough RPM or
pulsate rotation or excessive vibration or
stopped working
Solution: Changing, Lubricating, parts changing
M/Cs: Desizing machine, Padding mangle and
Dyeing machine
Problem: Pump Jamming
Cause: Dust deposition, Damage
Solution: Changing, Cleaning
M/Cs: Mercerizing machine, Desizing
machine

13. Common problems and
possible solutions
Problem: Take-up and let-
off/Padding/Winch/Engraved/Squeezer/Expender/Guide roller
Cause: Tension/Pressure device breakage, Gear teeth breakage, Roller
surface decay
Solution: Changing, Parts changing, cleaning, Pressure optimal control,
Surface grinding
M/Cs: Dyeing machine, Kier boiling machine, J-box bleaching machine,
Singeing machine, printing machine

14. Common problems and
possible solutions
Problem: Burner Damage
Cause: Total or partial blocking of flame
outlet, Dirty burner, Fuel supply pipe
blockage
Solution: Changing, parts changing, cleaning
M/Cs: Singeing Machine
Problem: Hooks breakage
Cause: Extreme pressure/load
Solution: Changing, SS hooks,
optimal pressure application
M/Cs: Raising machine

15. Common problems and
possible solutions
Problem: Sensor Damage
Cause: Water penetration, parts
broken
Solution: Changing, parts changing,
cleaning
Problem: Bolt/nut Break
Cause: Excessive vibration of motor,
surface decay, rust
Solution: changes, tightening/joining
where it breaks

16. Common problems and
possible solutions
Problem: Pressure Gauge Failure
Cause: Water penetration, parts broken,
excessive pressure
Solution: Changing, parts changing, cleaning,
pressure control
M/Cs: Kier boiling machine, J-box bleaching
machine
Problem: Belt Damage
Cause: Extreme pressure by
pulley, uncontrolled rotation
Solution: Changing, Belt
thickness/material unsuitable,
Uncontrolled rotation
M/Cs: Desizing machine, Padding
mangle

17. Common problems and
possible solutions
Problem: Gear Damage
Cause: Gear teeth breakage for
extreme/uncontrolled pressure
Solution: Changing, controlling the
pressure
Problem: Bearing Damage
Cause: Bearing ball/surface decay for
extreme pressure
Solution: Changing, controlling the
pressure, heavy bearing need to use

18. Common problems and
possible solutions
Problem: Rust on Metal parts
Cause: Being wet, Material not suitable,
No upper coat
Solution: Changing, cleaning, lubricating
M/Cs: Printing machine, Dyeing machine
etc
Problem: Corrosion on Metal
parts
Cause: Excessive pressure,
Material not suitable, No upper coat
Solution: Changing, Using
compressible blanket
Parts Effected: Gear, Bearing,
Shaft

19. Common problems and
possible solutions
Problem: Cylinder/Inlet pipe/Emulsion
tank/Vessel/Reserve tank leakage
Cause: Total or partial blocking of flame outlet, Dirty
burner, Fuel supply pipe blockage, Excessive pressure
Solution: Changing, cleaning, Neutral metal using,
Accurate pressure gauge
M/Cs: Singeing Machine, Desizing Machine, Dyeing
machine
Problem: Dust deposition on
roller/ felt blanket
Cause: Not having Dust sucker
machine, cleaning roller
Solution: Changing, Adding
M/Cs: Printing machine

20. Common problems and
possible solutions
Problem: Rubber blanket melting
Cause: High heat production, Material not
suitable
Solution: Changing, cleaning, Cooling the
blanket surface
M/Cs: Printing machine
Problem: Felt blanket tear
damage
Cause: Excessive pressure
Solution: Changing, Using
compressible blanket
M/Cs: Printing machine

21. Common problems and
possible solutions
Problem: Shafts Bending/ Breakage
Cause: Excessive pressure, Material not
suitable
Solution: Changing, lubricating, Controlling
pressure
M/Cs: Printing machine, Dyeing machine etc
Problem: Package holder
Damage
Cause: Excessive pressure/load,
Material not suitable
Solution: Changing, Controlled load
M/Cs: Printing machine, Dyeing
machine etc.

22. Common problems and
possible solutions
Problem: Heater Damage
Cause: Hygrometer damage, Heating
device getting too hot, Pressure gauge
problem, improper fuel supply
Solution: Changing, cleaning
M/Cs: Singeing Machine, Dyeing Machine
Problem: Heat Exchanger
and moisturing device
Cause: Excessive heat, Filter not
changing
Solution: Changing, Repairing

23. Types of Cost of
Maintenance

24. Maintenance Types

25. Maintenance Strategies

26. Maintenance Terminology
• Maintenance schedule: A list of items and the maintenance
tasks required, including the intervals at which maintenance
should be performed.
• Overhaul: A examination and restoration of an equipment or a
major part to an acceptable condition.
• Restoration: maintenance actions intended to bring back
equipment to its original conditions.
• Spare stock: Items needed to be in inventory as spare of
machine for ease of maintenance.

27. Maintenance Terminology
• Breakdown: Failure resulting in the non availability of an
equipment
• Feedback: A report on the success or failure of an action to
achieve its desired objectives and which can be used to
improve a process
• Inspection: the process of examining or detecting any
deviations from specifications
• Maintenance History: A history record showing repair spares
etc used to assist maintenance planning. Like buying and
storing lubrication

28. Conclusion
Prevention is always better than cure. So We
should always keep our focus on periodic
examination of machines and do needed
maintenance before it breaks down.

29. Thank You