This document provides information about Urmi Group and one of its concerns, Fakhruddin Textile Mills Ltd. It details the company profile, factory information, manpower and organizational structure, raw materials used, and production process of the textile mill. Fakhruddin Textile Mills Ltd is a leading Bangladeshi manufacturer and exporter of knit garments established in 2004. It has over 1200 employees and uses various natural and synthetic yarns, chemicals, and dyes to produce knitted fabrics and garments for the export market.
This document describes an industrial training report for Aman Tex Limited, a knit dyeing and garment manufacturing company in Bangladesh. It includes sections on the company overview, layout, departments, machinery, processes, and raw materials. Some key details:
- Aman Tex is a 100% export-oriented knit composite industry located in Gazipur, Bangladesh. It has various certifications and complies with labor standards.
- The company has different sections for knitting, dyeing, finishing, garments production, maintenance, and administration.
- The knitting section contains various circular, flatbed, and stripe knitting machines from Fukuhara primarily for single jersey, rib, and fle
The document provides details about the knitting department of Epyllion Knitex Ltd. and Epyllion Fabrics Ltd., including the types and capacities of knitting machines and fabrics produced. It lists the daily and monthly production capacities for jersey, interlock, rib, and fleece fabrics totaling over 27,000 kg per day.
Mihir Ranjon Das completed a two-month industrial internship at Niagara Textiles Ltd, a France-Bangladesh joint venture textile company. The report provides details of his experiences and observations in different sections of the company such as knitting, dyeing, finishing, quality control and utilities. It describes the production process and machinery used. It also discusses management systems, raw materials, maintenance procedures, social and environmental policies followed by the company. Overall, the internship helped Mihir gain practical knowledge of textile production processes and quality standards to complement his theoretical education.
This document provides an introduction and overview of M.M. Knitwear Ltd, a knitwear and dyeing factory in Bangladesh. It discusses the factory's history, facilities, production capacities, buyers, and organizational structure. Key points include that the factory has 310,000 square feet of space, produces over 7,000 tons of dyed and finished goods annually, and employs over 4,300 workers. The document also outlines the duties of various production roles like Production Officer and General Manager of Production.
The document provides details about an industrial training report submitted by students from the Department of Textile Technology at AUST. It was conducted at Dalas Fashion Ltd, a knit dyeing factory in Bangladesh. The report includes sections on the company profile, manpower management, machines used, raw materials, production processes, quality control, maintenance, utilities and costs. It aims to provide an overview of the factory's operations during the students' two-month long industrial training placement.
This document provides information about the single jersey knitting machine used in the Fabric Manufacturing Technology Lab. It describes the key parts of the machine including the latch needles, cams, sinkers, cylinder, creel, and yarn path. It also provides specifications for the cylinder such as a diameter of 15 inches and gauge of 25. The machine produces plain knitted fabrics and the document aims to provide an understanding of how a single jersey machine functions.
The document discusses the duties and responsibilities of a garment merchandiser. It explains that a merchandiser's main role is to collect export orders, arrange for garment production according to the order specifications, ensure quality control during production, and facilitate export and payment collection. It provides a detailed list of the major duties, which include procuring orders, establishing production schedules, sourcing materials, monitoring production progress and quality, arranging shipping and payments. The document also includes various industry definitions, formulas, standards and best practices.
This document describes an industrial training report for Aman Tex Limited, a knit dyeing and garment manufacturing company in Bangladesh. It includes sections on the company overview, layout, departments, machinery, processes, and raw materials. Some key details:
- Aman Tex is a 100% export-oriented knit composite industry located in Gazipur, Bangladesh. It has various certifications and complies with labor standards.
- The company has different sections for knitting, dyeing, finishing, garments production, maintenance, and administration.
- The knitting section contains various circular, flatbed, and stripe knitting machines from Fukuhara primarily for single jersey, rib, and fle
The document provides details about the knitting department of Epyllion Knitex Ltd. and Epyllion Fabrics Ltd., including the types and capacities of knitting machines and fabrics produced. It lists the daily and monthly production capacities for jersey, interlock, rib, and fleece fabrics totaling over 27,000 kg per day.
Mihir Ranjon Das completed a two-month industrial internship at Niagara Textiles Ltd, a France-Bangladesh joint venture textile company. The report provides details of his experiences and observations in different sections of the company such as knitting, dyeing, finishing, quality control and utilities. It describes the production process and machinery used. It also discusses management systems, raw materials, maintenance procedures, social and environmental policies followed by the company. Overall, the internship helped Mihir gain practical knowledge of textile production processes and quality standards to complement his theoretical education.
This document provides an introduction and overview of M.M. Knitwear Ltd, a knitwear and dyeing factory in Bangladesh. It discusses the factory's history, facilities, production capacities, buyers, and organizational structure. Key points include that the factory has 310,000 square feet of space, produces over 7,000 tons of dyed and finished goods annually, and employs over 4,300 workers. The document also outlines the duties of various production roles like Production Officer and General Manager of Production.
The document provides details about an industrial training report submitted by students from the Department of Textile Technology at AUST. It was conducted at Dalas Fashion Ltd, a knit dyeing factory in Bangladesh. The report includes sections on the company profile, manpower management, machines used, raw materials, production processes, quality control, maintenance, utilities and costs. It aims to provide an overview of the factory's operations during the students' two-month long industrial training placement.
This document provides information about the single jersey knitting machine used in the Fabric Manufacturing Technology Lab. It describes the key parts of the machine including the latch needles, cams, sinkers, cylinder, creel, and yarn path. It also provides specifications for the cylinder such as a diameter of 15 inches and gauge of 25. The machine produces plain knitted fabrics and the document aims to provide an understanding of how a single jersey machine functions.
The document discusses the duties and responsibilities of a garment merchandiser. It explains that a merchandiser's main role is to collect export orders, arrange for garment production according to the order specifications, ensure quality control during production, and facilitate export and payment collection. It provides a detailed list of the major duties, which include procuring orders, establishing production schedules, sourcing materials, monitoring production progress and quality, arranging shipping and payments. The document also includes various industry definitions, formulas, standards and best practices.
The document provides details about Sudhan Halder's internship report at Masco Group. It includes an acknowledgement, table of contents, and introduction to Masco Group which discusses the company's history, profile, management, locations, nature of projects, quality certifications, buyers, export countries, and factory features regarding social compliance. The report appears to provide information gathered during Sudhan Halder's internship at Masco Group across various production departments including knitting, dyeing, cutting, printing, embroidery, sewing, finishing, sample, commercial, and merchandising.
Feeder stripe, Engineering stripe and Auto stripe mechanismAzmir Latif Beg
Auto stripe machine give stable structure with auto-stripper device, which could get various colors. Auto stripe & Engineering is commonly mark in use that does not goes with their definition. Today I will discuss regarding knit stripe patter.
This document provides information about Montex Fabrics Ltd, a 100% export oriented composite knit industry in Bangladesh. Some key details:
- The factory was established in 2000 in Gazipur with an investment of 70 crore taka and has certifications including ISO 9001:2000.
- It produces basic t-shirts, sweaters, and other knitwear and garments for export with a production capacity of 7 tons/day for knitting and 70,000 pieces/day for sewing.
- The factory has over 6000 employees across its knitting, dyeing, finishing, printing and other sections. It aims to provide quality products on time to satisfy customers.
The document discusses an industrial training report completed at Fakhruddin Textile Mills Limited, a knit composite factory in Bangladesh. It provides details about the company's profile, including founding year, production areas, certifications, and major customers. It also describes the various departments within the factory, total manpower, and shift schedules. Specific sections cover the knitting department and processes, including raw materials used, knitting machine types and specifications. The goal of the training was to gain practical experience in knitting, dyeing, and finishing processes.
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.
This document provides organizational details for the fabrics finishing department of Fariha Knit Tex Ltd, including:
1. An organogram showing the required and existing positions in finishing, with a total workforce of 349 people and a variance of 68 positions.
2. Machine-wise manpower requirements and existing staffing for positions like assistant supervisors, operators, and helpers across various finishing machines.
3. Job responsibilities of the AGM and other managerial staff in the finishing department.
This document provides a summary of the author's industrial internship attachment at Bengal Hurricane Group, a knit garment manufacturing company in Bangladesh. Over three pages, the author outlines the major sections and processes within the company, including knitting, dyeing, washing, printing, garment production, quality control, finishing, and merchandising. For each section, the author describes the relevant processes, equipment, potential faults, and lessons learned. The overall summary provides insight into the full garment manufacturing process from fabric production to final product within a Bangladeshi export-oriented knitwear company.
Seam slippage is when a sewn seam opens under load and some of the opening remains even after the load is removed. It can be caused by loosely woven fabric, not using enough stitches per inch, poor stitch balance, or having too narrow of a seam margin. When two pieces of fabric are pulled at right angles to the seam, it can reveal a gap between the pieces called a seam grin, showing the thread in the gap. Proper testing can identify issues with seam slippage.
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.
This document discusses a project report submitted by two students, Ariful Islam and Mazadul Hasan, on knit dyeing faults and remedies. The report was submitted to their professor Rajib Shaha at Southeast University to fulfill the requirements for their B.Sc. in Textile Engineering. The report acknowledges the support received from their university, supervising professor, and the management and staff at Knit Concern Ltd. where they completed their industrial training.
Intern report montex fabrics (Mondol Group) by "NAZMUL HASAN"Nazmul Hasan
This document is an internship report submitted by Nazmul Haque for his bachelor's degree in apparel manufacturing management and technology. It provides information about his internship at Montex Fabrics, including descriptions of the company and various production processes at their factory. The report covers the knitting, batching, lab dipping, dyeing, and finishing sections of the factory. It includes organizational structures, process flows, equipment used, materials, quality control points, and common issues for each section.
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.
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.
Future Opportunities of Weaving & Knitting Sectors in BangladeshMd Rakibul Hassan
The document discusses the weaving and knitting sectors in Bangladesh and their future opportunities. It provides an overview of the weaving and knitting industries in Bangladesh, noting that textiles contribute significantly to the country's economy and employment. It then outlines several future opportunities for both sectors, including increasing production and exports, entering new markets and product categories, creating more jobs, and developing new technologies and skilled workers. The weaving and knitting sectors are poised for continued growth in Bangladesh.
This document provides information about garment merchandising and industrial engineering. It defines merchandising and outlines the key steps in the merchandising process from developing buyers to shipment. It also describes the work of merchandisers, including sourcing, pricing, order follow up, and ensuring on-time shipment. Additionally, it discusses industrial engineering and its focus on improving productivity through methods like time studies, layout optimization, and training. It provides details on cost analysis, production planning, and the different techniques used to set work standards.
The document provides details about Fakir Knitwears Ltd, including its management structure and various departments. It describes the company's profile, organizational chart, roles and responsibilities of key management positions like the Managing Director, Director, General Managers of different departments. The factory has different units like knitting, dyeing, garments production, maintenance, administration etc. overseen by senior managers.
Industrial training on amber denim mills limitedMd. Alam
This document provides a summary of the internship of Rakibul Hasan at Amber Denim Mills Ltd. in Bangladesh. It begins with an introduction and overview of the company profile, including information about Amber Group, the parent company of Amber Denim Mills. It then covers the various production processes at the mill in detail, from yarn preparation to weaving, dyeing, finishing, washing, quality control, and utilities. The document provides a comprehensive look at the end-to-end denim manufacturing process and quality systems in place at Amber Denim Mills.
Industrial attachment of m.s dyeing, printing & finishing ltd. by md omar...Rhymeles Hredoy
The document provides details about Mohammad Omar Faruk's internship at M.S Dyeing, Printing & Finishing Ltd., including:
- An introduction to the importance of practical, hands-on experience for an engineering student.
- Background on M.S Dyeing, Printing & Finishing Ltd., a composite knit fabrics and garments manufacturer located in Narayanganj.
- Outlines of the report contents which cover company profile, manpower, layout, raw materials, production, maintenance, utilities, inventory, cost analysis, and marketing.
This document provides an overview of APS Group (Dyeing Unit), a 100% export-oriented composite knitwear factory located in Pubail, Gazipur, Bangladesh. It details the factory's production capacities and facilities, including its knitting, dyeing, finishing, and garment sections. It also describes the factory layout, manpower structure, and sources and costs of raw materials like yarn, grey fabrics, dyes, and chemicals. The factory has a daily production capacity of over 15 tons and employs over 5,000 people across its operations.
Fleece fabric is one of the oldest knitted fabric designs that remains popular today. It has properties of being warm, cozy, easy to care for, washable, and can be produced at low cost using circular knitting machines. There are several types of fleece fabrics defined by the number of yarn threads used (one, two, or three thread) or the material (cotton, polyester, blends). Fleece fabrics are characterized by loops of yarn on the surface that provide insulation properties. They have many uses including outerwear, linings, and blankets.
This document provides an overview of Sadma Fashion Wear Ltd., a garment manufacturing company in Bangladesh. It details the company's profile, facilities, production capacity, certifications, buyers, and organizational structure. Key points include that it has over 200 employees, a production capacity of 20,000 pieces per day, and major buyers such as Walmart, C&A, and Sears. The company operates departments for knitting, dyeing, finishing, garments production and quality assurance.
This document provides an overview of Mitali Fashions Ltd., a knit composite garment factory in Bangladesh. It discusses the company's establishment in 2000, leadership, expansion, and certification. The factory has various production sections including knitting, dyeing, finishing, garments, and quality control. It employs over 5,000 people and produces knitwear and garments for major international brands. The document also includes organizational charts, maps of the factory premises, and lists of raw materials and major customers.
The document provides details about Sudhan Halder's internship report at Masco Group. It includes an acknowledgement, table of contents, and introduction to Masco Group which discusses the company's history, profile, management, locations, nature of projects, quality certifications, buyers, export countries, and factory features regarding social compliance. The report appears to provide information gathered during Sudhan Halder's internship at Masco Group across various production departments including knitting, dyeing, cutting, printing, embroidery, sewing, finishing, sample, commercial, and merchandising.
Feeder stripe, Engineering stripe and Auto stripe mechanismAzmir Latif Beg
Auto stripe machine give stable structure with auto-stripper device, which could get various colors. Auto stripe & Engineering is commonly mark in use that does not goes with their definition. Today I will discuss regarding knit stripe patter.
This document provides information about Montex Fabrics Ltd, a 100% export oriented composite knit industry in Bangladesh. Some key details:
- The factory was established in 2000 in Gazipur with an investment of 70 crore taka and has certifications including ISO 9001:2000.
- It produces basic t-shirts, sweaters, and other knitwear and garments for export with a production capacity of 7 tons/day for knitting and 70,000 pieces/day for sewing.
- The factory has over 6000 employees across its knitting, dyeing, finishing, printing and other sections. It aims to provide quality products on time to satisfy customers.
The document discusses an industrial training report completed at Fakhruddin Textile Mills Limited, a knit composite factory in Bangladesh. It provides details about the company's profile, including founding year, production areas, certifications, and major customers. It also describes the various departments within the factory, total manpower, and shift schedules. Specific sections cover the knitting department and processes, including raw materials used, knitting machine types and specifications. The goal of the training was to gain practical experience in knitting, dyeing, and finishing processes.
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.
This document provides organizational details for the fabrics finishing department of Fariha Knit Tex Ltd, including:
1. An organogram showing the required and existing positions in finishing, with a total workforce of 349 people and a variance of 68 positions.
2. Machine-wise manpower requirements and existing staffing for positions like assistant supervisors, operators, and helpers across various finishing machines.
3. Job responsibilities of the AGM and other managerial staff in the finishing department.
This document provides a summary of the author's industrial internship attachment at Bengal Hurricane Group, a knit garment manufacturing company in Bangladesh. Over three pages, the author outlines the major sections and processes within the company, including knitting, dyeing, washing, printing, garment production, quality control, finishing, and merchandising. For each section, the author describes the relevant processes, equipment, potential faults, and lessons learned. The overall summary provides insight into the full garment manufacturing process from fabric production to final product within a Bangladeshi export-oriented knitwear company.
Seam slippage is when a sewn seam opens under load and some of the opening remains even after the load is removed. It can be caused by loosely woven fabric, not using enough stitches per inch, poor stitch balance, or having too narrow of a seam margin. When two pieces of fabric are pulled at right angles to the seam, it can reveal a gap between the pieces called a seam grin, showing the thread in the gap. Proper testing can identify issues with seam slippage.
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.
This document discusses a project report submitted by two students, Ariful Islam and Mazadul Hasan, on knit dyeing faults and remedies. The report was submitted to their professor Rajib Shaha at Southeast University to fulfill the requirements for their B.Sc. in Textile Engineering. The report acknowledges the support received from their university, supervising professor, and the management and staff at Knit Concern Ltd. where they completed their industrial training.
Intern report montex fabrics (Mondol Group) by "NAZMUL HASAN"Nazmul Hasan
This document is an internship report submitted by Nazmul Haque for his bachelor's degree in apparel manufacturing management and technology. It provides information about his internship at Montex Fabrics, including descriptions of the company and various production processes at their factory. The report covers the knitting, batching, lab dipping, dyeing, and finishing sections of the factory. It includes organizational structures, process flows, equipment used, materials, quality control points, and common issues for each section.
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.
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.
Future Opportunities of Weaving & Knitting Sectors in BangladeshMd Rakibul Hassan
The document discusses the weaving and knitting sectors in Bangladesh and their future opportunities. It provides an overview of the weaving and knitting industries in Bangladesh, noting that textiles contribute significantly to the country's economy and employment. It then outlines several future opportunities for both sectors, including increasing production and exports, entering new markets and product categories, creating more jobs, and developing new technologies and skilled workers. The weaving and knitting sectors are poised for continued growth in Bangladesh.
This document provides information about garment merchandising and industrial engineering. It defines merchandising and outlines the key steps in the merchandising process from developing buyers to shipment. It also describes the work of merchandisers, including sourcing, pricing, order follow up, and ensuring on-time shipment. Additionally, it discusses industrial engineering and its focus on improving productivity through methods like time studies, layout optimization, and training. It provides details on cost analysis, production planning, and the different techniques used to set work standards.
The document provides details about Fakir Knitwears Ltd, including its management structure and various departments. It describes the company's profile, organizational chart, roles and responsibilities of key management positions like the Managing Director, Director, General Managers of different departments. The factory has different units like knitting, dyeing, garments production, maintenance, administration etc. overseen by senior managers.
Industrial training on amber denim mills limitedMd. Alam
This document provides a summary of the internship of Rakibul Hasan at Amber Denim Mills Ltd. in Bangladesh. It begins with an introduction and overview of the company profile, including information about Amber Group, the parent company of Amber Denim Mills. It then covers the various production processes at the mill in detail, from yarn preparation to weaving, dyeing, finishing, washing, quality control, and utilities. The document provides a comprehensive look at the end-to-end denim manufacturing process and quality systems in place at Amber Denim Mills.
Industrial attachment of m.s dyeing, printing & finishing ltd. by md omar...Rhymeles Hredoy
The document provides details about Mohammad Omar Faruk's internship at M.S Dyeing, Printing & Finishing Ltd., including:
- An introduction to the importance of practical, hands-on experience for an engineering student.
- Background on M.S Dyeing, Printing & Finishing Ltd., a composite knit fabrics and garments manufacturer located in Narayanganj.
- Outlines of the report contents which cover company profile, manpower, layout, raw materials, production, maintenance, utilities, inventory, cost analysis, and marketing.
This document provides an overview of APS Group (Dyeing Unit), a 100% export-oriented composite knitwear factory located in Pubail, Gazipur, Bangladesh. It details the factory's production capacities and facilities, including its knitting, dyeing, finishing, and garment sections. It also describes the factory layout, manpower structure, and sources and costs of raw materials like yarn, grey fabrics, dyes, and chemicals. The factory has a daily production capacity of over 15 tons and employs over 5,000 people across its operations.
Fleece fabric is one of the oldest knitted fabric designs that remains popular today. It has properties of being warm, cozy, easy to care for, washable, and can be produced at low cost using circular knitting machines. There are several types of fleece fabrics defined by the number of yarn threads used (one, two, or three thread) or the material (cotton, polyester, blends). Fleece fabrics are characterized by loops of yarn on the surface that provide insulation properties. They have many uses including outerwear, linings, and blankets.
This document provides an overview of Sadma Fashion Wear Ltd., a garment manufacturing company in Bangladesh. It details the company's profile, facilities, production capacity, certifications, buyers, and organizational structure. Key points include that it has over 200 employees, a production capacity of 20,000 pieces per day, and major buyers such as Walmart, C&A, and Sears. The company operates departments for knitting, dyeing, finishing, garments production and quality assurance.
This document provides an overview of Mitali Fashions Ltd., a knit composite garment factory in Bangladesh. It discusses the company's establishment in 2000, leadership, expansion, and certification. The factory has various production sections including knitting, dyeing, finishing, garments, and quality control. It employs over 5,000 people and produces knitwear and garments for major international brands. The document also includes organizational charts, maps of the factory premises, and lists of raw materials and major customers.
1. The document provides information about Divine Group of Industries Limited (DGI), a textile company in Bangladesh. It details DGI's facilities, production capacity, certifications, and clientele.
2. DGI aims to suit every fashion taste and demand from around the world. It has several factories producing knitted fabrics and garments.
3. The document outlines DGI's management structure, production processes from knitting to garments, and machinery used in key departments like CAD and sampling.
The document provides information about an industrial training internship at Olio Apparels Ltd, which is part of the Envoy Group. The objectives of the internship are to learn about the different departments of the company and gain practical knowledge about garment manufacturing. It also aims to compare theoretical knowledge learned in class to real-world practices and identify strengths, weaknesses, opportunities, and threats of the company. Olio Apparels Ltd is described as a large garment manufacturing facility that produces high quality products for European and American customers using modern machinery and technologies.
This document provides information about an industrial training completed by the author at Cotton Club (BD) Ltd. It begins with an introduction to the garment industry in Bangladesh and the purpose of industrial training programs. It then discusses the company details including history, mission, vision, competitors and organizational structure. The document focuses on the knitting section of the factory, providing definitions of knitting technology, types of knitted fabrics produced, machinery used and processes involved. It concludes with an overview of common knitting faults and their remedies.
The document provides information about industrial training and sample making at Sea Moss Knitwear Ltd., a garment factory in Bangladesh. It discusses the factory's training center which trains new workers on sewing machine operation and the garment production process. It also describes the different types of samples produced by the sample section, including original samples, photo samples, pre-production samples, and others. The purpose of each sample and the sample development process is explained. In summary, the document outlines the training programs and sample making procedures at this Bangladeshi garment factory.
This document provides information about an industrial training internship at Tusuka Jeans, Trouser & Processing Ltd. It outlines the objectives of the internship which are to learn about the various departments of the company and gain practical knowledge. It then provides details about the company profile, sister concerns, buyers, human resources management, machine descriptions, raw materials, production planning, merchandising, and compliance issues.
The document provides information about dyeing a single jersey cotton spandex fabric. It states that the fabric composition is 95% cotton and 5% spandex, with a weight of 160 GSM. It recommends using a 40s combed cotton yarn and 20 denier spandex. It describes the dyeing process as: 1) slitting the grey fabric tube using a slitting machine, and 2) heat setting the slit fabric using a stenter machine to avoid creasing and set the dye.
This document provides a project report on applying disperse and reactive dyes to a 65/35 polyester/cotton blended fabric using a two bath system. It acknowledges those who helped with the project and thanks the textile college and company for the opportunity. The abstract discusses challenges in dyeing poly/cotton blends and how dye selection can help control color value, strength, and other properties. Laboratory trials tested compatibility of reactive dyes and analyzed dye fixation using spectrophotometry. The introduction discusses the importance of practical experience and outlines the project goals of studying dye application in different textile industries in Bangladesh.
This document provides calculations and formulas related to yarn count, twist, winding, warping, sizing, weaving, and yarn quality parameters. It discusses three systems for calculating yarn count: indirect, direct, and universal. It also covers formulas for twist per inch, multi-filament yarns, winding calculations, warping calculations, sizing calculations, weaving calculations, and parameters for assessing yarn appearance, unevenness, linear density, and single thread strength.
1) A textile is a woven fabric made by interlacing warp and weft threads. Textiles now also refer to fibers, yarns and products made from them.
2) Weaving produces fabric by intersecting the warp (lengthwise) and weft (crosswise) threads. Yarn preparation involves winding yarn onto packages to facilitate weaving and removing faults.
3) Different types of fabrics include woven, knitted, non-woven and special fabrics. Proper yarn preparation and tension are important to produce good quality fabric during weaving.
The document provides information about the pretreatment process at Sinha Dyeing & Finishing Limited (SDFL). It discusses the theory and objectives of pretreatment. The key processes covered are singeing, desizing, scouring, bleaching, and mercerizing. Details are given about the singeing machines and gas singeing process at SDFL, which aims to remove protruding fibers from fabric surfaces before further processing.
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.
This document provides a project report on the reaction mechanism of reactive dyes in Bengal Hurricane Group on cellulose fiber. It discusses the raw materials used, including fabrics, dyes, and chemicals. It explains the importance of studying reactive dye usage in major Bangladeshi textile industries. The methods of dyeing and printing cotton with reactive dyes and the technical deficiencies, causes, and remedies are examined.
Elastomeric fibers are fibers that can stretch to very high elongations (400-800%) and rapidly recover their original length. They include fibers made from natural and synthetic rubbers as well as spandex and polyacrylates. Elastomeric fibers are produced via a spinning process where polymers are mixed and reacted to form long chains, then extruded through spinnerets into a water bath or air to solidify. The fibers have excellent elasticity and strength even at high elongations. Common applications include clothing, automotive and industrial parts, coatings and more where elasticity is required.
The document discusses acrylic fiber, including its definition, chemical composition, properties, characteristics, advantages, uses, and commercial applications. Acrylic fiber is a synthetic fiber made from polymers containing acrylonitrile. It is often used as an artificial replacement for wool in applications like sweaters, socks, and blankets due to its softness and insulating properties. Major uses of acrylic fiber include knit apparel, carpets, and home furnishings due to its ability to wick moisture, durability, and resistance to moths and chemicals.
This document provides information about carbon fiber, including:
1. What carbon fiber is composed of and its structure.
2. The process of forming carbon fiber from precursor materials like polyacrylonitrile through heating without oxygen.
3. Applications of carbon fiber in composites for aircraft, vehicles, and other products due to its strength and light weight.
4. Major manufacturers of carbon fibers and the growing market for carbon fiber composites.
The document provides an overview of the Hotapara Garments Ltd company, including its infrastructure, departments, manpower, production capacity, and product mix. The company has over 1850 workers split across various departments like knitting, dyeing, quality control, sewing, and maintenance. It has a daily production capacity of 40,000 pieces and manufactures items like T-shirts, polo shirts, jackets, and bottoms.
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.
The document provides information about Sajib Chakma's industrial training at Fakhruddin Textile Mills Ltd, a knit composite factory in Gazipur, Bangladesh. It includes details about the company such as its establishment, production facilities, departments, products, machinery, and raw materials used. Sajib completed his 8-week training learning about the knitting, dyeing, and finishing processes. He observed daily operations, implemented his knowledge, and prepared this report to document his experiences at the factory.
Micro Fiber Ltd. is a knit composite textile mill located in Ramarbagh, Narayangonj, Bangladesh. The mill has several departments including knitting, dyeing, printing, finishing, and garments. It processes materials like cotton, polyester-cotton blends, and melange yarns to produce gray and dyed knitted fabrics. The mill has over 5,000 employees and manufactures around 8,000 kg of gray fabric and 22-24 tons of dyed fabric per day. The report provides details on the mill's operations, management systems, raw materials, production processes, quality control, and other functions.
Industrial Internship Report on Opex Sinha Textile GroupNasif Chowdhury
This presentation summarizes an industrial internship at a large textile manufacturing complex in Bangladesh. The complex comprises 28 companies with 170 production lines. It produces a variety of woven and knit garments, denim, and other textile products. The presentation provides details about the factory profile, production processes, organizational structure, raw materials, quality control, maintenance, engineering, and merchandising departments. It concludes that knowledge of latest textile technologies is important for producing high quality products in today's competitive market.
Northern Fashion Ltd. is a state-of-the-art Knitting, Dyeing – Finishing & Garment Manufacturing
factory. The project has been a setting up of a 100% export oriented composite knit
garment unit. The project has been designed to fulfill the present world market demand for
producing most value added fabrics. The project is equipped with open width finishing line.
This helps saving all types of fabrics consumption. Also the quality of fabrics is improved
tremendously. The machinery of the project is Brand new and has been imported from
abroad. The project has been started its commercial operation in the mid of 2007.
The document provides details about an industrial training program at Knit Concern Limited (KCL), a knit composite industry in Bangladesh. It includes information about KCL such as its establishment year, location, departments, achievements, and history. Key details are provided on KCL's knitting, knit dyeing, and back sewing machines. In total, it outlines the industrial training placement and provides an overview of KCL's operations.
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
The knitting section has 20 circular knitting machines of different diameters and gauges from different brands like Pailung and Liskey. The machines can produce different knit fabrics like single jersey, 1x1 rib etc with a total daily capacity of around 6,000 kg.
Coast to Coast Group is a garment manufacturing and exporting company established in 1992 in Bangladesh. It operates 4 factories with over 2,400 machines and 4,800 employees. The company produces a variety of woven and knit garments for major American and European retailers. Coast to Coast prioritizes quality, reliability, and ensuring a healthy work environment for its employees. It has received several certifications and approvals for its operations and produces over 30 million USD in annual revenue.
Industrial Attachment of Norban Comtex Ltd.Rumman Samrat
The knitting section has 33 machines including 17 circular knitting machines and 16 flat knitting machines from brands like Pailung and Liskey. The circular machines range from 34 to 42 inches in diameter and produce single jersey, rib, fleece, and heavy jersey fabrics at capacities of 120 to 350 kg per day.
The document summarizes a student group's visit to the Shishir Knitting & Dyeing factory. It includes:
- An overview of the factory's operations, including its production capacity and number of employees.
- Descriptions of the various sections within the factory, such as the dyeing, sewing, inspection, and packing sections.
- Details about the machinery used, including knitting machines, sewing machines, and ironing equipment.
- Some noted areas for improvement, such as a lack of CAD and industrial engineering departments.
The conclusion states the factory has good safety and incentive programs but could improve its ventilation system.
Coast to Coast Group is a garment manufacturing and exporting company established in 1992 in Bangladesh. It operates 4 factories with over 2,400 machines and 4,800 employees. The company produces a variety of woven and knit garments for major American and European retailers. It has an annual turnover of $30 million and produces over 150,000 dozen items per month, focusing on jackets, pants, shorts, and shirts. Coast to Coast Group aims to contribute to community development through providing economic opportunities and upholding high standards for quality, workplace environment, and reliability.
The document provides details about Sinha Rotor Spinning Limited (SRSL), including:
1. SRSL produces cotton yarn using ring spinning and rotor spinning systems with a total installed capacity of 28,224 ring spindles and 960 rotor heads.
2. The factory has various departments like production, quality control, maintenance, utility, and others. It sources raw cotton from various countries and uses different mixing ratios of virgin and waste cotton.
3. The production process involves blowroom, carding, drawing, combing/simplex, rotor/ring frames, winding and other sections. Modern machinery from reputed manufacturers are used in each section for quality yarn production.
The document provides details about Apex Spinning and Knitting Mills Ltd., including its establishment, location, departments, production capacity, and management structure. It also describes the knitting process, quality control procedures, maintenance, and strategies for increasing production efficiency. Key details are given about raw materials, machine specifications, and quality standards.
The document is a report on an industrial training completed at Karnaphuli Knit Wear Ltd. It includes sections on the company background, organizational structure, manpower management, machinery, raw materials, production planning, quality assurance, maintenance, utilities, inventory control, knitting, dyeing, finishing, and marketing activities. The trainee conducted the training to gain practical knowledge on dyeing production, finishing, and knitting fabric production in accordance with their degree program requirements.
Interstoff Apparels Ltd. is a 100% export-oriented knit dyeing and finishing mill located in Gazipur, Bangladesh. It was established in 2003 as a joint venture between Bangladeshi and UK investors. The mill has a production capacity of 2-3 tons of knitting, 10-12 tons of dyeing, and 12-15 tons of finishing per day. It employs over 2,000 people and exports products to major brands such as Marks & Spencer, Tesco, and Esprit. The document provides details on the mill's facilities, machinery, production processes, and raw materials.
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.
1. The document provides details about Fakir Fashion Limited, a vertically integrated knit composite factory in Bangladesh. It discusses the company's history, facilities, production processes, quality control measures, certifications and commitment to employees.
2. Key details include Fakir Fashion having over 6000 employees and producing 25 tons of knit fabric and 150,000 garments per day. It has facilities for knitting, dyeing, finishing, cutting, sewing, washing and quality inspection.
3. The company prioritizes sustainability, occupational health and safety. It has received several certifications and its annual sales have grown to over $130 million USD in 2020.
The presentation is on the basis of visiting a spinning mills . It is normally for textile engineering's student. One can easily get a concept for industrial visit. Before a mill visit this presentation should see.
Masco is one of the largest garment manufacturers and exporters in Bangladesh. It has a vertically integrated production process from knitting to finishing. Masco believes in continuous sustainable development and long-term relationships with customers. It has several certifications for social and environmental standards and produces a range of baby, children's, men's, and women's garments. Masco has expanded its operations over time and now includes multiple production facilities.
Similar to Industrial attachment of urmi garments ltd (20)
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 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.
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.
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.
The document provides information about reactive dyes, including:
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- Important reactive groups include triazine, vinyl sulfone, and halogen groups.
- Reactive dyes were invented in 1956 and became popular for their bright colors, low temperature dyeing, and simple process.
- Common application methods are pad-batch and pad-dry processes at low temperatures. Proper pH, electrolyte, alkali, and time are required for effective dye fixation to the fiber.
This document discusses the development of looms from primitive hand looms to modern automated looms. It outlines the key stages of development including the fly shuttle loom, power looms, semi-automatic looms, and modern shuttle-less looms. The basic mechanisms and motions of weaving are described, including primary, secondary, and tertiary motions. Different parts of a loom and their functions are also summarized.
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.
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This document provides information about an industrial internship at Rupa Fabrics Ltd, a knit dyeing and finishing company in Bangladesh. It includes:
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Industrial attachment of urmi garments ltd
1. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
1 URMI Group
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT OF
URMI GROUP
2. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
2 URMI Group
CHAPTER – 1
COMPANY PROFILE
Name of Company : Fakhruddin Textile Mills Ltd.
(Concern of Urmi Group)
Address : GhargariaMasterBari,Kewa,sreepur,Gazipur,Bangladesh
Head Office : 235/B,Tejgaon Industrial Area,Dhaka-1208,Bangladesh
Phone : +88 02 8878584
Fax Number : +88 02 8878587
Website : www.urmigroup.net
Concern of URMI Group:
Fakhruddin Textile Mills Ltd.
Urmi Garments Ltd.
Attires Manufacturing Co. Ltd.
3. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
3 URMI Group
Inception of Urmi Group Dates back to n1984 when Urmi Garments Ltd. was set up. Today
they are one of the leading manufacturers & exporters of knit garments in Bangladesh. Over
the last Two Decades, by offering the best blend of quality, efficiency and productivity to
their valued customers, they have been able to grow up from a 50 machines stitching unit to a
composite textile having knitting, dyeing and finishing facilities of about 20 tons fabric and
70,000 pcs garments per day.
4. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
4 URMI Group
Strength of Fakhruddin Textile Mills Ltd.:
Their Goal is to achieve zero tolerance in production by upgrading total quality
management and proper production management.
FTML srength
Proffessional
Management
Team
Latest
Machinery &
Technology
Proactive
Planning
Competetive
Pricing
Focus on
Continuous
Improvement
Dedicated &
Competent
Workforce
5. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
5 URMI Group
FACTORY INFORMATION:
Factory Type : 100% Export Oriented Knit Composite
Industry.
Year of Establishment : 2004
Investor : Asif Ashraf
Cell No. :0171-521090
Location : Gargaria Master Bari, Kewa, Sreepur, Gazipur
Telephone : 9289539, 0171684935
E-mail:ftml@urmigroup.net,
Annual Turnover : About Tk. 50, 00, 00,000 to 55, 00, 00,000
Certification & Awards : ISO 9001: 2000, WRAP,OekoTex&
GOTS(Global Organic Textile Standard)
Bank Name & Address:
Islami Bank Bangladesh Ltd.
75, Motijheel C/A, Dhaka-1000, Bangladesh.
Telex:642525 IBANK BJ
S.W.I.F.T. –IBBLBDDH102
Contact Person:
Mr. Hafizur Rahman –Sr. General Manager, Cell no. - 01711-560980
Mr. RuhulKuddus –Deputy General Manager, Dyeing, Cell no.- 01713-013028
Mr. Moniruzzaman –Asst. General Manager, Knitting, Cell no. - 01712-106405
6. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
6 URMI Group
Capacity & Machineries
Floor space: 320,000 Square Feet
Knitting machine : 82 nos
Knitting per day : 15,000 Kgs
Dyeing machine : 27 nos
Dyeing per day : 20,000 Kgs
Finishing Per Day : 20,000 Kgs
Stenter machine : 02 nos
Open width compactor : 02 nos
Tension free dryer : 01 nos
Tubular compactor : 01 nos
Slitting & squeezing machine: 03 nos
Brushing machine : 02 nos
Tumble dryer : 02 nos
Fabric inspection machine : 06 nos
Printing Unit
Floor space : 26,000 square feet
Carosol print machine : 04 nos
Glass table : 16 nos with 400 feet
Capacity : 25,000 pcs per day with multi color average size printing
7. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
7 URMI Group
Embroidery Unit
Machines : 20 Head 04 nos,06 Head 01 nos
Capacity : 3000 million stitches per day
Main Production : Men’s, Ladies, Boy’s, Girls & Infant -Polo Shirt,
T-Shirt, Tank Tops, Shorts, Trouser, Fleece Jacket, Vest etc
Compliance & Certificates:
Fakhruddin Textile Mills Ltd. is extremely particular to meet all levels of compliances at
national and international levels
Fakhruddin Textile Mills Ltd. use AZO free dyes and chemicals and are certified by
OekoTex, WRAP GOLD Certificate, GOTS(Global Organic Textile Standard.
In Fakhruddin Textile MillsLtd..all personnel are equipped with the necessary safety gear and
trained to combat any accidents that may take place.
As they are ISO 9001:2000 for its QMS certificate for manufacturing responsible textile
manufacturing process.
8. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
8 URMI Group
Their Sporting skill in Textile production includes:
All Kinds of S/J, Rib, Interlock, Pique, French Terry,
Brushed Fleece, Drop Needle,different type of design etc. on :
100% Polyester,100% Cotton & Different blend of Cotton and Polyester.
Cotton –Elastane.
100% Organic Cotton.
Blend of Organic and normal Cotton.
100% Modal.
100% Viscos
Viscos- Elastane
Cotton-Modal
Polyamide- Elastane
T/C & CVC
We are Impregnable in producing Special Fabrics like :
Coolmax .
Soil / Stain Release.
Water Repellent
Silpur Finish ( Anti Bacterial)
UV Finish.
3X dry finish
Polyjen
9. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
9 URMI Group
Process Flowchart:
Stentering/Drying
Yarn
Special finish/
Brushing/Sueding
/ Print
Slitting/Dewateri
ng
Dyeing
Knitting
Greige
Batch preparation
Turning/reversing
Quality Check
As per confirmation of lab dip
Heat Setting
Quality Check
Physical Inspection Lab QC
Finished Goods
In line QC
Compacting
In line inspection
Check point: Yarn count Slub / Strength /
evenness
4-Point System
Quality Check
Shrinkage,
Rubbing, Bursting,
spirality, Fastness
to wash,
perspiration, pilling
etc.
Stentering/Drying
10. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
10 URMI Group
CHAPTER-2
MAN-POWER
MANAGEMENT
Manpower of Fakhruddin Textile Mills ltd.:
11. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
11 URMI Group
Unit Officer & Staff worker Total
FTML Textile 260 940 1200
FTML Garments 575 3248 3823
Total 835 4188 5023
Professionals Working For:
SL.no. Name of Education Persons
01 Masters 106
02 BBA/MBA 29
03 Industrial Engineering 06
04 B.Sc. In Textile Engineering 42
05 B.Sc. In Mechanical Engineering 02
06 B.Sc. In Electrical Engineering 03
07 B.Sc. In Computer Science and Engineering 03
08 CA (CC) 03
09 MBBS 02
10 PGDHRM 02
11 L.L.B 02
12 Diploma In Engineering 60
Total 260
ORGANOGRAM:
12. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
12 URMI Group
MD/Director
AGM
Work
Study
AGM
Commercial
Chief Operating Officer
AGM
Accounts &
Finance
AGM
Admin.HR &
Comp.
DGM
Commercial
DGM
Dyeing
DGM Project
Implementation
AGM
Cutting
AGM
Knitting
Sr. AGM
Accounts
& Finance
AGM
Production
AGM
Merchandising
AGM
Quality
DGM
Merchandising
DGM Production
[Factory Manager]
Textile
Garments
HR, Admin &
Compliance
Planning &
Work study
Store
Merchandising Project Commercial Accounts
& Finance
Sr. GM
Store Company
Secretary
Sr. GM
13. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
13 URMI Group
CHAPTER-3
RAW MATERIALS
Raw Material
Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in continuous production and for high quality fabric.
Types of Raw Materials:
14. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
14 URMI Group
1. Yarn
2. Grey Fabric
3. Dyes
4. Chemical
Raw Materials Sources:
Yarn:
Some Factory Name of Yarn Suppliers,
Square Textile Mills
Padma Textile Mills
Mosharaf Textile Mills ltd.
Prime Composite Mills
Israq Textile Mills ltd.
Badsha Textile Mills ltd.
Shamsuddin Spinning
Tara Textile Mills ltd.
PHP Textile Mills ltd.
Numan Spinning Mills ltd.
Different Yarn And Count for Knitting:
SL/No
Yarn Type
Composition
Yarn Count
01 Carded Yarn 100% Cotton 10s, 12s, 16s, 20s, 20/2, 22s, 24s, 26s,28s, 30,
32s, 34s,
02 Combed Yarn 100% Cotton 20s, 22s, 24s, 26s, 28s, 30s, 32s, 34s, 36s, 40s,
50s, 60s.
15. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
15 URMI Group
03 G/M (Viscose %) 1%, 2%, 5%, 10%, 15%, 20%, 30%, 40%
04 Spun Yarn 100% Polyester 36D, 70D, 72D, 75D,
05 PC Polyester + Cotton 24s, 26s, 28s,30s, 32s, 34s,
06 CVC Cotton + Polyester 24s, 26s, 28s, 30s, 34s, 36s, 40s
07 C/M Cotton 50% + Polyester
50%
26s, 28s, 30s,
08 Lycra Synthetic 20D, 40D, 70D,
Grey Fabrics:
Following types of grey fabrics are dyed-
Single jersey
Double jersey
Single jersey with lycra
Interlock
Single Lacoste
Double Lacoste
Rib
Lycra rib
1 x 1 rib & others
Collar & cuff
Polyester fabrics
Single Pique
Double Pique
Terry Fleece
Fleece
Sources:
The required grey fabric is produce in the industry.
Chemicals:
01. Soda ash light 24. Mcropan DPE
02. Caustic Soda 25. Cibapon R
03. Common salt 26. Ctobalance NSR
04. Glauber Salt 27. Rucozen RES
17. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
17 URMI Group
07. Reactive Deep Black N 27. Drimarin Navy CLB
08. Cottofix Black B 28. Drimarin Blue CT2R
09. Reactive Blue R(SP) 29. Bezaktrive Yellow S3R
10. Remazol Red RR 30. Bezaktrive Yellow SLF
11. Remazol Yellow RR 31. Bezaktrive Yellow V GL
12. Remazol Blue RR 32. Diss Yellow F5GL
13. Remazol Blue BB NEW 33. Diss Red BF
14. Remazol T. Blue G 34. Diss Blue FRL
15. Remazol B Yellow 3GL 35. Diss Navy 2GL
16. Remazol Red RGD 36. Diss Black EXNSF
17. Cibacron Red FN2BL 37. Terasil Black WNS
18. Cibacron Red FB 38. Terasil Red FB
19. Cibacron Red FN3G 39. Terasil Red WFS
20. Cibacron Red WB 40. Terasil Red W4BS
Remarks:
Fakhruddin Textile Mills Limited. uses best quality raw materials. It produces fabrics from
best quality yarn. They uses the best quality dyes like REMAZOL, REACTRON,
REACTIVE,TERACIL etc. During the time of using dyestuff they give importance upon the
quality of dyes than the price of the dyes and chemicals.
18. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
18 URMI Group
CHAPTER-04
INVENTORY CONTROL
AND UTILITY
Store & inventory control:
Frequency of Inventory Control:
Monthly inventory control
Annual inventory control
Scope of Inventory Control:
Raw materials
Dyes store
Others chemicals store
19. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
19 URMI Group
Grey fabrics
Finishing fabric
spare parts
General store
Capital equipment
Accessories
Stationary
Maintenance parts.
Inventory system for raw materials:
Raw materials partially received from production planning & directly from head
office.
Material Receiving & Inspection Report (MRIR) is prepared. Received quantity is
mentioned & noted down.
Submitted to QC department. Some are OK & few rejected.
Entry of data of goods in DATATEX.
Goods are arranged according to OK or rejected group.
Department gives store requisition to warehouse.
As per requisition materials supplied & this record is noted down.
Stages of grey fabric inventory control:
After knitting production
Grey inspection
Warehouse
Batch preparation
Dye house.
Stages of finished fabric inventory control:
Finishing section
After final inspection
Warehouse.
20. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
20 URMI Group
Utility:
SL MACHINE
NAME
BRAND ORIGIN QUANTITY
(Nos)
CAPACITY
01 GAS
GENERATOR
WAUKESHA U.S.A 02 750 KW
02 BOILER COCKRAN U.K 03 4500 KG
03 DIESEL
GENERATOR
DAIHATSU JAPAN 01 550 KW
04 COMPRESSOR COMP AIR GERMANY 01 5.5 m3/MIN
05 PUMP KSB INDIA 01 80-120 m3/Hr
06 BOOSTING
PUMP
KSB DPVF-65-
30
INDIA 06 65 m3/Hr
Moreover Urmi Group have the following facilities for smooth operation:
• Stand by Generator to run the full factory
• Fire protection system
• Sufficient volume of water reservoir at underground & overhead.
• Quality electrical cable with circuit breakers
• Separate toilets for male & female workers
• Sufficient ventilation is provided by installing ceiling fans, exhaust fans, large
windows
• Factory premises is always kept neat & clean
• We do not have any child labor
• Doctor & Nurse are provided to take care of workers health
• Canteen for workers
• Day care center
• Work study center
22. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
22 URMI Group
MARKETING STRATEGY
Marketing Strategy:
Marketing strategy is a very important factors to sale the products to the buyer . If
the marketing strategy is not so developed , it will be very hard to reach the goal .
In case of garments marketing the dealings with the buyer is a very important factor.
In Fakhruddin Textile Mills Ltd. mainly senior marketing officers , merchandiser &
higher officials deal with the buyer . There are some fixed buyers of the industry. The
buyers give their orders continuously all over the year . The marketing officers & the
merchandisers communicate with the buying houses to collect the orders .
Fakhruddin Textile Mills Ltd. is a 100% export oriented industry. All the goods produce in
this industry are exported to various country .
Clients of Fakhruddin Textile Mills Ltd.:
Buyer Country
Lidl Germany
S.Oliver Germany
23. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
23 URMI Group
Tchibo Germany
Puma Germany
Marks & Spencer UK
H&M Sweden
Ellos Sweden
LaRedoute France
Litex UK
Vertbaudet France
Auchen France
Decathlon France
Brylane USA
Toray Japan
Meters Bonwe China
Ernesting’s Family Germany
24. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
24 URMI Group
Main Products:
Polo Shirt, Sweat Shirt, Ladies rib tops, basic and fancy polo, T-Shirt,Tank-Tops, Sweat
Tops and bottoms for all age range of male and female.
CHAPTER-06
KNITTING SECTION
25. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
25 URMI Group
Knitting:
Knitting is a process of manufacturing a fabric by inters looping of
yarns. Knitting is the second most important method of fabric formation. It can be defined as
a needle technique of fabric formation, in which, with the help of knitting needles, loops are
formed to make a fabric or garment. Fabric can be formed by hand or machine knitting, but
the basic principle remains exactly the same i.e. pulling a new loop through the old loop.
In other words, Knitting is a method by which thread or yarn may be turned into
cloth or other fine crafts. It is a fabrication process i.e. intermeshing series of loops of one or
more yarns or from a set of yarns. Knitted fabric consists of consecutive rows of loops, called
stitches. As each row progresses, a new loop is pulled through an existing loop. The active
stitches are held on a needle until another loop can be passed through them. This process
eventually results in a final product, a garment. Knitting may be done by hand or by machine
.Different yarns and knitting needles may be used to achieve different end products by giving
the final piece a different color, texture, weight, and/or integrity. Using needles of varying
sharpness and thickness as well as different varieties of yarn can also change the effect. A
26. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
26 URMI Group
knitted fabric is the third major class of fabric, after woven and nonwoven fabrics.
In knitting, the inter-lopping is carried out by needles (may be Latch or beard or
compound needle etc), the needles are equipped on a cylinder and Needle butt moves
between the grooves of cams to accomplish knitting cycle and producing the fabric. The
shape of the needle cam grooves depends on the required knitting pattern.
All over the world, the majority of knit fabrics are manufactured on circular knitting
machines. The high performance level of these machines, the different materials and the
range of yarn counts that they are able to process, the wide variety of designs and stitches are
some of the reasons which have granted circular machines the market leadership in the
knitting sector.
Layout Of Knitting Section:
27. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
27 URMI Group
Knitting Machine Specification:
M/C M/C Name or Country Year M/C Type Dia& No. of No. of
28. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
28 URMI Group
No. Brand Name of Origin of
Manu.
Gauge Feeder Needle
01 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
02 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*24 84 2464
03 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*24 84 2464
04 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 30*28 90 2639
05 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 30*28 90 2639
06 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 30*28 90 2639
07 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 32*28 96 2815
08 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 32*28 96 2815
09 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 32*28 96 2815
10 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 34*28 102 2991
11 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 34*28 102 2991
12 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 34*28 102 2991
13 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 36*24 108 2715
14 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Double Jersey 36*24 72 2715
15 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Double Jersey 36*18 72 2036
16 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Double Jersey 36*18 72 2036
17 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Double Jersey 36*18 72 2036
18 KEUMYONG M/C
CO. LTD.
KOREA 2007 Double Jersey 38*18 90 2149
19 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Double Jersey 40*18 80 2262
20 PAOLO ORIZIO ITALIA 2002 Double Jersey 30*18 60 1697
21 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Double Jersey 42*18 84 2376
22 KEUMYONG M/C
CO. LTD.
KOREA 2007 Double Jersey 42*18 84 2376
23 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Single Jersey 24*24 72 1810
24 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Single Jersey 24*24 72 1810
25 PAI LUNG M/C TAIWAN 2004 Single Jersey 26*24 78 1961
29. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
29 URMI Group
CO. LTD.
26 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Single Jersey 26*24 78 1961
27 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*24 84 2112
28 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*24 84 2112
29 PAI LUNG M/C
CO. LTD.
TAIWAN 2003 Double Jersey 40*18 80 2262
30 PAI LUNG M/C
CO. LTD.
TAIWAN 2003 Double Jersey 36*18 72 2036
31 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Double Jersey 32*18 64 1810
32 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Double Jersey 32*18 64 1810
33 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Double Jersey 30*18 60 1697
34 KEUMYONG M/C
CO. LTD.
KOREA 2007 Single Jersey 40*24 120 3016
35 KEUMYONG M/C
CO. LTD.
KOREA 2007 Single Jersey 40*24 120 3016
36 KEUMYONG M/C
CO. LTD.
KOREA 2007 Single Jersey 36*24 120 2715
37 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Single Jersey 36*24 108 2715
38 PAI LUNG M/C
CO. LTD.
TAIWAN 2009 Single Jersey 34*24 102 2564
39 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 30*24 90 2262
40 PAOLO ORIZIO ITALIA 2002 Single Jersey 30*24 90 2262
41 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Single Jersey 30*24 90 2262
42 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Single Jersey 26*24 78 1961
43 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Single Jersey 30*24 90 2262
44 PAI LUNG M/C
CO. LTD.
TAIWAN 2004 Single Jersey 30*24 90 2262
45 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 32*24 96 2413
46 PAI LUNG M/C
CO.LTD.
TAIWAN 2004 Single Jersey 32*24 96 2413
47 PAI LUNG M/C
CO.LTD.
TAIWAN 2004 Single Jersey 32*24 96 2413
48 KEUMYONG M/C
CO. LTD.
KOREA 2007 Single Jersey 34*24 102 2564
49 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
51 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
30. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
30 URMI Group
52 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
53 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
54 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
55 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
56 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
57 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
58 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
59 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
60 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
61 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
62 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
63 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
64 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
65 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
66 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
67 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
68 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
69 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
70 JIUNN LONG M/C
CO.LTD.
TAIWAN Single Jersey 28*28 84 2464
71 FUKAHARA CHINA Auto Stripe
(Double Jersey)
72 FUKAHARA CHINA Auto Stripe (D/J)
Process flow chart of knitting:
Cone from spinning
Creeling the cone
31. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
31 URMI Group
Yarn feed by different tensioner
Adjust S/L, GSM, etc. by V.D.Q pulley
Produce 0.5 m fabric, if fault found, it adjust
After bulk production, cut the role
Marking the role such as S/L, Diameter, GSM etc.
Role inspection
Gray Store
Finishing/Dyeing
Sequence of Yarn Feeding:
32. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
32 URMI Group
Different Parts of Circular Knitting Machine:
1. Creel:Creel is a part of a knitting machine. Here yarn package are store and ready to feed
in the machine.
Creel
Yarn Tube/Pipe
Wheel
Yarn Sensor
Knot Catcher
Positive Feeder
Feeder
Final Yarn Guide
Needle
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33 URMI Group
2. Positive Feeders:Here number of yarn wounded on two positive feeder for smooth
feeding of two yarn in the machine.
3. Feed Sensor:It is used in positive feeder to help the little display at the time of yarn
breakage. At that time machine is stopped.
4. Final Yarn Guide:It controls the path of the yarn.
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5. Needle:Hooked metal part which is used to formation of loops.
6. Indicators:In any yarn breakage or any fault in the machine. Indicators are used to
identify them.
7. Lubricants:The lubricator provides lubrication to needle, cam tracks, lifters and other
knitting machine components.
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35 URMI Group
8. Fluff Blower:It removes the fiber, dust particle on the machine.
9. VDQ Pulley:It controls the stitch length as well as GSM of knit fabric.
10. Cam: Cams are knitting elements which cover rotary machine drive into a suitable
reciprocating action for the needles and other elements.
11. Cam Box:Where the cams are set horizontally.
36. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
36 URMI Group
12. Cylinder:Needles are situated here.
13. Dial:Needles are situated here. It is used in double jersey knitting machine.
16. Needle Detector:This part detects the any type of faults of needles.
37. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
37 URMI Group
17. Spreader:To control the width of the knitted fabric.
18. Taker-in:It is takedown the fabric in suitable tension.
19. Cloth Roller:Numbers of fabric layers are wound evenly.
Other parts,
38. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
38 URMI Group
Positive Feeder Belt
Knot Catcher
Top Gear Oil D/J
Yarn Tube/Pipe
Rotating Fan
Yarn Feeder Ring Ceramic
Yarn Feeder Ceramic
Lycra Guide/Wheel
Fabric Detector
Needle detector
Machine Gate
Take Down Side Gears
Fabric Roller Lock
Rubber Belt (Curling)
All Gear Greasing
All Type of Nut & Bolt
Terms of Knitting:
Course:
Horizontal row of loops produced by adjacent needles in knitting cycle is called the course of
the fabric. A course is a predominantly horizontal raw of needle loops produced by adjacent
needles during the same knitting cycle called course. (Loop length * No of loop).
Wales:
Vertical column of loops produced by same needle in knitting cycle is called the Wales of the
fabric.
39. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
39 URMI Group
A wale is a predominantly vertical column of intermeshed needle loops generally produced
by the same needle knitting cycles. i.e. The number of vertical columns of loop of knitted
fabrics is called wale.
Face loop:
If the legs of new loop is passes over the old loop is called face loop.
Back loop:
If the legs of new loop is passes under the old loop is called face loop.
Stitch density:
The term stitch density is frequently used in knitting instead of a linear measurement of
courses or Wales; it is the total number of needles loops in a square area measurement such
as a square inch or three square centimeters.
It is expressed as,
Course per inch × Wales per inch.
Stitch length:
Length of one loop in the course direction express in mm.
Number of needle:
Machine diameter × Machine gauge × 3.1416.
GSM:
The weight of one square meter of fabric express in gram is known as GSM.
Needle gauge:
The needle gauge of a knitting machine is a measure expressed the no. of needle per unit of
the needle bed or needle bar. As for example:
1. In case of circular weft knitting machine & Tricot warp knitting machine. [Gauge,
N= Number of needle per inch.]
2. In case of Raschel warp knitting machine. [Gauge, N= Number of needle per two
inch.]
40. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
40 URMI Group
Needle:
There are three types of needle-
1. Bearded needle
2. Compound needle
3. Latch needle-
One butt needle.
Two butt needle.
Three butt needle.
Four butt needle.
The most widely used needle is latch needle.
Fig: Main parts of latch needle.
Cam:
Cam is called the specific path of the needles to produce a specific type of fabric.
41. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
41 URMI Group
There are three types of cam used in circular knitting machine:
1. Knit Cam.
2. Tuck Cam.
3. Miss Cam.
Knit Cam:
It moves the needle upward enough to clear the old loop and receive the new yarn.
Tuck Cam:
It moves the needle upward not enough to clear. The old loop but receive the new yarn.
Miss cam:
It does not move the needle upward. The needles neither clear the old loop nor receive the
new yarn.
Sinker:
It is a thin metal plate with an individual or collective operation approximately at right angles
at the hook side between adjacent needles.
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42 URMI Group
Function of sinker:
In circular knitting m/c sinker helps to form the loop by holding down the yarn
Loop forming sequence of latch needle:
Latch Opening:
The needle goes upward and the sinker comes in action to hold down the loop. Then the old
loop press down the latch and it gets open.
Yarn Receiving:
43. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
43 URMI Group
The needle iscontinuous moving upward enough to receive the new yarn. The old loop
remains on the open latch that is called tucking on the latch position.
Clearing:
The needle goes to its ultimate height to clear the old loop and the new yarn still within the
reach of the needle.
Landing:
According to the path of cam, the needle starts moving downward. Being pushed by the old
loop the latch gets closed and the new yarn is entrapped within the closed hook.
Knock off:
The needle continues moving downward. When it reaches at the down position, the old loop
slides off from the back of the latch over the tip of the needle.This old loop then taken by the
take up roller hangs from the new loop.
Fabric Types:
Single Jersey
Rib
Interlock
44. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
44 URMI Group
Normal S/J
Fancy
Diagonal Fleece
Polar Fleece
Single Lacoste
Double Lacoste
High S/J
French Terry
Single Pique
Double Pique
(1*1) Rib
(1*2) Rib
Needle Drop Rib
Milano Rib
Flat back Rib
B-Waffle
FFL-Rib
Plain Interlock
Mesh
Net Mesh
Considerable points to produce knitted fabrics:
When a buyer orders for fabric then they mention some points related to production and
quality. Before production of knitted fabric, these factors are needed to consider. Those are as
follows-
Type of Fabric or design of Fabric.
Finished G.S.M.
Yarn count
Types of yarn (combed or carded)
Diameter of the fabric.
Stitch length
Color depth
Relationship between knitting parameter:
1. Stitch length increase with decrease of GSM.
2. If stitch length increase then fabric width increase and Wales per inch decrease.
3. If machine gauge increase then fabric width decrease.
4. If yarn count increase (courser) then fabric width increase.
5. If shrinkage increases then fabric width decrease but GSM and Wales per inch increase.
6. For finer gauge, finer count yarn should use.
7. Gray GSM should be less than finish GSM
Production Parameter:
Machine Diameter;
Machine rpm (revolution per minute);
No. of feeds or feeders in use;
45. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
45 URMI Group
Machine Gauge;
Count of yarn.
Responsibilities of a Production Officer :
Monitor and control shift wise production, plant utilization, waste generation etc.
implement correct work methods and maintain all records related to production.
Responsible for systematic planning and execution of production programs.
Adequate control over process in order to achieve quality of product & better waste
management.
Monitor shift wise production, utilization etc. and take corrective action for any
shortfall.
Maintain all the procedure of his department and shall incorporate amendments as and
when required in procedure.
Responsibilities for monitoring the performance of manpower under him and
identification of training needs.
Methods of increasing production:
By the following methods the production of knitted fabric can be increased –
By increasing m/c speed:
Higher the m/c speed faster the movement of needle and ultimately production
will be increased but it has to make sure that excess tension is not imposed on
yarn because of this high speed.
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.
By using machine of higher gauge:
46. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
46 URMI Group
The more the machine gauge, the more the production is. So by using machine
of higher gauge production can be increased.
By imposing other developments:
Using creel-feeding system
Applying yarn supply through plastic tube that eliminates the possibilities
of yarn damage
Using yarn feed control device
Using auto lint removal.
Factors that should be change in case of fabric design on quality change:
a) Cam setting
b) Set of needle
c) Size of loop shape
If shrinkage increases then fabric width decrease but GSM and Wales per
inch increase.
For finer gauge, finer count yarn should use.
Effect of stitch length on color depth:
If the depth of color of the fabric is high loop length should be higher because in case of
fabric with higher loop length is less compact. In dark shade dye take up% is high so GSM is
adjusted then. Similarly in case of light shade loop length should be relatively smaller
Some points are needed to maintain for high quality fabric:
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47 URMI Group
Brought good quality yarn
Machines are oiled and greased accordingly
G.S.M, Stitch length, Tensions are controlled accurately
Machines are cleaned every shift and servicing is done after a month
Grey Fabrics are checked by 4 point grading system
Changing of GSM:
Major control by VDQ pulley
Minor control by stitch length adjustment
Altering the position of the tension pulley changes the G.S.M. of
the fabric. If pulley moves towards the positive direction then the
G.S.M. is decrease. And in the reverse direction G.S.M will
increase
Tension:
Tension should be control for different yarns, because for tension variation yarns may be
broke. Tension measured by Tension Meter.
Yarn Tension (CN)
Cotton (S/J) 4-5
Polyester (Single Jersey) 3.5-4
Double Jersey 2-2.5
CVC/Viscose 6-7
For Fleece Yarn:
Yarn Tension (CN)
Binding Cotton 3-4
Polyester 1
Knit 4-5
Tuck 8-10
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48 URMI Group
Production Calculation:
We took all the necessary data which is related to calculating production (kg/hr) while
machine running. And here we show how to calculate different types of fabric production.
Machine No-46:
Single jersey (Plain):
= 16.34 kg/hr
= 130.73 kg/hr
= 392.2 kg/day
= 11765 kg/month or, 11.765 ton/month
= 141.18 ton/year
Machine No-20:
(Double Jersey Rib)
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49 URMI Group
= 7.12 kg/hr
= 56.96 kg/shift
= 5126.4 kg/month or, 5.13 ton/month
= 61.52 ton/year
Machine No-14:
(Double Jersey Interlock)
= 9.14 kg/hr
= 73.13 kg/shift
= 219.38 kg/day
= 6.58 ton/month
Relationship Between G.S.M, S/L & Count for different fabric:
Single Jersey (Plain):
G.S.M Count S/L (mm)
120 36/1 2.80
130 32/1 2.80
140 30/1 2.85
150 28/1 2.85
160 26/1 2.85/2.90
170 24/1 2.95
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52 URMI Group
Fabric Consumption:
Fabric Type = D-Fleece
Fabric GSM = 340
S/L of 30 Ne Dyed cotton yarn = 4.70
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53 URMI Group
S/L of 30 Ne Grey cotton yarn = 3.40
S/L of 10 Ne Dyed cotton yarn = 1.65
We know,
Composition = S/L ÷ Ne
Now, 4.7 ÷ 30 =0.15667
And, 3.4 ÷ 30 = 0.1133
And, 1.65 ÷ 10 = 0.165
Total = 0.434
Composition of 30 Ne Dyed yarn = (0.15667×100)÷0.434
= 36
Composition of 30 Ne Grey yarn = (0.1133×100)÷0.434
= 26
Composition of 10 Ne Dyed yarn =(0.165×100)÷0.434
= 38
So the composition are,
30 Ne Dyed cotton yarn : 30 Ne Grey cotton yarn : 10 Ne Dyed cotton yarn = 36:26:38
Sample analysis:
Normal S/J:
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54 URMI Group
Face Side Back Side
Diagonal Fleece:
Face Side Back Side
Polar Fleece:
Single Lacoste:
Face Side Back Side
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55 URMI Group
Face Side Back Side
Double Lacoste:
Face Side Back Side
Single Pique:
Face Side Back Side
Double Pique:
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56 URMI Group
Face Side Back Side
Rib (1*1):
Face Side Back Side
B-Waffle:
Face Side Back Side
Full Feeder Lycra-Rib:
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57 URMI Group
Face Side Back Side
Flat back Rib:
Face Side Back Side
Milano Rib:
Face Side Back Side
Plain Interlock:
58. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
58 URMI Group
Face Side Back Side
Mesh:
Face Side Back Side
Net Mesh:
Face Side Back Side
Quality Assurance System:
4 Point System:
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59 URMI Group
Fault Points
0-3” 1
3”-6” 2
6”-9” 3
>9” 4
HOLE<1” 4
HOLE>1” 4
< 20 Point-A
20-30 Point-B
Above- Rejected
Knitted Fabric Faults:
Conta
Hole/Hole mark
Loop
Slub
Patta
Drop Stitch
Cloth Fall Out
Cotton Knit (Dust)
Soil Mark/ Oil Mark
Needle Mark
Barrieness
Neps
Miss Yarn
Lycra Missing
Black Spot
Rust stain
Pin hole
Grease stain
Fly Dust
Cloth fall- out
Other fault
Calculation Related To Quality:
Formula:
60. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
60 URMI Group
Example 01:
Weight = 20 kg Points = 10
GSM = 180 Fabric Dia = 68
Now,
= 70 yds
= 7
Points = 7
So this is A Grade fabric.
Example 02:
Weight = 13.4 kg Points = 12
GSM = 160 Fabric Dia = 64
= 56 yds
= 12
Points = 12
So this is A Grade fabric
Quality Control M/C in Knitting Section:
Gray Inspection M/c, Brand : Uzu fabric inspection machine
Electric Balance for Fabric Weight.
Electric Balance for GSM check.
Compressor 2 pieces.
61. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
61 URMI Group
Faults & Remedies of knitting fabric:
Hole Mark:
Causes:
Holes are the results of yarn breakage or yarn cracks.
During loop formation the yarn breaks in the rejoin of the needle hook.
If the yarn count is not correct on regarding structure, gauge, course and
density.
Badly knot or splicing.
Yarn feeder badly set.
Remedies:
1.Yarn strength must be sufficient to withstand the stretch as well as uniform.
2.Use proper count of yarn.
3.Correctly set of yarn feeder.
4.Knot should be given properly.
Needle Mark:
Causes:
When a needle breaks down then needle mark comes along the fabrics.
62. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
62 URMI Group
If a needle or needle hook is slightly bends then needle mark comes on the
fabrics.
Remedies:
Needle should be straight as well as from broken latch.
Sinker Mark:
Causes:
When sinker corrode due to abrasion then some times can not hold a new loop
as a result sinker mark comes.
If sinker head bend then sinker mark comes.
Remedies:
Sinker should be changed.
Star Mark:
Causes:
Yarn tension variation during production.
Buckling of the needle latch.
Low G.S.M fabric production.
Remedies:
Maintain same Yarn tension during production.
Use good conditioned needles.
Drop Stitches:
Causes:
Defective needle.
63. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
63 URMI Group
If yarn is not properly fed during loop formation i.e. not properly laid on to the
needle hook.
Take-down mechanism too loose.
Insufficient yarn tension.
Badly set yarn feeder.
Remedies:
Needle should be straight & well.
Proper feeding of yarn during loop formation.
Correct take up of the fabric & correct fabric tension.
Yarn tension should be properly.
Oil Stain:
Causes:
When oil lick through the needle trick then it pass on the fabrics and make a
line.
Remedies:
Ensure that oil does not pass on the fabrics.
Well maintenance as well as proper oiling.
Rust stain:
Causes:
If any rust on the machine parts.
Remedies:
If any rust on the machine parts then clean it.
Proper maintenance as well as proper oiling.
Pin hole:
Causes:
Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies:
Change the needle.
64. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
64 URMI Group
Grease stain:
Causes:
Improper greasing
Excess greasing
Remedies:
Proper greasing as well as proper maintenance
Cloth fall- out:
Causes:
Cloth fall- out can occur after a drop stitch especially when an empty needle with an
empty needle with closed latch runs into the yarn feeder and remove the yarn out of the
hook of the following needles.
Remedies:
Make sure all the latches of needle are closed with feeding yarn after a
drop stitch.
Barrieness:
A fault in weft knitted fabric appearing as light or dark course wise (width
wise) stripe(s).
Causes:
This fault comes from yarn fault.
If different micro near value of fiber content in yarn.
Different luster, dye affinity of fiber content in yarn.
During spinning different similar classes of fiber is mixed specially in
carded yarn & these fibers have similar characteristics.
65. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
65 URMI Group
In draw fame different similar classes sliver is mixed and make one sliver.
Fly Dust:
Causes:
In knitting section too much lint is flying to and fro that are created from
yarn due to low twist as well as yarn friction. This lint may adhere or
attaches to the fabric surface tightly during knit fabric production.
Remedies:
Blowing air for cleaning and different parts after a certain period of time.
By cleaning the floor continuously.
By using ducting system for cleaning too much lint in the floor.
Over all ensure that lint does not attach to the fabric.
Yarn contamination:
Causes:
If yarn contains foreign fiber then it remains in the fabric even after
finishing,
If lot, count mixing occurs.
Remedies:
By avoiding lot, count mixing.
Fault less spinning.
Yarn Faults:
Naps.
Slubs.
Yarn count.
Thick/Thin place in yarn.
Hairiness.
66. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
66 URMI Group
Wastage:
Held up for further inspection by quality manager and Assistant General Manager. If quality
manager does not give any comment then he look up for AGM. And if AGM also does not
give any comment then it send to dyeing section. Dyeing section can ok this problem then
reject sample are considered as wastage or vice versa.
67. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
67 URMI Group
CHAPTER-07
DYEING AND
FINISHING SECTION
Layout Of Dyeing Section:
69. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
69 URMI Group
Symbol Description
01 ICI Pilling and Snagging tester
02 Pilling Assessment Viewer
03 Crockmeter
04 Perspiration Tester
05 pH Meter
06 Count Testing Machine
07 Digital Reeling Twist Tester
08 Tumble Dryer (Accudry2)
09 Tumble Dryer(Electrolux)
10-11 Washing Machine
12 Rota Wash
13-15 Lab Dyeing Machine
16 Lab Dryer
17 Automatic Pipette Machine
18 Light Box
Working Principle of Lab:
Central Laboratory divided into two sections.
70. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
70 URMI Group
Lab dip Development
Test
Fastness Test of fabric.
Water hardness measurement test.
Steps of Lab Operation:
Collect standard swatch / Panton from buyer
Calculate recipe by CCM (Computer Colour Matching) system.
No
Calculate difference I,e ensure that produced recipe is close enough to target sample
theoretically .
Yes
Produced sample.
Yes
Flow Chart of LAB DIP preparation:
Yes
Compare the target with produced sample.
Yes
Submit the sample for buyer approval.
Yes
Go to bulk production with correct recipe.
Laboratory Equipment’s:
SL/No Name of
Equipment’s
Model no./ Type Origin Unit
Correction
71. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
71 URMI Group
1 Spectrophotometer DATACOLOR / 650 USA 01
2 SDL “ECO” Infra-Red
Lab Dyeing System
d400IR/2 UK 03
3 Knit Shrinkage Tester Wascator from 71CLS
LABWASHER- Extractor
UK 01
4 Quick wash Plus Fabric
system
SDL-ATLAS UK 01
5 Rota Wash M 228 A UK 01
6 Standard Tumble Dryer 417 UK 02
7 Crock meter M238AA UK 01
8 Color Matching Cabinet G210A05 UK 01
9 Color Matching Cabinet Light Spectra LUX II DTM INDIA 01
10 Perspirometer M231 UK 01
11 Single End Yarn Strength
Tester
Y263 UK 01
12 Twist Tester Electronic Y220B UK 01
13 Yarn Examining machine 221 UK 01
14 ICI Pilling tester M227A UK 01
15 Digital PH /temp Meter G202 UK 01
16 Adventurer Electronic
Balance
G204/1A UK 01
17 Navigator Portable
Electronic Balance
G204VI UK 01
18 Fabric Yield Package
System
236/1 UK 02
19 Wrap Reel Electronic Y219BM UK 01
20 Electrolux washing m/c
Kit
FOM -71 UK 02
72. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
72 URMI Group
21 Electronic Sensor Dryer 471 UK 01
Laboratory dyeing procedure:
There are four dyeing process are followed in FTML.They are given below-
Cotton Dyeing
Polyester Dyeing.
White Color Dyeing.
Turquoise color dyeing
Preparation of Sample and Chemicals:
Liquor ratio 1:8
Making stock solution of dyestuff (0.25%,0.5%, 1%, 2%)
Making stock solution of chemicals. Soda ash = 20g/L, Glauber‟s salt = 20 g/L,
Leveling agent = 1cc.
Cotton Dyeing Procedure:
Add dyestuff, salt, leveling agent and alkali along with 5 gm sample fabric in a
beaker.
Then raise the temperature to 600C.
After that run the machine for 60 min by grading 3/ min.
At last drop the temperature to 50.
Wash Off:
Rinse the sample in running cold water until clear water come out.
Soaping with detergent at 70ºC for 05 min.
Rinse with cold water and squeezing is done
Dry up and ironing is done before assessing the shade.
Polyester Dyeing Procedure:
Add water, dyestuff, and salt, leveling and dispersing agent along with 5 gm sample
fabric in a beaker at pH 4.5 in 400 C.
After that raise the temperature to 130. Then run the machine for 45 min.
At last drop the temperature to 60.
Wash Off:
Rinse the sample with cold water until clear water come out.
Reduction clearing is done with 2 g/l caustic soda &hydrosol at 60-70 ºC
for 10 min.
Soaping with detergent at 80ºC for 05 min.
73. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
73 URMI Group
Dry up and ironing is done before assessing the shade.
White Color Dyeing Procedure:
Add Water,OBA (4BK),leveling agent along with 5 gm sample fabric in a beaker.
After that raise the temperature to 90. Then run the machine for 45 min by grading 2/
min.
At last drop the temperature to 50.
Wash Off:
Rinse the sample in running cold water.
Dry up and ironing is done before assessing the shade.
Cotton Dyeing with turquoise color Procedure:
Add dyestuff, salt, leveling agent along with 5 gm sample fabric in a beaker at 600C.
Then raise the temperature to 800C by grading 30C/min and keep the temperature for
15 minutes.
Next cooling the temperature to 600C by 20C/min.
After that add alkali (soda ash+ Caustic Soda) by dosing and raise the temperature for
80 by grading 3/ min.
At last drop the temperature to 60.
Wash Off:
Rinse the sample in running cold water until clear water come out.
Soaping with detergent at 80ºC for 05 min.
Rinse with cold water and squeezing is done
Dry up and ironing is done before assessing the shade
Description of Lab test Method:
Color Fastness to crocking (AATCC 8):
Standard Operating Procedure:
Objective:
To determine the amount of color transferred from the surface of colored textile materials to
other surface by rubbing.
Apparatus & Materials:
Crockmeter
Crockmeter test cloth
White AATCC testile blotting paper
AATCC chromatic transference scale
Grey Scale for staining
74. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
74 URMI Group
Specimen Size : 50 cm x 130 cm
Crock square Size: 5 cm x 5 cm
Conditioning:
Condition the specimen & crock square in conditioning atmosphere for 4 hrs.
Procedure:
For Dry Crocking:
Place a test specimen on the base of the crock meter resting flat on the abrasive cloth with its
long dimension in the direction of rubbing. Place specimen holder over specimen. Mount a
white test cloth square on the finger. Use the special spiral wire clip to hold the test square in
the place. Position the clip with loops upward. Lower the covered finger onto the test
specimen. Beginning with the finger positioned at the front end, crank the meter handle 10
complete turns at the rate of one turn per seconds to slide the covered finger back and forth
20 times. Set and run the motorized tester for 10 complete turns. Remove the white test cloth
square,
For Wet Crocking:
Wet out a crock square in the distilled water (Wet pick up s/b 65% ± 5%). Then continue the
test as dry crocking.
Air dry the specimen.
Evaluation:
Condition & evaluate the specimen using AATCC ref grey scale for color staining.
Mass per Unit Area (Fabric Weight) (ASTM D3776):
Standard Operating Procedure:
Objectives: To measure weight per unit area of textile
Specimen: 100cm2
Apparatus:
GSM cutter
Electronic Balance with an accuracy of 0.001
Condition:4hrs condition before test at 20±2 65±5 RH
Procedure:
Randomly cut five specimen by GSM cutter
Take weight individually
Let the weight in M
Calculation:
GSM = M x 100 ( g/m2)
= GSM x 0.029 (oz / yd2)
75. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
75 URMI Group
Take average of the five.
Color Fastness to Laundering (AATCC 61,2A):
Standard Operating Procedure:
Objective:
To evaluate the color fastness to laundering of textiles, which are expected to withstand
frequent laundering.
Apparatus & materials:
Launder meter sets
Canister (1200±50) ml
Stainless steel balls
Multifibre test fabric
1993 AATCC Standard Reference Detergent WOB.
Distilled water.
Preparation:
Specimen Size : 2” x 6”
Multifibre Size: 2” x 4”
Attach Multifibre (fused) & fabric face in shorter edge
Solution: 1.5 g AATCC WOB detergent per 1 liter distilled water
Procedure:
150 ml solution with 50 steel balls in a 1200 ml canister 45 minutes at 49
Adjust the laundering machine to temp. 49.
Preheat the solution in a 1200 ml canister with 50 steel balls for 2 minutes.
Then put the specimen onto the canister & run the machine for 45 minutes.
Empty the contents into beakers.
Rinse test specimen three times, in 3 separate beakers with distilled water at (40±3 for
1 min.
Dry the specimen in an air circulating oven in which the temperature dose not exceed
71
Evaluation:
After 1 hour condition, assess the specimen for color change & staining using AATCC Ref
Grey Scales.
pH of Water Extract of Textiles (AATCC 81):
Standard Operating Procedure:
Objectives: To determine the pH of an aqueous extract of a textile material.
76. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
76 URMI Group
Apparatus:
Glass Beaker
pH meter
Electronic Balance
Buffer Solution (pH 4.0 - 7.0 & 10.0)
Specimen:10 ± 0.1 gm specimen cut into small pieces
Solution: 250 ml distilled water in 400 ml beaker.
Procedure:
Boil 250 ml of distilled water at a moderate rate for 10 min.
Put the specimen; cover the beaker with a watch glass.
And boil for an additional 10 min.
Allow the covered beaker to cool to room temperature.
Remove the specimen with tweezers.
Evaluation:Measure the pH of the extract using a calibrated pH meter
Dimensional Stability to Washing (AATCC 135)
Standard Operating Procedure:
Objective:
To determine the shrinkage & Elongation of a textile component, after a defined number of
washing & drying cycles.
Apparatus:
Template
Indelible Ink
Metal rule graduated in mm
Condition:
Prior to making condition specimen for 4 hours at conditioning atmosphere.
Sample Preparation:
Place the template with one of its side parallel to the selvage & at least (150 ± 10) mm
from selvage.
Trace a square of 10” x 10” with the four corner hole using their exterior sides.
Cut out all around the template so that you have a sample of 15” x 15”
Procedure:
Measure with marking three length (L1, L2, L3) & width (W1, W2, W3) of the square
securing each bench mark 5 inch apart from another.
Perform the number of washing & drying required by the applicant.
Condition for 4 hrs, flat without fold.
Measure after wash length (L‟1, L‟2, L‟3) & width (W‟1, W‟2, W‟3)
Calculation:
77. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
77 URMI Group
Calculate shrinkage according to the formula:
Shrinkage % = (After wash – Before wash) / before wash x 100
Color Fastness to water (AATCC 107):
Standard Operating Procedure:
Objective:
To measure the resistance of water of dyed, printed or otherwise colored textile yarns or
fabrics
Specimen Size:
Specimen: 6 cm x 6 cm
Multifibre: 5 cm x 5 cm
Attach multifibre and fabric face side in shorter edge.
Solution: Fresh boiled, Distilled or deionized water.
Procedure:
Immerse the test specimen in the test solution with occasional agitation approximately
15 minutes.
Remove the test specimen from the test solution and only pass between squeeze rolls
to remove excess liquor (wet pick up 2.5 – 3.0)
Place the test specimen between glass or plastic plates and insert in the specimen unit
of the perspiration tester.
Adjust the perspiration tester to produce a pressure of 4.5 kg on the test specimen.
Keep in oven at 38±1 (100±2for 18 hr.
Remove the tester from the oven.
Place the multifibre fabric and test fabric specimen separately on a wire screen in a
conditioned atmosphere 21 ± 1(70 ± 2 ) and 65 ± 2 relative humidity overnight.
Evaluation:
After condition, Assess the specimen for color change & staining using AATCC Ref Gray
Scales.
Color Fastness to Perspiration (AATCC 15):
Standard Operating Procedure:
Objective:
To determine the fastness of colored textiles to the effect of acid perspiration.
Apparatus & Materials:
78. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
78 URMI Group
Perspiration test kit
Oven
pH meter with an accuracy of 0.01
Electric Balance accurate to 0.001g
Multi-fibre
Gray Scales for color change & staining
Sampling:
Specimen Size: 6 cm x 6 cm
Multifibre Size: 5 cm x 5 cm
Attach multifibre& fabric face side in shorter edge
Solution:
10±0.01g sodium chloride (NaCl)
1±0.01g lactic acid, USP 85 %
1±0.01g Sodium Phosphate, dibasic, anhydrous (Na2HPO4)
0.25±0.001 g l-histidine monohydrochloride (C6H9N3O2.HCL.H2O)
Fill the volumetric flask with distilled water to the 1 L mark
Test the pH of the solution with a pH meter.If it is not 4.3 ± 0.2 discard it.
Procedure:
Place the test specimen in a petri dish (9cm dia x 2cm depth )& pour the test solution
1.5 cm deep . Soak it with squeezing for 30+2 mins.
Remove the test specimen from the test solution and only pass between squeeze rolls
to remove excess liquor ( wet pick up 2.25±0.05)
Place the test specimen between glass or plastic plates and insert in the specimen unit
of the perspiration tester.
Adjust the perspiration tester to produce a pressure of 4.5 kg on the test specimen.
Keep in oven at 38±1 (100±2) for 6 hr.
Remove the tester from the oven.
Place the multifibre fabric and test fabric specimens separately on a wire screen in a
conditioned atmosphere 21±1 ( 70 ± 2 ) and 65± 2 relative humidity overnight
Pilling Resistance Test (ASTM D3512)
Standard Operating Procedure:
Objective: To define the resistance to pilling or surface fussing of a textile material
Apparatus:
Random Tumble Pilling Tester
Cork Liner
Cotton Sliver
Pilling Assessment Viewer
79. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
79 URMI Group
Specimen Size:
3 specimens each 105 mm square to be cut randomly along 45 degree angle with warp & weft
yarn.
Procedure:
Check the cork liner & door gasket. These should be clean and free from lint & dirt.
Each side of the cork liner should be discarded.
Open the chamber door, Place the specimen with 25 gm cotton sliver in the test
chambers, and close the chamber door.
Switch ON the „Operate‟ switch.
Set timer 30 minutes.
Turn on the air injection switch. Air pressure should be 2 – 3 psi.
Press the start button to begin the test. After 30 minutes machine will stop
automatically.
Then remove the specimen from the test chamber.
Evaluation: Evaluate the three specimen in the pilling assessment viewer
Batch preparation:
After knitting, fabrics are taken to the grey store room and made ready for dyeing/finishing.
Process of making them ready is called batching. Operations done in batching are:
•Fabrics to be dyed are arranged according to the Order sheet, Dyeing shade, m/c capacity,
m/c availability, type of fabric, priority of work.
•Fabrics are turned towards the back side.
•Fabrics that contain lycra, are slatted in slitter machine and send to stenter machine for heat
setting at 190°C
Flow Chart of Batch Preparation:
The priority as per dyeing plan was made
80. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
80 URMI Group
One specific Batch card was taken.
The Batch Card for own understanding was read
Required quantity of body fabrics from ware-house was taken.
Required no. of Rope maintaining equal weight was made.
Take collar/cuff as per size, keep the total weight.
The collar /cuff or Rib in each rope equally unsure equal weight was distributed
The production report form was filled up.
Purpose of Batch Section:
To receive the grey fabrics roll from knitting section or other source.
To turn out the tubular fabric in its grey stage and to safe the face side of the fabric
from any type of friction during the time of dyeing.
To prepare the batch of fabric for dyeing according to the following criteria-
Order sheet (Receive from buyer)
Dyeing shade (Color or white, light or Dark)
M/c available
Type of fabrics (100% cotton, PC, CVC)
Emergency.
To send the grey fabric to the dyeing floor with batch card.
81. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
81 URMI Group
To keep records for every previous dyeing.
Criteria of proper batching:
To use maximum capacity of existing dyeing m/c.
To minimize the washing time or preparation time & m/c stoppage time.
To keep the no. of batch as less as possible for same shade.
To use a particular m/c for dyeing same shade.
Stages required completing a whole Dyeing Process :
Amount ofdifferent Ingredients used in different
stages of pretreatment:
Ingredient Quantity
Wetting agent 1.2 g/l
Anti-creasing
agent
1.0 g/l
Sequestering
agent
1.0 g/l
Caustic 2.5 g/l
Stabilizer 0.5 g/l
Hydrogen per
oxide (H2O2)
3.0 g/l
NEUTRALIZATION
82. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
82 URMI Group
Dyeing:
Acetic acid 1 g/l
DYEING
Leveling agent 2 g/l
Dyes 10 g/l
Salt 2 g/l
Soda ash
AFTER
TREATMENT
Acetic acid 1 g/l
Soaping agent 1 g/l
SOFTENING
Acetic acid 0.5 g/l
Softener 1 g/l
83. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
83 URMI Group
Dyeing is the process of imparting colors to a textile material in loose fiber, yarn, cloth or
garment form by treatment with a dye.
Process Flow chart of Dyeing:
Fabric Receive From Inspection Section
Batching
Fabric Turning
Sewing & Fabric Loading
Pretreatment
Dyeing
After Treatment
Unload
DYEING MACHINE SPECIFICATION:
84. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
84 URMI Group
S
L.
N
o.
Brand
Name
Origin Model Year
of
Man
u.
Max.
Worki
ng
Temp.
°C
Max.
Workin
g
Press
Capaci
ty
(Kg)
Types of
Fabric
Dyeing
01 DILMENLER TURKIY
E
DM-EN-
729-3
2005 135 3 bar 15 All types of
Fabric
02 DILMENLER TURKIY
E
DM-EN-
729-3
2005 135 3 bar 15 All types of
Fabric
03 DILMENLER TURKIY
E
DIN-EN-
729-3
2004 135 3 bar 50 All types of
Fabric
04 DILMENLER TURKIY
E
DMS11
HT Jumbo
-Jetflow
2005 135 3 bar 175 All types of
Fabric
05 DILMENLER TURKIY
E
DMS11
HT Jumbo
-Jetflow
2004 135 3 bar 225 All types of
Fabric
06 DILMENLER TURKIY
E
DMS11
HT Jumbo
-Jetflow
2004 135 3 bar 450 All types of
Fabric
07 DILMENLER TURKIY
E
DMS11
HT Jumbo
-Jetflow
2004 135 3 bar 675 All types of
Fabric
08 DILMENLER TURKIY
E
DMS11
HT Jumbo
-Jetflow
2005 135 3 bar 350 All types of
Fabric
09 DILMENLER TURKIY
E
DMS11
HT Jumbo
2005 135 2.5bar 1050 All types of
Fabric
85. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
85 URMI Group
10 Tong Geng
Enterprise Co.
LTD.
TAIWA
N
TGRU-NUV-
6-
900
2006 98 - 900 Without
Polyester all
types of Fabric
11 Tong Geng
Enterprise Co.
LTD.
TAIWA
N
TGRU-NUV-
4-
600
2006 98 - 600 Without
Polyester all
types of Fabric
12 Tong Geng
Enterprise Co.
LTD.
TAIWA
N
TGRU-NUV-
8-
300
2006 100 - 300 Without
Polyester all
types of Fabric
13 DILMENLER TURKIY
E
DMS11
HT Jumbo
2007 135 2.5 bar 1400 All types of
Fabric
14 J&X CHINA HF-8-50 2008 100 Unlimited 50 Without
Polyester all
types of Fabric
15 J&X CHINA HF-8-100 2008 100 - 100 All Cotton
Fabric
16 DILMENLER TURKIY
E
DMS11
HT Jumbo
2008 135 2.5 bar 1050 All types of
Fabric
17 THEN CHINA SYN1000
G2
2013 140 3 bar 1000 All types of
Fabric
18 THEN CHINA SYN1200
G2
2012 140 3 bar 1000 All types of
Fabric
19 GUANGDON
G
HESHAN
HONGFA
COMPLETE
SOLUTIONS
MACHINE
LTD.
CHINA WGR202 2010 135 3 bar 20 Tape, Belt etc.
20 DILMENLER TURKIY
E
DMS11
HT Jumbo
2010 135 2.5 bar 175 All types of
Fabric
21 DILMENLER TURKIY DMS11 2010 135 2.5 bar 350 All types of
86. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
86 URMI Group
E HT Jumbo Fabric
22 EA (BD) PPM BANGL
ADESH
EA (BD)
PPM-15
2010 100 Unlimited 15 Without
Polyester all
types of Fabric
23 EA (BD) PPM BANGL
ADESH
EA (BD)
PPM-50
2010 100 Unlimited 50 Without
Polyester all
types of Fabric
24 THEN CHINA SYN1000
G2
2013 140 3 bar 1000 All types of
Fabric
25 EA (BD) PPM BANGL
ADESH
EA (BD)
PPM-15
2012 100 Unlimited 15 Without
Polyester all
types of Fabric
26 EA (BD) PPM BANGL
ADESH
EA (BD)
PPM-15
2012 100 Unlimited 15 Without
Polyester all
types of Fabric
27 EA (BD) PPM BANGL
ADESH
EA (BD)
PPM-25
2012 100 Unlimited 25 Without
Polyester all
types of Fabric
Production parameters:
Particulars PH Temperature Time
Scouring bath 11.00 980C 40-50 min
Enzyme bath 4.5-5.0 500-550C 50 min
Dye bath 5.5-6.5 --- ---
87. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
87 URMI Group
Soaping bath 6.5-7.0 900C-980C 20 min
Softening bath 6.0 400C-450C 20 min
Fixing bath 5.5-6.0 450-500C 20 min
Stages required completing a whole Dyeing Process:
Liquor ratio : 1:8
Scouring : 1: 8
Light and critical color : 1: 8
Normal and dark color : 1: 7
Turquoise Color : 1: 10
Soaping : 1: 8
Softening : 1:5 – 6
Pretreatment Process:
Process Flow Chart for Demineralization (If necessary):
Fabric load
↓
Water fill
88. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
88 URMI Group
↓
Nearpon BWLF/ NOF + A. Acid (Run time10´)
↓At 60ºC
Drain bath
Process Flow Chart for Scouring & Bleaching
Water fill
↓
Fabric Load
↓
Detergent/wetting agent + S.A + Stabilizer +Anticreasing agent (inject) at 500c
↓ At 600C
Caustic (Linear dosing 5´)
↓At 700C
H2O2 dosing 10 min
↓At 70ºC
Then temp. raised to 1100C & run 30´
↓
Cooling 800c
↓
Rinse 5 ‘
↓
Drain& Fill Water
↓
Normal Hot 900c at 10 min
↓
Rinse 5’ (Sample check)
89. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
89 URMI Group
↓
Water drain& Fill Water
↓
H2O2 Killer at 800C
↓20 min
Acetic Acid (PH check – 4.5)
↓
Enzyme (Dosing for 10´)
↓Run 60´ at 55ºC
Drain & Fill water
↓
Normal Hot at 800C
↓ Run 10´
Rinse 10’
↓
Water drain
Example of Recipe for Pretreatment (Approximately):
Demineralizing:
Detergent(Nearpon BWLF/NOF)- 0.8 g/l
Scouring & Bleaching:
Detergent (Nearpon BWLF/NOF) - 0.8 g/l
Ant creasing( Anticrease-D) – 0.5 g/l
Antifoaming ( Kappasol AF-200 ) - 0.1 g/l
Enzyme wash
90. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
90 URMI Group
Stabilizer (GEISTABS RS) – 0.5 g/l
Sequestering (Jinlov ECO DL/PS) – 0.5 g/l
Caustic soda ( caustic Soda L/C) – 2.0 g/l
Peroxide(Antiper R) -7.0 g/l
Neutral:
Peroxide killer (Geiszyme PR)
Acetic acid– 1.0 g/l
Enzyme:
Acetic acid L/C – 1.0 g/l
Enzyme(Bio Polish B6oon) – 1.5g/l
Dyeing process:
Dyeing process of Cotton:
After Pretreatment Fill Water
Cotton Leveling agent+S.A
Color dosing (500CX 10´)
(Run time: 10/15´)
91. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
91 URMI Group
Salt dosing (500C X 10´)
(Run time: 20´)
(Salt Sample Check)
Soda dosing (500C X 40´), [PH: 6-7]
(Run time: 20´)
Color steam, 60-700C (20/min)
(Run time: 60´)
Sample check
If Ok (Fixing & softening should be done)
If not ok then it will take more time about 40´ or 60´& if remain light shade 1st acid wash
then hot wash & if remain dark shade 1st hot wash then acid wash should be done.
Rinsing wash (15´/20´)
B.D& Fill water
Acetic acid (400C)
R.t:20´
Rinsing wash 10/15´
Drain & Fill Water
Washing agent
Hot wash for deep shade, 950C X 15/20´
92. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
92 URMI Group
For normal shade 900/800C X 10/15´
Cooling (Sample Check )
(If OK)
Rinse-10‟
Drain & Fill water
Fixing Agent (for deep shade, R.t:15´ X 400C)
Rinsing wash 10/15´
Drain & Fill water
Softening at 40/450 C X 20/25´
Final Sample check (if ok)
Rinse 10‟
Unload
Example of Recipe (Approximately):
Dye bath: Dyestuff:
Levelling (Croscolor ADM) – 1.5 g/l Bezactive yellow S-Matrix 150:
0.7800%
Ant creasing (TFV) – 1.0g/l Bezactive Red S-Matrix 150 :
0.800%
Sequestering (Jinsoft ECO ECA) – 0.5 g/l Bezactive Blue S-Matrix 150 :
2.3400%
Glubersalt (G.salt) – 80 g/l
Soda ash – 20 g/l
Aftertreatment:
93. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
93 URMI Group
Acetic acid L/C– 1.0g/l
Washing agent (Avolan IS W) – 0.5 g/l
Fixing agent (Kappafix-GG 100) – 1.5%
Softener AWSP – 5%
Common Dyeing Faults:
1. Uneven dyeing:
Causes:
- Uneven pretreatment (uneven scouring & bleaching).
- Improper color dosing
- Using dyes of high fixation property
- Uneven heat-setting in case of synthetic fibers
- Lack of control on dyeing m/c
Remedies:
- By ensuring even pretreatment
- By ensuring even heat-setting in case of synthetic fibers
- Proper dosing of dyes and chemicals
- Proper controlling of dyeing m/c
2. Batch to Batch Shade variation:
Causes:
- Fluctuation of Temperature
- Improper dosing time of dyes & chemicals
- Batch to batch weight variation of dyes and chemicals
- Dyes lot variation
- Improper reel speed, pump speed, liquor ratio
- Improper pretreatment
Remedies
- Use standard dyes and chemicals
94. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
94 URMI Group
- Maintain the same liquor ratio
- Follow the standard pretreatment procedure
- Maintain the same dyeing cycle
- Identical dyeing procedure should be followed for the same depth of the Shade.
- Make sure that the operators add the right bulk chemicals at the same time and temperature
in the process.
- The pH, hardness and sodium carbonate content of supply water should check daily
3. Crease mark:
Causes:
- Poor opening of the fabric rope
- Shock cooling of synthetic material
- If pump pressure & reel speed is not equal
- Due to high speed m/c running
Remedies:
- maintaining proper reel speed & pump speed
- Lower rate rising and cooling the temperature
- Reducing the m/c load
- Higher liquor ratio
5. Dye spot:
Causes:
- Improper Dissolving of dye particle in bath
- Improper Dissolving of caustic soda particle in bath
Remedies:
- By proper dissolving of dyes & chemicals
- By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the
large un-dissolved particles are removed
6. Softener Mark:
Causes:
95. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
95 URMI Group
- Improper mixing of the Softener
- Improper running time of the fabric during application of softener
- Entanglement of the fabric during application of softener
Remedies:
- Maintaining proper reel sped & pump speed
- Proper Mixing of the softener before addition
- Prevent the entanglement of the fabric during application of softener
Finishing:
The objectives of finishing operations are to treating textile product in to a presentable form.
Finishing process includes chemical and mechanical process. The extent of finishing process
depends on the fabric quality and the requirements of the finishing product. Finishing process
is employed for controlling fabric GSM, shrinkage, improving fabric appearance and to make
more lusters.
Objective of Finishing:
- Improving the appearance like Luster, whiteness etc.
- Improving the feel, this depends on the handle of the material and its softness, suppleness,
fullness, etc.
- Wearing qualities, no soiling, anti-crease, anti-shrink, comfort etc.
- Special properties required for particular uses water proofing, flame proofing etc.
- Covering the faults on the original cloth.
- Increasing the weight of the cloth.
96. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
96 URMI Group
Types of Finishing:
Finishing is done in two ways-
1. Open Finish
2. Tube Finish
a. The machines that are used for open line are given bellow –
b. The machines that are used for tube line are given bellow –
Flow-chart of Finishing:
Finishing
Open Finish Tube Finish
Slitting and Dewatering Squeezing
StenteringDryin
Inspection Compacting
Delivery Inspection
Delivery
97. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
97 URMI Group
Flow chart:
For Peach finish/Brush:
Slitting
↓
Stenter
↓
Sueding/Raising
↓
Stenter
↓
Compacting
For Lycra:
Slitting
↓
Heat Setting
↓
Sewing
↓
Drying
↓
Slitting
↓
Stenter
↓
98. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
98 URMI Group
Compacting
List of Machine for Finishing:
Sl. Brand Name Origin Manu.
Year
Model M/c Type Mx
Speed/min
01 BIANCO Italy 2010 - Slitting m/c 90
02 BIANCO Italy 2006 - Rib & Tube
Slitting m/c
80
03 BIANCO Italy 2004 M03575-017792 Slitting m/c 90
04 BRUCKNER Leon berg,
Germany
2009 - Stenter -
05 SUN SUPER
S
South Korea 2004 IS-SST-60P(V1.1) Stenter 100
06 FAB-CON Port Washington
N.Y
- PAT.N.4.175.738 Rib & Tube
Finish
-
07 LAFER SPA Italy 2010 KSA500 -
08 FERRARO Italy 2004 Comptex/RA-
2800
Compacting -
09 DILMENLER Turkiye 2006 Dryer m/c -
10 TUMBLE
DRYER
- - Garments
Drying
-
11 LAFER
ULTRA
SOFT-L
Italy - - peach m/c -
12 LAFER Italy - - One side
Brush m/c
-
Process of Finishing:
Rope Squeezing Machine:
Functions of the machine:
De-twisting the fabric rope
99. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
99 URMI Group
To remove the water from the fabric
To control the width of the fabric.
Apply chemicals specially to make the fabric soft.
To remove the crease mark of the fabric
Machine Set-up:
M/C parameters Set up value
Padder pressure 1 to 6 bar
Speed 20 to 90 m/min
Over Feed 10 to 20 %
Fig: Rope Squeezing M/C
Stenter machine:
A machine or apparatus for stretching or stentering fabrics. The purpose of the stenter
machine is to bringing the length and width to pre determine dimensions and also for Heat
setting and it is used for applying finishing chemicals and also shade variation is adjusted.
The main function of the stenter is to stretch the fabric widthwise and to recover the uniform
width.
Functions of Stenter Machines:
1.Heat setting is done by the stenter for Lycra fabric,Synthetic And Blended Fabric.
2.Width of the fabric is controlled by the stenter.
3.Finishing chemical apply on the fabric by the stenter.
100. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
100 URMI Group
4.Loop of the knit fabric is controlled.
5.Moisture of the fabric is controlled by the stenter.
6.Spirality controlled by the stenter.
7.GSM of the fabric is controlled by stenter
8.Fabric is dried by the stentering process.
9.Shrinkage property of the fabric is controlled.
10.Curing treatment for resin, water repellent fabric is done by the stenter.
Components of Stenter Machine:
Paders
Weft straightner(Mahlo)
Burners
Heat recovery
Attraction rollers
Circulating fans
Exhaust fans
Winder
Clips
Pins
Cooling Drums
Working Procedure of Stenter Machine:
The fabric is collected from the batcher to the scray and then it is passed through the padders
where the finishes are applied and some times shade variation is corrected.The fabric is
entered into the mahlo (weft straigtner) the function of the mahlo is to set the bow and also
weave of the fabric is griped by the clips and pins are also provided but the pins has a
disadvantage that they pins make holes at the selvedge but the stretchning of the pins are
greater than the clips.these clips and pins are joined to endless chain.there are 8 to 10
chambers provided on the machine each chamber contains a burner and filters are provided to
separate dust from air.the circulating fans blow air from the base to the upper side and
exhaust fans sucks all the hot air within the chambers. Attraction rollers ar provided to stretch
the warp yarn.
After stentering we can increase the width of the fabric up to 1.5-2 inch.The speed of the
machine is about 7-150 m/min.3 meters fabric can run in each chamber.temperature is
adjusted that according to the fabric as for,
101. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
101 URMI Group
1. PC 210 c
2. Cotton 110-130 c
After dyeing 160-170c and after print 130-140c.
Specification of a Bruckner Stenter Machine:
Brand Name Bruckner
Origin Germany
Year of
manufacture
2009
Speed range 15-30 m/min
Temperature range 50-220C
Used utilities Electricity, Gas, Compress air,
Steam
Per chamber lenght 3 meter
No. of chamber 8
Maximum fabrics
width
102”
Minimum fabric
witdth
30”
Steam pressure 2 bar
Air pressure 10 bar
Applied for Open tube fabric
No. of ratamatic
burner
16
No. of blower 32
M/C parts Burner,Nozzle, Exhaust air fan,
Over feed roller, Suction fan,
Chain arrangement
102. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
102 URMI Group
Fig: Bruckner Stenter Machine
Specification of a SUN SUPER S Stenter Machine:
Brand Name SUN SUPER S
Origin South Korea
Temperature range 50-220C
Used utilities Electricity, Gas, Compress air,
Steam
Per chamber lenght 3 meter
No. of chamber 6
Applied for Open tube fabric
No. of ratamatic burner 12
No. of blower 12
M/C parts Burner,Nozzle, Exhaust air fan,
Over feed roller, Suction fan,
Chain arrangement
103. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
103 URMI Group
Fig: SUN SUPER S Stenter Machine
Example:
Finishing Procedure for 100% cotton fabric:
Temp : 180
Over feed : 5
Speed : 34 m/min
Stretching : 10%
Bypass system : N/a (Color & Silicon are used in chemical bath)
Grey GSM : 160
Grey Dia : 48
After Finishing
GSM : 140
Dia : 51
Finishing Procedure for 95% Viscose+5% lycra fabric:
Temp : 160
Over feed : 39.3
Speed : 34 m/min
Stretching : 4%
Bypass system : N/a (Chemicals are used in chemical bath)
Grey GSM : 220
Grey Dia : 70
After Finishing
GSM : 196
Dia : 74
Finishing Procedure for 90% Polyester+10% lycra fabric:
Temp : 140
104. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
104 URMI Group
Over feed : 20
Speed : 43 m/min
Stretching : 2%
Bypass system : N/a (Color & Silicon are used in chemical bath)
Grey GSM : 120
Grey Dia : 62
After Finishing
GSM : 118
Dia : 64
Heat set procedure for Lycra Polyester:
Temp : 190
Over feed : 35
Speed : 30 m/min
Stretching : 6%
Bypass system : Without any water or chemical the fabric passing with the
Roller/padder
Grey GSM : 120
Grey Dia : 58
After Finishing
GSM : 115
Dia : 60
Compactor:
Function of the machine:
To control the GSM.(Increase & decrease)
To control the dia.
105. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
105 URMI Group
To control the shrinkage. (Increase & decrease)
To smooth the fabrics surface
Fig: Compactor m/c
Machine Set-up:
M/C parameters Set up value
Temperature 120-130 ºC
Compaction 2 to 10 %
Speed 8 to 40 m/min
Compactor 02:
Function of the machine:
To control the GSM.(Increase)
To control the dia.
To control the shrinkage. (Increase & decrease)
To smooth the fabrics surfa
106. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
106 URMI Group
Fig: Compactor m/c
Machine Set-up:
M/C parameters Set up value
Temperature 90 - 145 ºC
Compaction 2 to 8 %
Speed 8 to 40 m/min
Over Feed 10 to 30 %
Compaction measurement:
Compaction measurement is doing for make a report of shrinkage for a fabric. How much
increase or decrease in length or width of a fabric after finishing is measuring by compaction
measurement.Fabrics have the tendency to shrink in washing, due to tensions introduced
during the spinning, weaving, knitting, dyeing and in some finishing operations.This
operation consists in applying chemical products or mechanical treatments(compacting,
sanforizing and stentering machine) in order that the clothing hasthe minimum dimensional
alterations after being manufactured.
Compaction parameters for a fabric:
Gray GSM
Width
Length
After finishing:
GSM
Width
Length
Dryer:
Functions:
1. To dry the fabric with help of steam
2. To control the shrinkage
3. To prepare for next subsequent process
4. To dry tubular and open width fabric without tension
107. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
107 URMI Group
Main parts of the machine:
1. Heating chamber (3)
2. Blower (3)
3. Synthetic blanket as a conveyor
4. Folder
5. Exhaust fan
Heating system:Gas fired.
Utility:
1. Gas (to make fire)
2. Electricity (to rum the machine)
3. Compressed air (to spread the fire)
Working principle of dryer:
After de-watering then the fabric through the dryer. This machine contains two chambers.
Two mesh endless conveyors are placed lengthwise to the chamber named conveyor net and
filter net, each chamber contain a burner, which supply hot air .This hot air is guided through
the ducting line by suction fan .There are nozzles placed in between filter net and conveyor
net .When the fabric pass on the conveyor net, hot air is supplied to the wet fabric to dry it.
There are exhaust fan which such the wet air and deliver to the atmosphere through the
ducting line.
The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric. If
the m/c temp. is high then m/c speed also high and the m/c temp. is low then m/c speed also
low . The vibration speed of the m/c for heavy fabric is 730 m/min and normal fabric is 480
m/min.
108. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
108 URMI Group
Printing:
To add value in color Fakhruddin Textile Mills Ltd has in-house Garments printing facility.
Its printing section is well equipped with necessary equipment from film to screen
development. Printing section has the ability to print Pigment, Silicon, Puff, Flock, Glitter,
Metal stone and Rubber.
Printing System:
Hand screen printing
Screen Printing Automatic Flat (Revolving) screen printing
Automatic Rotary Screen Printing
Flow chart of Printing section:
Artwork from merchandiser
↓
Design input
↓
Design development
↓
Positive/film
↓
Print taken
↓
Requisition by merchandiser
↓
Panel (cutting fabric parts)
↓
Expose (frame adjusted)
109. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
109 URMI Group
↓
Fila and frame adjusted
↓
Water spray
↓
Panel send to buyer
↓
Buyer approval
↓
Sale sample
↓
Counter sample
↓
P P production
↓
Accessories booking
↓
Requisition by merchandiser for fabric
↓
Fabric received and store
↓
Count the fabric
↓
Inspection the fabric
↓
Fabric adjusted
↓
Bulk production start
110. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
110 URMI Group
↓
Hydro extractor from dryer
↓
Inspection
↓
Finishing
↓
Delivery
Types of print:
Rubber print
Pigment print(Water base print)
Foil print
Discharge print
Puff print
Glitter print
Afsan print
High density print
Plastisol print
Crack print
Gel print
Sticker/transfer print
Reflective
Design:
Artwork receive from development
111. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
111 URMI Group
↓
Detail design perform & analyze by Adobe Photoshop & illustrate
↓
Prepare individual film for different color by work express software
↓
Send to expose room
Screen Preparation:
Mesh fabric tight with frame
Applied chemical TXR (sensitizing emulsion) on the mesh & dried 8 min in air.
Placed design paper under the mesh.
Light passes through the design paper & mesh fabric for 3-4 min.
Remove the colored TXR from the design area by water spraying.
Sequence of printing:
Count garment parts
112. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
112 URMI Group
Screen preparation
Printing paste preparation
Applied garment part on the printing bed by (adhesive) gum in the marked portion
Printing the garment part by using screen
Drying the printed portion by hard dryer applying hot air flow
Curing the printed portion by passing through the conveyor dryer at 1600 - 1800 c
Inspection is done in qualify control department
Process for Foil Printing:
Add adhesive on the require design by screen
Place the fabric part on to the Pressing M/C
113. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
113 URMI Group
Pressing the upper part of the M/C at 100PSi, Temp-1500 For-6 Sec
Garments Printing Chemicals:
1. White paste-i)
Asublanc E-BT
ii) Asublanc E-V 375
iii) Asulak E 961
2. Matt clear paste-i)
Asulak E-BT
ii) Asulak 250
iii) Asulak E-pu
iv) Asulak E-po
3. Paste for m/c print :
i) Asublance P
ii) Asulak E-ns
iii) Asulance E-ns
4.pigment paste:
i) Asuprint E-BT
ii) Asuprint E-NS
5.Binder:
I) Asucryl EAP 50 NEW
6. Thickener:
i) clear EPG AC
7.Discharse paste
8.Pearl paste
114. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
114 URMI Group
9.Alternate of Flock print: Asulak E-peach Coat
10.Cross linking / Fixing agent
11. Radium paste
12.Foil paste
13.Glitter Binder
14.Reflective paste
15.Pritig softener
16.Table gum/Adhesive
Common print defects:
Measuring fault
Print missing
Wrong color
Hand feel not correct
Color migration problem
Not properly attach
Dirty marks
Uneven print
Air bubble
Air hole
Shade variation
Major causes of print defects:
Screen & print body are not in same axis
Irregular wash of screen frame
Wrong color recipe
Insufficient drying of previous color
115. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
115 URMI Group
Inaccurate composition of fixture
Improper heat & pressure
Dirty environment
Auto screen shot:
Faster production
High color combination
Immediate drying between two consequetive print
Not suitable for:
Large & complete body print
High density, flock & multiple colour, discharge print.
Manual screen shot:
Generally all types of print are performed
More time consuming
Drying performed by hand or auto dryer
HEAT PRESS M/C:
GENERALLY USED FOR Foil & Sticker print
Matt & glossy appearance also provide by this technique
Print performed at a certain temp. & pressure
Drying:
Hand drying
Auto drying
116. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
116 URMI Group
It is performed to dry previous color temporally
Color migration occurred due to improper drying of previous color
Curing:
Curing is the ultimate drying of print. Proper curing is the vital issue for a quality print.
Curing also liable for fabric shade change due to high temp.
118. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
118 URMI Group
Sequence of garments manufacturing process:
Side operation Operation Method
Design / Sketch Manual/Computerized
Basic Block Manual/Computerized
Working pattern Manual/Computerized
Sample section Sample making Manual
Basic manufacturing difference Manual
Approved sample Manual
Costing Manual
Production pattern Manual/Computerized
Marker making Manual/Computerized
Cutting section Fabric spreading Manual/Computerized
Cutting Manual/Computerized
Numbering Manual
Sorting & bundling Manual
Sewing Manual
Initial inspection Manual
Finishing / Pressing Manual
Final inspection Manual
Packing Manual
Cartooning Manual
Send to buyer Manual
Flow sequence of merchandising section:
119. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
119 URMI Group
Received PDF sheet
Consumption
Costing
Negotiation with buyer
Order received
Purchase order sheet received
L.C opening
Purchase fabric & accessories
Time and action setting
Approval for bulk production
Related work to production planning
Start bulk production
Inspection
Handover to buyer nominated agents
Work done by Merchandiser:
Sourcing
Pricing (CM,C&F,CIF,FOB)
Order follow up and execution
Arranging final inspection
Ensuring on time shipment.
Order follow-up and execution:
They do it during running the production. As a result if any fault occurring it rectified in the
primary stage.
Arranging final inspection:
After completion the garment making merchandiser arrange final inspection date with quality
department. Inspection is also depending on the wishes of buyer.
120. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
120 URMI Group
Ensuring on time shipment:
Once the inspection is done and the goods found ok for shipment, then the goods handed over
to the clearing and forwarding agent for on time shipment.
Types of order:
FOB (Free on Board) Order.
FOA (Free on Air) Order.
C & F (Cost & Freight) Order.
CIF (Cost Insurance Freight) Order.
CIFC (Cost, Freight, Insurance and Commission) Order.
CMT (Cost of Making and Trimmings) Order.
CM (Cost of Making) Order.
TT (Telephone Transfer) Order.
Subcontract Order.
Exchange Order.
CMC (Cutting, Making and Cartoon) Order
Cost Analysis:
Costing:
Costing of garment is a very necessary and important task. In this factory costing is carried
out by the merchandising department. Firstly, merchandiser contacts with the buyer and
collects order. Then he is provided a sample from sample section according to the buyer‟s
specification. The sample also supplies the fabric consumption. Cost of the fabric is
determined according to this consumption. Then he makes costing the other materials,
accessories, trimmings etc. He adds then all the production cost, Transport cost, Commission
(buying house, C&F agent) and profit.
Costing of Garments:
Fabric Cost
+
Accessories Cost
121. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
121 URMI Group
+
Production Cost
+
Transport Cost
+
Commission
+
Profit
Accessories:
Sewing thread and sew able item
a. Thread
b. Button
c. Main label
d. Size label
e. Care label
f. Velcro (Hook and loop fastener)
g. lace
Finishing item:
a. Price ticket
b. Hang tag
c. Poly bag
d. Back board
e. Neck board
f. Collar inside
g. Butter fly (Single, Double)
h. Tag pin
i. Tissue paper
j. Draw string and stopper
122. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
122 URMI Group
Flow sequence of sample section is given below:
Receive developed sheet from buyer
Develop the sample
Send the sample to buyer for approval
Approval of sample/comments about the sample (if necessary)
Send pre-production sample to buyer
Start bulk production
Pattern making:
After receiving an order in most cases buyer gives them a complete pattern and they make
sample according to given pattern. But in some cases they prepare the pattern by own when
buyer don not give any pattern.
Marker making:
Marker is a thin paper which contains all the pattern pieces of a garment. It is made just
before cutting and its purpose is to minimize the wastages. The width of a marker is equal to
the width of the fabric and it should not be greater than the width of the fabric i.e. the width
of the marker is kept less than or equal to the width of the Fabric. The pattern pieces should
be placed very carefully in such a way that it will obviously minimize wastages.
Objects of Marker making:
To reduce cost;
To improve the quality of the garments;
To reduce the cutting time;
To facilitate large scale production
CUTTING SECTION
123. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
123 URMI Group
Sequence of spreading and cutting:
Automatic Cutting Machine
STRAIGHT KNIFE CUTTING
MACHINE
Cutting Section Quality Control:
The step by step process by which we check quality in the Cutting Section.
Quality Inspection for Marker:
Every parts Measurement check,
Calculate the total no. of parts of each Garments,
Marker length & width determined.
Fabrics Roll spreading Inspection:
Roll number,
GSM,
Shade number,
No. of lays,
Ends of Bits
Spreading Quality Control (Defects):
Table marking,
Ends,
Inspection
Marker making with the aid of CAD
Spreading (Manual or Spreading m/c)
Cutting(Manual or
Computerized
Received
Pattern from
Sample
section
Sorting and Numbering
Inspection
Pieces sent to Sewing
Received Finished Fabric
124. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
124 URMI Group
Splices or Joints,
Leaning,
Tension,
Counts,
Remnants,
Fabrics flaws,
Marker placing,
During Cutting Quality Control:
Miss cut,
Matching plies,
Ragged Cutting,
Notches,
Pattern Check
After Cutting
100% part Checking.
Numbering & Bundle Quality Control.
Reject Panel Replacement.
SEWING SECTION
Sewing:
The process of joining fabric or seam is called Sewing.
Elements of Sewing:
Sewing Thread,
Needle &
Sewing Machine
Flow-Sequence of Sewing Section:
Cutting fabric load in sewing section
Line plan according to style or design
Marking
Matching according to bundle no.
Sewing according to Garments design or style
Quality inspection during sewing
Quality inspection after sewing
125. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
125 URMI Group
Excess Thread cutting
Remove dirt & dust from Gmts surface
Quality Audit
Send to next process.
Sequence of garment production:
Sewing sequence of Jacket:
Contrast joint with the pocket by pressing.
Pocket rolling
Number matching with body & Pocket
Pocket joint
ZigZag top sin over Pocket
Numbering & gathering back & front pants
Solder joint
Top sin on the solder joint line
Collar make
Chain stitching on collar marking line
Collar Joint
Collar over locked in joining line
Numbering sleeve and body part
Sleeve joins with body
Zigzag top sin on Arm hole
126. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
126 URMI Group
Zipper piping
Side sewing /body sewing by over lock
ZigZagtopsin (side sewing line)
Bottom hem tuck sewing
Tuck bottom hem with body parts
Arm hole tuck
Botton hem top sin Zigzag
Cuff making
Cuff joint
Cuff top sin ZigZag
Zipper joint with body part
Collar tape part joint with zipper side
Collar taping part join with body part
Zipper top sin
Collar top sin
Label joint with body part
Quality Table
(Arm hole point, sleeve hem, Bottom hem, Top sin, side seam, Thread cutting. Spot etc are
inspected)
SEWING SEQUENCE OF T-SHIRT:
Number matching front 2 back pant (back on pant on upper side)
Solder stitching (By over lock m/c)
Neck rib truck (By plain m/c)
Neck rib sewing by plain m/c
Neck rib joins with body pant
127. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
127 URMI Group
Neck top sin
Solder to solder back tip
Size label sewing
Solder to solder back top sin
Sleeve marking ad number matching with body parts.
Sleeve tuck with body part (Sleeve mark point & solder mark point)
Sleeve joint with the body part
Side sewing and care label joint
Bottom hem tuck (at the end side)
Bottom hem sewing
Arm bottom hem joint
Inspection
Sewing Defects:
Needle damage,
Skip stitches,
Thread Breakages,
Broken Stitches
Seam Grin
Seam Puckering
Pleated Seam
Wrong stitch density
Uneven stitch density
Staggered stitch
Improperly formed stitches
Work-study department:
This department evaluates, each apparel sewing line for planned output and actual output. If
the actual output is less than the planned output than on the shop floor executive of this
department do the case study and try to find out the reason and solution so that desire output
must come out fromsewing line. Following are the main tools of these departments;
128. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY
128 URMI Group
1. Line balancing: - Sewing line must be evaluated after learning curve for time and
work balancing of each operator. If any unbalances observed because of the different
level of efficiency of different operator than after evaluation a new plan must be made
for smooth flow of work.
2. Method improvement: – For every sewing operation, plenty of method may be use.
Therefore for any bottleneck operation a new better method must be find out for
assisting or helping operator.
3. Trained and motivated employee: – For higher productivity this is an important tool
and company should start policies and schemes for trained and motivated employee.
For example „target with quality achieve incentive‟ etc.
Line balancing:
Line balancing is the allocation of sewing machine according to style and design of garment.
It depends of that what type of garment we have to produce.
The Objectives of Line Balancing:
Line balancing is a main part of a mass production. These kinds of systems, regardless of
being different in details, are workstations in a sequence. Row material is included in the line
at the beginning or in the middle. Parts included in the system transfers from one workstation
through the other and at the end leaves the system as a completed product. Transfer lines uses
manpower very little when compared to assembly lines. The certain properties of Transfer
lines are transfer and process of a product automatically through a line.
Objectives that should be gained balancing an assembly line are as follows;
Regular material flow;
Maximum usage of man power and machine capacity;
Minimum process times;
Minimizing slack times;
Minimizing workstations;
Maximum outputs at the desired timed;
Agreed quality maintenance of the garments;
Reduce production costs.
Importance of Line Balancing:
The importance of line balancing could be summarized as follows –
Good line balancing increases the rate of production;
This is the pre-condition for smooth production;