The document provides information about GTA Sports Ltd., a knitwear factory in Bangladesh. It includes an organogram of the company's management structure and sections. The knitting section is described in detail, outlining the knitting process, types of knitting machines and their parts. It also discusses methods to increase production quantity. The dyeing and finishing sections are briefly introduced, including raw materials, machinery and quality control processes.
Effect of stitch length on Lycra And Without Lycra plain Single jersey fabric...Md. Mazadul Hasan Shishir
This document summarizes an experimental study on the effects of stitch length on plain single jersey cotton fabrics with and without lycra. It describes the sample fabric production including fabric type, yarn type and count, and machine parameters. It then summarizes the results of various tests conducted including spirality, pilling resistance, GSM, courses/wales per inch, dimensional stability, fabric thickness, and color fastness. The tests showed that increasing the stitch length increased spirality and decreased other properties like GSM and fabric thickness. The document concludes by emphasizing the importance of textile education to develop competitive human resources.
Knitting, dyeing and finishing, and cutting were the major sources of wastage, accounting for over 85% of total wastage. Cutting had the highest wastage percentage at 51.3% due to low marker efficiency for baby styles. Dyeing wastage of 35.77% was primarily from scouring, bleaching, and peach finish. Suggested solutions included improving worker skills, using manual CAD pattern arrangement, and automating processes. The total wastage percentage was calculated to be 21.89% of raw materials, costing over $1,300.
This document provides an overview of Apex Weaving & Finishing Mills Limited, a textile company located in Gazipur, Bangladesh. It describes the company's various subsidiaries and business sections, which include weaving, dyeing, printing, finishing, and garments. The document also lists the types of machinery used in each section of the facility, such as 231 shuttleless looms, rotary printers, loop steamers, and sewing machines. Finally, it includes photos of the different areas of the plant, including the weaving floor, wet processing section, printing area, laboratories, and maintenance facilities.
An investigation on the inspection of grey & finished knit fabric in wet proc...Md. Mazadul Hasan Shishir
This document discusses fabric inspection processes at Aman Tex Ltd, a knit fabric dyeing and garment manufacturing company in Bangladesh. It outlines the company's operations and describes their grey fabric and finished fabric inspection procedures. For grey fabric, common defects like needle marks, holes, and dropped stitches are defined. For finished fabric, defects from dyeing and finishing like uneven dyeing, dye spots, and crease marks are explained. The aims of inspection are to ensure quality, reduce costs from defects, and improve production efficiency. Inspection standards like the four point system used by Aman Tex are presented.
The document provides information about GTA Sports Ltd., a knitwear factory in Bangladesh. It includes an organogram of the company's management structure and sections. The knitting section is described in detail, outlining the knitting process, types of knitting machines and their parts. It also discusses increasing production quantity and common knitting faults. The dyeing and finishing sections are briefly introduced, including raw materials, machinery and quality control processes.
This document provides information about Interstoff Apparels Ltd., a garment manufacturing company in Bangladesh. It discusses the company profile, including its name, business type, employees, and address. It also describes the knitting, quality control, dyeing, and project work sections of the company. The knitting section details the types of yarns, knitting machines, production calculations, and common knitting faults. The quality control section lists inspection equipment. The dyeing section outlines the dyeing process and possible faults. The project work section explains common knitting defects and their causes and remedies.
Implementation of Six Sigma: A case in Textile IndustrySayeef Khan
This document summarizes a study that implemented Six Sigma to improve the process of a textile company experiencing warp yarn ruptures at a rate of 4.85% defective products. The researchers applied the DMAIC process, identifying the main causes as weaving parameters. A 24 factorial design experiment optimized the parameters, significantly reducing defects. The key parameters of warp yarn tension and harness frame height were found to most influence the defect rate. The new optimized parameters reduced defects compared to the original settings.
This document contains information about standard finishing parameters for different fabrics at MAA Garment & Textiles factory, including:
- A table listing buyers, fabric types, colors, knitting parameters, and required stenter machine parameters like temperature, speed, and overfeed for achieving the required widths and GSMs.
- Instructions for coordinators and operators on procedures like shade and GSM checking, machine cleaning, and arrangements to maintain quality during finishing.
Effect of stitch length on Lycra And Without Lycra plain Single jersey fabric...Md. Mazadul Hasan Shishir
This document summarizes an experimental study on the effects of stitch length on plain single jersey cotton fabrics with and without lycra. It describes the sample fabric production including fabric type, yarn type and count, and machine parameters. It then summarizes the results of various tests conducted including spirality, pilling resistance, GSM, courses/wales per inch, dimensional stability, fabric thickness, and color fastness. The tests showed that increasing the stitch length increased spirality and decreased other properties like GSM and fabric thickness. The document concludes by emphasizing the importance of textile education to develop competitive human resources.
Knitting, dyeing and finishing, and cutting were the major sources of wastage, accounting for over 85% of total wastage. Cutting had the highest wastage percentage at 51.3% due to low marker efficiency for baby styles. Dyeing wastage of 35.77% was primarily from scouring, bleaching, and peach finish. Suggested solutions included improving worker skills, using manual CAD pattern arrangement, and automating processes. The total wastage percentage was calculated to be 21.89% of raw materials, costing over $1,300.
This document provides an overview of Apex Weaving & Finishing Mills Limited, a textile company located in Gazipur, Bangladesh. It describes the company's various subsidiaries and business sections, which include weaving, dyeing, printing, finishing, and garments. The document also lists the types of machinery used in each section of the facility, such as 231 shuttleless looms, rotary printers, loop steamers, and sewing machines. Finally, it includes photos of the different areas of the plant, including the weaving floor, wet processing section, printing area, laboratories, and maintenance facilities.
An investigation on the inspection of grey & finished knit fabric in wet proc...Md. Mazadul Hasan Shishir
This document discusses fabric inspection processes at Aman Tex Ltd, a knit fabric dyeing and garment manufacturing company in Bangladesh. It outlines the company's operations and describes their grey fabric and finished fabric inspection procedures. For grey fabric, common defects like needle marks, holes, and dropped stitches are defined. For finished fabric, defects from dyeing and finishing like uneven dyeing, dye spots, and crease marks are explained. The aims of inspection are to ensure quality, reduce costs from defects, and improve production efficiency. Inspection standards like the four point system used by Aman Tex are presented.
The document provides information about GTA Sports Ltd., a knitwear factory in Bangladesh. It includes an organogram of the company's management structure and sections. The knitting section is described in detail, outlining the knitting process, types of knitting machines and their parts. It also discusses increasing production quantity and common knitting faults. The dyeing and finishing sections are briefly introduced, including raw materials, machinery and quality control processes.
This document provides information about Interstoff Apparels Ltd., a garment manufacturing company in Bangladesh. It discusses the company profile, including its name, business type, employees, and address. It also describes the knitting, quality control, dyeing, and project work sections of the company. The knitting section details the types of yarns, knitting machines, production calculations, and common knitting faults. The quality control section lists inspection equipment. The dyeing section outlines the dyeing process and possible faults. The project work section explains common knitting defects and their causes and remedies.
Implementation of Six Sigma: A case in Textile IndustrySayeef Khan
This document summarizes a study that implemented Six Sigma to improve the process of a textile company experiencing warp yarn ruptures at a rate of 4.85% defective products. The researchers applied the DMAIC process, identifying the main causes as weaving parameters. A 24 factorial design experiment optimized the parameters, significantly reducing defects. The key parameters of warp yarn tension and harness frame height were found to most influence the defect rate. The new optimized parameters reduced defects compared to the original settings.
This document contains information about standard finishing parameters for different fabrics at MAA Garment & Textiles factory, including:
- A table listing buyers, fabric types, colors, knitting parameters, and required stenter machine parameters like temperature, speed, and overfeed for achieving the required widths and GSMs.
- Instructions for coordinators and operators on procedures like shade and GSM checking, machine cleaning, and arrangements to maintain quality during finishing.
The document describes the process for manufacturing knit fabrics from cotton yarn spinning through dyeing and printing. It involves several steps:
1) Cotton yarn is produced through processes like blowing, carding, combing, drawing and ring spinning to produce combed cotton yarn.
2) The yarn is then knitted into greige fabric and inspected before dyeing.
3) Dyeing is done by various methods like jet dyeing followed by drying and heat setting.
4) For printed fabrics, the greige or dyed fabric is printed using screen printing then baked and heat set before final inspection.
Fabric wastage and sewing fault analysisRumman Samrat
This document is a project report submitted by three students to their professor. It discusses fabric wastage and sewing faults at a knitwear production company. The report includes an introduction, objectives, acknowledgments, abstract, and table of contents. It then analyzes fabric wastage at different stages of production and recommends ways to reduce wastage. It also examines common sewing faults, their causes, and proposed remedies. Finally, it calculates the production impact of sewing faults.
This document summarizes common faults that can occur during textile manufacturing processes and their potential causes and remedies. It discusses knitting, dyeing, finishing, printing, cutting, sewing, and garment faults. Examples of specific faults mentioned include holes, loops, lycra out, uneven dyeing, crease marks, squeezer marks, unfused edges, miss prints, weak stitches, seam puckering, and stains. Potential causes provided for each fault and recommended remedies such as properly cleaning machines, ensuring even dyeing conditions, using standard procedures, and removing contamination. The conclusion emphasizes the importance of care during processing and prevention to minimize faults.
Routine maintenance such as cleaning filters and checking equipment is performed weekly. The pH meter and blower meter are calibrated every 4 months. Every 2 years, more extensive maintenance is carried out like greasing bearings and changing pump oils to replace worn parts. Performing maintenance according to this schedule helps ensure the wastewater treatment plant operates efficiently.
The document provides details about an internship at Jaya Shree Textiles, the largest manufacturer of linen fabric in India. It describes the various processes involved in linen fabric production from bale opening to packaging, including hackling, drawing, roving, wet spinning, dyeing, warping, weaving, bleaching, and quality inspection. Key aspects of each process are highlighted such as the machines used, production rates, parameters, and quality control measures.
The document discusses maintenance of textile machinery. It defines different types of maintenance including reactive, preventive, predictive, and capital replacement. It then provides details on maintenance needs and procedures for specific textile processes like singeing, desizing, scouring, bleaching, dyeing, and finishing. Checklists are also included for yearly, half-yearly, and monthly maintenance of machinery. The goal of maintenance is to keep equipment functioning properly to maximize productivity and minimize downtime.
The document describes procedures for various textile testing methods, including:
1. Color fastness tests for wash, perspiration, water, and rubbing (dry and wet) which involve preparing samples, exposing them to specified solutions, and evaluating color change and staining.
2. Measuring dimensional stability by testing for shrinkage and spirality before and after washing samples based on calculated formulas.
3. Determining the pH of dyed fabric by cutting samples, soaking them, and measuring the pH of the resulting solution.
Knit Finishing in Arvind Ltd. bY Anupam Vowmic, created by Manojit Barman MANOJIT BARMAN
The document describes Anupam Bhowmick's summer training report at Arvind Limited in their Knits Finishing Division. It discusses the various processes involved in knit fabric finishing like slitting, drying, heat setting, compacting and different types of finishing. It also outlines the objectives of the training program, provides acknowledgements, and details the various machines used and defects observed in the knit fabrics.
The document provides information about a compactor machine used to control fabric shrinkage. It summarizes the machine's functions, operating parameters, and components. Key points include:
1. The compactor machine compacts fabric in the lengthwise direction and provides overfeed to control shrinkage during processing with steam.
2. It lists the machine's functions such as improving hand feel, reducing thickness, and controlling shrinkage.
3. It describes the machine components and operating parameters like temperature, speed, and overfeed percentage for different fabric types.
4. Diagrams show the mechanism and fabric path through a blanket and tube compactor machine.
The document discusses the process of fabric manufacturing from yarn production through several steps. There are three basic steps: 1) yarn production where fibers are spun into threads, 2) weaving or knitting where yarns are interlaced or looped to form fabric, and 3) further processing like bleaching, dyeing, and finishing to produce the final fabric. It then focuses on different types of knitting, including weft and warp knitting, and finishing processes like ironing, folding, and cartoning of knitwear products. The knitwear industry in Bangladesh is mainly located in the Narayanganj district.
This document discusses root causes of faults in knitted fabrics and their remedies. It begins by introducing the aims of analyzing fabric faults. It then covers causes and remedies for faults originating from yarns, such as barriness, spirality, shrinkage, and thick/thin places. Knitting-related faults like cracks, pin holes, contamination, and broken needles are also examined. Finally, dyeing and finishing faults such as shade variation, pin holes, creases, spots, and dust are analyzed. The conclusion restates that identifying fault sources allows knitters to take steps to prevent defects and improve quality and productivity.
This document discusses techniques for improving productivity in knitting departments. It identifies several key areas for improvement, including maintaining optimal temperature and humidity levels, using cool dry compressed air, and proper yarn and fabric storage. Controlling the environment helps reduce faults and waste while improving quality. Implementing these recommendations could increase productivity by over 25% and reduce costs through lower needle breakage and maintenance needs.
The document discusses sizing, which is the process of applying a protective coating to yarn surfaces to improve weaving efficiency. It defines sizing and describes why it is done for weaving. Various types of sizing are described, such as light, pure, medium and heavy sizing. Key factors to consider for size ingredients and properties of size ingredients are outlined. Common size ingredients for different fiber types like cotton, jute and polyester are listed. The functions of size ingredients and technological changes in yarn properties due to sizing are summarized. Different sizing faults and their causes are described. Finally, drying systems for sized yarn including cylinder drying are briefly discussed.
The document is a presentation on a study of operations and maintenance at Esquire Knit Composite Ltd, a leading garment manufacturer in Bangladesh. It covers the company overview, utilities, dyeing, finishing, sewing, and effluent treatment processes. It also discusses problems found, solutions, and recommendations. The presentation contains diagrams of the facilities and processes to explain the utility systems, dyeing machines, finishing equipment, sewing lines, and ETP plant.
This document provides an overview of Square Knit Fabrics Ltd (SKFL), including its location, departments, production capacities, certifications and achievements. SKFL has dyeing, knitting, finishing, quality control and R&D departments. It uses 66 knitting machines including circular and flat bed machines. Daily production capacity is 18-20 tons for knitting and 24 tons for dyeing. SKFL has received awards for being labor friendly and environmental standards. It is ISO and Oeko-Tex certified.
Six Sigma Approach for Industrial Quality Improvement and Defect EliminationMd. Injamamul Haque
This slide contains information about a case study of six sigma methodology, DMAIC approach. How to do an analysis, find the root cause and area to be improved through DMAIC methodology, just covered in this slide.
Wet processing is the treatment of textiles using water and involves three main divisions: pretreatment, coloring, and finishing. Pretreatment prepares fabrics for dyeing and printing by removing impurities. Coloring includes dyeing and printing to add color. Finishing makes fabrics suitable for the market by adding properties like anti-creasing. The typical wet processing sequence involves preparatory steps like desizing and scouring, followed by bleaching and dyeing/printing, and ending with washing and finishing. Key terms related to wet processing like grey fabric, stitching, and mercerizing are also defined.
The document provides an overview of the finishing processes at a textile company. It describes the slitting machine, which cuts fabric from tube form to open form. It then discusses the santax machine, which dries fabric using steam. Finally, it outlines the stenter machine, which controls width, GSM, and shrinkage of fabric during drying and allows for final softener applications. The stenter machine has multiple heating chambers and functions to maintain quality parameters during drying.
This document summarizes Noorul Islam Saiful's internship experience at Crystal Composite Ltd. It provides details about the company, his activities and responsibilities in different departments, including knitting, dyeing, sewing, and finishing. It also discusses fabric and garment defects, quality control measures, and standard minute values for sewing operations. Overall, the internship helped him gain work experience and professional skills.
Special Instruction:
Fabric shrinkage must keep within ±5%
Color fastness should be 4-5 range
Pilling range 3 to 5
pH range 5.5 to 7
Fabric weight will be allowed ±02%
Fabric quality should be s per approved swatches & Lab-Dips.
Batch to batch color matching should be 4-5
Batch to batch “Shade Band Swatch” must be submitted for approval.
Maintenance is important to maximize the useful life of textile machinery. It includes both preventive and breakdown maintenance. Preventive maintenance involves routine inspection and maintenance to prevent production issues, while breakdown maintenance repairs equipment after an issue occurs. Proper maintenance is needed to keep machinery running continuously at maximum production levels and minimize downtime. Regular maintenance includes checking utilities, mechanical and electrical parts, and following schedules for routine maintenance on a daily, weekly, monthly, quarterly, and yearly basis. The right tools are also needed to properly maintain machinery.
The document describes the process for manufacturing knit fabrics from cotton yarn spinning through dyeing and printing. It involves several steps:
1) Cotton yarn is produced through processes like blowing, carding, combing, drawing and ring spinning to produce combed cotton yarn.
2) The yarn is then knitted into greige fabric and inspected before dyeing.
3) Dyeing is done by various methods like jet dyeing followed by drying and heat setting.
4) For printed fabrics, the greige or dyed fabric is printed using screen printing then baked and heat set before final inspection.
Fabric wastage and sewing fault analysisRumman Samrat
This document is a project report submitted by three students to their professor. It discusses fabric wastage and sewing faults at a knitwear production company. The report includes an introduction, objectives, acknowledgments, abstract, and table of contents. It then analyzes fabric wastage at different stages of production and recommends ways to reduce wastage. It also examines common sewing faults, their causes, and proposed remedies. Finally, it calculates the production impact of sewing faults.
This document summarizes common faults that can occur during textile manufacturing processes and their potential causes and remedies. It discusses knitting, dyeing, finishing, printing, cutting, sewing, and garment faults. Examples of specific faults mentioned include holes, loops, lycra out, uneven dyeing, crease marks, squeezer marks, unfused edges, miss prints, weak stitches, seam puckering, and stains. Potential causes provided for each fault and recommended remedies such as properly cleaning machines, ensuring even dyeing conditions, using standard procedures, and removing contamination. The conclusion emphasizes the importance of care during processing and prevention to minimize faults.
Routine maintenance such as cleaning filters and checking equipment is performed weekly. The pH meter and blower meter are calibrated every 4 months. Every 2 years, more extensive maintenance is carried out like greasing bearings and changing pump oils to replace worn parts. Performing maintenance according to this schedule helps ensure the wastewater treatment plant operates efficiently.
The document provides details about an internship at Jaya Shree Textiles, the largest manufacturer of linen fabric in India. It describes the various processes involved in linen fabric production from bale opening to packaging, including hackling, drawing, roving, wet spinning, dyeing, warping, weaving, bleaching, and quality inspection. Key aspects of each process are highlighted such as the machines used, production rates, parameters, and quality control measures.
The document discusses maintenance of textile machinery. It defines different types of maintenance including reactive, preventive, predictive, and capital replacement. It then provides details on maintenance needs and procedures for specific textile processes like singeing, desizing, scouring, bleaching, dyeing, and finishing. Checklists are also included for yearly, half-yearly, and monthly maintenance of machinery. The goal of maintenance is to keep equipment functioning properly to maximize productivity and minimize downtime.
The document describes procedures for various textile testing methods, including:
1. Color fastness tests for wash, perspiration, water, and rubbing (dry and wet) which involve preparing samples, exposing them to specified solutions, and evaluating color change and staining.
2. Measuring dimensional stability by testing for shrinkage and spirality before and after washing samples based on calculated formulas.
3. Determining the pH of dyed fabric by cutting samples, soaking them, and measuring the pH of the resulting solution.
Knit Finishing in Arvind Ltd. bY Anupam Vowmic, created by Manojit Barman MANOJIT BARMAN
The document describes Anupam Bhowmick's summer training report at Arvind Limited in their Knits Finishing Division. It discusses the various processes involved in knit fabric finishing like slitting, drying, heat setting, compacting and different types of finishing. It also outlines the objectives of the training program, provides acknowledgements, and details the various machines used and defects observed in the knit fabrics.
The document provides information about a compactor machine used to control fabric shrinkage. It summarizes the machine's functions, operating parameters, and components. Key points include:
1. The compactor machine compacts fabric in the lengthwise direction and provides overfeed to control shrinkage during processing with steam.
2. It lists the machine's functions such as improving hand feel, reducing thickness, and controlling shrinkage.
3. It describes the machine components and operating parameters like temperature, speed, and overfeed percentage for different fabric types.
4. Diagrams show the mechanism and fabric path through a blanket and tube compactor machine.
The document discusses the process of fabric manufacturing from yarn production through several steps. There are three basic steps: 1) yarn production where fibers are spun into threads, 2) weaving or knitting where yarns are interlaced or looped to form fabric, and 3) further processing like bleaching, dyeing, and finishing to produce the final fabric. It then focuses on different types of knitting, including weft and warp knitting, and finishing processes like ironing, folding, and cartoning of knitwear products. The knitwear industry in Bangladesh is mainly located in the Narayanganj district.
This document discusses root causes of faults in knitted fabrics and their remedies. It begins by introducing the aims of analyzing fabric faults. It then covers causes and remedies for faults originating from yarns, such as barriness, spirality, shrinkage, and thick/thin places. Knitting-related faults like cracks, pin holes, contamination, and broken needles are also examined. Finally, dyeing and finishing faults such as shade variation, pin holes, creases, spots, and dust are analyzed. The conclusion restates that identifying fault sources allows knitters to take steps to prevent defects and improve quality and productivity.
This document discusses techniques for improving productivity in knitting departments. It identifies several key areas for improvement, including maintaining optimal temperature and humidity levels, using cool dry compressed air, and proper yarn and fabric storage. Controlling the environment helps reduce faults and waste while improving quality. Implementing these recommendations could increase productivity by over 25% and reduce costs through lower needle breakage and maintenance needs.
The document discusses sizing, which is the process of applying a protective coating to yarn surfaces to improve weaving efficiency. It defines sizing and describes why it is done for weaving. Various types of sizing are described, such as light, pure, medium and heavy sizing. Key factors to consider for size ingredients and properties of size ingredients are outlined. Common size ingredients for different fiber types like cotton, jute and polyester are listed. The functions of size ingredients and technological changes in yarn properties due to sizing are summarized. Different sizing faults and their causes are described. Finally, drying systems for sized yarn including cylinder drying are briefly discussed.
The document is a presentation on a study of operations and maintenance at Esquire Knit Composite Ltd, a leading garment manufacturer in Bangladesh. It covers the company overview, utilities, dyeing, finishing, sewing, and effluent treatment processes. It also discusses problems found, solutions, and recommendations. The presentation contains diagrams of the facilities and processes to explain the utility systems, dyeing machines, finishing equipment, sewing lines, and ETP plant.
This document provides an overview of Square Knit Fabrics Ltd (SKFL), including its location, departments, production capacities, certifications and achievements. SKFL has dyeing, knitting, finishing, quality control and R&D departments. It uses 66 knitting machines including circular and flat bed machines. Daily production capacity is 18-20 tons for knitting and 24 tons for dyeing. SKFL has received awards for being labor friendly and environmental standards. It is ISO and Oeko-Tex certified.
Six Sigma Approach for Industrial Quality Improvement and Defect EliminationMd. Injamamul Haque
This slide contains information about a case study of six sigma methodology, DMAIC approach. How to do an analysis, find the root cause and area to be improved through DMAIC methodology, just covered in this slide.
Wet processing is the treatment of textiles using water and involves three main divisions: pretreatment, coloring, and finishing. Pretreatment prepares fabrics for dyeing and printing by removing impurities. Coloring includes dyeing and printing to add color. Finishing makes fabrics suitable for the market by adding properties like anti-creasing. The typical wet processing sequence involves preparatory steps like desizing and scouring, followed by bleaching and dyeing/printing, and ending with washing and finishing. Key terms related to wet processing like grey fabric, stitching, and mercerizing are also defined.
The document provides an overview of the finishing processes at a textile company. It describes the slitting machine, which cuts fabric from tube form to open form. It then discusses the santax machine, which dries fabric using steam. Finally, it outlines the stenter machine, which controls width, GSM, and shrinkage of fabric during drying and allows for final softener applications. The stenter machine has multiple heating chambers and functions to maintain quality parameters during drying.
This document summarizes Noorul Islam Saiful's internship experience at Crystal Composite Ltd. It provides details about the company, his activities and responsibilities in different departments, including knitting, dyeing, sewing, and finishing. It also discusses fabric and garment defects, quality control measures, and standard minute values for sewing operations. Overall, the internship helped him gain work experience and professional skills.
Special Instruction:
Fabric shrinkage must keep within ±5%
Color fastness should be 4-5 range
Pilling range 3 to 5
pH range 5.5 to 7
Fabric weight will be allowed ±02%
Fabric quality should be s per approved swatches & Lab-Dips.
Batch to batch color matching should be 4-5
Batch to batch “Shade Band Swatch” must be submitted for approval.
Maintenance is important to maximize the useful life of textile machinery. It includes both preventive and breakdown maintenance. Preventive maintenance involves routine inspection and maintenance to prevent production issues, while breakdown maintenance repairs equipment after an issue occurs. Proper maintenance is needed to keep machinery running continuously at maximum production levels and minimize downtime. Regular maintenance includes checking utilities, mechanical and electrical parts, and following schedules for routine maintenance on a daily, weekly, monthly, quarterly, and yearly basis. The right tools are also needed to properly maintain machinery.
This document provides information about reactive dyes and disperse dyes. It discusses the dyeing conditions for different types of dyes including acid, basic, direct, disperse, and reactive dyes. It also summarizes the types and properties of reactive dyes and disperse dyes, as well as the dyeing processes for polyester fibers using disperse dyes. Finally, it lists some of the author's textile-related Facebook pages for additional information.
Viyellatex Group is a knit composite industry located in Gazipur, Bangladesh established in 2001. It has various departments including knitting, dyeing, and garments. The company produces fabrics and garments from materials like cotton, polyester, and nylon. It employs over 3,500 people and exports products to major brands around the world. The document provides details on Viyellatex's history, facilities, production processes, organizational structure, and machinery.
Viyellatex Group is a knit composite dyeing and garment manufacturing company located in Gazipur, Bangladesh that was established in 2001 and has over 4,000 employees. The company has knitting, dyeing, finishing, and garment production facilities and produces a variety of knit fabrics and garments for major international brands. The document provides detailed information on Viyellatex's organizational structure, production processes, machinery, and customer base.
This document provides an overview of Reedisha Knitex Limited, a leading knit composite factory in Bangladesh. It details the factory's location, production capacity, product mix, physical infrastructure, manpower, organizational structure, and machinery. The factory has over 20 dyeing machines and 8 finishing machines from brands like Thies, Fong's, and Dilmenler. It produces knitted fabrics and garments for major international brands and has over 1,800 employees across departments like knitting, dyeing, finishing, and quality control.
This document is a student project report from Southeast University's Department of Textile Engineering. It discusses fabric defects, their causes, and remedies. The objectives are to learn about knit fabric faults, the knitting process, and how to reduce defects and improve quality. Several types of defects are described such as drop stitches, barrenness, and imperfections. Potential causes include issues with materials, machines, and processes like knitting, dyeing and finishing. Remedies focus on machine adjustments and quality control measures.
1. The winch dyeing machine dyes fabrics like wool and silk through a process where fabric ropes are circulated through a dye bath and around a winch or reels.
2. It has a front compartment where dyestuffs and auxiliaries are added to the main dyeing chamber gradually.
3. The fabric ropes are immersed in the dye bath and circulated through the dye bath and around the winch, with the dyestuffs being dosed manually or automatically.
This document contains information about Mazadul Hasan Sheshir, including his name, student ID, batch, department, email, and blog. It also contains summaries and diagrams of different types of dyeing machines used in textile processing, including jigger, jet, beam, and winch dyeing machines. Diagrams show the dyeing process and internal workings of soft flow jet, beam, and winch dyeing machines. Pad printing and different pad processes are also summarized.
Jet dyeing machines dye polyester fabrics using disperse dyes in a continuous loop system similar to winch dyeing. The jet dyeing machine eliminates the reel and uses a closed tubular system where fabric is transported through the tube by a jet of dye liquor supplied through a venturi. This creates turbulence to help dye penetration while preventing fabric contact with tube walls. Little dye bath is needed in the bottom of the vessel due to the fabric's exposure to higher dye concentrations within the transport tube.
This document discusses water saving technology in the textile industry. It proposes using solophenyl dyes for dyeing cotton and cotton-polyester blends, which can save significant amounts of water compared to conventional reactive dyes. For 100% cotton fabrics, solophenyl dyes can reduce water consumption from 60-80 liters/kg to 20-30 liters/kg. For cotton-polyester blends, a one-batch dyeing process using solophenyl dyes has the potential to save water consumption from 120-140 liters/kg down to 30-40 liters/kg. Adopting these new dyeing techniques could help textile factories minimize their environmental impact and reduce production costs.
This document outlines guidelines for textile engineering students completing an industrial internship. It details key areas and processes to study across the textile production workflow, including knitting, dyeing, finishing, garment production (patternmaking, cutting, sewing), printing, embroidery, washing, merchandising, commercial, quality control, and work study. The goal is for students to gain hands-on experience and technical knowledge of textile engineering by observing each stage of fabric and garment production firsthand during their internship.
AKH Knitting & Dyeing Ltd. is a garment manufacturing and exporting company located in Savar, Dhaka, Bangladesh. It has an estimated project value of $9 million USD and produces knitted garments. The company is a private limited company managed by an executive board and exports to international markets in Europe and North America. It has all necessary certifications and licenses to operate as an export-oriented garment factory in Bangladesh.
This document discusses the effect of finishing processes on knit fabrics. It describes how finishing improves physical properties like feel, strength and shrinkage. The techniques of finishing depend on factors like the fabric composition and its intended end use. Common finishing treatments aim to impart properties like softness, luster and dimensional stability. The document then examines specific finishing stages like hydroextraction, drying, slitting, stenting and compacting. Graphs show how properties like GSM and shrinkage are affected differently for various fabric types as they progress through finishing. The discussion analyzes the results and references additional sources for information on textile finishing.
This document discusses a stenter machine, which is used in textile processing. It has three main units: a padder to apply finishing agents uniformly, weft-straightening devices, and control equipment. The stenter machine is used for processes like equalizing fabric skew and bow, controlling printed designs, setting fabric width, applying finishing chemicals, and drying. It works by conveying fabric between two endless chains through heated compartments to dry and set the fabric. Key aspects of operation include temperature uniformity and control, and devices to straighten the weft of the fabric.
This document provides an overview of ERP software for the textile industry. It discusses what functions are included in textile ERP systems, some major ERP vendors, key factors in selecting a system, common barriers to implementation, and linked functions. It also briefly mentions whether companies are using electronic commerce. The document aims to explore ERP systems in textile manufacturing and investigate various issues related to their use.
MX dyes are a family of "cold" reactive dyes first developed by Imperial Chemical Industries of Britain. They are very popular for dyeing cellulose fibers like cotton. MX dyes are less commonly used by industrial dyers due to their high reactivity making them harder to control and their relatively high cost. Care should be taken when using MX dyes due to the potential to cause respiratory allergies from inhaling dye dust.
This document provides information about Mazadul Hasan Sheshir, including his name, student ID number, batch, department, email, blog, and university information. It then lists various knitting machine cam arrangements, including 3-thread fleece, auto stripe cylinder, diagonal terry, polar fleece, 1x1 rib cylinder, 1x1 rib dial, polar fleece sinkar cam, single jersey, single lacoste, and stop rib cylinder. Finally, it provides links to several of Mazadul's Facebook pages related to textile manufacturing technologies and his textile lab blog.
The document summarizes the operation of a slitting machine used in textile processing. The slitting machine cuts open tubular knitted fabrics and removes excess water. It consists of a blade and sensor that detects the needle line to properly cut open the fabric. The fabric passes through rollers and a basket with an exhaust fan before being cut, padded with softeners, squeezed, and delivered as an open width fabric.
This document is a presentation on knitwear design that includes:
- An introduction comparing knit and woven fabrics
- Descriptions of different types of knitting, knit garments, and knitting terminology
- Explanations of different types of knitting machines and the elements of circular knitting machines
- Details about a knit factory including its capacity, machines used, and end products
- Samples of different knitted fabrics produced and faults that can occur in knitted fabrics
- Quality control processes for knitted fabrics
This document provides an overview of the textile manufacturing process from spinning to processing at a textile company. It includes descriptions of the machinery and processes in various departments like spinning, knitting, dyeing, finishing and quality control. It also lists common fabric types, finishes, and faults observed during production. Key departments and their functions are outlined along with process flows, material types and testing procedures.
The document provides details about the weaving process from warping to final folding of the woven fabric or towel. It involves key steps like warping, sizing, drawing-in, looming, and folding. Warping involves winding yarn parallel onto beams. Sizing adds size to strengthen the yarn. Drawing-in threads the yarn through heddles and reed according to the weave pattern. Looming uses looms like Sulzer or air jet to weave the warp and weft yarns. Folding inspects and packs the final woven product.
Production Process of fully fashioned knitwear manufacturing.Muhammad Rahat
Fully fashioning is a method of shaping knitted structure by increasing or decreasing the number of Wales or needles. Fully fashioned knitwear is manufactured through knitting the whole structure.
This document provides information about an industrial training at Biswas Synthetic Ltd, a textile company in Bangladesh. It includes details about the company profile, various production sections like knitting, dyeing, finishing, and quality control. The knitting section describes the different types of knitting processes, primary knitting elements, and end products produced on single jersey circular knitting machines.
This paper deals with the result of an investigation by using different count yarn but same
parameters of knitting machine to produce cotton-elastane single jersey fabric. Here,the all parameters of
knitting machine including gauge, dia ,Stitch length, rpm, machine tension etcare same. Dyeing process also
carried out at same parameter for all fabrics. Finishing process like Heat setting, Stentering, compacting are
done in same condition But we use different count cotton yarn. In this paper, we mainly deal with the physical
properties of single jersey cotton fabric. we try to identify how the properties of single jersey knitted fabric like
fabric diameter(gray& finished condition) ,WPI&CPI(gray& finished condition),Fabric GSM(gray& finished
condition),Shrinkage (%) length &width wise, spiralityare changing with Count .Finally the findings are as
expected with some variation with the result that are thought theoretically.
Karnaphuli Knit Wear Ltd is a knit composite factory located in Dhaka, Bangladesh. It has 750 employees and produces knit fabrics and garments for export. The factory has 62 knitting machines, 26 dyeing and finishing machines, and over 800 sewing machines. It produces a variety of knit fabrics including single jersey, pique, interlock and fleece. Raw materials include grey fabric, dyes, chemicals and sewing thread. Production follows steps of fabric inspection, batching, pretreatment, dyeing, drying, slitting, compacting and inspection before packing and delivery. Planning involves analyzing orders, scheduling knitting, dyeing, cutting, printing, embroidery, sewing, finishing
This document provides information about knitting processes and elements. It includes:
1. A process flow chart showing the steps from yarn feeding to inspection.
2. An organogram of a knitting section organizational structure.
3. Descriptions of the three primary knitting elements - needles, cams, and sinkers - and their types and functions.
4. Types of knit fabrics and features of single jersey and flat bed knitting machines.
This document provides information about Tua-Ha Textile Ltd., a knitting, dyeing, finishing, and garment manufacturing factory in Bangladesh. It details the factory's objectives to meet client expectations, gain buyer confidence, be known for quality Bangladeshi products, create jobs, and use modern communication technologies. It also outlines the factory's compliance with regulations regarding labor, health, and safety. The document focuses on the factory's knitting section, describing the types of fabrics it produces, raw materials used, production processes, machinery, and potential faults in knitting.
Metro Knitting & Dyeing Mills Ltd. is a composite textile factory located in Narayanganj, Bangladesh. It produces knitted fabrics and garments for export. The factory uses yarn and fabrics as raw materials and produces items like t-shirts, polo shirts, and sweaters. It has several knitting machines from brands like Orizio and Fukuhara. The factory performs quality control testing and has utilities like boilers and air compressors. The purpose of the student visit was to learn about knitting processes and quality practices.
The document provides an overview of Horizon Group Ltd, a garment manufacturing factory in Bangladesh. It details the factory's production processes which include yarn dyeing, fabric dyeing, knitting, cutting, printing, sewing, finishing, and utility sections. It describes the machinery, production capacity, buyers, and sister organizations. It also discusses the factory's compliance policies and effluent treatment processes.
This document provides information about an industrial attachment at Square Fashions Ltd., a textile factory in Bangladesh, completed by four students from Bangladesh University of Textiles. It includes details about Square Fashions such as its establishment, production capacity, departments, manpower organization, shift changes, knitting section layout and machines. It also summarizes the dyeing, finishing, quality control, utility and effluent treatment processes at the factory.
This document discusses ring spun yarn production. It provides details on the production process including bale management, blow room operations, carding, drawing, combing, roving using a simplex machine, ring spinning, autoconing, heat setting, and packing. Production parameters are given for 24s, 30s, and 40s ring spun yarn as well as 24s and 30s combed yarn. The document provides a comprehensive overview of the ring spinning process from raw cotton to finished yarn.
FakirApparels Limited is a 100% export oriented knitwear factory established in 1998 in Bangladesh. It has 700,000 square feet of production space with 7500 employees. The factory produces 140,000 garments per day along with 20 tons of knitting and 30 tons of dyeing daily. It uses modern production planning software and has an annual turnover of $75 million. The factory aims to be a world-class quality apparel manufacturer through lean processes, management systems, and flexibility with customers.
Raymond Textiles provides an internship opportunity at its textile division in Vapi, India. The Vapi plant has a capacity of 154 looms and 21840 spindles across 94.4 acres. It produces 25 million meters of fabric annually using a fully digital and automated manufacturing system. The internship aims to provide understanding of processes from yarn production to finishing of fabrics, including quality aspects. Key departments include spinning, weaving, designing, quality control and supply chain management. The textile processes involve scouring, combing, dyeing, recombing, winding, warping, drawing, weaving and finishing. Quality is ensured through stringent testing at various stages in the laboratory.
This document summarizes a student group's presentation on their industrial visit to Noman Composite Textile Ltd. The key points covered include:
1. An introduction to the company and factory location.
2. The purposes of the visit were to observe the woven fabric manufacturing process, familiarize with the industry environment, and understand the machinery and utilities.
3. Raw materials used include yarn from various spinning mills and sizing chemicals.
4. Products manufactured are woven fabrics and home textiles sold to major brands like H&M, Zara, and Walmart.
5. The document outlines the various production processes from winding to finishing.
Efficiency losses calculation and identify causes of losses of circular knitt...Elias Khalil (ইলিয়াস খলিল)
This thesis deals with a major problem of production loss of a knitting industry. The knitting machine has to stop when defects occurred and then faults are corrected, which results in time loss and efficiency loss. Not only that the knitted fabric may be rejected if quality requirements are not met. An effective monitoring is required to avoid defects and to avoid productivity and quality losses. The study identifies two main categories of defects (average time required for correcting defects and machine down time) are responsible for reducing productivity. The thesis reflects that due to yarn breakage machine stopped for seen minutes per days, for maintaining machine stopped for two hours per month, for needle breakage six minutes per day and for technical problem machine stopped for several times.
This document provides information about the industrial processes at Noman Terry Towel Mills Ltd. It details the company profile, raw materials used, and manufacturing processes including winding, warping, sizing, weaving, dyeing, garment production, and effluent treatment. A variety of machinery is used at each stage to produce finished towel products for buyers.
Weft knitting machine & parameters of weft knitted fabricAzmir Latif Beg
Knitting is the interloping of yarn which is interlocking in various ways to form fabric. Knitting is the process of manufacturing fabric by transforming continuous strands of yarn into a series of interlocking loops, each row of such loops hanging from the one immediately preceding it. The basic element of knit fabric structure is the loop intermeshed with the loop adjacent to it on both sides and above and below it.
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This document provides definitions and background information on various textile terms. It begins with an introduction to textiles and defines key terms like fiber, filament, yarn and fabric. It then discusses the history of natural fibers like cotton, wool and silk. The document also summarizes the development of various man-made fibers like rayon, nylon, acrylic and polyester. It provides timelines of when these fibers were first invented and commercialized. The document is intended to serve as a reference for textile engineering students.
This document provides information about garment manufacturing and exporting processes. It was prepared by Md. Kamrul Hasan, a Textile Engineering graduate from Southeast University in Bangladesh. The document contains several sections that discuss key topics like buyers and buying houses, major garment exporting countries, GSP status, garment export procedures, costing, purchase orders, letters of credit, and timelines. It aims to serve as a reference for students and professionals in the garments sector.
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9. 4.1 KNITTING:
Knitting is defined as the construction of fabric by interlocking loops of a single
yarn with the help of hooked needles. Knitting is the method of creating fabric by
transforming continuous strands of yarn into a series of interlocking loops, each raw of
such loops hanging from the one immediately preceding it.
4.2 TYPES OF KNITTING:
There are two types
1. Warp Knitting.
2. Weft Knitting.
Warp Knitting: In a warp knitted structure, each loop in the horizontal direction is made
from a different thread and the number of threads are used to produce such a fabric is at
least equal to the no of loops in a horizontal row.
Fig: Warp Knitting
Fig: Weft Knitting
Weft Knitting: In a weft knitted structure, a horizontal row f loop can be made using one
thread and the threads run in the horizontal direction.
11. Process Flow chart of Knitting (Circular):
Sample Fabric
Design analysis
Machine Selection
Machine Setting for the Required Design
Knitting
Conform Required Quality
Withdraw the Rolled Fabric and Weighting
Inspection
Delivery
14. KnittingM/Cparts
A. Needle
B. Sinker
C. Cam
D.Cylinder
E. VDQ pulley
F. Cam box
G. Sinker box
H.Creel & creel stand
I. Yarn guide
J. Accumulator
K. Toothed belt
L. Thread signal light
M.Central signal lamp
N. Yarn feeder
O. Cleaning fan
P. Air gun
Q. Oil box
R. Needle detector
S. Fabric spreader
T. Take up roller
15. Needle
Needle is the 1st basic Element of knitting.
There are following types of needles.
Latch needle
Bearded needle
Compound needle
Carbine needle
Among them latch
needle is most widely used. Carbine
needle is used in warp knitting.
Latch
Hook
Butt
16. Cam
Cam is the 3nd basic element
of
knitting .Cams are arranged in
Cam box. A cam box contain
four track. This track
determine
The path of different butt’s
Needle.There are following
Types of cam.
A.Knitting cam
Knit cam
Tuck cam
Miss cam
Tuck cam
Miss cam
Knit cam
Cam box
B.Engineering cam
17. Sinker
• Sinker is the 2nd knitting
element.
• It is a thin metal plate.
• During knitting sinker
perform the following
three tasks.
Functions :
• Loop formation
• Holding down
• Knocking over
18. VDQ pulley
• Variable dia for quality(VDQ) pulley is used to control the yarn
feeding speed.
• If yarn is fed more than stitch length will be increased.
• One VDQ pulley contain two slot. Each slot for different types
yarn.
• Some times more than one slot used for the same yarn.
• Dia of VDQ pulley determines the yarn feeding speed.
• When dia is more, then toothed belt runs faster & drives
accumulator with more speed as a result yarn is fed more.
19. Toothed belt
Toothed belt indirectly involved in controlling stitch
length.
If toothed belt not connected with VDQ pulley then
accumulator can not move accurately & produced
fabric will be faulty.
20. Yarn signal light
• Thread signal light indicate each yarn tension.
• If tension is not accurate then lights on.
• Mainly when yarn breaks this lights on.
• If this light not off then m/c will not run.
• This light helps to find out the faults present on which
yarn.
21. Needle detector
• Needle detector used to detect weather any
needle is broken or not.
• It is positioned along needle latch.
Needle detector
22. • Single Jersey:
– Single Jersey Plain
– Single Jersey Half feeded
Lycra
– Single Jersey Full feeded
Lycra
– Fleece
– Slab
– Pique (S/D)
– Single Lacoste
– Double Lacoste
– Micro polar fleece
• Double Jersey :
• Rib
• 1*1 Rib
• 2*1 Rib
• 2*2 Rib
• Lycra Rib
• Interlock
• Jacquard
27. 1. Clean the machine & adjacent area.
2. Put required count of yarn in the creel.
3. Make knot with old yarn.
4. Check air pressure, m/c condition & adjust the PC controller.
5. Keep the door closed.
6. Switch on power.
7. Run the machine by hand drive for a while.
8. If the machine is not running smoothly adjust the machine(as required).
9. Run the machine with very low speed for 3-5 min.
10. Adjust all parameters.
11. Run the machine with full speed.
12. Check the yarn tension for at least 5 feeders.
13. Re-check the parameters(correct it if required).
14. Check the fabric quality during operation.
15. After competition of the adjusted revolution, m/c will automatically stop.
16. Open the door.
17. Take out the knitted roll.
18. Close the door again.
19. Clean the machine.
20. Press oil flash up to 3 revolution
Following the steps for knitting operation :
28. PROCESS OF INCREASING PRODUCTION
QUANTITY
1. By increasing m/c speed:
Higher the m/c speed faster the movement of needle and ultimately production will be increased.
2. By increasing the number of feeder:
If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in
one revolution at a time.
3. By using machine of higher gauge:
The more the machine gauge, the more the production is. So by using machine of higher gauge production can be
increased.
4. By imposing automation in the m/c:
a) Quick starting & stopping for efficient driving system.
b) Automatic m/c lubrication system for smoother operation.
c) Photo electric fabric fault detector
5. By imposing other developments:
a) Using creel-feeding system.
b) Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage.
c) Using yarn feed control device.
d) Using auto lint removal.
32. Batching is the process to get ready the fabrics that should be dyed and
processed for a Particular lot of a Particular order.
Batch Management :
Primarily Batching is done by dyeing manager taking the above criteria
under consideration..
Batch process follow-up :
1.Grey fabric inspection
2.Batching
3.Fabric Turning
4.Storing for dyeing
Criteria of proper batching :
1.To use maximum capacity of existing dyeing m/c.
2.To minimize the washing time or preparation time & m/c stoppage
time.
3.To keep the no. of batch as less as possible for same shade.
Batching :
33. Lab dip is a process by which buyers supplied swatch is matched with the varying dyes
percentage in the laboratory with or without help of “DATA COLOR”
Lab dip plays an important role in shade matching & and detaching the characteristics
of the dyes and chemicals are to be used in the large scale of production so this is an
important task before bulk production.
There are two section in dyeing Lab
1.Laboratory
2.Lab-Dip Procedure
34. Development of Lab Dip
Drying
Cold wash
Hot wash
Acid wash
Normal wash
Unload
Pot dyeing
Manual dispersion (pipatting)
Start up recipe given
Recipe start up software
Spectrophotometer reading
Receiving standard swatch
35. Quality Assurance System
Quality Assurance System Can be divided as:
On Line QC-
1. Raw Material Control 2. Color Match 3. Process Control
Off Line QC-
1.GSM 2. Shrinkage 3. Width or dia 4. Light Fastness 5. Wash
Fastness 6. Rubbing Fastness 7. Pilling Test 8. Perspiration Test
9. Spirality
36. DYEING SECTION
Production Capacity per Day: 8 Ton
Total No of Machines: 10 pcs.
Available Machine : Winch Dyeing M/C &SampleDyeingM/C
Machine Capacity(kg): 1200, 900, 800, 600, 450, 50, 10
Machine Temperature: 135 C, 98 C
Brand Name of Machines: Dillmenler & Suntex.
Country Of Origin: All are Turkey.
38. RAW MATERIALS FOR DYEING:
Raw materials used in the dyeing section are:
• 1. Grey Fabrics
• 2. Dyes
• 3. Chemicals
Grey Fabrics:
Following types of grey fabrics are dyed:
• Single jersey
• Single jersey with Lycra
• Single Lacoste
• Fleece
• Interlock
• Rib
• Rib with Lycra
• 1*1 Rib
• 2*2 Rib
• Different types of collar & cuff
39. Name of Dyes
• Reactive Black B
• Reactive Red – 3BS
• Reactive Yellow – 3RS
• Reactive orange – 2RX
• Kiractive N Blue ME 2GL
• Reactive Red ME 6BL
• Reactive Navy Blue GG
• Kiractive Red KHW
• Kiractive Yellow KHW
• Dychhefix Black GR
• Dychhefix Yellow 3R – XF
• Dychufix Red 3BXF
• Arcazol Yellow 4GL
• Beazactive Red S2B
• Remazol Blue RSPL
• Remazol T Blue G
40. Chemical Used
• Detergent
• Leveling Agent
• Sequestering Agent
• Anti creasing agent
• Stabilizer
• Anti-Foam
• Per-Oxide killer
• Enzyme
• Softener
• Salt
• Fixing Agent
• Alkali
• Bleaching Agent
• Brightener
41. Pabna Textile Engineering College
Flowchart of Dyeing
Grey Fabric
Scouring
Bleaching
Neutralization
Enzyme
Washing
Dyeing
Neutralization
Softening
42. Dyeing Parameter
PH Check during Wet Processing:
•
• Bleaching Bath PH : 10.5-11
• Neutralization / After bleaching : 5.5-6.5
• Initial Dye Bath PH : 5.5-6.5
• After Salt addition PH : 6.5-7.5
• After Alkali addition PH : 10.5-11.2
After Dyeing ph : 5.0-6.0
• Fixation Bath PH : 4.0-5.0(For color)
• Softener Bath PH : 5.5-6.0 (For white)
Fixation Time:
•
• For light Shade : 30-40min.
• For Medium Shade : 45-50min.
• For Deep Shade : 50-60min.
M : L Ratio : 1:6 - 1:9
43. Various Faults in Dyeing
• Uneven Dyeing
• Patchy Dyeing
• Specky Dyeing
• Dye spot
• Shade variation
• Pilling
• Crease marks
45. Finishing : Finishing is a chemical or mechanical
process applied on textile goods after dyeing and
printing process just to give it some quality development
according to the demand of user or customer or buyer.
Objective of Finishing:
• Improving the appearance – Luster, whiteness, etc.
• Improving the feel, this depends on the handle of the
material and its softness, suppleness, fullness, etc.
• Wearing qualities, non – soiling, ant crease, ant
shrink, comfort, etc.
• Special properties required for particular uses–water–
proofing, flame proofing, etc.
• Covering of the faults in the original cloth.
• Increasing the weight of the cloth.
46. Flowchart of Finishing
Finishing
Open Line
Make Open by Slitting m/c
Stentering m/c
Open Compactor m/c
Final Inspection m/c
Rolling m/c or Packaging
De-Watering m/c
Dryer
Tubular Compactor m/c
Final Inspection m/c
Rolling m/c or Packaging
Tube Line
48. Stock Solution:
• 0.100 gm dyes and 100 cc water = 0.1 % Stock
• 0.500 gm dyes and 100 cc water = 0.5 % Stock
• 1 gm dyes and 100 cc water = 1 % Stock
• 2 gm dyes and 100 cc water = 2 % Stock
• 1 gm dyes and 50 cc water = 2 % Stock
• 20 gm dyes and 100 cc water = 20 % Stock
49. Calculation for Dyeing Agent
Recipe% * Sample Weight (gm)
• Dyeing Solution = ──────────────────── ml
Stock Solution %
gm/l * Sample Weight (gm)
• Salt = ────────────── ml
100
gm/l * Total Liquor
• Soda Solution = ────────────── ml
Stock Solution %* 1000
1*50
• Leveling = ────────────── ml
Stock Solution %* 1000
50. Final Inspection….
Inspection refers to an investigation process of accepting or
rejecting the final finished fabric from the bulk. It is an observation
process of finding out each & every visible fault in the fabric.
• Equipment used
Nazar inspection m/c, Pakistan
Inspection table
Vervide Day Light box
Following faults are detected & identified in final inspection for body
• Penalty points legend:
H = Hole WX = White speaks
CS = Chemical stain. R= Rub mark
W = Water spots. DS = Dye Stain
Fy = Fly yarn. D= Dirt Stain
YM = Yarn contamination. RS=Rust Stain etc.
51. • Faulty appearance:
US = Uneven shade N= Needle line
N= Neps BR= Barre mark
CR= Crease mark CM= Crumple mark
HR= Hairy DC= Dead cotton
MS= Machine stoppage BW= Bowing
Besides, roll to roll and meter to meter variation is checked.
Acceptance calculation:
Total point per 100 square yards
Actual points counted 36 = x x 100
Actual Roll length Actual width= Points/100 square yards.
Classification of Inspection Fabric:
< 40 points = A
41-60 points = B
61-80 points = C
80 above = Reject
52. Effluent Treatment Plant (E.T.P)
GTA Sports Ltd has an ETP for treating the
waste water from different processing section
like dyeing. ETP has different sectors like
Equalization tank, Bio-reactor etc.
Objects of E.T.P:
-To control the P.H
-To remove the coloring matter from the water.
-To maintain the proper value of BOD (Biological Oxygen Demand)
and COD (Chemical Oxygen Demand).
53. Water Treatment Plant (W.T.P)
GTA Sports Ltd use water from land which is
pumped by deep tube well. There is a standard
quality water treatment plant (WTP) in MFL
where the hardness of water is being treated
continuously and being soft which is required for
the dyeing purposes. Besides this they are using
water to produce steam by heating. It is done
by boiler.
54.
55.
56. ORGANIZATIONAL STRUCTURE
DIRECTOR (OPERATION)
↓
MERCHANDISING MANAGER
↓
MERCHANDISER
↓
TRAINEE MERCHANDISER
Main functions of a merchandiser to execute the export
order perfectly on time.
– Fabric consumption calculation.
– Accessories consumption calculation (e.g. thread, button, interlining,
label, poly bag, Carton etc.)
– Sourcing of fabrics.
– Sourcing of accessories.
– Possible date of arrival of fabrics & accessories in the garments factory.
– Costing.
– Garments production planning.
– Pre-shipment inspection schedule.
– Shipping document.
57. Objects specifically for merchandising purposes:
• 1. Sell by showing and promoting.
• 2. Create an emotional connect between the viewer and the
display.
• 3. Encourage the shopper to enter the store.
• 4. Get the customer to pause and “shop” the selling floor.
• 5. Establish, promote, and enhance the store’s image.
• 6. Entertain customers and enhance their shopping experience.
• 7. Introduce and explain new products.
GARMENTS MERCHANDISING
58. Merchandising helps in:
• educating the customers about the product/service in an effective
and creative way.
• establishing a creative medium to present merchandise in 3D
environment, thereby enabling long lasting impact and recall
value.
• setting the company apart in an exclusive position.
• establishing linkage between fashion, product design and
marketing by keeping the product in prime focus.
• combining the creative, technical and operational aspects of a
product and the business.
• drawing the attention of the customer to enable him to take purchase
decision within shortest possible time, and thus augmenting the selling
process.
59. The main procedures of merchandisers
are as followed:
• ►Understanding Sample Order
• ►Managing order route card and production time
table
• ►Using route card to reschedule activities
• ►Submitting pre-production samples
• ►Solving shortage problem
60. Merchandiser must be known as:
• Thread details
• Printing details
• Washing
• Dyeing
• Knitting (Based on fabrication)
• Consumption (Based on fabrication,
correspondence & communication)
• Price (Yarn + Knitting + Dyeing + Finishing +
Process loss)
• Wastage
62. Faults in Knitting
• Introduction:
Faults in circular knitting production can
be caused in various ways and quite a few of them can not be related to
just one cause. The following explanations are expected to be helpful in
trying to locate the causes of these faults easier.
• Sources of faults could be-
1. Faults in yarn and the yarn package
2. Yarn feeding and feed regulator.
3. Machine setting and pattern defects.
4. Machine maintenance.
5. Climate conditions in the knitting defects
63. Knitting fabric faults with causes & remedies
Name of the faults:
Hole mark
Needle mark.
Sinker Mark.
Star mark.
Drop stitches
Oil stain
Rust stain.
Pin hole.
Lycra katta.
Yarn contamination
Crease mark.
Lycra out.
Loop.
Tana loop.
Dia mark.
64. Thick & Thin Color spot
Oil sport Lycra spot
Heat set problem Star mark
Softener mark
Pin hole
Needle drop Color mark
65. Causes & remedies
1. Name : Hole mark
Cause : a. Due to yarn breakage.
b. Faulty yarn count.
c. Faulty feeder setting.
d. Badly knot or splicing.
remedies: a.Improper feeder setting
2. Name: Needle mark.
Cause: a. Due to needle breaks during the knitting cycle.
b . If a needle or needle hook is slightly bends
then needle mark comes on the fabric.
remedies: a. Cleaning the needle group
b.Change the needle
3. Name: Sinker Mark.
Cause: a. when sinker corrodes due to abrasion then
sometimes cannot hold a new loop as a result
sinker marks comes.
b. If sinker head bend then sinker mark comes.
remedies: a. cleaning the sinker group
b. Change the sinker
4. Name: Star mark.
Causes: a. Yarn tension vari ation due to production.
b. Buckling of the needle latch.
c. Low G.S.M fabric production.
remedies: a. proper yarn tension
b. change the needle
5. Name: Drop stitches
Causes: a. Defective needle.
b. Take down mechanism too loose.
c . Insufficient yarn tension.
66. d. Improper setting of feeder.
remedies: a. Reset the needle
6. Name: Oil stain
Causes: a. when oi l lick through the needle
trick then it pass on the fabric & make a line.
b. Excess oil pressure in the oil line.
remedies: Proper lubrication and clean machine
7. Name: Rust stain.
Causes: If any rust on the machine parts.
remedies: clean the m/c
8. Name: Pin hole.
Causes: Due to break down or bend of latch,
pin hole may come in the fabric.
remedies: a. Concentrate on needle and latch
9. Name: Lycra katta.
Causes: a. Improper tension.
b. Dust deposit in the pulley.
remedies: clean the feeder & lycra
10. Name: Yarn contamination
Causes: a. If yarn contains foreign fibre then it remains in the fabric even
after finishing.
b. If lot, count mixing occur.
remedies: same count of yarn has to used
67. • The textile materials that are used in different sphere to meet the demand
and to solve the various technical problems and to improve the quality in
need is called technical textiles.
Fiber used in Technical Textiles
The following fibers are used in technical textile product manufacturing.
1. Conventional fibers.
2. High strength and high modulus organic fibers.
3. High chemical- and combustion-resistant organic fibers.
4. High performance inorganic fibers.
5. Ultra-fine and novelty fibers.
6. Civil and agricultural engineering fibers.
7. Automotive and aeronautics fibers.
8. Medical and hygiene applications fibers.
9. Protection and defense fibers.
Technical Textiles:
68. Yarn used in technical textiles
Technical yarns are produced for the manufacture of technical textiles.
They have to meet the specific functional requirements of the intended
end-use. This may be achieved through special yarn production techniques
or through the selection of special fibre blends or a combination of both.
This chapter describes the yarn production technologies that are applicable
to technical yarns and discusses the structures and properties of the yarns
that may be produced using these technologies.
Staple fibre yarns
1. Ring spinning
2. Rotor spinning
3. Friction spinning
4. Wrap spinning
5. Air-jet spinning
6. Twistless spinning
69. • Normally in technical fabrics production woven, knitted and non woven
structure are used.
• Woven Fabrics: Plain, sateen, twill, etc are used.
• knitted Fabrics: Weft & warp knitted designs and their derivatives are
used.
• Non- Woven Fabrics:
• 1. Air laying .
• 2. Wet laying .
• 3. Dry laying wood pulp .
• 4. Spun laying .
• 5. Flash spinning .
• 6. Melt blown .
• 7. Chemical bonding .
• 8. Thermal bonding .
• 9. Solvent bonding .
• 10. Needle felting .
• 11. Stitch bonding .
• 12. Hydro-entanglement.
• Etc are used.
Structure of Fabrics used
70. Categories Of Technical Textiles
Technical textiles can be classified into many categories, depending on their
end use. The classification developed by Techtextil, Messe Frankfurt
Exhibition GmbH is widely used in Europe, North America and Asia.
reporting solutions
The classifications are :
Agrotech (Agro-textiles)
Mobiltech (Automotive and aerospace textiles)
Buildtech (Construction Textiles)
Clothtech (Clothing Textiles)
Geotech (Geo-textiles)
Hometech (Domestic Textiles)
Indutech (Industrial Textiles)
Medtech (Medical textiles)
Mobiltech (Textiles used in transport)
Oekotech or Ecotech (Environmentally-friendly textiles)
Packtech (Packaging textiles)
Protech (Protective textiles)
Sporttech (Sports textiles)
71. Geo-textile
Definition:
Textiles used in the ground are termed “Geo – textiles”. Any permeable
textile materials used for filtration, drainage, separation, reinforcement and
stabilization purposes as an integral part of civil engineering structures of
earth,
rock or other construction materials.
Materials and structures:
Natural & synthetic materials can be used. Jute, Absorbent cotton,
substitute, polypropylene, acrylic, rayon, monofilament, spun yarn and
thermoplastic yarn can be used. Woven, non-woven and knitted fabrics can be
used as Geo textile material.
Classification of Geo textile:
Geo textiles should include constituent polymers or fibres elements, the
form or method of construction, weight and thickness, engineering function,
end
use and engineering properties.
1. According to polymers or fibrous elements:
a. PP
b. PE
c. PES
d. Nylon
2. According to form or method:
a. Melt bonded Fabric
b. Woven
c. Non woven
d. Needle punched
e. Resin bonded
f. Combined non woven technique.
3. Knitted fabric
a. Warp knitted fabric
72. b. Weft knitted fabric
Warp knitted weft insertion geo textiles offer the following
advantages when compared to woven geo textile:
1. Strength: For strength they are lighter than woven geo textiles using the
same yarn. This makes for easier handling & laying on site, thus transport
& labour costs are less in real terms.
2. Knitted geo textile has exceptional tear strength. Additional strength can
be designed & built in to the weft insertion.
3. Knitted geo textiles can be incorporate as additional fabric to form a true
composite geo textile, the fabric being simply knitted in.
4. The individual yarns in the warp knitted weft insertion geo textiles are
straight when incorporated. So, they are able to take up the strain
immediately on loading.
What functions are performed by Geo textiles?
The functions are:
� Filtration
� Separation
� Drainage
� Protective shield against erosion
� Reinforcement
� Land stabilization/support
� Earth filling
� Moisturizer
Discuss the potential areas of application of Geo textile:
Applications are:
1. Road construction: Construction of road over soft land (Link road)
2. Rail road: To prevent upward pushing of mud.
3. Road surface: For the reinforcement of asphall in road surface.
4. Area stabilization: Swam plants.
5. Foundation for industrial development
6. Waste disposal: Cover and seal in waste.
7. Ground drainage
8. Canal and river lining
9. Marine erosion control
73. 10. Construction of new land area
Geo Jute
Introduction:
It is a biodegradable soil stabilizing blanket to control erosion on
disturbed earth surface while encouraging the growth of protective
negotiation
.
Give the typical specification of Geo Jute:
Raw materials: Cuttings, Caddis & lowest part of long jute.
Warp/10 cm: 6.5
Weft/10cm: 4.5
Width: 122 cm
Weight: 600 gm/linear meter
1000 gm/linear meter
What are the prime functions of Geo Jute?
The functions are:
1. Control erosion of base soil allows the formation of vegetation to give long
term protection.
2. On initial rainfall jute will absorb up to 2.5 lift of water per square of geo
jute, so reduces over land flow.
3. Helps to reduce loss of grass seeds
4. Mesh structure of jute forms micro tarraus which controls rates of flows.
5. Prevents dehydration of soil.
End use:
� Road & railway slopes, bridge alentments, medium strips.
� Drainage, ditches, culvert and table drain out let
� Lake, canal & river banks.
� Farm & forestry.
� Green ward development in sports ground, airports, housing estates
� Sand dune, stabilization.
74. Buildtech (Construction Textiles)
Textiles used in the building of the concrete reinforcement and before the
foundation is, fittings, insulating materials, fitting, air conditioning, noise
prevention, eye protection, sun protection, building safety . In the cold
isolation of the country in the walls and ceiling, but the mass communication
is one of the most significant criteria of advanced constructions and
architectural constructions. build-tech is valuable in providing protection
against the external environment and internal documents such as bars and
cement.
Application:
Textiles and complex materials applied in building of constructions,
dams,bridges, tunnels and roads fall into this class. Illustrations of
productions are compounds built architectural technology, sun blinds,
canopies, objective reinforcement, lamp, table linen, blankets, roof, the
network structure of scaffolding, signaling, waxing and textile structures are
taken and rolled products.
Interesting and enjoyable to use aesthetic is the function of textile membranes
for the construction of housing. This region is also known textile architecture.
PSE covered tenacity, PVC, Teflon woven fiberglass or silicone PSA covered for
their losses by pulling function. A example of the construction steps are in
football, airports and hotels.
75. Medical Textiles:
Due to astounding technological developments, techincal textiles are
extensively used in the healthcare industry today. In the field of medical
application, technical textiles are not just used in contact with the skin, but
also fulfill important functions within the body (intra-corporal applications
like implants). Technical textiles offer medical and hygiene industry with
unparalleled protection, comfort and cost saving.
These highly specialized and bio- compatible technical textiles, used for
medical and hygiene applications are called “MEDTECH.” The characteristics
required of MEDTECH vary depending on the task for which they are to be
used. Some applications demand a protective function, others a high
absorptive capacity and some other others impermeability. Special
antimicrobial finishes are an important characteristic of these textiles
Depending on the nature of application, most of the medical products are
disposable in nature and are made of nonwoven fabrics. In global markets
disposables are fast replacing non-disposable health care textiles.
Application:
Healthcare/ hygiene products- Include bedding, clothing, surgical
clothes, products for feminine hygiene like sanitary napkins, baby and
adult diapers etc.
Non-implantable materials- For wound care that includes absorbent pad
(wound contact layer, base material viscose, plastic film) and bandages
(simple inelastic/elastic, orthopaedic, plasters, gauzes, lint, padding)
Textiles in Extracorporeal devices- Like artificial kidney, liver and lungs.
Implantable materials- Like sutures (biodegradable and non-
biodegradable), soft tissue implants, artificial tendon (meshes), artificial
ligament, artificial cartilage, orthopedic implants artificial joint,
cardiovascular implants vascular grafts, heart valves.
Healthcare/hygiene products- Include bedding, clothing, surgical gown
clothes, filters, bandages, support and protective material, surgical
sutures etc
76. Sports Textile
Sports textile is one of the branch of technical textile. Now a days
sophisticated technology are used in technical textile to produce sports wear.
Textile has done it successfully . Hi-tech textiles in sport are nothing new. In
recent years we have seen the design of fabrics that can take moisture away
from the body, patches on all black jerseys so players can dry their hands for
better grip, fabrics that can sense high impact stresses on players joints, and
fabrics that can sense heart rate, temperature and other physiological data .
Properties of Sports Textile:
Sports textile must have comport ability, easy to wear, easy handling.
Sports textiles fabrics have a very high electrical conductivity, so they can
permit the effectual dissipation of electrical charge.
It should be light as best as possible.
Filaments fabrics are made highly effecting in moisture management & thus
they can wick the moisture as known as sweat away from the body & keeps
body dry.
Sports textile should have good perspiration fastness.
As this sports fabric has a special property well known as heat conductivity
make possible to feel the user cooler in summer & warmer in winter.
Garments manufactured from sports textiles fabrics, keeps the normal
stability of body comfort, because these fabrics are ultra-breathable, fast
drying and possess outstanding moisture managing properties, which rapidly
wick moisture away from the body.
These garments are also very less in weight & feature elasticity properties,
which provides immense comfort and independence of movement.
Keeping a normal level of bacteria on the skin offers a high level of comfort
and personal hygiene, especially during athletic activities.
Sports textiles fabrics remove UVA and UVB rays that are dangerous to the
skin, and guarantees an improved level of defense compared to the majority
general natural and man-made fibres.
77. It also provides superior strength and durability.
The athletics & the leisure activities for their better performance in the sports.
Application:
Sports textile has versatile use. Some uses of Sports Textile are given below:
Shoes, sports equipment, flying and sailing sports, climbing, angling, cycling,
winter and summer sports, indoor sports wear. Some of the sports where
these textiles are being used are Golf, Tennis, Mountaineering, Skiing, Cricket
and Paralympic Sports.
A few areas where these textiles are being increasingly used are:
Swimming costume
Artificial turfs, sleeping bags, ballooning and parachute fabrics
Material technology and design,of equipment
Biomechanics and the engineering aspects of sports machinery
Surface treatment of equipment
Sports footwear
78. WATER PROOF TEXTILES
• Waterproof breathable fabrics
Waterproof breathable fabrics are designed for use in garments that provide protection from the
weather, that is from wind, rain and loss of body heat.Waterproof fabric completely prevents the
penetrati and absorption of liquid water, in contrast to water-repellent (or, shower-resistant)
fabric. Traditionally,fabric was made waterproof by coating it with a continuous layer of impervious
flexible material. The first coating materials used were animal fat, wax and hardened vegetable
oils. Nowadays synthetic polymers such as polyvinylchloride (PVC) and polyurethane are used.
Coated fabrics are considered to be more uncomfortable to wear than water-repellent fabric, as
they are relatively stiff and do not allow the escape of perspiration vapour. During physical activity
the body provides cooling partly by producing insensible perspiration. If the water vapour cannot
escape to the surrounding atmosphere the relative humidity inside the clothing increases causing a
corresponding increased thermal conductivity of the insulating air, and the clothing becomes
uncomfortable. In extreme cases hypothermia can result if the body loses heat more rapidly than it
is able to produce it. If perspiration cannot evaporate and liquid sweat (sensible perspiration) is
produced, the body is prevented from cooling at the same rate as heat is produced. The ability of
fabric to allow water vapour to penetrate is commonly known as breathability.This property should
more scientifically be referred to as water vapour permeability.Although perspiration rates and
water vapour permeability are usually quoted in units of grams per day and grams per square
metre per day, respectively, the maximum work rate can only be endured for a very short time. It
has also been shown that the maximum performance of a subject wearing clothing with a vapour
barrier is some 60% less than that of a subject wearing the same clothing but without a vapour
barrier.
• Types of waterproof breathable fabric
There are several methods which can be used to obtain fabrics which are both breathable and
waterproof. These can be divided into three groups:
• • densely woven fabrics
• • membranes
• • coatings.
79. DEFENCE TEXTILES:
Introduction
Defence forces on land, sea, or air throughout the world are heavily reliant on
technical textiles of all types – whether woven, knitted, nonwoven, coated,
laminated or other composite forms.Technical textiles offer invaluable
properties for military land forces in particular, who are required to move, live,
survive and fight in hostile environments. They have to carry or wear all the
necessities for comfort and survival and thus need the most lightweight,
compact, durable, and high performance personal clothing and equipment. The
life-critical requirements for protecting individuals from both environmental and
battlefield threats have ensured that the major nations of the world expend
significant resources in developing and providing the most advanced technical
textiles for military use.
Textiles for environmental protection
Military forces have to be prepared to operate in all parts of the globe from
arctic,through temperate, to jungle and desert areas. As such they experience
the widest range of climatic conditions possible encountering rain, snow, fog,
wind, lightning, sunlight,dust, attendant heat, cold, wetness,UV light, windchill &
other discomforts on land, sea, and in the air. The environment is considered
the highest priority where protection of the individual is considered .Whether
forces are operating at headquarters, during training, on internal security, or
peace-keeping duties, or involved in full scale war, the environment is ever
present.The battlefield threats – whilst probably much more life threatening.
80. Cause of ballistic casualties in general war
Cause of casualty
Percentage
Fragments
59
Bullets
19
Other
22
inflict several wounds, ranging in severity, depending on the
source and distance of the blast.There may also be casualties
from the secondary effects of bombs, including collapsing
buildings, exploding aircraft, sinking ships, and flying debris.
1. Levels of protection
Total fatalities –no armour
If helmets are worn –19% reduction
If armour is worn –40% reduction
Armour & helment –65% reduction
Estimated reduction in casualties resulting from wearing body
armour .The ultimate clothing system for whole body and head
protection is the EOD suit.
81.
82. • Because of secrecy act, the data on costing and
marketing activities has not been supplied in details.
• In spite of our limited time, we could not study in detail.
• Some of the points in different chapter are not
described as these were not available.
• It is not possible to hold the whole thing of a textile
industry in such a small frame as this report, hence our
effort spent on summarizing them.
LIMITATIONS OF THE REPORT: