This is a assignment on washing factory visit. Factory Name modern Industrial washing Ltd. Factory Location 54, Box Nagar, Mirpur-1, Dhaka-1216, Bangladesh.
Objectives of Production Planning :
To determine capacity of all manufacturing departments and to plan systematically coordinated
To translate orders received from sales department into orders on the works department and to ensure steady plans of production activities.
To promote fuller utilization of plants.
To assist labor towards right and greater earnings.
To train staff in the effective performance of their duties
Objectives of Production Planning :
To determine capacity of all manufacturing departments and to plan systematically coordinated
To translate orders received from sales department into orders on the works department and to ensure steady plans of production activities.
To promote fuller utilization of plants.
To assist labor towards right and greater earnings.
To train staff in the effective performance of their duties
In the last two decades, spectacular progress has been made in the field of weaving technology and the most significant being the replacement of convectional looms by shuttleless looms for increasing productivity and quality of the end product. New developments in weaving have taken place in such a direction, which ensures reduced time, energy and cost involved. Heavy mechanical parts are now being replaced with electronic or microprocessor controlled alternatives.
Industrial attachment of Shohagpur Textile Mills Ltd. Subir Kar
Industrial attachment of Shohagpur Textile Mills Ltd. Its a Spinning based Industry. Every People of the industry is so much cooperative & kind hearted.
Calculation of standard minute value of T shirtAzmir Latif Beg
This research project is based on calculation of standard minute value of T-shirt. An experimental investigation for the distribution of SMV for each and every operation require for making a T-shirt and provides a clear and details concepts for determining line balancing, machine requirements, man power allocation for setting a definite target within a reasonable efficiency. This project is a details discussion and distribution of SMV which will assist to minimize SMV by having a better synchronization with man, machine, materials and methods to achieve higher efficiency.
Computer application in different sectors of textile technology
Research and development of materials and textile process
Computer-aided textile production and process control
Production planning
Process control
Quality control
Inventory control
Analysis of engineering data
Solution of engineering problems
Textile machine manufacturing
Automation of textile machines, equipment's and processes
Scope of Computer Based Technology for Textile Application:
Generally, there are three terms that are frequently used:
CAD (Computer-Aided Design)
CAM (Computer-Aided Manufacturing)
CIM (Computer Integrated Manufacturing)
Somemore is there like,
4.CAT (Computer-Aided Testing)
5.CAE (Computer-Aided Engineering
In the last two decades, spectacular progress has been made in the field of weaving technology and the most significant being the replacement of convectional looms by shuttleless looms for increasing productivity and quality of the end product. New developments in weaving have taken place in such a direction, which ensures reduced time, energy and cost involved. Heavy mechanical parts are now being replaced with electronic or microprocessor controlled alternatives.
Industrial attachment of Shohagpur Textile Mills Ltd. Subir Kar
Industrial attachment of Shohagpur Textile Mills Ltd. Its a Spinning based Industry. Every People of the industry is so much cooperative & kind hearted.
Calculation of standard minute value of T shirtAzmir Latif Beg
This research project is based on calculation of standard minute value of T-shirt. An experimental investigation for the distribution of SMV for each and every operation require for making a T-shirt and provides a clear and details concepts for determining line balancing, machine requirements, man power allocation for setting a definite target within a reasonable efficiency. This project is a details discussion and distribution of SMV which will assist to minimize SMV by having a better synchronization with man, machine, materials and methods to achieve higher efficiency.
Computer application in different sectors of textile technology
Research and development of materials and textile process
Computer-aided textile production and process control
Production planning
Process control
Quality control
Inventory control
Analysis of engineering data
Solution of engineering problems
Textile machine manufacturing
Automation of textile machines, equipment's and processes
Scope of Computer Based Technology for Textile Application:
Generally, there are three terms that are frequently used:
CAD (Computer-Aided Design)
CAM (Computer-Aided Manufacturing)
CIM (Computer Integrated Manufacturing)
Somemore is there like,
4.CAT (Computer-Aided Testing)
5.CAE (Computer-Aided Engineering
Firstly I collected some sewing faults fabric picture from the sewing floor, finishing floor and the inspection section of “GTA sports Ltd” to complete my project work. Then I separate the collected pictures of the faults in different categories so that I can analyze the sewing defects very effectively. After that I targeted to find out the real causes of these faults in the industrial area. Then I try to analyze them very effectively to find out the track of the source and tried how to solve those problems.
Knit Finishing in Arvind Ltd. bY Anupam Vowmic, created by Manojit Barman MANOJIT BARMAN
IN SUMMER TRAINING REPORT AT ARVIND LIMITED
IN KNITS FINISHING DIVISION
bY Anupam Vowmic,
created byManojit Barman
As part of our syllabus, I have undergone industrial training in Arvind Limited at KHATRAJ KNITS MARKETING DIVISION, from 01-07-2016 to 31-08-2016. First of all, I are very thankful to whole Arvind Group for providing me the best facility & good environment during the whole training period.
I would like to express our heartiest gratitude to Mr. Subhanish Malhotra (H.R. Manager) and Ms. Krupa Raval (HR) who granted us the permission to undergo training in such a prestigious organization. I am also very grateful to our instructors Mr. Kalyan Bhattacharyya (Head of Knits Marketing) and Mr. Hiren B. Patel (Manager) & Mr. Azaruddin Solanki who gave their valuable time, guidance and gave attention on us during our whole training period.
Finally I would like to thank all the mill employees for their cooperation and support without which it would not have been possible for us to make such an understanding about the different aspects. I am very happy to have attended this training because of the support every person of the department extended to us; they gave us a lot of information and knowledge about the machines.
I am also greatly indebted to the teachers of our institution, Prof. Swapan Kumar Ghosh (H.O.D.) and Prof. Debasish Das who helped in coordinating the program. I am very grateful to all our teachers at Institute of Jute Technology, Department of Jute and Fibre Technology, University of Calcutta who developed our knowledge and widened our view, instilled interest in the subject and encouraged us to undertake this training in a renowned industry even so far away from our University.
ANUPAM BHOWMICK
B.TECH. IN JUTE & FIBRE TECHNOLOGY
(7TH SEMESTER)
DEPARTMENT OF JUTE AND FIBRE TECHNOLOGY UNIVERSITY OF CALCUTTA
A wrinkle, also known as a rhytide, is a fold, ridge or crease in the cloth or garments. Wrinkle is a particular type of pressure in the finished fabric. It is produced during finishing operations by the thickness of the seam used to join pieces for processing.Resin & its use in Denim garments industry to create unique & vintage looks which add value to denim garments & improves it sale ability in market. In 80’s we have seen Resin being used to give non press , iron free trousers & now we are using in Denims to make wrinkles & creases to look natural vintage which stays after multiple home laundries.
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Washing Factory Visit At Modern Industrial Washing Ltd.
1. Faculty of Engineering
Department of Textile Engineering
ASSIGNMENT ON
Washing Factory Visit
At
Modern Industrial Washing Ltd.
Course Title: Apparel Manufacturing-III
Course Code: TE-417
Submitted To :
Md. Mominur Rahman
Assistant Professor
Department of TE
Daffodil International University
Submitted By :
Md. Aminur Rahman
ID: 163-23-4795
Kazi Tazbi UL Hasan
ID: 163-23-4822
Section: A
Department of TE
Daffodil International University
Date of Submission: 17-11-2019
2. ii
ACKNOWLEDGEMENT
At the beginning we would like to show our appreciation to Almighty Allah for giving us the
chance to fulfill our assignment.
Firstly, our special thanks go to Md. Mominur Rahman, Assistant Professor, Department of
Textile Engineering, Daffodil International University for his encouragement and valuable
suggestions. Who helped us in all the time for writing of this assignment. His scientific
curiosity, encouragement and guidance throw out this work have been important for this
assignment.
We would like to thank the management of the Modern Industrial Washing Ltd. For giving us
the opportunity to visit the washing factory and helping us for completing the assignment
successfully.
3. iii
EXECUTIVE SUMMARY
The factory visit is the most effective way for Textile Engineering student to be archived the
knowledge about the practical field of the Textile Manufacturing. It brings an opportunity to
all the learners to enrich their academic knowledge by practicing with the experts of the field
of textile.
Modern Industrial Washing Ltd. is one of the small washing garments manufacturers. They
have dry and wet process. Dry process is a mechanical process and wet process is a chemical
process. All the machine, equipment and chemicals used in different process. The factory
workers are well trained. They follow all the system for their machines maintenance so
production can not hamper.
In this assignment we have tried to give some information about Modern Industrial Washing
Ltd. and we observed they are produce good quality washing garments by following various
recognized method.
4. iv
Table of Contents
Acknowledgement…………………………………………………………………………...II
Executive Summary………………………………………………………………………...III
1. Introduction………………………………………………………………………………..1
2. Information about Factory………………………………………………………………..2
2.1 Owner…………………………........................................................................................2
2.2 Worker…………………………………………………………………………………...2
2.3 Space…………………………………………………………………………………….2
2.4 Group of Company………………………………………………………………………2
3. Description…………………………………………………………………………………3
3.1 Sample Section……………………………………………………………………………3
3.1.1 Layout…………………………………………………………………………………..3
3.1.2 Organogram…………………………………………………………………………….4
3.1.3 Operation in the Section………………………………………………………………..4
3.1.4 Machine Details………………………………………………………………………...5
3.2 Dry Process Section……………………………………………………………………….6
3.2.1 Layout of Dry process section………………………………………………………….6
3.2.2 Whiskering……………………………………………………………………………..7
3.2.3 PP Spray………………………………………………………………………………..7
3.2.4 Grinding………………………………………………………………………………...7
3.2.5 Destroy…………………………………………………………………………………8
3.2.6 Tagging…………………………………………………………………………………8
3.2.7 Wrinkle………………………………………………………………………………...8
3.2.8 Hand Scraping………………………………………………………………………….8
3.3 Chemical Section………………………………………………………………………….9
3.3.1 Washing chemicals……………………………………………………………………10
3.4 Wet Process Section……………………………………………………………………..12
3.4.1 Layout of Wet process section………………………………………………………..12
3.4.2 Normal Wash………………………………………………………………………….13
3.4.3 Enzyme Wash…………………………………………………………………………14
5. v
3.4.4 Bleach wash…………………………………………………………………………...15
3.4.5 Caustic Wash………………………………………………………………………….17
3.4.6 Acid Wash ……………………………………………………………………………19
3.4.7 Super White Wash…………………………………………………………………….21
3.4.8 Silicon Wash…………………………………………………………………………..23
3.4.9 Stone Enzyme Wash…………………………………………………………………..24
3.4.10 Boiler………………………………………………………………………………...26
3.4.11 Washing Machine……………………………………………………………………27
3.4.12 Hydro-Extractor……………………………………………………………………...27
3.4.13 Dryer………………………………………………………………………………....27
3.5 Quality Section…………………………………………………………………………...28
4. Impact of Visit……………………………………………………………………………28
4.1 Sample Section………………………………………………………………………….28
4.2 Dry Process Section……………………………………………………………………..28
4.3 Chemical Section………………………………………………………………………..28
4.4 Wet Process Section…………………………………………………………………….29
4.5 Quality Control Section…………………………………………………………………29
5. Conclusion………………………………………………………………………………...30
6. vi
List of Figure
Name of figure Page no
Fig 3.1: Layout of sample section 3
Fig 3.2: Boiler 5
Fig 3.3: Washing machine 5
Fig 3.4: Hydro-extractor 5
Fig 3.5: Dryer 5
Fig 3.6: Layout of dry process section 6
Fig 3.7: Whiskering 7
Fig 3.8: PP spray 7
Fig 3.9: Grinding 8
Fig 3.10: Destroy 8
Fig 3.11: Tagging 8
Fig 3.12: Wrinkle 9
Fig 3.13: Hand scraping 9
Fig 3.14: Chemical section 9
Fig 3.15: Layout of wet process section 11
Fig 3.16: Quality control section 28
8. 1
1. INTRODUCTION
Modern Industrial Washing Ltd is one of the local washing oriented industries in Bangladesh.
The main object of the company is to washing the garments. The washing capacity of the
company is 9000 pieces per day. They have local branded machines. They mainly wash denim
fabrics. Their skilled workers works hard that helps to give buyer all type of assurance and
guarantee for quality and shipment. Last week we visited this factory to make an industrial
assignment. In this assignment we are trying to introduce about this factory.
9. 2
2. INFORMATION ABOUT FACTORY
2.1 Owner
Dr. Mohammad Kamal
2.2 Worker
Total worker 120 (two shift)
2.3 Space
1800 square foot
2.4 Group of Company
Modern Industrial Washing Ltd. Savar, Dhaka.
13. 6
3.2 Dry Process Section
3.2.1 Layout of Dry process section
Fig 3.6 Layout of Dry process Section
PP Spray
Tagging Grinding Destroy
Whiskering
Wrinkle
Store
14. 7
3.2.2 Wishker
Whiskers are one of the most important designs of a used look garment. The idea of whiskers
is taken from the worn out lines and impression patterns generated by natural wearing on hips
and front thigh area. On old jeans, a number of patterns can be finding consequential to fabric,
body shape of user or sitting posture. It is also known as Cat's Whisker
Fig 3.7 Wishkering
3.2.3 PP Spray
PP Spray is being done on denim garments to achieve local abraded area to appear whiter than
back ground indigo color shade. This can be applied by sponges dipped in to PP Solution &
rubbed on desired area followed by neutralization in wet process. This process can be done in
rigid after doing hand scrape or in the middle of the wash. Doing after enzyme or bleach cycle
will give more natural & white effect that doing in rigid. There are many additives can be added
in order to achieve desired intensity and look.
Fig 3.8 PP Spray
3.2.4 Grinding
Grinding is being done on pocket edges & bottom hems edges by running against abrasion
surface or stone to achieve worn out effect. Many different make of machines & pen grinding
tools are available in the market which runs with pneumatic system.
15. 8
Fig 3.9 Grinding
3.2.5 Destroy
One of the most popular distressing effects currently, ‘Destruction’ is an art which make denim
look unique & used. To make destruction pen type of stone tools being used in mid of wash
process to apply on desired area. It can also be achieved by cutting it thru knife the warp yarns
& keep the weft yarn as is to show white thread. Holes also can be made by cutting weft &
warp yarn
Fig 3.10 Destroy
3.2.6 Tagging
Tacking is a process which is being done by swift tag machine with the help of plastic or nylon
tag pins in rigid form of garment to get very heavy contrast ( rigid & washed ) on waistband,
bottom hems, back pocket & front pocket corners etc.. After completing wash cycle, it must be
removed from garment before making softening.
Fig 3.11 Tagging
16. 9
3.2.7 Wrinkle
The process is kind of resin finishing process. In this process of applying resin on textile
material, resin form cross-linking inside the amorphous region and block the free hydroxyl
(OH) group and preventing hydrogen bond formation thus improve wrinkle free finishing.
Mainly it is applied on twill fabric, single jersey and denim fabric.
Fig 3.12 Wrinkle
3.2.8 Hand Scraping
To create the impression or visibility of pocketing fabric of any inside materials visibility to
the face side of the jeans pants with the help of emery paper is called hand scraping. Emery
paper comes in different number generally starts from 40 till 600 and above, higher the number
finer the emery paper, lower the coarseness of the paper. In garment industry from 220, 320 &
400 number papers are most popular & widely used.
Fig 3.13 Hand Scraping
3.3 Chemical Section
Fig 3.14 Chemical section
17. 10
3.3.1 Washing Chemicals
1. Enzyme: The action of enzyme during enzyme wash it hydrolysis the cellulose. At first it
attacks the having projecting fibers and hydrolyzed them. Then it attacks the yarn portion inside
fabric and party hydrolyzed the yarn portion. As a result color comes out from the yarn portion
and faded affect is produced.
2. Detergent: Chemical character is fatty alcohol polyglycol ether in an aqueous, glycolic
solution. Detergent is widely applicable in the continuous and discontinuous pretreatment of
all types of fiber and their blends. To remove impurities, mineral oil contamination and sizes
from the garments.
3. Acetic Acid: Acetic Acid is used to neutralize the garments from alkaline condition and to
control the pH value in wash bath.
4. Anti-stain: Anti-stain is used to prevent the staining on weft yarn of the denim (white yarn),
white pockets of garment, levels, and contacted fabrics of garment and increased the brightness
of fabrics; it is also acts as anti-creasing agent.
5. Bleaching powder: Bleaching powder is an oxidizing agent. It is used in washing plant for
color out from the denim garments. We can achieve deferent shade of color on garment i.e.
Dark, Medium, Light shade.
6. Sodium hyposulfite: Sodium hyposulphite is used to neutralize the garments from chlorine
bleach.
7. Caustic Soda: Caustic created the role in bleach technique without color change the garment
and has a good cleaning power. It is work as fading affect/old looking affect come rapidly on
garments.
8. Soda Ash: Soda ash creates alkaline medium for the breakdown of pigment dye. Soda ash
help to uniform bleaching action on bleach bath. It has a cleaning power and help color fading
effect of garment. It is used also for color fixing in dye bath.
9. Sodium Bicarbonate: Sodium bicarbonate is used in washing plant in the bleach bath with
bleaching powder for Denim Light shade because easily color out with in shot time. As a result
production increase and costing is low.
10. Potassium permanganate: Potassium permanganate is used in Acid wash with Punic stone
for color out from the garments. It is used also spray chamber by nozzle for colour out (whitish
affect) from the garments.
11. Flax softener: Softener is used to make the garments treated textiles a surface feel that is
both sickly and soft and also provides excellent lubricating properties.
12. Micro Emulsion Silicon: Amino Silicon is a textile finishing agent consisting mainly of
amino modified silicon. When applied on fabrics, it gives durable softness, lubricity, elastic
handle, anti-pilling, dimensional stability, tear resistance and fabric to be cut and sewn more
easily allows and improving wear and easy care properties.
13. Salt (sodium chloride): It helps to exhaust dye in to the fiber
18. 11
14. Buffer: Buffer is used in washing plant for pH control of enzyme bath, softener bath,
desizing bath.
15. Hydrogen peroxide: Hydrogen peroxide creates the prime role in bleach wash technique.
In alkaline medium, hydrogen peroxide breaks up and gives some perhydroxhyl ion, which
discolor the coloring materials and as a result fading affect is developed. Hydrogen peroxide is
used in scouring, bleaching bath for white/ready for dyeing of gray fabric garments. It is used
also neutralized the garment from alkaline condition.
16. Stabilizer: Hydrogen peroxide is work a good condition at temperature above 90°c, when
temperature raise to 90°c then break the Hydrogen peroxide. Stabilizer is used to protect break
the hydrogen peroxide and peroxide works in bath smoothly.
17. Fixing agent: Fixing agent is used for unfixed dye to fix on fabrics, when fabric color will
be proper fixing then color fastness & rubbing fastness will be increased.
18. Catanizer: Catanizer is used in pigment exhaust method processing. Pigment is color not
dyestuff. Pigment colors have no affinity to fabric when catanizer is used in fabric then increase
the affinity between pigment color & fabrics.
19. Optical Brightener: Two types of optical brightener are used in the washing plant –a) Red
brightener. b) Blue brightener. Mainly optical brightener is used for improve the brightness of
garments.
20. Resin: Resin is high efficiency textile resin based on etherified dimethylolglyoxalin
monoureineurea. Resin is used for the creation of semi-permanent creases in denim and other
cellulose fabrics. It is used also cotton and polyester fabric. Fabric retains soft handle after
washing.
21. Sodium Meta bi sulphite: Sodium meta-bi-sulphite is used in the washing plant to neutralize
the garment from potassium permanganate.
22. Desizing agent: Desizing agent is used to remove mainly starches, cmc, waxes, fats
pectin’s, minerals & unfixed indigo dye from denim, twills, poplin & canvas fabrics etc.
20. 13
3.4.2 Normal Wash
Process in which heavy or slight soiling is removed and transferred to the water in the form of
a solution or dispersion. Washing has the effect of cleaning surfaces. The resulting effect is
several physical/chemical processes (Washing process). Washing and cleaning constitute a
complex process, during which soiling is removed by means of physical separation, with or
without substance conversion, from a substrate. Industrial washing processes can be
categorized as solution washing, dispersion washing and reaction washing.
Objective:
1. To remove dust, dirt, oil spot, impurities from the garments.
2. To remove size materials from the garments.
3. To remove starch presents on the garment fabrics.
4. For soft feeling to wear the garments after purchasing.
5. To achieve buyer washing standard.
Recipe:
First Step: Desizing
Lot size: 70 kg Twill/Canvas Garment.
Add water @ L: R = 1: 8-10 ............560 --700 Liter.
Machine Running.
Add detergent 0.5 gm. / liter ............ 280-350 gm.
Temperature..... Sometime cold & sometime 40°c to 60°c.
Time: 5 to 10 min.
Drop the liquor and Cold wash.
Second Step: Softening
Add water @ L: R = 1: 6 ......... 420 liter.
Washing machine running
Add Flax softener 0.6 gm. / liter .......... 252 gm.
Add Acetic Acid 0.5 gm. / liter........... 210 gm.
Time................................... 5 to 10 min.
Drop the liquor. Unload the Garments on trolley.
Third Step: Hydro Extractor Machine
Hydro-extractor the garment to remove excess water from the Garment.
Fourth Step: Drying Steam Dryer / Gas Dryer.
Load on steam dryer -50 kg
21. 14
Temperature: 60°c -70°c
Time: 40 -50 min for dry.
Time: 10 -15 min for cold dry.
Fifth Step: Delivery
After drying it will be quality checking and good quality Garments will be delivery to
Garments factory.
3.4.3 Enzyme Wash
Enzyme wash is done on the garments made from heavy fabrics like jeans and denim. Cellulose
enzyme is used for this types of wash. These cellulose Enzyme hydrolyses the projecting hairy
cotton of the garment fabric surface and also removes color.
Objective:
1. To remove size material from the garments.
2. To achieve the buyer reference sample /washing standard.
3. Enzyme attack as chemically not mechanically for this reason low damage.
4. Enzyme improves anti-pilling properties
Recipe:
First Step: Desizing
Lot weight (80 pieces) ............ 60 kg denim long pant.
Add water @ L: R = 1: 9.............. 540 Liter
Machine Running.
Temperature.......................... 60°c.
Add Desizing agent: 0.6 gm. / liter ............ 324 gm.
Add Detergent: 0.8 gm. / liter.................... 432 gm.
Time...............................10--20 min.
Drop the liquor.
Wash 1 time by cold water.
Second Step: Enzyme
Add water @ L: R = 1: 8.............. 450 Liter
Temperature.......................... 45°c.
Add Acetic Acid: 0.6 gm. / liter ................... 270 gm.
Add Anti back staining: 0.6 gm. / liter........ 270 gm.
Add Acid Enzyme: 2.00 gm. / liter ................ 900 gm.
22. 15
Time: 40--60 min (Depend upon the shade).
Increase temperature to 90°c and run 1 minute (enzyme killing).
Drain the bath.
Rinse Twice, each 3 minutes.
Third Step: Softening
Add water @ L : R = 1 : 8 ..................... 450 Liter.
Add Acetic Acid: 0.6 gm. / liter ............ 270 gm.
Cationic Softener: 1 gm. / liter.............. 450 gm.
Temperature................................... Cold.
Time ................................................ 15 to 20 min.
Drain the bath. Then unload the garments on trolley.
Fourth Step: Hydro-extractor Machine
After unloading garments from the washing machine then they are sent to hydro-extractor
machine to remove excess water from the washed garments.
Fifth Step: Drying Machine
Load 60 kg garments to gas dryer.
Temperature set -75°c to 85°c.
Run about 40 min.
After then run 10 min in cold dryer.
Sixth Step: Delivery
After dryer, garment goes to quality section for quality checking and good one delivery.
3.4.4 Bleach Wash
Bleach wash or light stone wash refers to light blue shades of denim. The additional step is
bleaching to stone wash. This bleaching is usually carried out by strong oxidizing agents. In
industry, most widely used chemicals are sodium hypo-chlorite, calcium hypo-chlorite,
hydrogen per oxide and potassium permanganate.
Objective:
1. To produce fading affect or old looking effect on garment.
2. To remove size material from, starch from the garment.
3. For soft hand felling to wear the garment.
4. To achieve the buyer washing standard.
Recipe:
First Step: Pre-treatment/Desizing
23. 16
Batch size....................... 60 kg Denim Long Pant.
Add water @ L: R = 1: 9.............. 540 liters.
Start the machine.
Temperature.................... 60°c
Add Desizing agent: 0.6 gm. / liter ............ 324 gm.
Add Detergent / Anti-stain: 1 gm. / liter..... 540 gm.
Time................................ 15 to 25 min.
Drop the liquor.
Second Step: Hot Wash
Add water @ L: R = 1: 9.............. 540 liters.
Temperature....................................... 60°c.
Time................................................... 5 min.
Third Step: Bleaching
Add water @ L: R = 1: 8.............. 480 liters.
Machine running.
Add bleaching powder: 10 gm./liter.. 4800 gm.
Add soda ash @ 5 gm./liter ............................... 2400 gm.
Temperature............................................................ 60°c.
Time (Depend upon the shade).................... 12 to 15 min.
Drop the liquor.
Rinse twice, each 3 minutes.
Fourth Step: Neutral Wash
Add water @ L: R = 1: 9.......................... 540 liters.
Add sodium hyposulphite @ 3 gm./liter ....... 1620 gm.
Temperature ......................................................... 40°c.
Time (Depend upon the shade).............. 10 to 12 min.
Drop the liquor.
Rinse one.
Fifth Step: Soft Wash
Add water @ L: R = 1: 8.............. 480 liters.
24. 17
Add Acetic Acid @ 0.6 gm./liter ..................... 288 gm.
Cationic softener @ 1 gm./liter ........................ 480 gm.
Time................................ 5 min.
Drop the liquor.
Unload the garments to trolley.
Sixth Step: Hydro-extractor Machine
Hydro-extraction the garment to remove excess water from the washed garments.
Seventh Step: Drying Machine
Load 40 kg garments
Set temperature ................ 75°c to 85°c.
Time ......................... 35 to 40 min.
Time ..................... 10 minutes in cold dry.
Eighth Step: Delivery
After quality checking garment will be delivery.
3.4.5 Caustic Wash
Caustic Wash is one of the popular and mostly used process of Garment Washing. Caustic
wash is a treating a product with a solution of caustic soda to remove impurities. Caustic wash
generally doing on Reactive dye, Sulpher dye, Direct dyed or printed Garments.
Objective:
1. To fading/old looking effect on Garment and seam abrasion affection seam area.
2. To remove the size materials, starch from the garments.
3. Dust, dirt, oil spot, impurities etc. are removed that may come from during process i.e.
cutting, stitching and the back process.
4. To increase the color fastness & rubbing fastness.
5. For soft feeling to wear the garments.
6. To increase the hairiness on garments this increases its old look appearance.
7. To achieve the buyer reference sample.
Recipe:
First Step: Desizing
Lot size: - ...................... 80 kg.
Add water @ L: R = 1: 8.............. 640 Liter
Machine Running.
Add Caustic soda (NAOH)..... @ 1.60 gm. / liter........ 1024 gm.
25. 18
Add Detergent ........................ @ 0.8 gm. / liter ............ 512 gm.
Temperature........... 50°c to 60°c.
Time (Depend upon the shade) ....... 20 to 60 min.
Drop the liquor.
Wash cold water for 3 min.
Second Step: Neutral Wash
Add water @ L: R = 1: 5 ...................... 400 liter.
Add Acetic Acid @ 1 gm. / liter ............. 400 gm.
Time .......................................................... 5 min.
Here acetic acid is used to neutralize the garments from alkaline medium.
Third Step: Softening
Add water @ L: R = 1: 6.............. 480 Liter
Machine Running.
Add Acetic Acid @ 0.5 gm. / liter ............ 240 gm.
Add Flax softener @ 0.6 gm. / liter........... 288 gm.
If more soft use silicon @ 0.4 gm. / liter ... 192 gm.
Time................................ 10 to 20 min.
Drop the liquor.
Unload the garments on trolley.
Fourth Step: Hydro-extractor machine
Hydro-extraction is done to remove excess water from the Garment. Time required about 2- 4
minutes.
Fifth Step: Steam Dryer
Load on steam dryer - 50 kg
Running the machine
Temperature - 60°c - 70°c
Time - 40 - 50 min for dry.
Time - 10 - 15 min for cold dry.
Sixth Step: Delivery
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After drying garments go to quality section and check the garments, good quality garment
will be delivered and Deep shade again rewash, other quality Garments are rectified then
delivered.
3.4.6 Acid Wash
During Acid wash, pumice stones are used. By the action of pumice stones, irregular fading
affect is developed on the heavy garments like denims, thick canvas/twill, and sweater. The
pumic stones act a brushing action on the garment fabric surface. The area where more brushing
action takes place there more fading affect is developed and the area where less brushing action
takes place less brushing action and takes place less fading affect will be developed. The multi-
layer fabric areas like –collar, calf, pocket, placket, side seam etc. area will be brushed more
than the single layer areas. As a result irregular fading affect will be developed on the garments
fabric surface. Thus in this way fading affect may be developed on the garment by acid wash
technique.
Objective:
1. To produce irregular fading affects or old looking effect.
2. For soft feeling to wear the garments i.e. to improve softness.
3. To achieve the buyer washing standard.
4. To increase rubbing fastness.
Recipe:
First Step: Pretreatment/Desizing.
Add water @ L: R = 1: 10.............. 600 liters.
Start Machine.
Add desizing agent @ 1 gm./liter .................600 gm.
Add detergent @ 1 gm./liter ........................ 600 gm.
Temperature............................. 60°c.
Time........................... 20 min.
Drop the liquor.
Rinse one for 3 minutes (cold).
Second Step: Hot wash
Add water @ L: R = 1: 10.............. 600 liters.
Temperature............................. 60°c.
Time........................... 5 min.
Drop the liquor.
Here hot wash is used to remove the adhering materials from the garment surface.
Unload the garments from the washing m/c in the trolley.
27. 20
Load the pretreated garments in the dryer m/c.
Dry the garment completely & unload the garments.
The pumic stones used for acid wash need to pre-treat in the following chemical solution:
Water ..................... 100 L
Potassium permanganate.............. 1000 gm.
Phosphoric Acid............................... 250 gm.
Stire the solution in a stainless steel tub with dry pumic stone.
Soak the stones with the chemical solution ......... 10 –15 minutes.
The stones will pick up the solution. Then the soaked stones are dried in the open air
for.............. 2 to 3 hrs.
Then pre-treated garment 30 –40 kg per batch load in the dry washing machine.
Load the per-treated stones (about 50 kg) in washing machine.
Start machine running for each batch ........................ 7 to 10 min.
Stop machine running.
Unload the treated garment separately. Pumic stones with P.P. solution hit on garment surface
as a result fading will be developed.
Then load the stones treated garment in another washing machine.
Third Step: Wash for Cleaning
Batch wt................................ 70 kg.
Add water @ L: R = 1: 8.............. 560 liters.
Add detergent @ 1 gm./liter .............560 gm.
Temperature............................. 40°c -50°c.
Time ..................................10 min.
Drop the liquor.
Here detergent is used to remove the breaking stone dust and chemicals from the garment
surface.
Fourth Step: Whitening/Neutralization
Add water @ L: R = 1: 8.............. 560 liters.
Machine running.
Add Metabisulphite @ 5 gm./liter..... 2800 gm.
Cold temperature.
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Time 5 min.
Drop the liquor.
Fifth Step: Soft Wash
Add water @ L: R = 1: 7.............. 490 liters.
Machine running.
Add Acetic acid @ 0.6 gm./liter ..................... 294 gm.
Add Softener @ 1 gm./liter ........................ 490 gm.
Then unload the garments.
Sixth Step: Hydro Extractor Machine
Hydro extractor machine to remove excess water from the garments.
Seventh Step: Dryer Machine.
After hydro extraction the garments are sent to drying m/c for complete drying.
Eighth Step: Quality & Delivery.
After drying the garments go to quality checking & rectify washing fault and then good one
delivery.
3.4.7 SuperWhite Wash
Super white washing is a washing process which is carried out in mainly for increasing the
whiteness effects of a white fabric. Super white wash is done specially on the garments made
from cotton grey fabric. The garments after washing look extremely white. In this washing
mainly used chemical is optical brightening or whitening agent.
Objective:
1. To make white the garments.
2. To achieve the buyer washing standard.
3. For soft feeling to wear the garments.
4. To remove size materials from the garments.
Recipe:
First Step: Desizing
Batch size: 60 kg cotton grey fabrics
Water @ L:R: 1:8
Machine running
Temperature up to 90°C
Add detergent @2%(OWF)
Cold caustic soda@8% (OWF)
29. 22
Add Soda ash @ 5% (OWF)
Hydrogen per oxide @ 12% (OWF)
Stabilizer @ 5% (OWF)
Time: 70minutes
Drop the liquor
Second Step: Bleaching
Add detergent @1% (OWF)
Add Caustic soda @ 3-4% (OWF)
Hydrogen per oxide @ 6-8% (OWF)
Stabilizer @ 2% (OWF)
Time: 45-60 minutes
Temperature: 90°C
Third Step: Hot Wash
Temperature: 50°C-80°C
Time: 5-10 minutes
Drop the liquor
Fourth Step: Neutralization
Add Acetic acid @ 1%
Time: 5-10 minutes
Cold wash
Fifth Step: Brightening
Add optical brightener agent @ 0.5-0.6%
Time: 5-10 minutes
Sixth Step: Softening
Add softener @ 0.5-1%
Time: 5-10 minutes
Seventh Step: Hydro-extractor machine
After unloading garments from the washing machine then they are sent to hydroextractor
machine to remove excess water from the washed garments.
Eight Step: Drying machine
30. 23
Load 60kg garments to gas dryer
Machine running
Temperature: 75°C-85°C
Time: 40 minutes in hot dryer
After then run 10 minutes in cold dryer.
Ninth Step: Delivery
After dryer garment goes to quality section for quality checking and good on delivery.
3.4.8 SiliconWash
Silicon wash is an important and common wash in garment washing. Is also popular washing
process. Silicone wash can be applied on all types of fabrics such as Knit, Corduroy, Denim,
Canvas, Twill etc. This wash gives elastic handle, durable softness of garments. It helps to tear
resistance, anti-pilling affects, and dimensional stability of fabric. It also helps to fabrics to be
cut and sewn more easily. Process flowchart of silicon wash is given below.
Objective:
1. It gives durable softness, elastic handle.
2. It helps to anti-pilling affects, dimensional stability, and tear resistance.
3. It helps to fabrics to be cut and sewn more easily allows and improving wears and
easy care properties.
Recipe:
First Step: Desizing
Lot weight (Approx. 125 pieces) ............ 60 kg.
Add water @ L: R = 1: 10.............. 600 Liter
Machine Running.
Add Desizing agent @ 0.6 gm. / liter ............ 360 gm.
Add Detergent @ 0.5 gm. / liter.................... 300 gm.
Temperature.......................... 50°c.
Time...............................10-20 min.
Drop the liquor.
Rinse one time 3 minutes.
Second Step: Softening
Add water @ L : R = 1 : 8 .............. 480 Liters.
Add Acetic Acid @ 0.6 gm. / liter ............ 288 gm.
Cationic Softener @ 1 gm. / liter.............. 480 gm.
31. 24
Silicon (ME) @ 0.5 gm. / liter ................ 240 gm.
Temperature.......................... 40°c..
Time................................ 15 to 20 min.
Drain the bath.
Then unload the garments on trolley.
Third Step: Hydro-extractor Machine
After unloading garments from the washing machine then they are sent to hydro-extractor
machine to remove excess water from the washed garments.
Fourth Step: Drying Machine
Load 60 kg garments to gas/steam dryer.
Temperature set -75°c to 85°c.
Run about 35 to 45 min.
After run 10 to 15 minutes for cold dryer.
Fifth Step: Delivery
After dryer garment go to quality section for quality checking and then delivery.
3.4.9 Stone Enzyme Wash
Stone enzyme wash is done by using pumice stone and enzyme chemical. It is one of the
revolutionary developments in garments washing. Stone enzyme wash are three types such as
stone enzyme wash, medium stone enzyme wash and heavy stone enzyme wash. Garments or
apparel or clothing look like too much pretty after applying stone enzyme wash. As its
importance this article has shown the correct process flow chart for stone enzyme wash.
Objective:
1. To create irregular fading effect on old looking effect on garments.
2. To remove dust, dart, oil spot, impurities from the garments.
3. For soft feeling to wear the garments i.e. to improve softness.
4. To achieve the buyer washing standard.
5. To remove the size materials from the garments.
6. To improve anti-pilling properties.
Recipe:
First Step: Pretreatment/Desizing
Batch size....................... 60 kg Denim Long Pant.
Add water @ L: R = 1 : 9 ............................ 540 liters.
32. 25
Start the machine.
Temperature.................... 60°c
Add Desizing agent @ 0.6 gm. / liter................. 324 gm.
Add Detergent / Anti-stain @ 1 gm. / liter ......... 540 gm.
Time................................ 15 to 25 min.
Drop the liquor.
Second Step: Hot Wash
Add water @ L: R = 1: 9.............. 540 liters.
Temperature.................................... 60°c.
Time................................................. 5 mts.
Third Step:
Add water @ L : R = 1 : 8 .............. 480 liters.
Add pumic stone @ ½ vol of garments.
Add Enzyme @ 1.50 gm./liter ..................... 720 gm.
Add Acetic Acid @ 0.6 gm./liter .................. 288 gm.
Add Anti-stain @ 0.8 gm./liter ..................... 384 gm.
Temperature......................................... 40°c to 50°c
Time (Depend upon the shade) .......... 60 to 70 min.
Then temperature raise to 90°c for 1 minute.
Drop the liquor.
Rinse Twice, each 3 minutes.
Then pumic stone out from washing machine
Fourth Step: Bleaching
Add water @ L: R = 1: 8.............. 480 liters.
Machine running.
Add bleaching powder (k.c.i) @ 10 gm./liter ....4800 gm.
Add soda ash @ 5 gm./liter................................ 2400 gm.
Temperature........................................................... 60°c.
Time (Depend upon the shade) ..................... 12 to 15 min.
Drop the liquor.
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Rinse twice, each 3 minutes.
Fifth Step: Neutral Wash
Add water @ L: R = 1: 9 ............................ 540 liters.
Add sodium hyposulphite @ 3 gm./liter ....... 1620 gm.
Temperature..................................................... 40°c.
Time ............................................................. 10 to 12 min.
Drop the liquor.
Rinse one.
Sixth Step: Soft Wash
Add water @ L : R = 1 : 8 .............. ..............480 liter.
Add Acetic Acid @ 0.6 gm./liter ..................... 288 gm.
Cationic softener @ 1 gm./liter ........................ 480 gm.
Time................................ 5 min.
Drop the liquor.
Unload the garments to trolley.
Seventh Step: Hydro-extractor Machine
Hydro-extraction the garment to remove excess water from the washed garments.
Eighth Step: Drying Machine
Load 40 kg garments
Set temperature ................ 75°c to 85°c.
Time ......................... 35 to 40 min.
Time ..................... 10 minutes in cold dry.
Ninth Step: Delivery
After quality checking garment will be delivery.
3.4.10 Boiler
Boiler is an essential machine, which is used in dyeing & washing industries to produce steam
from water. It contains huge amount of water in it and convert those water in to steam to raise
temperature.
The equipment used for producing steam is called steam generator or boiler. The boiler used
for producing steam in IAL is Cochran boiler which is a fire tube type boiler. Simple vertical
boiler of fire tube type is mainly used in small plant requiring small quantity of steam and
where floor area is limited.
34. 27
Here, gas is fed to the burner which run by thermo motor and produce flame. The flame
produces hot flue gases, which pass through the tubes that are surrounded by water. This water
is supplied from the soft water tank to the feed water tank, which is situated above the boiler.
The heat energy of the flue gas is transfer to water which is converted into steam. This steam
is supplied to the whole plant. The spent gases are then discharged to the atmosphere through
chimney.
3.4.11 Washing Machine
The main function of garments washing machine is to remove the Starch and to make the
garments soft. If any dirt is generated in the fabric surface it can be removed by washing. It
gives garments new outlook.
Capacity: 100-120 pcs Long
250-350 pcs Short
Origin: Bangladesh
Use: Any kind of wash.
3.4.12 Hydro-Extractor
Hydro extractor is used to remove excessive water from the garments. Knitted fabrics should
not be squeezed in pressure mangles. Hydro extractor is used for such kind of fabrics to remove
excess water before go for drying. Hydro extraction is a batch process which works on
centrifuge principle. Fabrics put into the perforated case, made for copper or galvanized iron,
which is mounted on a central spindle and contained in steel or iron casing. When the perforated
casing rotates at high speed, a centrifugal force is developed which forces the wet fabrics to the
inner wall of the case. Water is then forced out from the fabrics through the perforation of the
casing. It is the best process for removing water giving the most efficiency.
Capacity: 100-120 pcs Long
250-350 pcs Short
Time: 15-25 min
Origin: Bangladesh
Use: Remove excess water of garments.
3.4.13 Dryer
After hydro extraction the garments are turned to drying machine for better drying. Dryer is
specially used for garments drying. Here the fabrics are dried at maximum relaxation state.
That’s why shrinkage and GSM can be controlled.
Capacity: 100-120 pcs Long
250-350 pcs Short
Time: 20-25
35. 28
Origin: Bangladesh
Use: Remove moisture from garments.
3.5 Quality Control Section
All the garments are checked here by maintaining buyers approved wash reference sample or
shade band. Quality is of prime importance in any aspect of business. Customers demand and
expect value for money. As producers of apparel there must be a constant endeavor to produce
work of good quality. In the quality control section the operator checking the product. If the
operator fined any defect in the product than try to rectification of the product by repair or
replace.
Fig 3.16 Quality Control section
4. IMPACT OF VISIT
4.1 Sample Section
Introduction with sample department.
Machine operating system.
4.2 Dry Process Section
We have learned about whiskering.
We have learned about Grinding.
We have learned about hand scraping.
We have learned about PP spray.
We have learned about destroy.
We have learned about tagging.
4.3 Chemical Section
36. 29
Introduction with different type of chemical.
Different chemical used in different process.
4.4 Wet Process Section
We have learned about normal wash.
We have learned about enzyme wash.
We have learned about bleach wash.
We have learned about acid wash.
We have learned about super white
We have learned about caustic wash.
4.4 Quality Section
How to find the defect.
How to check the product.
How to repair the product.
37. 30
5. CONCLUSION
Industrial visit provide the learning scope to enhance the curiosity of our knowledge to enter
into the practical life. Modern Industrial Washing Ltd is a good washing factory. They are well
equipped with all of the machines and the working environment is good. The relation between
top management to bottom level is so nice devoted to satisfy the customer demand by their
activities. From this industrial visit the details ideas about the industry environment, production
process, management process etc. We are lucky to get opportunity to having visit in this factory.
The factory run by skilled worker. They are very sincere, co-operative and helpful. At the end
of the day we realized that industrial visit make our knowledge’s application practically and
make us confident to face any problem of our job sector.
