Md masum billah

Bangladesh University of Business & Technology (BUBT)
Department of Textile Engineering
Industrial Attachment
Landmark Textile Mills Ltd
Submitted By
Name ID. No. Intake
Md. Masum Billah 13141107044 10th
Chairman:
Professor Dr. Mohammed Rubaiyat Chowdhury
Professor and Chairman
Supervised By
Md. Mahabub Hasan
Assistant Professor

Letter of Transmittal
Date: 10.18.2017
To
Professor and Chairman
Mirpur-2, Dhaka -1216.
Subject: Submission of Industrial Attachment Report.
Sir,
We are glad to submit our internship report on ―Landmark Textile Mills Ltdǁ with your
kind supervision and continuous guidance throughout the Industrial Attachment Report. We
have collected as much information which we include in the report.
We believe that this industrial attachment program has enriched both our knowledge and
experience. We hope that you will appreciate us with any short of recommendation and
valued suggestion, and will cordially receive this Attachment for your kind assessment
Sincerely yours,
Name ID. No. Intake Signature
Md. Masum Billah 13141107044 10th

SUPERVISING FACULTY’S APPROVAL
…………………………………………
Md. Mahabub Hasan
Assistant Professor
………………………………………….
Professor & Chairman

ACKNOWLEDGEMENT
A number of people have made significant contributions to the preparation of this report.
Their insights, advice and suggestions help us a lot.
Firstly, we are very much thankful to our supervising teacher Md. Mahabub Hasan for his
encouragement and valuable suggestions for incessant improvement of the report. We would
also like to thank Professor Dr.Mohammed Rubaiyat Chowdhury( professor&Chairman of
Textile department) for all necessary information delivery as well as for many technical help.
During the attachment with Landmark Textile Mills Ltd., we worked in all the departments
related with the Wet Processing Section. Not only we gave priority to the Wet Processing but
also wanted to learn sincerely in the Fabric Section, Garments Section, Utilities, Maintenance
and Effluent Treatment Plant. Besides these, we learned about Quality Control Section and
Finished Fabric Inspection Section, warehouse, Store & Inventory, finishing & specially
dyeing.
We owe a particular debt of gratitude to Bishwajit Chowdhury (Sr. Manager-Dye House)
in Landmark Textile Mills Ltd. . He gave some of his valuable time regularly to helping us to
achieve our goal.

Contentss
Landmark Textile Mills Ldt...................................................................................................................
Introduction ........................................................................................................................................
Project Description ........................................................................................................................ 2
Organogram of Production Unit:........................................................................................................ 6
Management System:.................................................................................................................... 6
Shift Change: ............................................................................................................................. 6
Responsibilities of Production Officer: ....................................................................................... 6
Job Description:......................................................................................................................... 7
Job Summary:............................................................................................................................ 7
Job Description:......................................................................................................................... 7
Job Summary:............................................................................................................................ 7
Remarks: ................................................................................................................................... 7
Dyeing machinery:......................................................................................................................... 9
Machine no.-01 ............................................................................................................................. 9
Machine no.-02 ............................................................................................................................. 9
Machine no.-04 ........................................................................................................................... 10
Salt Dozing Machine: ................................................................................................................... 11
Raw material:.................................................................................................................................. 17
Grey Fabrics:................................................................................................................................ 17
Dyes: ........................................................................................................................................... 17
Chemicals:................................................................................................................................... 19
Pretreatment: ................................................................................................................................. 22
Scouring: ..................................................................................................................................... 22
Bleaching:.................................................................................................................................... 22
Dyeing:............................................................................................................................................ 22
Chemical composition of raw cotton:........................................................................................... 22
Classes of dyes based on suitability of dyeing different fibers: ..................................................... 23
Dyeing Recipe:................................................................................................................................. 24
100% Cotton Fabric Dyed in Deep Shade with Hot Brand Color.................................................... 24
100% Cotton Fabric Dyed in Light Shade with Hot Brand Color .................................................... 24
100% Cotton Fabric With Optical Brightening Agent .................................................................... 25
100% PET Fabric Dyed in Deep Shade– ........................................................................................ 25
100% PET Fabric With Optical Brightening Agent– ....................................................................... 26

100% Viscose Fabric With Optical Brightening Agent .................................................................. 26
100% Viscose Fabric in Deep Shade with Cold Brand Color–......................................................... 26
C.V.C Fabric Dyed in Deep Shade– ............................................................................................... 27
Finishing:......................................................................................................................................... 27
Dewatering M/C Setting........................................................................................................... 27
Gas Burnt Tensionless Dryer M/C Setting................................................................................. 28
Compactor Setting................................................................................................................... 28
Stenter Setting......................................................................................................................... 28
Dyeing Process: ............................................................................................................................... 29
Process flow chart for 100% Cotton (White Color): ...................................................................... 29
Process flow chart for100% Cotton (Black Color): ........................................................................ 30
Daily Production Report:.............................................................................................................. 33
Monthly Average Production:...................................................................................................... 34
Remarks: ..................................................................................................................................... 34
Quality Policy: ................................................................................................................................. 36
Quality Assurance Procedure:...................................................................................................... 36
Inspection area:........................................................................................................................... 37
PROBLEMs ENCOUNTERED IN DYEING:........................................................................................ 37
Batch to Batch Shade Variation.................................................................................................... 38
Crease Mar.................................................................................................................................. 38
Running Marks ............................................................................................................................ 38
Intensive Foaming.................................................................................................................... 38
Miscellaneous Problems .......................................................................................................... 39
Process of Shade Matching:......................................................................................................... 39
Pentone Book:............................................................................................................................. 39
List of Equipments: ...................................................................................................................... 39
Maintenance of Machinery:............................................................................................................. 45
Routine:....................................................................................................................................... 45
Maintenance Procedure: ............................................................................................................. 46
Machine: Dyeing Machines.......................................................................................................... 46
Machine: Stenter Machine.......................................................................................................... 46
Machine: Dewatering Machine.................................................................................................... 47
Machine: Compactor Machin....................................................................................................... 47
Machine: Tensionless Dryer......................................................................................................... 47
Machine: Boiler ........................................................................................................................... 47
Maintenance Tools and Equipments: ........................................................................................... 48

Utility Services Available:................................................................................................................. 50
Electricity- ................................................................................................................................... 50
Water-......................................................................................................................................... 50
Steam...................................................................................................................................... 51
Compressed Air-.......................................................................................................................... 51
Cost of Different Utility:............................................................................................................... 52
Consumer of Products: ................................................................................................................ 54
Country of Export: ....................................................................................................................... 54
Local Market:............................................................................................................................... 54
Marketing Strategy:..................................................................................................................... 54
Duties & Responsibilities of Marketing Officer: ............................................................................ 54
Machine Description: ...................................................................................................................... 57
1. Batching or Bulking Unit........................................................................................................... 57
2. Cabinet Dyeing M/C................................................................................................................. 57
3. Hydro Extractor M/C................................................................................................................ 57
4. Dyer......................................................................................................................................... 57
5. Packing M/C ............................................................................................................................ 58
Features of Acrylic Yarn Dyeing Process:...................................................................................... 58
Process Flowchart: .......................................................................................................................... 58
Process Description: .................................................................................................................... 59

Introduction
Industrial attachment is an essential part of four years B.Sc. in Textile
Engineering course of Bangladesh University of Business And Technology.
We had the opportunity to perform the industrial attachment with Knit
Concern Ltd.
The industrial attachment is the most effective process of achieving the
practical experience. It provides us sufficient practical knowledge about
management, evaluation, productivity, production planning & control,
Production cost analysis inventory control, purchasing. Utilities and
maintenance of machinery and their operation technique etc.
As a textile engineer we should have an experience in the study of Wet
Processing technology, machineries products and overall situation of the
factory before work in the industries.
During 2 month long attachment, we studied the man, machine, material
aspects of the Circular & Flat knitting section, quality control section,
planning section, grey fabric inspection, finished fabric inspection, dyeing &
finishing section of the mill. According to our studies there we have prepared
the following report and would like to present.

1 | P a g e
CHAPTER–1
PROJECT DESCRIPTION

2 | P a g e
Project Description
Name of the Company : Landmark Fabrics Ltd.
Project Name : Landmark Textile Mills Ltd.
Type : Knit Composite Textile Industry.
Year of Establishment : 2000
Address :
Head Office : House#488/a, Road#32,
New DOHS Mohakhali
Dhaka-1206,Bangladesh.
Ph: 88-02-8811679, 8814839
Fax: 88-02-8823999,8815868
E-mail: gbilmd@citechco.net
Factory : Boro Ashulia, Saver, Dhaka
Ph:88-02-9289365-7
Fax:88-02-9289364
E-mail: knitfty@dhaka.net
Sponsors : The industry is sponsored by Jumna Bank Ltd
Product Mix : 100% cotton
100% polyester(micro + commix)
100% viscose
CVC (chief value cotton)
P/C
Gray mélange
Nylon/Cotton
Annual Production Capacity : Knit Dyeing–3000 ton ; Yarn Dyeing–1400 ton
Project Cost : Initial investment is approximately 25 Core Tk
History of Project
Development
:
 The construction work of the factory was started at 1999, after
acquiring 20 bights of high land at Shadhurpara, Boro
Ashulia, Savar, Dhaka.
 The construction work was completed at the beginning of
2000. At the very beginning, the project consisted only
Knitting, Knit dyeing, Garments section and Utility supply
section
 In 2001, Acrylic yarn dyeing and sweater manufacturing unit
was started
 In 2002, production capacity of knit dyeing section was
increased with the addition of new Jet dyeing m/c, Stander
m/c, Raising m/c.
 In 2004,Spray dyeing unit was started
 Effluent treatment plant was under construction.
Future plans to establish Acrylic Yarn Manufacturing unit,
hospital, designing and packaging unit.

3 | P a g e
Location :
Fig: Landmark Complex






4 | P a g e
 Different Departments:
To ensure smooth running of various activities, some departments are available they are given bellow:
 KNITTING SECTION:
1. Knitting
2. Inspection
 KNIT DYEING SECTION:
1. Batch section
2. Store house for dyes & chemicals
3. Dye house
4. Dyeing & QC lab
5. Finishing
 GARMENTS SECTION:
1. Merchandising
2. Sample
3. Production
 MAINTENANCE:
1. Electrical
2. Mechanical
 ACCOUNTS & COMMERCIAL SECTION
 ADMIN SECTION
Physical Infrastructure:
 Buildings-2 ten storied buildings,
 1 five storied building,
 3 two storied buildings and
 1 dyeing shade.
Buildings are made by concrete.
Total Area of Industry: 30 Bights.
Remarks:
The company owns 30 big has of high land property at Sadhurpara, Baro Ashulia,Savar, Dhaka;
which is 40 km from the heart of the capital city. Charming sights along with natural beauty of rural
areas with no hazards or air pollution attracts the foreign buyers during their visits. The company has
the desire to achieve recognition of the project as the ‘Landmark Industrial Park’ and to set up within
the park area industries and health care center in near future. Plans include for Acrylic Yarn
manufacturing unit, Packaging unit, Designing unit and Hospital.

5 | P a g e
CHAPTER–II
MANPOWER MANAGEMENT

6 | P a g e
Organogram of Production Unit:
Landmark Fabrics LTD.
BORO ASHULIA, SAVAR, DHAKA
Administration Knitting Dyeing Finishing Lab Batch Maintenance
General Manager
Manager
Asst .Dyeing
Master
Mechanical
Engineer
Asst. Admin.
Officer
Production
Officer
In-charge In-
charge
In-charge Electrical
Engineer
Store In-charge Supervisor Supervisor Q.C.
Supervisor
chemist Supervisor Mech. Fitter&
Electrical
Super visor
Store Keeper Operator Operator Operator Assistant Helper Asst.
Mechanic
Office Boy Helper Helper Helper Helper Electrician
Cleaner Cleaner Cleaner Asst.
Electrician
Management System:
 Buyer sample is send to G.M.
 Matching is done by lab in charge.
 Sample is prepared by asst. dyeing master
 Sample is send to the buyer for approval.
 Approved sample is returned and taken as std. Sample for bulk production .
 Asst. dyeing master gives responsibilities to production officer.
 Then production officer, with the supervisors start bulk production.
 On line and off line quality check is done by lab in charge and asst. dyeing Master . 
 After dyeing finishing in charge controls the finishing process with the Supervision of
production officer.
 After finishing, the material is checked by asst. dyeing master .
 Finally G.M. checks the result with asst. dyeing master and decision is taken for delivery.
Shift Change:
Two shifts (day and night): each of 12 hrs
Day shift 8 a.m. to 8 p.m.
Night shift 8 p.m. to 8 a.m.
Responsibilities of Production Officer:
 Over all supervision of production both dyeing & finishing.
 Batch preparation and pH check.
 Dyes and chemical requisition, issue and check.

7 | P a g e
 Write fabric loading and loading time from machine
 Programmers making , sample checking, color matching.
 Control the supervisors, operators, asst. operators and helpers of dyeing machine
 And also other work when it is required by top level management.
Job Description:
Title: Asst. Dyeing Master
Dept/section: Dyeing and Finishing.
Report to: G.M.
Job Summary:
 After having the work order, prepares production plan
 To execute and follow up the plan along with quality conformation.
 To face various difficulties of production and overcome them.
 Inspecting the material for conformation to buyer requirement.
Job Description:
Title: Asst. Production Officer
Dept/section: Dyeing and Finishing
Report to: Asst. Dyeing Master.
Job Summary:
 To execute the plan given by asst. dyeing master.
 Organizing personnel under him.
 Control the supervisors, operators, asst. operators and helpers of dyeing machine.
 Checking of shade match.
Remarks:
The manpower management system of Landmark Textile Mills Ltd. is wellarranged. Every officers &
stuffs are responsible for their duty. But there are only threetextile engineers in the industry(General
manager, Asst. dyeing master and Productionofficer). It is not sufficient for smooth production. More
technical people is required.

8 | P a g e
CHAPTER–III
MACHINE DESCRIPTION

9 | P a g e
Dyeing machinery:
In dyeing section of Landmark Fabrics Ltd, there are 7 Dyeing Machines, amongthem 2 m/c’s are for
sample dyeing and 5 m/c’s are for bulk production. Besides these, aSalt Dozing m/c and an Air Turner
m/c are available.
Machine no.-01
Name of the m/c : Sample Jet Dyeing Machine
Brand Name : Thiess
Manufacturing Country : Germany
Year of Manufacturing : 2001
M/C Specification :
M/C capacity : 20 kg
No. of nozzle : 01Max
Temp : 135c
Motor :
winch motor : 01
pump motor : 01
stirring motor : 01
Machine no.-02
Name of the m/c : Bangle Winch Dyeing M/C.
Brand Name : None
Manufacturing Country : Bangladesh
M/C Specification :
M/C capacity : 25kg
No. of nozzle :
02
Machine no.-03
Name of the m/c : Jet Dyeing M/C
Brand Name : Thiess
Manufacturing Country : Germany
M/C Specification :
M/C capacity : 170kg
No. of nozzle : 01
Temp : -
Motor :
winch motor : 01
pump motor : 01
stirring motor : 01

10 | P a g e
Machine no.-04
Name of the m/c : Jet Dyeing Machine
Brand name : Thiess
Manufacturing country : Germany
Year of manufacturing : 2001
M/C specification :
No .of nozzle : 02
Motor :
winch motor : 02
pump motor : 01
stirring motor : 01
Machine no.-05 & 06:
Brand name : Thiess
M/C specification :
No .of nozzle : 03
Motor :
winch motor : 03
pump motor : 01
stirring motor : 01
Machine no.-07:
Brand name : Thiess
M/C specification :
No .of nozzle : 04
Motor :
winch motor : 04
pump motor : 01
stirring motor : 01

11 | P a g e
Salt Dozing Machine:
Brand name : Fong’s National Eng (Shenzhen Co.)
Manufacturing country : China
M/c capacity : kgs
Function of the m/c :
It is an additional m/c only used for the large m/c(capacity-1000kgs).When large amount of salt are to
be added, in that case salt are added by dosing system which are Maintained by this m/c.
Air Turner M/C:
Brand name : Dong Nam Industrial Co.
Manufacturing country : Korea
Function of the m/c : To turn the fabric
Finishing Machinery:
In finishing section of Landmark Fabrics Ltd, the machines which are availableare listed below:
1. Slitter m/c 2.
2. Stenter m/c 3.
3. Dewatering & Detwisting m/c 4.
4. Gas Burnt Tensionless Dryer m/c 5.
5. Tubular Compactor m/c
Slitter M/C:
Specification:
Brand name : BIANCO
Manufacturing Country : Italy
M/c speed : 60 meter/min
M/c width : 80 inch
Purpose of the m/c:
 To open the fabric from tubular form to open width form
 Fabric is cut according to the needle drop
Main parts:
Turntable Beater
Rope Squeeze Centering Unit
De-twister Slitting Unit
Pulley Drive Squeezing

12 | P a g e
Utilities used:
 Electricity(to drive the m/c only)
 Compressed air(to keep the tubular fabric to be cut in proper tension)
Stenter m/c:
Fig : Stenter m/c
Specification:
Brand name : Mahlo + Bruckner
Production/day : 12,000 Kg/day
Maximum steam pressure : 2 bar
Maximum air pressure : 10 bar
Purpose of the m/c:
To control the fabric GSM
To control the fabric with or dia
To control the fabric shrinkage
For heat setting in case of p/c & 100% polyester fabric
To make the fabric dry
Main parts:
Heating Chamber (7) Blower (14)
Width Control Device Biasing Unit
Selvedge Trimming Device Softener Applicator
Selvedge Gumming Device Folding Device
Heating system : Gas Burner
Gripping system of fabric edges : pinning
Utilities use:
Electricity
Gas
Steam

13 | P a g e
Controlling points:
Fabric speed
Fabric width
Temp rature
Overfeed %
Dewatering & Detwisting m/c:
Specification:
Brand name : Santex group
Manufacturing country : Switzerland
Purpose of the m/c:
 To remove excess water of fabric by squeezing after pretreatment and Dyeing
To remove twist of fabric when fabric is open
Main parts:
De-twisting device(to deliver the fabric roll in untwisted form)
Over feeding wheel (to control shrinkage)
Stretcher (to control width)
Squeeze roller (to remove water)
Folding device (to deliver the fabric in folded form)
Utilities used:
Electricity
Compressed air(to form the tube fabric into balloon to ensure the delivered Fabric
to be crease free)
Chemical used:
1. Softener (10g/l)
2. Acetic acid (1g/l)
Controlling points:
Over feed control Fabric speed
Pressure of squeeze R/r Width control
Gas Burnt Tensionless Dryer:
Specification:
Brand name : Santex Group
Purpose of the m/c:
To dry the fabric uniformly in tensionless state
To control the shrinkage
To control the shrinkage

14 | P a g e
Main parts:
Heating chamber (2) Folding device
Blower () Exhaust fan
Teflon conveyor Mesh
Heating system: Gas Burner
Utilities used:
Gas
Electricity
Compressed air
Controlling points:
Speed control Motor control
Temperature control Net vibration
Exhaust fan control Heating chamber height
Tubular compactor:
Fig : Tubular Compactor Fig : Tubular compactor
Specification:
Brand name : Santex Group
Pro/day : 12,000 Kg/day
Purpose of the m/c:
Used for tubular fabric as final finishing
Amount of shrinkage is given to the fabric in compaction zone as per buyer
requirement
Final finished width and GSM can be obtained as buyer requirement
Main parts:
Stretcher
Steam heated roller
Blanket
Teflon R/r
Folding device

15 | P a g e
Utilities used:
Electricity
Steam
Compressed air
Raising M/c:
This m/c is used only for raising finishing which imparts a hairy surface to the fabric. A layer of
fabric fibers lifting from the body of the fabric is achieved by passing it over a no. of pile R/r and
counter R/r. It is mostly applied on Terry fabric, Polar fabric etc.
Specification:
Brand name : Yenta
Manufacturing country : Taiwan
Type of m/c : Gear type raising
m/ c No. of pile R/r : 12
No. of counter R/r : 12Roller
Width : 2000 mm Avg.
Speed of m/c : 30 m/min
Remark:
Landmark Fabrics Ltd is a well-equipped industry. It contains machinery of well known brands like
Thiess, Bruckner, Bianca, Santex, etc. The availability of these m/c’sare helpful to increase the
productivity of the industry. The arrangement of machines is very beautiful and there is enough space
for movement of the workers.

16 | P a g e
CHAPTER–IV
RAW MATERIAL

17 | P a g e
Raw material:
Landmark Fabrics Ltd is a knit composite textile industry. In the industry the rawmaterials used for
production are:
1. Grey Fabrics
2. Dyes
3. Chemicals
Grey Fabrics:
Following types of grey fabrics are processed
Single jersey Terry & French terry
Single jersey/lira Polar
Interlock Eyelet & mini-eyelet
Rib Mesh (warp knitted fabric)
1X1rib/lycra waffle
Combined rib Collar & cuff
Lacoste Pique
Source40% comes from the Knitting Department of Landmark Fabrics Ltd another 60%
comes from outward as sub-contract.
Daily Fabric Production Capacity
Item Quantity
Single jersey, Pique 1000 kg/day
Lactose Interlock 3500 kg/day
Rib 3500 kg/day
Collar & cuff 6000 pc
Dyes:
In Landmark Fabrics Ltd. the following types of dyes are used
Reactive dyes (cold brand & hot brand)
Disperse dyes

18 | P a g e
The commercial name of the dyes with their prices are collected from the dyestock report
The commercial name of the dyes with their prices are collected from the dyestock report
Sl.
No
Names of the dyes
price
inTk/kg
Sl.
No
Names of the dyes
price in
Tk/kg
1 Kemazol black-B - 32 Dramamine Red CL-5B 800/-
2 Kemazol Turqu.BlueG2-HC - 33 Dramamine Blue CL-2RL 2250/-
3 Kemafix red 2B 600/- 34 Dramamine Blue CL-2RL - 2250/-
4 Kemafix black GR 456/- 35 Dramamine Orange CL-3R 720/-
5 Kemafix yellow 4G 350/- 36 Dramamine Yellow CL-2R 800/-
6 Kemafix yellow FRL 250/- 37 romaine Yellow CL-3G 1000/-
7 Kemafix red-3BC 300/- 38 Dramamine Blue CL-BR 1100/-
8 Kemafix Blue F2R 430/- 39 Dramamine Turquoise CL-B 750/-
9 Kemafix Orange 2RL 440/- 40 Dianix Black CCR 340/-
10
kemafix N.Blue MER-
150%
- 41 Dianix Navy CC 650/-
11 Kemafix Red HE-3B - 42 acorn Black SE-EXNT 300% 300/-
12 Kemactive Orange HER - 750/- 43 Taicron N.Blue SE-EXNT 300% 480/-
13 Kemactive Red HE-3B 634/- 44 Taicron Rabine SEBL-T 200% - 550/-
14 Solacion Red HE-3B 380/- 45 aicron Scarlet EBT 200% - 680/-
15 Teasel Red WFS - - 46 Taicron Yellow SE-4GT 200% 550/-
16 Teasel Yellow W6HG - - 47 Taicron Orange E-BRT 200% 380/-
17 Teasel Red W4BS - - 48 Taicron Red EE-BNT 200% 600/-
18 Teasel G.Yellow W3R - 48 Taicron Red EE-BNT 200% 600/-
19 Teasel Blue 3RL - - 49 aicron Blue EBRT 200% 720/-
20 Terasil Blue WBLS - 50 Taicron T.Blue SE-2BT 200% 1100/-
21 Remazol Brilliant Red 5B - - 51 Taicron Blue SE-2BT 750/-
22
Foron D.Blue RD-2RE-300-
6RN -
- 52 Taicron Black HWT 440/-
23
Foron D.rubin RD-GFL-
200% -
- 53 Taicron Scarlet-HWT 650/-
24
Foron black RD-BRE-300-
GRM -
- 54 Taicron Navy-HWT 450/-
25
Foron brilliant orange ERL-
200% -
- 55 Taicron Red-XFT 650/-
26
Foron yellow RD-4GRL-
300-6RN -
- 56 Cibacron Yellow EN-2R 1700/-
27
Foron yellow brown F2RL-
300% -
- 57 Cibacron Red FNR 1600/-

19 | P a g e
Sources
Matex Grasim
Dyestar Ahmed Enterprise
Chemicals:
In Landmark Fabrics Ltd., the following chemicals are used. The names of the chemicals with their
prices are collected from the dye stock report:
Sl
no
.
Names of the chemicals Price
in
Tk/kg
Sl
no.
Names of the chemicals Price
in
Tk/kg
1 Caustic soda(Alkaline Medium) 26- 22 TC Antistatic kemps(Antistatic
Electricity Agent)
-
2 Hydrogen per oxide(Bleaching Agent) 32/- 23 Powersoft-18(Silicon Softener)
-
-
3 Acetic acid (Acid Medium) 65/- 24 Nalco 450(Boiler Chemical) -
4 Common salt(Exhausting Agent) 5/- 25 Protect SB-157(Boiler
Chemical)
-
5 Soda ash(Alkaline Medium) 18/- 26 Sindonerin MC(Silicon
Softener)
-
6 Rucostab LGE(Multi-Purpose Chemical
as alkali, stabilizer, sequestering agent)
120/- 27 Oxalic acid(Sequestering
Agent)
46/-
46/-
7 Vernon LGA(Multi-Purpose Chemical as
alkali, stabilizer, sequestering agent)
120/- 26 Oxalic acid(Sequestering
Agent)
-
- 28 Adasen SM(Silicon Softener) 274/-
8 Bittex-0X(O.B.A Agent for Cotton ) 250/- 29 Lenox AM-400(Silicon
Softener)
-
9 Avatar HOS(Stabilizer) 120/- 30 Adasen ME(Silicon Softener) 178/-
10 Lamaze HTS(Stabilizer) - 31 Gissapol-115(Wetting Agent)
160/-
161/-
11 Elysian(Acid Buffer) 34/- 32 Fell son NOF(Oil Remover) 161/-
12 Multisoap SR(Soaping Agent) 120/- 33 Biopolish AL(Acid Enzyme) -
13 Lenox SPL(Oil &mineral Iron remover) - 34 emapon-173(Ant creasing
Agent)
135/-
14 Mollan-130(Sequestering Agent) 140/- 35 Welsoft-40(Silicon Softener) -
28 Foron blue SE-2R - - 58 Cibacron Blue FNR 2600/- 2600/-
29 Foron turquise S-2B - - 59 Cibacron Dk. Blue WR 1150/- 1150/-
30
Foron scarlet RD-FRS-
200% -
- 60 Cibacron Red EB-150% 1100/- 1100/-
31 Foron black RD-3G-300% - - 61 Best Acid Yellow BMR -

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15 Avatar 66-C(Fixing Agent) 135/- 36 Belasis 615(Cationic Softener) -
16 Glibber salt(Exhausting Agent) - 37 Valzyme(Acid Enzyme) 330/- 330/-
17 Alva soft EG(Cationic Softener) 155/- 38 Steamroll BL(Dispersing
Agent)
65/-
18 Alva soft EG(Cationic Softener) 155/- 39 Pala gal FAH8(Leveling Agent) 138/-
19 Fern ice(Hydrophilic Softener) - 40 Glycerin(Solvent) -
20 Taboo FTR(Leveling Agent) - 41
21 Unite EBF(O.B.A Agent for Polyester) - - 42
Sources  BASF Mates
High-tech – Oxichem Friends International Global Colourchem Ltd
Remarks: Landmark Fabrics Ltd is so careful about its raw materials. The raw materials areaways
collected from those suppliers who supply the dyes & chemicals of higher quality.

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CHAPTER-V
Process description

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Pretreatment:
Pretreatment is the preparation period of fabric from dyeing. For getting proper fastness of fabric
and proper dyeing pretreatment is a mandatory process.
Scouring:
The process to remove fats, oil, waxy substances and added the impurities by certain percentage of
alkali treatment and which increase the absorbing power of the textile units, is called scouring.
Bleaching:
The process by which the natural color of a fiber can be removed and make the textile this pure
white and bright is called Bleaching.
Dyeing:
Dyeing is a method which imparts beauty to the textile by applying various colors and their shades
on to a fabric. Dyeing can be done at any stage of the manufacturing of textile- fiber, yarn, fabric or a
finished textile product including garments and apparels. The property of color fastness depends
upon two factors- selection of proper dye according to the textile material to be dyed and selection
of the method for dyeing the fiber, yarn or fabric. After dyeing, dye molecules have uncut chemical
bond with fiber molecules. The temperature and time controlling are two key factors in dyeing. Fakir
Knitwear’s Ltd., they used to do knit fabric dyeing and knit garments dyeing.
Fig: Dyeing Machine Land Mark Group
Chemical composition of raw cotton:
Component Main location Relative amount
Cellulose Secondary wall 86.8 %
Oil and Wax Cuticle 0.70 %
Pectins Primary cell wall 1.2 %
Carbohydrates Primary cell wall 0.50 %
Protein Lumen 1.3 %
Salts Lumen 1.0 %
Water Whole 6.8 %
Others 2.0 %
Source: http://textilelearner .blogspot.com

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Classes of dyes based on suitability of dyeing different fibers:
Sl. no Name of dyes Suitable for Fibers
01 Acid dyes Wool, silk and Nylon
02 Basic dyes Nylon, Acrylic, Acetate Rayon, Silk, Wool and Jute
03 Direct dyes Cotton, Viscose Rayon, Linen, Nylon, Wool and Silk
04 Azoic dyes Cotton, Viscose and Linen.
05 Vat dyes Cotton, Viscose and Linen.
06 SulPHer dyes Cotton, Viscose and Linen.
07 Reactive dyes Cotton, Viscose, Linen, Wool, Silk and Nylon.
08 Disperse dyes Polyester, Nylon, Acrylic, Acetate Rayon and Triacetate Rayon.
Dyeing Parameters:
a. pH:
- During H2O bleaching pH 9.2–12
- During reactive dyeing pH 10.5–12.5
- During disperse dyeing pH 4.5–6.0
b. Temperature:
- For cotton scouring 105C
- For cotton cold wash 300C
- For cotton hot wash 700
- For cotton acid wash 45
- For cotton dyeing 98–-8000C (For hot brand)
- Polyester dyeing: 135
c. Time:
Set Actual
- For scouring & bleaching 90 mins - For scouring & bleaching 30 mins
- For reactive dyeing 60-90 mins - For reactive dyeing 150 mins
- For disperse dyeing 60-90 mins - For disperse dyeing
d. M:L ratio:
- For reactive dyeing M:L ration maintained between 1 : 6 to 1 : 8

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Dyeing Recipe:
100% Cotton Fabric Dyed in Deep Shade with Hot Brand Color
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
Soda
3.04% Kem Orange HER
0.046% Kem Navy Blue HER
3.76% Kem Red HE7B
Multisoap SR
Acetic Acid
Alvatex 66C
Acetic Acid
100% Cotton Fabric Dyed in Light Shade with Hot Brand Color
Gospel 115
Filose NOF
emanon 173
Avatar HOS
Caustic Soda
H2O2
Gospel 115
Acetic Acid
Common Salt
Soda
10.4%Kem Black GR
1.38% Kemp Red 3BS

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1.39% Kemp Yellow FRL `
Multisoap SR
Acetic Acid
Avatar 66C
Acetic Acid
3. 100% Cotton Fabric With Optical Brightening Agent
0.5% Girasol 115
3.5% Caustic Soda
Rucostab LGE
H2O2
0.6% Bittox.ox (BYB)
Acetic Acid
4. 100% PET Fabric Dyed in Deep Shade–
2% Soda
Girasol 115
Filose NOF
Hot Wash
Acetic Acid
Steamroll BL
Pala gal FA8
Elysian-S
5% Tai Black HWT
2% Diana Black CCR
1% Tai Orange HWT
4% Hydrous
3% Caustic Soda
1% Steamroll BL
Hot Wash

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5. 100% PET Fabric With Optical Brightening Agent–
2% Soda
0.5% Filose NOF
Hot Wash
Acetic Acid
algal FA8
Elysian-S
0.6% Ultra phone BN
6. 100% Viscose Fabric With Optical Brightening Agent
1% Multisoap SR
2% soda
2% H2O2
Alvatex HOS
Multisoap SR
0.25% Bittox.ox (BYB)
Acetic Acid
100% Viscose Fabric in Deep Shade with Cold Brand Color–
2% Soda
0.5% Felosun NOF
0.5% Gisapol 115
Hot Wash
Acetic Acid
Mollan-130
Tabanol FTR
Glouber Salt
Soda
7% Kem Black GR
0.83%Kem Red 3BS
0.53% Kem Yellow FRL
Acetic Acid
Alvatex 66-C
Acetic Acid

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C.V.C Fabric Dyed in Deep Shade–
Setamol BL
Palagal FA8
Eulysin-S
1.1% Terasil G. Yellow W3R
0.25% Megaperse Red RNA
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
common Salt
Soda
2.0% Kem Orange 2RL
0.11% Kem Red 3BS
0.1% Kem Yellow FRL
Multisoap SR
Acetic Acid
Alvatex 66-C
Acetic Acid
Finishing:
Dewatering M/C Setting
Fabric type Fabric
speed(m/min)
Over
feed%
Single jersey(Viscose) 80 30
single jersey(cotton/lycra) 80 22
Single jersey(cotton) 80 10-11
1X1 Rib 80 11
Interlock 80 14-15
Terry 80 5-9

28 | P a g e
Gas Burnt Tensionless Dryer M/C Setting
Fabric type Fabric speed(m/min) Temperature Over feed%
Single jersey(cotton) 6.5 140 15
Single
jersey(cotton/lycra)
6.5 140 15
1x1 Rib 6 140 15
Interlock 5 140 15
Terry 5 140 15
Compactor Setting
Fabric Type Fabric speed
(m/min)
Steam
pressure
(psi)
Compacting
pressure
(psi)
Tempc Overfeed%
Single jersey
(cotton)
25 60 70 120-150 5-7
Single
jersey(cotton/lycra)
20 50 60 120-150 6-7
Single
jersey(viscose)
25 60 70 120-150 8
1x1 Rib 25 60 70 120-150 3-4
Interlock 25 60 70 120-150 3-4
Terry 25 60 65 120-150 8
Stenter Setting
FABRIC TYPE FABRIC SPEED
(m/min)
TEMPERATURE (C) OVER FEED%
Single jersey (Cotton) 30-40 160 Upto 30
Rib/Interlock (cotton) 25-30 160 Upto 30
Single jersey (Viscose) 26 185 Upto60
Mini-eyelet(Polyester) 20-25 185 Upto 4
Mesh (Polyester) 20-25 Upto 60

29 | P a g e
Dyeing Process:
Process flow chart for 100% Cotton (White Color):
Fabric loading
Demineralization
(Wetting /Detergent +Ant creasing+demineralizing agent)
Dosing time 5min at 400
C temp
Temp raised at 550C Run time 20 min
Draining
(5-min)
Scouring & Bleaching
(Detergent /wetting agent +Anti creasing agent + NaOH +Hydrogen per oxide)
[Dosing time 20 min at temp 50
0
C + 10 min Run time]
Temp raised 70
0
C
H2O2(50%) added [70
0
C * 10 min]
Temp raised at 1100C * 60 min
M/C Cooled (temp drop 800C)
Brightening agent added
[Dosing time 30 min 80
0
C ]
Temp raised 98
0
C Run time 30 min
Sample check
Drain wash

30 | P a g e
Normal hot wash[90
0
C * 15 min]
PH control at 4.5 (acetic acid leveling agent)
Enzyme wash + Peroxide killer
(550C * 60 min)
Temp raised 800 * Runtime 10 min [enzyme killing]
Normal hot wash (90 degree for 15 min)
Soap washes (90 degree for 9 min)
Cold wash
Process flow chart for100% Cotton (Black Color):
Fabric loading
Enzymatic Scouring & Bio-Polishing
Check PH
(PH-6.5)
Enzyme dosing time 10 min temp at 55
0
C temp
Run time (60 min)
Enzyme killing
Stem up 80 degree for 15 minute ()
PH Check (6.9-7)
Leveling agent
(Dosing*450
C * 10 min)
Runtime 20 min at 450
C temp
Color dosing
Dosing time 30 min at 45o
C temp
Runtime 20 min 45 0
C

31 | P a g e
Salt dosing
½ salt Dosing time 15 min 45
0
C * Run time 15 min
½ salt Dosing time 10 min 45
0
C * Run time 20 min
PH
= 7-7.5
Alkali
Dosing time -20 min 45
0
C
C temp
Dosing time -30 min 50
0
C
Stem up to 600
C temp
(PH
= 11)
Color steam
(60
0
C 60 min)
As required
Sample check
Drain out 15 min
Acetic wash
PH
-4.5;at 60
0
C * 20 min runtime
Soap wash
At 800
C temp for runtime 12 min
Normal wash
Process flow chart S/J Lycra (Cotton 65%+Polyester 35%) For Blue Color:
Fabric loading
Demineralization

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(Wetting /Detergent +Anti creasing+ Demineralizing agent)
Dosing time 5min at 400
C temp
Temp raise at 55
0
C Run time 20 min
Draining
(10-min)
Scouring & Bleaching
(Detergent /wetting agent +Anti creasing agent + NaOH (8 g/l) +Hydrogen per oxide)
[Dosing time 20 min at temp 50
0
C + 10 min Run time]
Temp raised 70
0
C
H2O2(50%) added [70
0
C * Runtime 10 min]
Temp raised at 110
0
C * 60 min
M/C Cooled (temp drop 80
0
C)
Sample check
Drain wash
Normal Hot wash
C temp
Acid, added, PH
- 4.5
Enzyme (Bio polishing)
(Dosing 550
× 10min)
C temp
Temp raised 80
0
C for 10 min (Enzyme killing)
PH
Check at 4.5

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Dispersing /leveling agent with sequestering
(50
0
C*10 min run)
Color
At 500
C temp 20 min dozing time
Temp raised 500
– 1300
C
Color steam
At 130
0
C for 45 min (as required)
Temp drop at 80
0
C check sample
Draining 30 min
Soap wash (800
C for 30 min)
Normal hot wash (80
0
C * 10 min)Added acetic acid 1%
Cotton dyeing(Previous Dyeing Process)
Note:-
Polyester fiber or fabric can be dyeing with disperse dye and applied at high temperature is, 1300
-
1400
C. Disperse dyes have as conic groups and are insoluble in water. With the help of a dispersing
agent dyes can be dispersed in the dye bath. Reduction clearing is done in case of medium and deep
shade only to improve the wash fastness. This high temperature process is
Nontoxic and hygienic process. At high temp like 1300
C acid getting weaker so for getting PH 4.5
Butter solution is used in polyester dyeing process and it is strong acidic along with dispersing agent.
Daily Production Report:
The daily production report is recorded in the logbook and it contains followinginformation
Machine No. Quantity
Date Loading Time
Batch No. Unloading Time
Order No.
 Runtime
 Fabric Type
 Shift
 Color

34 | P a g e
Monthly Average Production:
The monthly average production of dyeing unit of Landmark Textile Mills Ltd. is250 tons.
Remarks:
The production process, followed by the Dye-house of Landmark Textile MillsLtd. is impressive. The
processes are being carried out very quickly and accurately. Dueto the excellence of process,
machineries and lab trials very few cases of re-dyeingisperformed.

35 | P a g e
CHAPTER–VI
QUALITY ASSURANCE SYSTEM

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Quality Policy:
It is the policy of Landmark Textile Mills Ltd. to produce quality dyed knit fabrics
that meet the customer’s expectations & needs. To implement this policy the top management
of Landmark Textile Mills Ltd. is committed to provide adequate resourcesin terms of good
raw materials and trained personnel & continually improve / upgrade its processes and
systems. The quality control policy of Landmark Textile Mills Ltd. is stated below-
 Leadership program from the top.
 In-process quality control during manufacturing operation.
 Evaluation programs in all areas of knitting, dyeing, cutting, sewing and finishing.
 Maintain chain of responsibility.
 Follow strict stuffing, auditing and reporting.
 Use inspection machines in required points.
 Maintain standard AQL.
 Sufficient lighting and sanitation.
 Final inspection prior to packaging.
 Meeting the appropriate expectations of clients.
Quality Assurance Procedure:
Landmark Textile Mills Ltd.assures the quality of their products in the followingthree steps:
1. In laboratory.
2. In dyeing section
3. In finishing section
The quality assurance procedures are described below:
In laboratory:
 Swatch card from buyer according to their requirement is received.
 Recipe prediction for sample dyeing using CCMS.
 Sample dyeing until matching with the swatch card. Acceptable color difference is less than
1.
 If matching is OK, then it is sent to the buyer for approval.
In dyeing section:
 After approval from the buyer, sample dyeing is done in dyeing m/c, in dyeing shed & again
matched with the approved sample
 If result is OK, then balk production is commenced.
 During dyeing process, before the final acid wash, samples are taken and checkedfor accurate
shade matching.
 After dyeing sample is collected & matching is done.
 Rubbing and wash fastness tests are carried out.
In finishing section:
 Correctly dyed, after treated & matched fabrics are allowed for finishing.
 By using series of finishing machines correct width, softness & appearance are maintained
according to requirements.
 Then sampling is done several times to test GSM, Shrinkage & fastness properties.
 Finally fabric is inspected & prepared for delivery.

37 | P a g e
Inspection area:
Shade match of fabric
G.S.M.
Fabric diameter
Spirality
Shrinkage (%)
Length wise
Width wise
Wash fastness
Rubbing fastness
Faults
Dyeing faults
Knitting faults
Finishing faults
Knitting Faults
Hole
Slub
Needle mark
Stripe
Missing yarn
Contamination
Dyeing Faults
Uneven shade
Running shade
Fastness property
Dye spots
Finishing Faults
GSM variation
Spiraled
Shrinkage control
Marks
PROBLEMs ENCOUNTERED IN DYEING:
Uneven Dyeing
1. It can be caused due to rapid addition of dyes and chemicals. For this purpose the dosing
of soda ash should be maintained properly.
2. Pressure difference.
3. Over loading in the m/c.
4. Yarn lot mixing.
5. Improper control of temperature.
6. Less amount of leveling agent.
7. Improper pretreatment.
Uneven Shade in Rope to Rope
Improper rope length in each chamber.2. Improper fabric flow speed in each nozzle.
Off Shade
1. Improper M: L ratio.
2. Lower amount of auxiliaries.
3. Improper mixing of dyestuffs.

38 | P a g e
Dye Spots
This is most common fault caused by operator not correctly mixing and thoroughly dissolving
dyestuffs in the right amount of water.
Batch to Batch Shade Variation
If any of parameters of dyeing are changed then it will produce problems in batch to batch
consistency. In order to avoid this defect the following steps should be followed-
1. Maintain the same liquor ratio.
2.Check that the fabric has the same dye affinity.
3. Use the same standard program procedures for each batch.
4. Making sure that the operators add the right bach of chemicals at the same time
& temperature in the process.
5. Check the water supply daily especially, hardness & Na 2 CO 3 content.
Crease Mark
Causes:
1. Poor opening of the fabric rope
2. Due to high speed of machine running
3. Unequal pump pressure and reel speed
Running Marks
Running marks are frequently related to the material construction and are caused by poor opening of
the fabric rope.
1. Reducing the machine load and running at a slightly higher nozzle pressure, or using the next
largest available nozzle size, may also help.
2. Either pre setting or pre relaxation of the fabric before dyeing can avoid this problem.
3. Running and crack marks can also be a result of incorrect process procedures. A higher fabric
speed, combined with slower rates of rinse and cooling will often correct the problem.
4. Care should be taken to check that bath draining temperatures are not very high especially
viscose blends are involved.
5. Shock cooling of static material will also cause crack marks. Running marks are frequently
related to the material construction and are caused by poor opening of the fabric rope.
Intensive Foaming
In case of intensive foaming, which is caused when; the pumps try to pump admixture of air and
water. This resets in the loss of nozzle pressure & floating of flake. If the foaming is severe it is
better to drop the bath & restart the process, after adding an anti foaming agent to the new bath.
Patchy Dyeing
It is caused, if dye solution is not correct and also scouring is improper.

39 | P a g e
Miscellaneous Problems
Batch to batch processing may vary due to the improper calculation of dyes and chemicals and
improper strength of salt soda and H2O etc. Beside hardness of water and caustic may lead to an
improper shade.
Process of Shade Matching:
The required shade provided by the buyer is reproduced in the lab in lab dyeing machine after the
recipe prediction. The lab in-charge first uses the Computer Color Matching System, to obtain the
closest shade match recipe. Then he consults the shade card and Pantone book to verify the obtained
recipe. If he thinks that certain changes in the recipe is necessary, he then alters the recipe according
to his experience. This recipe is used to dye a sample of 5 gm fabric in the lab dyeing machine with
following parameters.
a) Temperature and time 
Cold Brand Reactive Dye-65c temp;
60 minHot Brand Reactive Dye-98c temp;
60 min Turquoise Color (Cotton)-85c temp;
60 minPolyester-130c temp; 30 min
b) M:L ratio 
The samples are usually dyed using 1:15 ratio.
Pentone Book:
Pentone Textile Color Selector
Total shade–1701
Color numbering system– 6 digit + suffix
First two digits  11 to 19 ( range of lightness)
Middle two digits  01 to 64 ( range of hue)
Last two digits  01 to 64 ( range of chrome)
List of Equipments:
1. Light Fastness Tester
Fig : Light Fastness Tester
Brand–Star

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2. I.C.I. Pilling Box Tester
Fig: Pilling Tester
Brand– SDL
Operation Time– 6 hours
R.P.M.– 60
Total Revolution– 21600
Scale Range for Pilling– 1 to 5
Accepted Level– 4 to 5
3. Rubbing Fastness Tester
Fig: Rubbing Fastness Tester
Brand– SDL
Instrument Name– Crock meter
Measured Elements– Wet and Dry Rubbing Fastness
Number of Rubbing– 10
Scale Range– 1 to 5
Accepted Scale Range– For Wet 3 to 4 and For Dry 4
4. Single Yarn Strength Tester
Measured Elements–Breaking Strength (in gram) and Breaking Elongation (in percent
and mm).

41 | P a g e
5. Yarn Twist Tester
Fig: Yarn Twist Tester
Test Method– Twist-
Dewiest Yarn Length– 10 inch
6. Yarn Appearance Tester
Brand– SDL
Grades Used– A, B, C & D
Grade Scale Applicability– For 24 to 36 Ne Yarn
7. Yarn Count Tester
Number of Revolution– 80
Total Length of Yarn– 150 meters
Circumference– 1.875 meters
8. C.C.M.S.
Brand– Macbeth
Program Menu Normally Used---Formulation–Recipe prediction for given sample to
reproduce the shade. Gives 10 best combination of tricho matic color match. Quality–
Gives color difference (i.e.E) and indicates the excess of a particular depth of color. It
also gives a remark whether the dyed sample is acceptable on the basisof E and gives a
pass or fail . Acceptable color difference is less than 1%.
9. Light Box
Fig: Light Box
Brand– Verivide
Origin– England
Lamp Option– TL-84 (tube light), D65 (normal daylight), UV (optical brightener),
F (fluorescent).

42 | P a g e
10. Tumble Dryer
Fig: Dryer
Brand– Miele
Lowest Material Loading– 1 kg
Time– 40 to 45 minutes
Temp- 120c
11. Washing Machine
Fig: Washing machine
Brand– Samsung
Option---
Delicate– Polyester (wash-main; spin-600)
Speed– Cotton (wash-main; spin-900)

43 | P a g e
12. Data Color Sample Dyeing Machine
Brand– SDL
Heat Source– Infrared
Wash Fastness Tests---
Cotton- 40c temp; 20 min
Polyester- 60c temp; 20 min
Dyeing---
Cold Brand Reactive Dye - 65 c temp; 60 min
Hot Brand Reactive Dye - 98 c temp; 60 min
Turquoise (Cotton) - 85 c temp; 30 min
Polyester - 130 c temp; 30 min
Quality Standard:
Landmark Textile Mills Ltd. follows ISO standards. The company received ISO9001:2000
certification for its excellent maintenance of quality. Following quality criteria’s are maintained
strictly in Landmark Textile Mills Ltd.
Shrinkage: Should not exceed 4.
Wash Fastness:
Fastness to washing DIN EN ISO 20105 C 03: 60c: at least 4-5.
Staining on Cotton, Polyester, Polyamide, and Wool: at least 4.
Rubbing Fastness:
Fastness to rubbing DIN EN ISO 105 X 12: Dry at least 4 & wet at least 3.
Color Difference, E: Should not exceed 1.
Remarks: Landmark Textile Mills Ltd. Is always aware about the quality of their product. The
quality of the product is maintained as per requirement of the buyer. They follow the quality standard:
ISO 9001: 2000. Landmark Textile Mills Ltd. is well equipped for checking the quality of the product.
They send the quality report to the buyer from time to time/ batch to batch.

44 | P a g e
CHAPTER-VII
MAINTENANCE

45 | P a g e
Maintenance of Machinery:
Maintenance of machinery is very essential mechanical effort for achieving smooth running of
different machines. Maintenance is a process by which equipment looked after in such a way that
trouble free services and increased machine life cane ensured and specific product quality required
by the customers is sustained. Onetime maintenance increase m/c lifetime & ensures trouble free
services.
In Landmark Textile Mills Ltd. 2 types of maintenance are done
1. Break down maintenance
2. Routine maintenance
1. Break down maintenance: Break down maintenance is done instantly when problem arises in
machine. In this case, repairs are made after the equipment is out of order and it cannot
perform its normal functions.
2. Routine maintenance: After a particular period of operation, the machines are cleaned &
reordered, that is routine or schedule maintenance. The maintenance department does it once
in a month. Schedule maintenance varies, time in time & also depends on situation according to
types of machines, because maintenance is directly related to products
Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also done. Workers
inform about the problem areas of the machines. Depending on their information maintenance is done.
Maintenance engineer analyze the records and take.
Routine:
Maintenance is a necessary task in any industry. But the degree and interval of maintenance is
dependent upon the age of the machineries. Landmark Textile Mills Ltd.has relatively new
machineries, which are very modern and state-of-the-art. Due to this reason a relatively less amount of
Maintenance
Routine
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Break Down
Maintenance
Mechanical
Maintenance
Electrical
Maintenance

46 | P a g e
maintenance is needed to be carried out in Landmark Textile Mills Ltd. Never-the-less, routine
maintenance of the machineries of the dyeing section is carried out once a week. As the dyeing
section remains closed in Friday, the routine maintenance is carried out in Friday. As for break down
maintenance (very few break down cases occur), proper steps are taken to rectify the problem.
Manpower Setup for Maintenance:
Post Number of Employees
Mechanical Engineer 1
Electrical Engineer 2
Mechanical Fitter 1
Electrical Supervisor 1
Asst. Mechanic 2
Electrician 1
Asst. Electrician 2
Maintenance Procedure:
Maintenance: Mechanical
Machine: Dyeing Machines
Sl. No. Item needed to be checked & Serviced
1 Greasing of the winch bearing
2 Complete cleaning of machine
3 Cleaning of drain valves, replace seals if required
4 checking of air supply filter, regulators, and auto drain seals
5 Cleaning of filter elements
6 Greasing of unloading roller bearings
7 Checking and cleaning (if required) of addition tank level indicator
8 Checking the oil level of pump bearing and refill if required
9 Checking the function of heat and cool modulating valves
10 Checking of all belts and belt tension
11 Check circulation, reel and other pumps
12 Checking of all door seals
Machine: Stenter Machine
1 Removal of gas burnt deposits from chains
2 Checking of gas burners
3 Cleaning of softener application unit
4 Checking and cleaning of steam pipe lines
5 Checking and cleaning of gas pipe lines
6 Grinding of fabric gripping pins
7 Cleaning of ventilation duct
8 Cleaning of m/c cabinet

47 | P a g e
Machine: Dewatering Machine
1 Cleaning of softener application unit
2 Checking of rotating device of rotating trolley unit
3 Checking of pneumatic pressure valves
4 Checking and replacement (if necessary) of rubber pads of stretching unit
5 Checking of plaiting device
6 Checking of speed regulating unit
Machine: Compactor Machin
1 Checking of gas pressure and gas supply line
2 Dosing of softening chemicals to supply water
3 Checking of belt conveyor system
6 Checking and replacement (if necessary) of compacting shoe
7 Cleaning of compacting shoe
Machine: Tensionless Dryer
1 Checking of gas pipe lines
2 Checking of gas burners
3 Checking of belt conveyor system
6 Cleaning of ventilation duct
Machine: Boiler
1 Checking of gas pressure and gas supply line
2 Dosing of softening chemicals to supply water
3 Checking of all steam lines
4 Cleaning of burner tank (after six month interval)
5 Checking and replacement of valves

48 | P a g e
Maintenance Tools and Equipments:
Sl.
No.
Maintenance tools/equipments Functions
1 Adjustable wrench Used for setting nut & bolts
2 Pipe Spanner For pipe fitting
3 Spanner Fixed Spanner for nut & bolts fitting
4 Socket spanner Handle system for nut & bolt
fitting
5 Hammer To apply load where required
6 Screw driver To release any screw
7 Punch Used to fit any worn out shaft
8 Lock opener To open the clip of bearing
9 Hack saw To cut any metallic thing
10 Outside calipers To measure outside dia
11 Inside calipers To measure inside dia
12 Slide calipers To measure very small dia
13 Vernier scale To measure very small dia
14 Chain ton To lift heavy load
15 Welding machine To join metallic parts
16 Grinding machine To make the smooth fabrics
17 Tester To test electric circuit
18 Pliers To grip anything & cut anything
19 Avometer/Voltmeter To measure voltage
20 Steel tape To measure length, width &
height
21 Chisel To cut any metal
Remarks:
The maintenance department of Landmark Textile Mills Ltd. is well equipped. It has sufficient
maintenance manpower including mechanical and electrical engineers. They perform maintenance
tasks of the machines during the holidays and vacations. Otherwise, they perform breakdown
maintenance, which as stated earlier is very rare in Landmark Textile Mills Ltd. To increase the
lifetime of the machineries and ensure the proper running of the machines, the task of this department
is very important.

49 | P a g e
CHAPTER- VIII
UTILITY SERVICES

50 | P a g e
Utility Services Available:
Electricity
Gas
Water
Steam
Compressed air
Capacity & Other Technical Details:
Electricity-
The electricity is supplied form PDB from the national power grid. The electricity supplied is of
11,000 volts which is transformed into 440 volts using transformer of ‘ENERGYPAC’. But two
standby power generators are also kept to meet the need of electricity if necessary.
PARAMETER GENERATOR 1 GENERATOR 2
Company Musgrave Generators Ltd. Technol Power Generation
Origin England UK
Mfg. 2001 2003
Fuel Gas Driven Gas Driven
Power 500 KVA 720 KVA
Frame/Core HC.1544D1 HC.1634G1
KVA Base Rate 500 720
KW Base Rate 400 567
Hz. 50 50
RPM 1500 1500
Volts 400/230 380/220
Phase 3 3
PF 0.8 0.8
Rating Cont. Cont.
Ex. Volts 43 58
Ex. Amps 2.3 2.5
Ambient
Temp.
40C 40C
Insulation
Class
Class H Class H
Total power is then distributed as per requirements of different section of Landmark Textile Mills
Ltd. Gas - Gas is mainly used for steam production. The gas is supplied by TITAS GAS DISTRI
Water-
Continuous supply of water for different section of Landmark Textile
Mills Ltd. must be ensured by pump. In total six (6) pumps are used for water pick up.
TYPE OF
PUMP
NOS. CAPACITY SETUP
Submersible 2 # 100% open
Pressure 2 100% open
Centrifugal 2 100% open

51 | P a g e
Steam- Pure steam with required temperature must be produced to meet the
continuous demand of steam in different sections. There are two Fire tube type boilersused for steam
generation, to meet the requirement of different sections.
Specification of Boiler No. 1
Company-BIB COCHRAN LTD.
Origin-Scotland
Product type-Thermax
Year-2003
Capacity-9 ton/hr
Design pressure-11 Bar
Design temperature-188c
Supply voltage-400 V/ 3 phase / 50 hz
Specification of Boiler No. 2
Company-BIB COCHRAN LTD.
Origin-Scotland
Year-2001
Capacity-5 ton/hr
Design pressure-11 Bar
Design temperature-188c
Supply voltage-400 V/ 3 phase / 50 hz
Compressed Air-
The requirement of compressed air is fulfilled by air compressor m/c. In
this m/c, natural gas is drawn by pipe through the filter above the compressor & the air is compressed.
In such a case the air becomes slightly hot. Hence cold water is drawn to reduce the temperature of
compressed air. While doing so, the cold water becomes slightly hot & it is transferred through outlet
pipe to the overhead reservoir. There the vapors are condensed and outlets drop by drop. Then the
water is let to fall slowly through the reservoir to the compressed air to obtain moist compressed
air.The moist compressed air is transferred to the dryer & a slight warm compressed air is delivered
trequired sections of Landmark Textile Mills.

52 | P a g e
Specification of Compressor
ELECTRIC
220-230 V/ 50 Hz1.28 KW16 amp
REFRIGERANT
R 134A / 1, 35 KgPSL–16 bar
, PSH–20 bar
TSL–(-10)C , TSH-120C
COMPRESSED AIR
PS–16 barTSL-2C ,
TSH-60C
REFRIGERANT VESSEL
VOL–777 literPS–20 bar , TS-
120C
Module A cat.1
COMPRESSED AIR
VESSEL
VOL–191 literPS–16 bar
, TS-60C
Module A1 cat.11
REFRIGERANT TUBE
DN-16 mmPS–16 bar , TS-
60C
Module art. 3(3)
COMPRESSED AIR
TUBE
DN-PS– TS-
Module
Source of Utility:
Electricity : PDB & Gas Generator
Steam : Boiler
Water : Pump
Compressed air : Compressor
Gas : TITAS GAS DISTRIBUTION CO.
Cost of Different Utility:
We could not collect the cost of different utility from the industry due to official secrecy.
Remarks:
Utility services are the life-line of a production unit. In Landmark Textile Millstadt. the capacity of
the utility services is enough to meet the current demand. But as further expansion of production units
takes place, the capacity of the utility service will have to be increased.
COMPLETE UNIT
PED 97/23/ECTSL-2C ,
TSH-50C
Fluid Grp. 2Module A1 cat.11

53 | P a g e
CHAPTER–XI
MARKETING ACTIVITIES

54 | P a g e
Consumer of Products:
1. Textile Pressing Germany (TPG)
2. Amanda fashion (Indian buying house)–U.K.
3. Euro centre
4. Kafue hoff5. Gulden Pfenning6. Metro Sandra
Country of Export:
Holland
Germany
Italy
Finland
USA
Others
Local Market:
Landmark Textile Mills Ltd. is a 100% export oriented industry. But the dye-house of Landmark
Textile Mills Ltd. do take orders from several local companies onsub-contract basis when they are
free. These local companies are following.
Belkuchi Knit
Kist Design
Beq Knit
Marketing Strategy:
Marketing strategy is a very important factor to sale the products to the buyer. If he marketing
strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing the
dealings with the buyer is a very important factor.
In Landmark Textile Mills Ltd. mainly senior marketing officers, merchandiser &higher officials deal
with the buyer. There are some fixed buyers of the industry. These buyers give their orders
continuously all over the year. The marketing officers & the merchandisers communicate with the
buying houses to collect the orders.
By both side understanding the rate & the order quantity are fixed.
Duties & Responsibilities of Marketing Officer:
Dealing with the buyer & convincing the buyer is the main duty of marketingofficer. A marketing
officer also has some other duties. The main duties &responsibilities of a marketing officer are given
bellow-
To prepare cost sheet by dealing with the buyer.
To take different steps by discussing with the high officials & merchandisers.
To maintain a regular& good relationship between commercial officers &
merchandisers.
To maintain communication with the buyers and buying houses.
Communicate with better knowledge of the products.
Actually the responsibilities & duties of marketing officer begin from getting order of buyer & ends
after receiving payment by the buyer. So, he should be always smart, energetic & sincere.

55 | P a g e
Remarks:
Landmark Textile Mills Ltd. has an energetic and motivated marketing &merchandising team. They
are always in communication with the buyers. The marketing section also looks after the quality &
quantity requirement of the buyers.

56 | P a g e
CHAPTER–XII
ACRYLIC YARN DYEING

57 | P a g e
Introduction:
Now-a-days yarn dyeing is being very much popular as a means ofproducing raw material for woven
and knitted stripe fabric and sweaters. Landmarkgroup has developed a project for Acrylic Yarn
Dyeing to produce raw materials forsweater production in the year 2001. It’s a large project with
m/ccapacity of 1600 kgsand production per year is about 1400 tons. Here the Acrylic yarn is dyed in
hank dyeingsystem using cabinet type m/c.
Machine Description:
1. Batching or Bulking Unit
Brand : Made locally
Machine No : 01
2. Cabinet Dyeing M/C
Brand : Fong’s International Engineering Ltd
Origin : China
Machine No : Total 9 (nine) sets
Mode : Y-25, CY-100, CY-200, CY-450, CY-600, CY-
800
Capacity : 1600 kg
3. Hydro Extractor M/C
Brand : Tai Yat Industrial Extractor
Origin : Taiwan
Machine No. : 01
Capacity : 100kg
4. Hydro Extractor M/C
:
Brand : United Machinery Manufactures Co. Ltd
Origin : China
Machine No. : 2
Capacity : 100kg
5. Dyer
Brand : Fong’s International Engineering Ltd
Origin : China
Machine No. : 02
Capacity : 200kg

58 | P a g e
6 Packing M/c
Brand : Power Pack
Origin :
Machine No. : 01
Capacity :
Operating : Pneumatic Pressure Operated
Features of Dyeing Machines:
Dyeing is done by overflow method
.Yarn hank is kept on stick inside the cabinet.
Temperature can’t exceed 98C i.e. atmospheric pressure m/c.
Sampling device remains at every m/c where sample is separately joined befor
dyeing commences. So it is possible to check shed without stopping the machi
Liquor circulation is done flowing three times up and three times down.
All the machines have own control unit, which can be programmer according necessity
Manual dozing system i.e. dozing is not computer controlled.
Features of Acrylic Yarn Dyeing Process:
Bulking is necessary to assure better penetration of dye.
Basic dye (here Tai–acrylic dye) is use for acrylic yarn.
Dyeing is done in acidic condition (pH 4-5).
Retarder and leveling agent is used to maintain dyeing accuracy.
In this process retarder calculation is very important.
There is a constrain in selecting dye%. It depends on the retarder calculation
.Softener and washing chemical is used if required at the end of the dyeing process
.As dyeing is done above the Tg of Acrylic yarn, temperature gradient must be
maintained carefully. Special dyeing curve is followed very carefully with specifi temperature
gradient.
High migration is another special feature of this dyeing.
M:L is maintained at 1:25.
Process Flowchart:
Batching

Dyeing

Hydro extraction

Drying

Packaging

59 | P a g e
Process Description:
Batching
Application of steam for 15 minutes to make the Acrylic yarn (hankform) fluffy. This aids penetration
of the dye molecules.
Dyeing :
Chief ingredients in the recipe–
1. Basic Dye
2. Acetic Acid–To maintain pH of 4–5.5. Usually 0.7 gm/liter is used.
3. PAN–Retarder (Not used for deep shade as color may bleed e.g. black)
4. AN–Leveling agent. Usually 0.6% is used.
5. Taisoft SSK–Cationic Softener (Requires acidic medium). Usually 0.5%


Dye Percentage Constraint
–There is a constraint in selecting dye percentage. For example say a sample is
dyed with 0.04% Tai Red GTL, 0.0135% Tai Red 6BNT and 0.047% Tai
BlueRGN.Theyestuffsfvalue of 0.58, 0.75, 0.33 respectively. Say, the
amountofretar.8anthesaturativalueofretarderderusedis1is 0.6.Now,
(Amount of particular dyef value) + (Retarder amountSaturation value of retarder)= (0.040.58 +
0.01350.75 + 0.0470.33) + (1.80.6)
= 1.46
The calculated value is less than 1.8 which is the saturation value of acrylic fibre. If this value exceeds
the saturation value of fibre, then the recipe is incorrect.
Hydro Extraction : For Acrylic yarn one passage is given.
Drying : Drying is done at 80c-100c.
Topping : PAN is not used. Only 50% amount of AN is used with
required dye addition.
Stripping : The dyed Acrylic yarn can be stripped with treating the
material with NaClO3andoxalic acid at 98c for 15 minutes. Then the material is washed for 10
minutes.
Quality Standard:
Landmark Yarn Dyeing Ltd. follows ISO:9001 2000 standardization for quality product
manufacturing.

60 | P a g e
CHAPTER–XIII
CONCLUSION

61 | P a g e
Landmark Textile Mills Ltd. is a well-planned versatile project. The administrations, management,
chain of command– all are well organized. They are devoted to satisfy the customer with their
activities.
Landmark Textile Mills Ltd. has following excellent features, which are worth mentioning in this
conclusion. These are,
The dyeing process of Landmark Textile Mills Ltd. is very quick and accurate. It is amazing that
with only 3.5 ton machine capacity Landmark is capable of 10 ton production daily. Furthermore very
limited amount of re-dyeing is carried out in Landmark, which proves the excellence of the dye-
house.
Landmark Textile Mills Ltd. has a very good labor management policy, which enables the smooth
running of the production line.
The Dye-house is very clean with excellent working atmosphere due to plenty of air circulation
and planned layout.
Landmark Textile Mills Ltd. has following drawbacks,
There is no water treatment plan in Landmark Textile Mills Ltd. The water obtained from the
pump is directly flowed to the dyeing machine without any treatment.
Due to shortage of textile engineers, night shifts some time continue production without any
production officer. As a result in some cases quality level drops.
College of Textile Technology has given us the chance to perform the industry a attachment in
Landmark Textile Mills Ltd. This attachment, acts as a bridge to minimize the gap between theoretical
and practical knowledge. Undoubtedly, this attachment taught us more about textile technology,
industrial management and production process. Besides it gave us the first opportunity to work in an
industry. I believe that, the experience of this industrial attachment will help us in our future career as
textile technologist.

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