Industrial attachment of reedisha knitex ltd.

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTReedisha Knitex Ltd

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CONTENTS

Topics Page no.

Acknowledgement……………………………………………………..2

Introduction………………………………………………………………3

Chapt-1: Project Description………………………………………….4

Chapt-2: Man-power management……………………………….. 10

Chapt-3: Machine Description………………………………………. 15

Chapt-4: Raw Materials……………………………………………….. 29

Chapt-5: Production Planning , Sequences & Operations…….. 33

Chapt-6: Quality Assurance System…………………………………56

Chapt-7: Maintenance………………………………………………...62

Chapt-8: Utility Services………………………………………………...65

Chapt-9: Store & Inventory Control………………………………….73

Chapt-10: Cost Analysis………………………………………………..76

Chapt-11: Marketing Activity………………………………………… 78

Chapt-12: Conclusion…………………………………………………. 81

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INTRODUCTION

Reedisha Knitex Limited. one of the countries leading knit composite factories. Thefactory is equipped with the latest facilities of modern time to meet up the global demandof knit garments. It is a 100% export oriented factory so quality is the first considerationabove all. After establishment it has made it reputation to such extent that it has got someof the finest buyer who depends on the quality of the product of this factory.

The list of buyers is a long one, that composed of ZARA, WALMART, H&M, KIABI,BENETTON, LIE & FUNG and many others. From the list of buyers we can certainly make anassumption of the quality they maintain.

The harmonically mix of man and machine and the boost of powerfulmanagement made this factory run so smoothly. The skilled and technical manpower anddevoted labor force made the factory a success.

With the quality of product the factory and management always feels the liabilitiesto the environment as well as to the public health, as a result effluent treatment andchemical used are very strictly maintained. As a result the factory got the CONFIDENCE INTEXTILE CHEMICAL and WRAP certification.

Considering all the above features to learn about technology of textilemanufacture as well as management to ensure such quality Reedisha Knitex Limited was agood choice. We feel very lucky to complete our industrial attachment with this mill.

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Chapter One

PROJECT DESCRIPTION

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PROJECT LOCATION

The project is located in Dhanua, Sreepur under the district of Gazipur, about50km distance from the intertnational airport Dhaka, Bangladesh. A well developed roadcommunication is there to reach the factory from the airport as well as from the Dhakacity. The head office of the project is located in the heart of the of Dhaka City in tejgaonindustrial area.

Location map:

Reedisha Knitex Ltd. Naynanpur, Dhanua, Shreepur

Mauna chaurasta

Gazipur National Park

Gazipur chaura sta

Zia internationalAirport

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PROJECT AT A GLANCE

Name of the mill : Reedisha Knitex Limited.Type : 100% export oriented knit compositeStatus : Private limited company.Year of establishment : 2003Location : Location map is attached.

Address:

Factory addressReedisha Knitex Ltd.Dhanua,Nayanpur,Gazipur.Tel : 01713-013126Fax: 01713-013127.

Head office:36 Shaheed Tajuddin Ahmed SaraniTejgaon Industrial Area , Dhaka-1208.Tel: 9897816, 9897817-20.Fax: 880-2-8826086.

Sponsor:

KOHINOOR GROUP of company LTD.

Product mix:a) Knitted grey fabrics : Plain single Jersey, Heavy jersey, Polo pique,

Lacoste, Rib & Interlock double jersey, Drop needle, 2/3 Thread fleece( Brushed/Unbrushed), Stripe fabric, French terry, Collar & cuff etc.

100% cotton, 15% viscose + 85% cotton,10% viscose + 90% cotton, 30%viscose + 70% cotton, 100% polyester, Spandex etc.

b) Knit Garments: T-shirt, polo shirt, sweat shirt, Golf shirt, cardigan, Joggingsuit, Short/ Trouser, Legging, Children wears & Fashion dress etc.

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Poduction capacity:

Production capacity : 12tons/day (Knitting).Production actual : 7-8tons/day.Production capacity : 15tons/day (dyeing).Actual Production : 13-14tons/day.Production capacity : 1600000 pcs/month(Garments)

Final product:

Long sleeve/ Short sleeve T-shirt, Polo shirt, Ladies wear, Sports Wear, Tank tops, Kids wear,Trouser, Pants, Jacket, Children Wear etc.

Project area:

25 acre(land premises), 415000sqft(Industrial building area)

Total manpower at a glance:

1800(Technical&professional)

Different departments:

1.Production oriented department :

Knitting.Batching.Dyeing lab.Dyeing floor.Chemical house.Finishing.Quality control.Finished ware house.Maintenance.Utility.

2. Supporting department :

Procurement. Marketing. HRD. Finance & accounting.Personnel administration. Security.

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Physical infrastructure:

Physical infrastructure of REEDISHA KNITEX LTD. is a simple one. It is fabricated by steelstructure, somewhere it is R.C.C & brick wall structure.

Building wise location list :

Slno.

Name of building Name of floor Name of unit

01. UtilitySingle storied building40,000 sqft

05 generators, 02 boilers, 05compressor and others

02.Dyeing Single storied building

70,000 sqftDyeing, chemical store andlaboratory

03.Knitting 90,000 sqft 03storied buliding

Ground floor Circular knitting and greyfabric store

1st floor(master unit) Cutting, sewing , finishingand quality

2nd floor Sample section, accessoriesstore and finished cartoon

04.Security building 6,000sqft 03 storied buliding

Ground floor Security officer and visitorsroom

1st floor Mens prayer hall and securityofficer rest room

2nd floor Officers mess

05.Adminstrative building9,000 sqft

Ground floor Admin and store office

1st floor Directors chamber

2nd floor Conference room and resthouse

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3rd and 4th floor Officers dormitory

06.Warehouse 02 storiedbuilding 22,000 sqft

Ground floor General engineer and fabricstore

1st floor Fabric and Ex fabric store

07.Garments building 07storied building 1,89,000sqft

Ground floor Embroidery and chemicalstore

1st to 5th floor Separate an completegarments unit

6th floor Workers dining and canteen

Finished cartoon store,training room, women’sprayer hall

08.Shed building-08, 12,00sqft

Printing shed Printing section

09.Shed Building-09 Wastage godown

10.Shed Building-10 Security forces rest room

11.Shed Building-11 ETP building

12.Shed Building-12 Day care centre

Remarks:Reedisha Knitex Ltd. is a member concern of Kohinoor Group of companies, a leadinghouse & Commerce in Bangladesh,having printing & packaging Industry, papermanufacturing unit,country wide network of color film processing laboratory units,representing world famous Fuji color Film products, personal,hygiene productsmanufacturing & real estate development etc.

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Chapter Two

MAN-POWER MANAGEMENT

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ORGANOGRAMS

Adminstration:

Chairman & Managing Director

Director Finance Executive Director

Deputy generalmanager

Generalmanager

Manager

Executiveofficer

Adminstrativeofficer

Computersection

Store Time section Transportsection

Security section

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Production:

Finance:

A.G.M (Dyeing) A.G.M (Knitting)

General Manager(Dyeing)

Dyeing Manager

Senior Production officer

Production officer

Senior Production officer

Production officer

Director Finance

Manager(Commercial)

Accountsofficer

Purchaseofficer

Import officer Export officer

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Management system:

The company has skilled administration, management and marketing team guided byproficient, dexterous & experienced leaders to offer right solution for the consumers withthe right eminence & with the shortest lead-time for the export market in Bangladesh.

The best use of continuous development of Human Resources by providing themInternational standard environment & equal opportunity is the keys for achievingcomprehensive competence in all level of the organizational Hierarchy.

Shift change

3 shift per day.

a) Day shift : from 8 A.M.-3 P.M.b) Afternoon shift : from 3 P.M – 11P.Mc) Night shift : from 11P.M.-8 A.M.

Shift is changed for each employee in the production floor after every 7 days.

Responsibilities of production officer:

1. To give dye-line or the programme slip according to daily production plan.2.Batch preparation and Ph check.3.Control of supervisor, operator, asst.operator & helper of dyeing floor.4.To match shade in connection with fabric quality.5.To find out fabric fault as early as possible.6.To rectify the finished fabric which rejected from quality controldepartment.7.To check daily production report.8.To study dye & chemicals nature delivery by the manufacture and apply them correctlyto the production to get best product.

Job description:

Title : Production officer.Dept./section : Dyeing.Report to : Sr.Production officer.Job summary : To plan, execute & follow up the production activities & control

the quality production with related activities.

Title : Sr.Production officer.Dept./section : Dyeing.Report to : Dyeing manager.Job summary : To plan ,execute & follow up the production activities & control the

quality production with related activities.

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Technical personnel in dyeing floor:

In total there are 13 textile engineers in the dyeing floor. The posts they areoccupying are mentioned below

01. General Manager02. Asst. General Manager03. Manager(2 posts)04. Senior Production Officer(5 posts)05. Production Officer(4 posts)

Remarks:

In this dyeing plant all the P.O , S.P.O & P.M. are technical person. Thats why, efficiency ofthis section is very high.

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Chapter Three

MACHINE DESCRIPTION

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FLOOR LAYOUT

Reedisha Knitex Limited. at first started the project with only a dyeing floor with 14 dyeingmachine and one finishing line only. With the extending demand for their quality fabricproducts all around the world there was a need for expanding their available capacity.

From this thought a new floor of atmospheric pressure dyeing machine floor wasdeveloped. Both these floors are running in full swing to give the most of the production itcan handle.

Reedisha Knitex Limited. is equipped with the worlds most advanced dyeing and finishingequipments. Among them the worth to be mentioned are the world famous brand nameslike the “Thies”, “Fong’s”, “Dilmenler”, “Monforts”.

The machines are all set according to a definite plan to increase the productivity. Thelayout plans are done by very professional and skilled persons.

To understand the machinery functions it’s very important to know their location in thenfactory. For this purpose the layout of two floors are given in the following section.

Layout description of old floor:

01. Maintenance department

02. Dilmenler Dyeing m/c


04. Fong’s Dyeing m/c



07. Thies Dyeing m/c





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16. Color kitchen

17. Manager’s room

18. Batch section

19. Slitting machine

20. L.K & L.H Stenter

21. Ferraro compactor

22. Fabric inspection table

23. Q. C department

24. Toptex dryer

25. Monforts stenter

26. Montex compactor

Lay out description of new floor:

1. Toilet zone







8. Atta sample dyeing m/c

9. Atta sample dyeing m/c

10. Bianco squeezer

11. Enzyme room

12. Dilmenler dryer

13. Tubetex

14. Inspection table

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MACHINERIES AT A GLANCE

Total machineries:

Department Total no. of m/c M/c Type No. of m/c

Batching 02 Turning m/c 02

Grey inspection 02 Grey inspection m/c 02

Dyeing 22 Winch m/c 08

Finishing 08 Hydro extractor m/c 01

Open Squeezer 01

Slitting m/c 01

Open Compactor 01

Tube Compactor 01

Dryer 02

Padder 01

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Machineries of Dyeing(Old floor):

M/c sl. no. Name Brand Make Capacity(Kg)

01 Sample dyeing m/c Dilmenler Turkey 25


03 Sample dyeing m/c Fong’s Hong kong 10

04 Sample dyeing m/c Fong’s Hong kong 60


06 Sample dyeing m/c Thies Germany 50

07 Winch Dilmenler Turkey 150

08 Winch Fong’s Hong kong 250

09 Winch Thies Germany 250





14 Winch Fong’s Hong kong 1500

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Machineries of dyeing (New Floor):

M/c Sl. No. Name Brand Make Capacity(kg)01 Sample

Dyeingm/cAtta Taiwan 10

02 Sample dyeingm/c

Atta Taiwan 10

03 Winch Dilmenler Turkey 15004 Winch Dilmenler Turkey 30005 Winch Dilmenler Turkey 30006 Winch Dilmenler Turkey 45007 Winch Dilmenler Turkey 60008 Winch Dilmenler Turkey 900

Machineries of Finishing:

Main parts of a dyeing machine:

1. Kier.(Dye-bath)2. Heat exchanger.3. Filter.4. Hot water reserver.5. Addition tank.

SL. No Name Brand Make01 Hydro extractor Bangla Local02 Slitting m/c Bianco Italy03 Open squeezer m/c Bianco Germany04 Padder m/c Bianco Italy05 Dryer Monforts Germany06 Tensionless dryer Dilmenler Turkey07 Open compactor Monforts Germany08 Tube compactor Tube-tex U.S.A

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MACHINE SPECIFICATION

Machine number: 01Machine function: Dyeing (HT)Machine brand: DilmenlerMachine capacity: 25kgCountry of origin: Turkey

Machine number: 02Machine function: Dyeing (HT)Machine brand: DilmenlerMachine capacity: 25kgCountry of origin: Turkey

Machine number: 03Machine function: Dyeing(HT)Machine brand: Fong’sMachine capacity: 10kgCountry of origin: Hong Kong

Machine number: 04Machine function: Dyeing(HT)Machine brand: Fong’sMachine capacity: 60kgCountry of origin: Hong Kong

Machine number:05Machine function: Dyeing (HT)Machine brand: DilmenlerMachine capacity:25kgCountry of origin: Turkey

Machine number: 06Machine function: Dyeing(HT)Machine brand: ThiesMachine capacity: 50kgCountry of origin: Germany

Machine number:07Machine function: Dyeing (HT)Machine brand: DilmenlerMachine capacity: 150kgCountry of origin: Turkey

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Machine number:08Machine function: Dyeing (HT)Machine brand: Fong’sMachine capacity: 250kgCountry of origin: Hong Kong

Machine number:09Machine function: Dyeing (HT)Machine brand: ThiesMachine capacity: 250kgCountry of origin:Germany

Machine number:10Machine function: Dyeing (HT)Machine brand: ThiesMachine capacity: 500kgCountry of origin: Germany

Machine number: 11Machine function: Dyeing (HT)Machine brand: ThiesMachine capacity:500kgCountry of origin:Germany

Machine number:12Machine function:Dyeing(HT)Machine brand: ThiesMachine capacity: 750kgCountry of origin: Germany

Machine number: 13Machine function: Dyeing(HT)Machine brand: ThiesMachine capacity:1000kgCountry of origin: Germany

Machine number:14Machine function: Dyeing(HT)Machine brand: Fong’sMachine capacity: 1500kgCountry of origin: Hong Kong

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Dyeing machine features:

M/Cno

Brand Capacity(Kg)

Minimumliquorreqd.

Additiontankcapacity(LT.)

Reserve tankcapacity(LT.)

Winchspeed

Pumpspeed

01 Dilmenler 25 160 40 - 100 90

02 Dilmenler 25 160 40 - 100 90

03 Fong’s 10 80 15 - 100 90

04 Fong’s 60 200 50 - 150 90

05 Dilmenler 25 160 40 - 130 90

06 Thies 50 180 30 - 150 90

07 Dilmenler 150 500 150,150 900 230 80

08 Fong’s 250 800 80,150 1500 250 80

09 Thies 250 800 130 2000 250+ 80

10 Thies 500 1600 250 3100 250 80

11 Thies 500 1600 250 3100 250 80

12 Thies 750 2500 500 5000 250 85

13 Thies 1000 3500 500 6000 250 85

14 Fong’s 1500 6000 450,900 8000 300 80

Specification of finishing machineries:

01.Hydroextractor m/c

Model : Local.R.P.M : 250-300.sYear of made : 2003.Extraction% : 60%(apprx.)

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02.Slitting m/c

Brand : BIANCOCapacity : 12,000kg/dayCountry of origin : Italy

Function:

1.To cut the tubular fabric for opening.2.Rubber pressure roller removes a slight amount of water.

Utility used:

Electricity.

Controlling points:

- Maximum slitting speed is 92 m/min.-For single jersey fabric slitting speed is maintained as 90m/min.-For rib fabric slitting speed is maintained as 60-70m/min.-Production capacity is10 tons/day.

03. Squeezer(Tube form):

Brand :BiancoCapacity :8,000 kg/dayCountry of origin : Italy

Main parts:

-Squeeze roller(dewatering)-Over feeding roller(to delivers as per feed)-Folding device(to delivers the fabric in folded form)-Softener tray.(to impart soft finish)

Utilities used:Electricity.Compressed air.

Padder pressure:5-7 bar.

Pressure of 2nd padding zone:Enzyme wash fabric: 1 bar.1x1 Rib or Interlock: 2 bar.

Main parts :-Revolving platform.-J-box squeezer.

Application of softener :In the 2nd padding zone chemicals are applied when fabrics are seems to be hard.

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Maximum line speed:80 m/min.

Chemicals used:Detergent, Anti creasing aagent, Softener.

Pressure of 1st padding zone:Enzyme wash fabric

Controlling of diameter:Dia is controlled by stretcher & maximum 2-3 inch width can be increased.

05.Dryer

There are two dryers are available for the finishing purpose of the knit fabric.

01.Brand : Montex(MONFORTS)Capacity :10,000 kg/dayCountry of origin : Germany

02.Brand : DilmenlerCapacity :10,000 kg/dayCountry of origin : TurkeyFunction:

To dry the fabric properly.To dry the fabric without tension.

Main parts:

1.Heat chamber.2.Burner.3.Blower.4.Exhaust fan.5.Synthetic blanket.6.Folding device.

Heating system:Gas fired(Monforts), Steam(Dilmenler).

Utility used:-Gas-Electricity-Compressed air-Steam

Air pressure:4 bar (avg)

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Maximum line speed:60 m/min.

Setting according to fabric construction:

Fabric type Speed (m/min) Temperature(C) Overfeedspeed(%)

Single jersey 15 140 20

Interlock 10 140 25-30

Rib 10 140 15-20

T/C,P/C,Viscose 20-23 130 40-45

Lacoste 30 140 40-45

Collar 20 140 40-45

Lycra fabric 17 130 45-50

O6.Tube Compactor :

Brand : Tube TexCapacity :8,000 kg/dayCountry of origin : U.S.A

Maximum line speed:100 m/min

Maximum dia:62".

G.S.M :Maximum 20% increase after compacting.

Shrinkage:±5%(max)

M/c temperature:95ºC

Production capacity:8 tons per day.

Main function:1.Dia control2.G.S.M. controlling3.Shrinkage removing

Utility used:

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-Gas.-Electricity.-Steam.

Sensor position:-On the stretcher.-After compacting unit.-On the conveyor.-Delivery position.

07.Stenter m/c:

There are two stenter machines are available.

01.Brand :MonfortsCapacity :10,000 kg/dayCountry of origin : Germany

02.Brand : LK & LHCapacity :10,000 kg/dayCountry of origin :Taiwan

Features:

-Heat setting is available only for Lycra fabric.-Width is set in such a way so that it gives the required GSM & shrinkage.-Suitable for open compactor.-Course and wales become align and even distribution by Mahlo in the feed side.-Bowing of fabric become straight.-4 burner,4 chamber,8 blower.-In case of heavy fabric temp 210C and for light fabric it is 180-190C .-Maximum width is not used because pin penetration is difficult and chains are locked.-Over feed speed is maintained as per delivery speed so that it can give the desiredquality.-Temperature control depends on shade condition.-In every chamber fabric width should be same.

Controlling points:1.Fabric speed.2.Fabric width,3.Temperature.4.Over feeding speed.

Utility used:1.Gas2.Electricity.3.Steam.

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Settings:

Fabric type Over feeding (%) Temperature (C) Speed (m/min)Single jersey Max.50% 140-150 20-30

Rib Max.50% 180 20-30Interlock Max.50% 160 20-30Lacost Max.50% 180 20-30

T.C Max.50% 190 20-30Pique Max.50% 140-150 20-30

**For heat-setting overfeed% is kept 20%.**For heat-setting temp. is kept 180-185ºC.**Overfeed % Fabric tension Shrinkage GSM.

08. Open compactor :

There are two compactors available to finish wide range of knit fabrics.01.Brand : Toptex(MONFORTS)Capacity :8,000 kg/dayCountry of origin : Germany

02.Brand : FerraoroCapacity :8,000 kg/dayCountry :Italiy

Functions:1.To impart dimensional stability.2.To obtain required width and G.S.M.

Main parts:-Heated cylinder(steam)-Steaming device.-Blanket.-Teflon roller.-Sensor.Overfeed %: upto 50%.Steam pressure: 5-6 bar.

Remarks:All the machineries are of state of the art technology so the quality of product is naturallythe best.

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Chapter Four

RAW MATERIALS

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RAW MATERIALS USED

To run the production smoothly raw material is a unparallel substances in a oriented textileindustry .Materials that goes into final products i.e. raw materials can be categorized asfollows:

-Grey fabric.-Dye-stuffs.-Chemicals & auxiliaries.

Fabric used:

Different types of knitted fabrics are dyed in the dyeing floor according to the buyer’srequirements. In the knitting floor fabrics are knitted on specific machines according todesign. Then passing the batching section the fabrics come to the dyeing floor. The type offabrics dyed in the floor is mentioned below:

Types:-Single jersey.-Lycra single jersey.-Interlock.-Double jersey.-Polo pique.-Melange.-Rib-Fleece fabric.-Auto-stripper.-Single & Double lacost.

Dye-stuffs Used:

Different dyes of different brands and tones are used to produce a specific color. There is acomprehensive list of used dyestuffs are given below:

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Sl no. Name of dyes used01. Kirazol BlackB02. Kiractive BlackB03. Chemifix Blue F2R04. Kiractive G. Yellow MERL05. Kiractive Red ME6BL06. Bezactive Red S2B07. Bezactive Blue SFR08. Drimarine Blue CL5B09. Drimarine G.Yellow K2R10. Dromarine Turquoise K2B11. Remazol Red RR12. Remazol Blue RR13. Remazol Yellow RR14. Imcozin Yellow V4GL15. Imcozin Blue ERL16. Disperse Yellow 4G17. Disperse Yellow F5GL18. Kiractive Red ME5BL19. Bezactive Cosmos-S-MAX20. Drimarine Navy CL-GN

Chemicals used:

Different types of chemicals and auxiliaries are used. A comprehensive chart is givenbelow:

Sl. no Name of chemical usedBasic chemicals

1. Acetic acid(India)2. Acetic acid(China)3. Acetic acid(Thailand)4. Neutracid NVM 2005. Soda Ash6. Hydrogen Peroxide 50%7. Caustic Soda

Salt or Electrolyte1. Salt(Common)2. Salt(Gluber )Taiwan3. Salt(Gluber) China

Detergent and Scouring Agent1. Sandoclean PCLF Paste2. Felosan NOF/NG

Anti foaming Agent1. Anitmussol HTS

Anticreasing Agent

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1. Premazol JET2. Setavin ECS3. Lubatex ECS

Peroxide Stabilizer1. Stabilizer SOF

Sequestarent and stabilizer1. Sirrix 2UD2. Optavon 4UD

Washing Agent1. Reactive W2. Claracup S

Reactive fixing Agent1. Cibafix ECO2. Gemfix RNK3. Permafix RDX

Reducing Agent1. Hydrosulphite/Hydrose

Enzyme finishing Agent1. Biopolish AL2. Epy Ace Olive x3. Retrocel PLX

Optical brightener for cotton1. Cyno white 4BK2. Lucophor BMB3. Cyno white BYB

Softener weak (Cationic or non-ioninc)1. Alcaamine CWS2. Sapamine CWS3. Crosoft NBC pearl-CWS4. Tubingal 1112

Softener non-ionic(Silicon)1. Adasil SM/19132. Adasil ME

Dyebath leveling Agent1. Gemsol SQD2. Secho SQD

Remarks:

The annual requirement was not determined because the project’s age was not a year atthe time of our training. Annual requirement of dyes & chemical depend on the order ofproduction .But for various reasons such as improper weighting, carelessness of operators,hydrolysis of dyes, uneven process control, wrong recipe formulation, incorrect batching,improper storage facilities& for different unwanted expenditure , extra dye consumptionincreased dye & chemical requirement.

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Chapter Five

PRODUCTION PLANNING,SEQUENCES & OPERATIONS.

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FLOW PROCESS OF PRODUCTION

Tube form Open form

Grey fabric inspection

Batching

Pretreatment

Dyeing

Dewatering

Dring

Compacting

Inspection

Packing

Delivery

Slitting

Drying

Stentering

Compacting

Inspection

Packing

Delivery

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PRODUCTION PROCESSES

Production parameters:

Process Temp. (C) P H Time(min) M:L ratioScouring-bleaching

100 10.5 30 1:8

Enzyme wash 5070

5 3010

1:8

Reactivedyeing light

shade

60 10.5 60 1:6

Reactivedyeing med. to

dark shade

60-65 10.5 60 1:6

Turquise colordyeing

70-80 10.5 90 1:6

Polyesterstripping

90 4.5 30-45 1:8

Cottonstripping

100 11 30 1:8

Polyesterdyeing

130 4.5-5.5 60 1:8

Cottonwhitening

100 30 1:6

BATCHING:

Batching instruments:-weight m/c.-Turner m/c.-Sewing m/c.-Trolley.

Must be checked in a batching card:-Order no.-Buyer’s name.-M/c no. for each batch.-Lot no.

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-Turning requirements.-Length of fabric in each tube should be same.

Process description :Batch preparation is the process where visually inspected grey fabric are divided intodifferent batches with reasonable quantity in order to make them suitable for dyeingoperation. For fabric dyeing batching is very important. Fabric is weighted according tom/c capacity. So that equal amount of fabric is passed through each nozzle of the m/c.for batching it is important-

To make a batch (body, cuff, collar, rib) from the same raw material. Accurately weighted for correct recipe formulation to avoid dye & chemical

wastage.

SCOURING & BLEACHING:

-Scouring-bleaching is carried out in the same bath and at the same time simultaneously.-Bleaching is not carried out for black shade.-Scouring is carried out for every type of shade.

Scouring-Bleaching chemicals:

Procedure of Scouring-Bleaching process:

1. Firstly the fabric is load on to the bath.2. Required amount of water is taken to the bath.3. Wetting agent i.e.NOF, & anticreasing agent i.e.ECS is added.4. Steam pipes are on & scouring agents (i.e., caustic soda/soda ash) added by the

aid of dosing when the temperature reaches at 60C.5. When the temperature reaches at 60C, then stabilizer is added.6. Then H202 is added by the aid of dosing system in 10 mins in 70ºCand the material is

run for 10-15 mins to reach the temp. 100C.7. Temperature is then raised to 100C & the process is then carried out for 60 mins

depending on the requirements.8. The liquors are the drained at 75C at 1.5 grade.

Agent BrandWetting agent Felosan NOF/NG

Alkali Caustic sodaAnt creasing agent Lubatex ECS

Bleaching agent H 2 O 2

Stabilizer Optavon 4UDAcid Acetic acid

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60 min100C

5 min70C

ECS

H202

50C

NOF Caustic Stabilizer

Curve: SCOURING-BLEACHING .

Procedure of Hot wash:

1.Water is taken to the bath from hot water reserver.2.Steam inlet pipes are on for heating dye-bath to 90C3.Material is run for 10-15 mins. & cooling start & at 75C the bath is drained.

Procedure for Acid –Wash:1.Again new water is taken from hot water reserver.2.At 60C acid is dosed & run for 15 mins. Then the fabric is rinsed about 5 mins & then bathis dropped.

ENZYME WASH:

Objects:

٠ To remove hairiness from the material.٠ This treatment can be done before dyeing & after dyeing. Sometimes double enzymetreatment occurs if buyer wants.٠ The fabric knitted with carded yarn always requires enzyme wash for obtaining combedeffect by biopolishing. This process is very sensitive to PH (4-5) & temperature.

Chemical used:Biopolish-AL(1 g/l)

70C x10´Curve(Enzyme wash):

55C x 60´5´

drain

Ph check Enzyme dosing

Process:1.Firstly the Ph of the liquor should be checked & it should be within 4 to 5 .2.Dosing of enzyme in 5 mins.3.The material runs at 55C for 60 mins. & at 70C for 10 mins.

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DYEING:Dyeing process that is practiced in Reedisha Knitex Ltd. can be described as following:

Cotton Dyeing:Cotton dyeing is the main concern of the factory, mainly cotton dyeing is done in thefactory very frequently. Enormous no of different color shades are matched everyday.Some of the most frequent color names are mentioned below:

Deep shade: Navy, Red, Black, Green, etc.Medium shade: Khaki, Yellow, Blue, Orange, Olive, Royal, etc.Light shade: Sand, Beige, Stone, Pink, Rose, Purple, Rose petal, etc.Sensitive shade: Red, Black, and Turquoise.

Dyeing Programme:

As an established factory Reedisha Knitex has developed some exquisite dyeing programs.According to color development the programs are set into the dyeing machine. Theprograms are given below:

M/C programme and S/L number:

SLno.

Name Pretreatmenttime(Min)

Color dosingtime(Min)

Runtime(Min) Sodadosing

time(Min)1. Turquoise color 80ºC 60 30 25 402. Critical color 60 ºC 60 20 25 403. L.S.J Light color 60 ºC 60 15 20 254. L.S.J Deep color 60 ºC 60 20 25 305. L.S.J Critical color 60 ºC 60 20 25 406. Any Light color 60 ºC 40 15 20 257. Any Deep color 65 ºC 40 20 25 308. Any Normal white9. L.S.J White10. C.V.C Polyester part11. L.S.J Deep color 65 ºC 60 20 25 3012. L.S.J Critical color 65 ºC 60 20 25 4013. Critical color 65 ºC 60 20 25 4014. Topping normal color15. Topping Critical color16. Stripping Color17. Any Average 60 ºC 40 15 25 3018. Any Average 65 ºC 40 15 25 3019. L.S.J Average 60 ºC 60 15 25 3020. L.S.J Average 65 ºC 60 15 25 30

39

Details dyeing procedure:

To understand different dyeing processes here some programmes are described below for1.Light shade2.Medium shade3.Extra deep shade4.Viscose dyeing

The processes are given below:

1.Procedure of Light shade dyeing:

Color : Pantone number-07000Fabric type : 1cm Drawsting

Recipe:

Chemical g/l %Pre treatment

NOF 1ECS 0.54UD 1

Caustic 2.5H 2 O 2

2.5

4BK 0.63Acetic Acid 1

DyeingSQD 0.5ECS 0.25

Gluber Salt 15Rema Blue RR 0.0416Rema Red RR 0.0128

Rema Yellow RR 0.03Soda 3

Acetic Acid 1CCS 0.5

After TreatmentCWS 1.5

Acetic Acid 0.1

Dyeing flow procedure of Pantone no-07000 color:

Water added at 60 º C

NOF, ECS and 4UD is added

40

Caustic is added at 60º C

Then H2O2 is added at 70 º C

Tempeature is raised to 100 º C

Runtime 10 min

Cooling at 75 º C

Water drain

Water collect

Hot wash

Drain

Acid wash is given at 60 º C temp for 15 min

Drain

Water collect

P H check(P H =4-5)

Bio –AL and NOF is added at 55 º C for 60 mins

Then temp is raised to 70 º C for 10 mins

Rinsing with cold water

Sample is cut

Water drain

Rinse with hot water at 90 º C for 10 min

Temp decrease to 80 º C

Rinse

Drain

Water is taken at 80 º C

Then ADM and SQD is added at 80 º C

Salt is added at 80 º C

P H check(P H = 6)

41

Runtime for 10 mins

Color dosing at 80 º C for 10 min

Runtime for 25 mins

Soda dosing at 80 º C for 30 min

Runtime 40 mins

After 20 min a sample is cut

Again after 20 mins another sample is cut

Bath drop

Cold wash

Normal hot at 55 º C for 15 mins

Rinse

Acetic acid and Netra-acid is given at 50 º C for 15 mins

Cold rinse

ECS & CCS is given at 90 º C for 15 mins

then hot wash is given

Acetic acid & Netra-acid is given

P H check(P H =4-5)

CWS and ECS at 45 º C for 20 mins

Unloading

Process curve:

LevellingAgent 15 min 15 min 25 min

60ºC P H check Runtime20’Salt Color Soda

Dosing Dosing

Drop with rinse 10”

42

Rinse:10 min

Acid:15 min 10 min

Acid

Hot Wash:20 min

90ºC

10 min

Rinse:

10 min

Procedure for medium shade dyeing:

Color : PORCELAIN.Fabric type : Lycra single jersey.

Recipe:


NOF 1ECS 14UD 1

Caustic 2.5H 2 O 2

2.5

Acetic Acid 1Bio Al 1.25NOF 0.1

DyeingADM 0.25SQD 0.5

Gluber Salt 40Dri Turquooise CLB 0.27

Dri Blue HFRL 0.192Dri Yellow HF3GL 0.12

Soda 8Acetic Acid 1

CCS 0.5ECS 0.3

43

After TreatmentCWS 2

Acetic Acid 0.1ECS 0.3

Dyeing flow process of PORCELAIN color:

Water loaded at 60 º C


Caustic is added at 60 º C

Then H2O2 is added at 70 º C

Temperature is raised to 80 º C

Temperature raised to 100 º C

Runtime 60 min

Cooling at 80 º C

Rinse

Water drain

Normal Hot wash at 90 º C for 15 min

Temperature decrease to 80 º C

Rinse

Drain

Acid wash is given at 60 º C temp for 15 min

Rinse

Drain

Water collect

P H check(P H =4-5)

Bio –AL and NOF is added at 55 º C for 60 mins

Then temp is raised to 70 º C for 10 mins

Rinsing with cold water

Sample is cut

44

Water drain

Rinse with hot water at 90 º C for 10 min

Temp decrease to 80 º C

Rinse

Drain

Water is taken at 80 º C

Then ADM and SQD is added at 80 º C

Runtime 10 min

G.Salt is added at 80 º C for 15 min

P H check(P H = 6)

Runtime for 10 mins

Color dosing at 80 º C for30 min

Runtime 25 mins

Salt sample cut after 15 min

soda dosing at 80 º C for 45 min

Runtime 60 mins


Bath drop (50 mins)

Acid wash at 40 º C for 15 min

Cold wash

ECS & CCS is given at 90 º C for 15 mins

Then hot wash is given

Acetic acid is given

P H check(P H =4-5)

CWS and ECS added at 45 º C for 20 mins

unloading

45

Process curve:

LevellingAgent 15 min 30 min 40 min

10’ 10'80ºC Runtime25’

Salt Color SodaDosing Dosing

Drop with rinse 10”

Normal hot:

50ºC

Rinse:10 min

Rinse:

10 min

Acid:15 min 10 min

Acid

Hot Wash:15 min

90ºC

10 min

Rinse:

10 min

46

Procedure for extra deep shade dyeing:

Color : NOIR CAVIA.Fabric type : Lycra single jersey.

Recipe:


NOF 1ECS 14UD 1

Caustic 2.5H 2 O 2

2.5

Acetic Acid 1Bio Al 1NOF 0.1

DyeingSQD 0.5ECS 0.5

ACID 0.2Gluber Salt 100

Kira Black GRE 6Kira Red ME6BL 1.25

Kira Yellow MERL 1.7Soda 25

Acetic Acid 1CCS 1ECS 0.3

Netracid 1After Treatment

CWS 1.5Acetic Acid 0.1

ECS 0.3Netracid 0.2

Dyeing flow process of NOIR CAVIA color:

Water added at 60 ºC


Caustic is added at 60 ºC

Then H2O2 is added at 70 ºC

Temperature is raised to 80 ºC


Runtime 60 min

47

Temperature is decreased at 80 ºC

Cold rinse

Water drain

Water collect

Hot wash at 90 ºC for 15 mins

Temperature is decreased at 80 ºC

Rinse

Drain

Acid wash is given at 60 ºC temp for 15 min

Rinse

Drain

Water collect

P H check(P H =4-5)

Bio –AL and NOF is added at 55 ºC for 60 mins

A sample is cut at 55 ºC temp

Water drain

Rinse with hot water at 90 ºC for 10 min

Temp decrease to 80 ºC

Rinse with cold water at 50 ºC for 10 mins

Drain

Water is taken at 50 ºC

Then SQD and ECS is added

M/C run time for 10 mins

G. salt is added at 50 ºC

P H check(P H = 6)

Runtime for 10 mins

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Color dosing at 60 ºC for 20 min

runtime 25 mins

soda dosing at 50 ºC for 40 min


Run time for 60 mins


Bath drop

Normal hot at 50 ºC for 15 mins

Rinse

Acetic acid is given at 40 ºC for 15 mins

Cold rinse

ECS & CCS is given at 90 ºC for 15 mins

Rinse

Acetic acid is added

P H check

CWS and ECS at 45 ºC for 20 mins

Unloading

Process curve:

Levelling 65ºCAgent 15 min 20 min 30 min

90ºC P H Check Runtime25’Salt Color Soda

Dosing Dosing Drop with rinse 10”

Normal hot:

50ºC

10 min

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Acid:15 min 10 min

Acid

Hot Wash:

15 min90ºC

10 min

Rinse:

10 min

Procedure for viscose dyeing:

Color : 4569.Fabric type : Lycra single jersey viscose.

Recipe:


NOF 1ECS 14UD 1

Viscocolor 3NOF 1ECS 1

Acetic Acid 1Dyeing

ADM 1SQD 0.25ECS 1

ACID 0.2BRR 0.013

Kira Red ME4BL 2.142Kira Orange ME2RL 2.076

G.Salt 80Soda 20

After TreatmentCCS 0.5

Acetic Acid 1ECS 0.3

50

Dyeing flow process of 4569 color:

Fabric loading at 60 ºC

Runtime for 5 min

Viscocolor dosing for 10 min

Runtime 30min in 80 ºC

Rinse for 10 mins

Drain

Water taken

NOF & ECS added

Runtime of 10 min at 80 ºC

Rinse for 10 min

Drain

Water taken

Acid added at 50 ºC for 15 min

Drain

Water taken and temperature rise to 60 ºC

ADM & ECS is added

Runtime for 5 min

PH check

Dye dosing for 35 min

Runtime for 15 min

Salt dosing for 45 min

Runtime 30 min

Soda dosing for 90 mins

Runtime for 30 min

Shade cut

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Hot wash at 90 ºC

Acid wash

Unload

Stripping recipe for cotton

Stripping process is done by three steps:

100CX30'

100C X30'

100C X30'

Acid wash (2 g/l) for 10'.

Wetting agent: 0.5 g/lCaustic soda: 2 g/l

Stabilizer: 0.5 g/lH202: 2 g/l

NOF: 1 g/lCaustic soda: 3 g/l

Hydrose: 3 g/l

Wetting agent: 0.5 g/lCaustic soda: 2 g/l

Stabilizer: 0.5 g/lH202: 2 g/l

Acid wash( 2g/l)for10 min

52

Printing

In Reedisha Knitex lLd. hand screen printing is carried out. Here various types of screenprinting are done. They are mentioned below:

1. Base/pigment printing2. Rubber printing3. High density printing4. Plastisol5. Discharge6. Mettalic7. Puff8. Foil9. Glitter10. Transfer11. Flock12. Water jetpoint13. Pearl

Process flow chart:

Design obtained from swatch

Design selection and colour separation

Production of design repeats by using software

Preparation of screen manually and adding photo sensitive polymer

Design is replaced in mesh fabric by exposing to light

Placing the fabric on the printing table as measured taken

Printing paste preparation

Printing the fabric by screen

Curing the fabric at required temperature(140-180ºC)for 1-3 mins

Software used for design:

1. Abobe photoshop2. Adobe illustrator3. Corel draw

Paper used:

Delta laser sheetSometimes tracing paper is also used for small motif.

53

Mesh of fabric:

16(Dot design) , 90(High density printing) , 110 , 60 etc.

Screen size:

1. 14´´× 16´´2. 16´´× 18´´3. 18´´× 20´´4. 28´´× 32´´ etc.

Squeezee:

1. China : For dot printing2. Bangladesh : For solid

Printing Table:

Dimension

1. 4ft×80ft2. 100ft×2.5ft

Made of :

1. Local: Hard board and rexin2. China: Glass

Drier used:

Drier(Ahjin machine company).

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Sample collection

RECIPE SAMPLES

Kira Black GRE-7.2%Kira MERL-0.05%

Kira R ME6BL-0.22%

Dri. Tr. CL-B-0.50%Dri Yellow CL-2R-0.044%

Dri Red HF3GL-0.48%

Dri. Blue CLBR-2.40%Dri. Yellow CL3GL-0.04%

Chemi B.F2R-2.86%Kira R ME4BL-1.0%Kira Y. MERL-1.88%

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PRODUCTION REPORT

Shift wise production:

M/C no Buyer Color Shade Fabrics Lot Quantity(Kg)

1. Li&Fung Sky blue light L-RIB 1452 5

2. Knitting navy deep Singlejersy

1452 8

3. Benetton 07000 medium L-S-J 1453 40

4. Benetton 501 light L-S-J 2491 200

5. Kiabi Rosecameo

deep 1×1 Rib 2474 253

6. Kiabi Vert Jaune Light 1×1 Rib 2451 394

7. Walmart Rio Red Extradeep

L/S/J 2430 420

8. Walmart Off white L/S/J 2043 641

9. HighFashion

Lilaac Rose Medium L/S/J 2453 493

10. Goal line Brasil Deep S/J 2464 360

11. Kiabi Orangemock

Light 1×1 Rib 2464 394

12. Kiabi Turquoise Deep Pique 2470 656

13. Kiabi Gris Bung Medium Pique 2456 865

14. Walmart Sandshell Light L/S/J 2464 1050

Remarks:

The process is a developed one. It should require lower time to conclude the operationwhich reduces idle time & hence increase the profit.

56

Chapter Six

QUALITY ASSURANCE SYSTEM

57

Quality assurance system can be divided into following steps:

1. On line Quality assurance system and2. Off line Quality assurance system.

Again on line Quality assurance system ca be divided into the following steps:(a) Raw material control.(b) Process control.

Online Quality control

Raw material control:

Reedisha Knitex Ltd. always very concern about the quality of the product. So, they knitgrey fabric from the best quality yarn & utilizes technical evaluation in every stage of theproduction, as we know the quality product depends on the raw material quality.

Process control:

The method chosen for process must be provided with the necessary accurateparameters. In the every stage pH should be maintained sincerely.

Lab:

Lab is the heart of a dyeing industry. An efficient lab can increase the efficiency of dyeing.So lab in-charge is sometimes called Pilot. Before bulk production a sample for approvalfrom buyer is sent to buyer. Lab supplies the recipes to the floor.

Purpose of Lab:(a) Get color approval from buyer.(b) Recipe supply to the floor.(c) Shade correction.(d) Minimize the deviation between bulk & lab.

Machineries in Lab:

1. Light boxType –Verivide model – CAC 60- 5M/C Brand- SDL internationalOrigin- EnglandIlluminants present- D65, TL-84, TL-83, F, UV

2. GSM weighing scaleBrand- OHAHUSM/C Capacity-150gOrigin- China

3. M/C name- CrockmasterBrand- James H. HealOrigin- England

58

4. M/C name- Rubbing testerBrand – SDL internationalOrigin – England

6. M/C name- Perspiration testerBrand – SDL internationalOrigin – England

7. M/C name – Rota WashBrand – SDL internationalOrigin – England

8. M/C name- WashcatorBrand – SDL international (Electrolux)Origin- England

9. M/C name- Tumble drierBrand – CREDAOrigin- England

10. M/C Name – Lab DipBrand – IR DyerPot- 23Origin – Taiwan

11. M/C name – Lab dipBrand – AHIBAHeating – InfraredPot -19Origin – USA

12. Computer color matching systemDatacolor-600.

Lab line:

a) Standard Sample:At first recipe% of standard sample is measured by CCM(Computer ColorMatching)system.

b) Lab trial:Then by taking that recipe lab officer produce lab trial and match with standardaccording to buyer requirements.

c) Approved Sample:Then sample swatch which is matched with the standard & send to buyer for approval.

59

Salt & Soda used in the lab dyeing according to shade:

Shade% Salt (g/l) Soda (g/l)

0.01-0.08 10 2

0.09-0.19 15 3

0.2-0.4 20 4

0.4-0.6 25 5

0.6-0.8 30 6

0.8-1.6 40 8

1.6-2 50 10

2-3 60 15

3-4 65 16

4-6 70 18

6-10 80 20

Program used in sample dyeing machine (For AHIBA NAUNCE):

Program No. Process Temperature (C) Time (min)1 Cotton White

Dyeing100 20

2 PolyesterWhite Dyeing

130 15

3 Cotton Dyeing(Soft)

60 30

4 Cotton Dyeing(Soda)

60 60

5 PolyesterDyeing

130 30

7 TurquoiseDyeing

80 40

9 Wash 90 20

Finished product quality control:

After the dyeing and finishing process, when the fabric moves away from the compctingmachine the finished quality of the fabric is assessed according to the buyer requirement.From here if the QC department of dyeing section okays the quality of the fabric then it isdelivered to the garments for further process. Here the faults upto the acceptance level ismeasured by means of four point system. A reference sheet that calculates the faults andpoints is attached.

60

Off line quality control :

After dyeing the material is received by the finishing section. Before receiving the followingthings are checked:

1. Shade condition.2. Wash fastness.3. Condition of softening.4. Condition of enzyme wash.

Before delivery the finished fabric to the customer it should be pass against therequirements.The following tests are done-

GSM check.Shrinkage test. Shade check.Rubbing test.Wash fastness test.Color fastness to perspiration.

GSM check:

GSM of the finished fabric essentially should be check according to the buyer’srequirement.Checking time: at finished state.Equipment used: GSM cutter.Sample area:100 sq.cm.Manufacturer : Local brand.

Shrinkage test:

Testing time: After dryer or before compacting.Equipment used: Shrinkage board ,shrinkage scale, measurement tape, scissor, washingmachine, detergent.Lengthwise shrinkage = (-ve) %.Lengthwise extension = (+ve) %.Test method : ISO 6330:2000.Shrinkage tolerance: ±5%.The fabric is cut according to the shrinkage board. Then the fabric is washed by washingm/c with PCLF for 60 min. at 40. Then the shrinkage% is determined by the shrinkage scale.

Shade check :

Testing time: During in the process & after finishing.Equipment used: Verivide light box.Country of origin: U.K.Light sources: D-65,TL-83,TL-84,F,UV.

61

Rubbing fastness test:

Equipment used: Crockometer.Test method: BS EN ISO 105x12. Dry rub & wet rub is including in this method.Testing time: Finished fabric.

Wash Fastness test :

Equipment used: Wascator washing m/c.Chemicals used: 4 g/l detergeTime:40 minTemp:60Cthen the shade change is measured by color change scale & staining scaleTest Method: ISO 105 C06.

Color Fastness to Perspiration:

Equipment used: Rota-Wash.Two artificial perspiration solution are made up as follows:

Chemical name Solution A Solution Bl- histidine mono-hydrochloride mono-hydrate 0.5g 0.5g

Sodium chloride 5.0g 5.0gDi-sodium hydrogen orthophosphate 2.5g 2.2g

Distilled water 1000ml 1000mlP H (Adjusted with N/10 NaOH) 8.0 5.8

Test fabric is dipped into the solutions separately, then it is dried and pressed by a weightof 4.5 kg and kept for 4 hour at 37ºC. Then by means of grey scale assessment is done forcolor change and color staining.Test Method: ISO 105E04.

Remarks:

As quality is the main factor for any export oriented factory in the world, in REEDISHA KNITEXLTD. a very precise quality is maintained by means of the QC and the lab of the factory.The success of the factory many parts depends on the quality control system.

62

Chapter Seven

MAINTENANCE

63

MAINTENANCE OF MACHINERY

The machineries used in textile wet processing should be subjected to scheduledmaintenance activities for their optimum performances at their following points:

1. Routes of different utilities like water, stem, gas, electricity, compressed air, etc.2. Dyestuff & chemical dosing system.3. Drainage system of waste water, color & chemical.4. Driving arrangement of different machineries.5. Power transmission to different machineries.6. Fabric guiding system through the machineries.7. Cleanliness of machine parts.

Manpower Set-up for Maintenance:

Maintenance Schedule For Dyeing Section:1. Perform visual inspection2. Check bearing.3. Clean & grease.4. Inspecting all sides.5. Clean & oiling.6. Cleaning of drain valves.7. Checking of all electrical wires.8. Checking of circuit breaker, magnetic contractors.

Position No. of Person Department

B.Sc. Engr. 1 Elect. & Mechanical.

Foreman 2 Elect. & Mechanical

Fitter 2 Elect. & Mechanical

Assistant Fitter 2 Elect. & Mechanical

Welder 2 Elect. & Mechanical

Helper 6 Elect. & Mechanical

64

Maintenance and relevant equivalent:

The most important maintenance tools that are used frequently are :

Maintenance Tools FunctionGrease Lubrication

Tread tape Joining of broken metallic partsCutting disc For cutting pipes, rods.Globe valve Fitting for stem line.

Maintenance Tools FunctionUnion Fittings for water, steam line.

Union elbow Fittings for water, steam line.Cutting oil LubricationGear oil Lubrication

Hydraulic oil LubricationOil gun Oil application

Spanner Tightening of nut boltsMaster range Tightening of nut bolts

Flat screwdriver Screw tightening & looseningStar screwdriver Screw tightening & looseningHacksaw blade CuttingHacksaw frame CuttingSpray gun WP40 Spraying a chemical named WP40 that lubricates

bearings.Drill machine Drilling to make holes

Grinding machine Grinding

Remarks:

As maximum machines are new , so they need a few maintenance that is the breakdownmaintenance.

65

Chapter Eight

UTILITY SERVICES

66

UTILITIES

In RKL the following facilities are available-

Gas Electricity Water Steam Compressed air.

a. 3 gas generator supplying electricity to the entire factory & adjacent head office.b. 1 diesel generator that are also used to produce electricity.c. 2 air compressor supplying compressed air.d. 2 deep tube-well to supply water to the plant.

Capacity & source of different utilities:

Utility Source M/C used Brand Capacity MakeElectricity REB &

GeneratorGas

generatorGuascor 936 KW Spain

Waukesha 900 KW U.S.AWaukesha 600 KW U.S.A

Steam Fire tubeboiler

---- CleavererBrookes

10 tons/hr U.S.A

Gas Titas gascompany

---- ---- ---- ----

Water Naturalwater

Submersiblepump-1 MILLAR’S

30 h.pSpain

Submersiblepump-2

30 h.p.

Compressedair

Natural air Compressor BOGE 5.38cubic.met/mi

n

Germany

Technical details :

Water:

Water is supplied by pump. Pump supplies water on the basis of pressure. Pump pressureranges from 0-10 bar. Water is stored in the water treatment plant. The water is collectedfrom the 120 ft. below to the earth. In this region, the water is not so hard enough that can

67

cause create problems in dyeing & other sections. But we have water softening plant. Thiswater is treated with resins mainly.

Air:

The natural air is sucked by compressor& it can suck air 5.38 m3/min. Here we have two aircompressor. The air is reserved by the air-reservoir. Here the compacted by this air reserver.Then it passes to the air dryer. We know air has H20, S & other microscopic materials. Airdryer removes the above materials & it cools the air & then it is supply to factory.

To m/c’s

Steam:

Steam is an important utility for the dyeing section. Steam produced by the boiler. So it isnecessary to set up a boiler section in the factory. Boiler creates pressure & for this reason itis called steam pressure (7.5 Kg or 110 PSI).Supply water is simply treated in the boiler section by the two softener tank. Then waterreserves to the feed water tank & this feed water tank warms the water. Then water passesto the boiler whose capacity 10 tons/hr. Boiler produces steam & that steam supplies to thefactory.

Main parts of the boiler: Gas chamber. Blower Gauge glass Float valve Burner

Specification(Boiler):-

Feed water temp. 60 CFeed water hardness 2

Stem pressure 500 PSIType of steam Wet steamSteam temp 150-180C

Fuel used Natural gas

Electricity:

It is impossible to continue the production without electricity. A frequent supply ofelectricity is very need for soundless production. In RKL all machineries in dyeing & finishingsection are provided electricity by the own generator of the industry.

AIRCOMPESSOR

AIRCOMPESSOR

AIRRESE-RVER

AIRDRYER

68

Technical information(Generator):

Gas pressure 53 BarLine voltage 404volt

Total load 400 voltRPM 1500

Frequency 50HzBattery voltage 24V

Out water temp. 80ºCOil pressure 5 Bar

There are two chillers are present in order to cool down the temperature of the coolant(water) used in generators.

Stand by generator:

Diesel generator- EG WILSON- England- 320 KW.

Utility consumption :

Water - 80L/Kg of material.Gas required - 40 m3/hr.Electricity -950 Kw/hr.

Cost of different utilities:

1 unit electricity -2.60 Tk.1 Kg steam -0.50 Tk.1 Ton water -7.30 Tk.

Remarks:

For smooth running of factory main utilities like gas or electricity is very essential. ReedishaKnitex Ltd. use Titas gas. Sometimes gas pressure is low than required pressure. Governmentshould have to ensure proper gas supply for industrial purpose.

Effluent treatment plant:

Now a days the waste of a textile industry is taken as a threat to the environment as well asto the human health. Also the buyers are also demanding efficient treatment plants tosave our green earth. To fulfill the above requirements REEDISHA KNITEX LTD. hasestablished an ETP in the factory premises to treat the wastes from dyeing and other area.It is a mixture of chemical , mechanical and biological treatment plant. It is a effectiveplant and works in full swing to make the environment safer.

69

EFFLUENT TREATMENT PLANT

In Reedisha Knitex Limited . The following type of ETP plant is in action, that is describedbelow. A typical layout of the plant is attached with this report.

Different parts of the Effluent treatment plant and their functions:

1. Equalisation tank: In this tank the waste water is carried in and stored. Then bymeans of blower air is blown through it to reduce the oxidation temperature.

2. Flash mixing tank: Here two chemicals are mixed with the waste water. a)Lime andb) Ferrous sulphate. Lime cleans the water and destroy the germs. Ferrous sulphateaids lime to change the color of water.

3. Flocculation tank: In this tank poly electrolyte is used to make the sludges bigger insize and also separate them from water.

4. Tube settler tank-1: The main function of this tank is to settle down the sludge.5. P H correction channel: In this channel HCl is used to maintain the P H range of 7-8.6. Biological reaction tank 1&2: Made the bacterias work on wastes to make it into

the sludges.

Operational processes:

Primary treatment:

Coagulation and flocculation (To remove color and effluent suspended)

The homogeneous effluent will then be pumped to a flash mixing tank followed by aflocculation tank. In the flash mixing tank coagulants like lime(Ca(OH) 2 ) and flocculant

like ferrous sulphate (Fe(SO) 4 ) are dosed. The basic idea of adding coagulant is to bringtogether all the suspended and dyed particles so that they can be precipitated out in theflash mixing tank and flocculation tank by coagulation and flocculation mechanism. Thechemical reaction that occurs in the coagulation and flocculation process is shown below:

CaO+H 2 O=Ca(OH) 2

70

The above reaction takes place in lime dosing tank when lime reacts with water and weget Ca(OH)2 solution. This solution reacts with ferrous sulphate solution, which as follows:

Ca(OH) 2 +Fe(SO) 4 =Ca(SO) 4 +Fe(OH) 3 +Fe(SO) 4 (Unreacted)+Fe(OH) 2

Precipitation and sedimentation in tube settler-1 :

The effluent will further flow by overflow system to P H correction tank.

P H correction(To adjust the inlet P H ):

The effluent from tube settler -1 tank is then taken by overflow method to P H correctionchannel for neutralization. Where 33% HCl Acid is dosed for neutralizing the P H valuearound 7-8.

Secondary treatment:

Biological treatment in the fludized aerobic bio reactor (Also called MBBR)-1&2(To reduce the remaining BOD & COD aerobically)

The neutralized effluent is then taken by gravity into the biological treatment tank forbiological degradation of available organic matter to reduce the remaining BOD & CODaerobically. The biological treatment tanks are designed on extended aeration principle.The fluidized aerobic bio reactor 1&2 includes two tanks of any shape filled up with smallcarrier elements. In course of treatment a bio film develops on the elements, which movealong with the effluent in the reactors. The thin bio film on the elements enables thebacteria to act upon the bio degradable matter in the effluent and reduce the BODcontent while the rapid and turbulent movement of the effluent in the presence of oxygenavailable from the air, certain amount of COD is also removed. The chemical reactionsthat took place in the FAB reactor can be defined according to the following threeprocesses:

A. Oxidation process

COHNS+O 2 + Bacteria+ DAP &Urea=CO 2 +NH 3 +Energy +Other end products

DAP & Urea is used as food for the micro organism.

B. Synthesis process

COHNS+O 2 +Bacteria=C 5 H 7 NO 2 + New cells

C. Endogenous respiration

C 5 H 7 NO 2 +5O 2 =CO 2 +NH 3 +2H 2 O

Tube settler-2(To remove the biological solids generation):

From the biological reactor the treated effluent flows by gravity to the tube settler-2. Thebiological solids generated are removed from the tube settler -2 by the help of tube settlermedia.

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Filter feed pump(To collect effluent for next processes):

The treated effluents from the tube settler 2 overflow into the filter feed pump. From thefilter feed pump the effluent is pumped to the pressure sand filter at first and then throughactivated carbon filter. From here the disinfected effluent is pumped by means of pressuresand filter feed pump to the pressure sand filter. The pump is normally operated inautomatically with interlock to the level switch in the filter pump.

Pressure sand filter(To remove suspended matter):

From the filter feed pump the effluent is pumped to the pressure sand filter. The filtrationtakes place in the downward mode . The filer is filled with a layer of graded sand mediasupported by a layer of graded gravel. The suspended matters in the effluent are filteredout in this unit. The iffluent is then flown into the activated carbon filter.

Activated carbon filter(To absorb the dissolved organic matter):

The treated and filter effluent from the pressure sand filter flows into the activated carbonfilter. In this unit too the feed flow is downward through a layer of granular activatedcarbon filter in which dissolved organics of the effluents are absorbed. It is necessary tobackwash the carbon filter every 8 hours.

Treated effluent disposed off(Ready for disposed off):

The treated effluent emerging from the ACF is directly disposed off through the outletchannel to environment.

Sludge treatment and handling:

The sludge generated in the flash mixing tank, flocculation tank, tube settler-1&2 andbiological reactor is taken to a sludge pump. Here also aeration is carried out. The waste isthen pumped to a sludge thickener tank where the sludge is concentrated at the bottomof the tank. The thickened sludge from the thickener is pumped to centrifugal pump fordewatering. At first the centrifuge is started and then the thickener feed pump is started.At the slurry of sludge flows polyelectrolyte solution is dosed in the centrifuge as a result thesludge will be separated from the water. The centrifuge is run for 20-30 mins and thenswitched off.The dewatered sludge is transformed into cake form. The dried cake may be disposed ofto deliver in the brick field for burning. The overflow from the sludge thickener wii be flowback to equalization tank for further treatment. In some cases due to the nature of wastewater characteristics it is not possible to dewater the sludge into a cake form, in that casethe sludge is collected in the form of slurry in a bucket .

Capacity of the ETP:

The treatment plants capacity is 40 m 3 /hr.

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Remarks:

For smooth running of factory main utilities like gas or electricity is very essential. Thefacilities of effluent treatment are also very important as concerned to environment. So thepart of this chapter are very important to maintain for the mill.

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Chapter Nine

STORE & INVENTORY CONTROL

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STORE & INVENTORY SYSTEM

Inventory system for Raw material :

In Reedisha Knitex Ltd. there are different inventory systems for different raw materials. Theflow is given below —

Raw material receive

Material Receive Report(MRR) Sent to head office.

Store in main go-down by bin card.

Running go-down.

Production floor.

Grey fabrics store:

All the grey fabrics are stored in the fabric store, near the batch section. Different types offabrics are listed in the sheet according to the fabric types, quantity & consumer’srequirements. Fabrics GSM , shrinkage, diameter & other properties are also taken intoconsideration. The bathes are prepared by taking the required fabrics from the grey store.At present the grey fabrics store of RKL containing the following types of fabrics-

Single jersey. 1x1 Rib. 2x2 Rib. 2x1 Rib. Melange. Pique. Single jersey (with Lycra attachment) 1x1 Rib (with Lycra attachment) etc.

Dyes & Chemicals store:

There is a different store for dyes & Chemicals. Various types of dyes & chemicals arestored here according to the dyes & chemical company. Different types of dyes of dyes &chemicals are listed in a sheet. In the sheet the stored quantity of dyes & chemicals are

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also included. Every day the is updated & a copy of this is supplied to the dyeingmanager, Dye house & lab section.

Spares:

In RKL required amount of spares of different machines are stored in the mechanicalstoreroom. All the spares are listed in a sheet, which is controlled by the mechanical &maintenance personnel. Spares are arranged in the storeroom according to their size,quantity & requirements. There are shelves in the store room to keep the small spare parts.

Finished goods:

RKL supplies its finished dyed fabrics to its garments section. So, dyed finished fabrics arestored for short time in the finishing section. All the delivered fabrics are noted on the tallykhata according to the Lot no., quantity, fabrics diameter, buyer’s name, colors, &considering other parameters.

Others :

There is a central store at RKL . In that store the various types of forms, papers, stationary &other necessary goods are kept.

Remarks:

The storing capacity of the mill is sufficient. The inventory system is a planned & systematicway.

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Chapter Ten

COST ANALYSIS

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Price of the product:

As this is very confidential, so we can’t collect sufficient data.

Costing of the Product:

Cost of the product depend on cost of raw materials, dyes & chemical their availability &other various factor. A schematic analysis of costing is shown below :The operation of costing for a finished garments starts from the at the beginning like fromthe yarn producing. Here we will only discuss about the dyeing department. As aconfidential matter we were provided with previous year dye chemicals costs and otherexpenses were not revealed to us, we were just let to know the costing procedure. Which ismentioned below:

S/L no. Chemical/dye name Price/kg1. Caustic soda 242. Stabilizer 1353. Hydrogen peroxide 31.54. Acetic Acid 655. Bio-polish AL 4556. Glubar Salt 10.57. Rema Red ME4BL 3508. Rema Orange MER2RL 3759. Soda ash 13.50

Steps:

When a fabric comes to the dyeing floor for the purpose of dyeing then according fabricweight the consumption of dyes and chemicals are calculated. Then according to theprice list the cost for dyes chemicals are calculated. Then the following costs are added tothe cart to calculate the final cost for dyeing.-Packing Material-Labor-Variable Factory Overhead-Fixed Overhead-Operating Expenses

Remarks :

As we have not got the price list of the other section, so we can’t calculate the adjust costof the product. We get only the guideline to calculate the cost of product.

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Chapter Eleven

MARKETING ACTIVITIES

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PRODUCT MARKETING

Consumer of the products:

1. Zara.2. Kiabi3. I.C. company.4. H&M.5. Teba.6. Lie & Fung7. Benettone.8. Walmart.9. Hi fashion10. Blend she

Manpower :

Marketing plays a vital role in the field of displaying/ showing the good criteria of theproducts to the buyer & to communication with the buyer. There are about 7 peoples inthe marketing section of the industry.

Importing countries :

Following countries mainly imports products from RKL through many internationally wellrecognized buyers.

1. Europe countries like UK, France, Germany, etc.2. USA

Marketing strategy :

Marketing strategy is a very important factors to sale the products to the buyers. If theMarketing strategy is not so developed, it will be very hard to reach the goal. In case ofgarments marketing the dealings with the buyer is a very important factor.In RKL mainly General Manager, Marketing Executives, Merchandisers & higher officialsdeal with the buyer. There are some fixed buyer of the industry. The buyer gives their orderscontinuously all over the year. The marketing officers & the merchandisers communicatewith the buying houses to collect the orders. By both side understanding the rate & theorder quantity are fixed.

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Duties & Responsibilities of Marketing Officer:

Dealing with the buyer & convince the buyer is the main duty of the marketing officer. Amarketing officer also has some other duties. The main duties responsibilities of a marketingofficer are given below :-

-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 officer & merchandisers.-To maintain a regular communication with the buyer & buying houses.-Communicate with the new buyers.-Display the better criteria of the products.

Remarks :

The marketing activities of this mill are so good. The marketing & merchandising section iswell organized.

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Chapter Twelve

CONCLUSION

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We have completed our industrial attachment successfully by the grace of Allah.

Industrial attachment sends us to the expected destiny of practical life. The completion ofthe two months Industrial attachment at REEDISHA KNITEX LTD., we have got theimpression that factory is one of the most modern export oriented knit composite complexin Bangladesh. Though it was established only a few year’s ago, it has earned “very goodreputations” for its best performance over many other export oriented textile mills.

During our training period, talking with the clients of this mill we knew that the mill is fulfillingthe country’s best export oriented white finished fabric as well as very good colored fabricdue to its modern machinery & good management system.

Mill is settled with utility to give all convenient supports to the productions for twenty-fourhours. It had self-power generator system to satisfy total power consumptions of the mill.

We are enough fortunate that we have got an opportunity of having a training in this mill.During the training period we are received co-operation and association from theauthority full & found all man, machines & materials on appreciable working condition. Allstuffs & officers were very sincere & devoted their duties to achieve their goal.

Industrial attachment of reedisha knitex ltd.

Engineering

Transcript of Industrial attachment of reedisha knitex ltd.