Industrial attachment of viyellatex group

Industrial attachment Page no. 1
VIYELLATEX GROUP
SOUTHEAST UNIVERSITY
Department of Textile Engineering
251/A&252, tejgaon, I/A Dhaka-1208
Dhaka, Bangladesh
VIYELLATEX GROUP

VIYELLATEX GROUP
PROJECT DESCRIPTION
CHEPTER 01
VIYELLATEX GROUP

VIYELLATEX GROUP
Project description:
1. Name of the Company: VIYELLATEX GROUP
2. Status: Private Ltd. Company
3. Type: 100% Export oriented composite knit Dyeing Industry
4. Year of establishment: 2001
5. Year of starting
production:
2002
6. Location: Gazipura, Tongi
7. Address:
Factory : 297, Khortoil, Tongi, Gazipur- 1712
Head office: 297, Khortoil, Tongi, Gazipur- 1712
Tel. No. 8819281-2 Fax No. 880-2-8810445
E-mail : viyellatex@youngonesgroup.com
8. Sponsors: Mr. Rezaul Hasnat
9. Product Mix: 100% cotton,
100% polyester
a) Spun
b) Filament
Nylon
Chief Value Cotton (CVC)
Polyester Cotton blend
Gray mélange (15% Viscose 85% cotton
10% Viscose 90% cotton
30% Viscose 70% cotton)
Ash mélange (1% Viscose 99% cotton)
10. Production Capacity:
a) Knitting section 9 Ton per day (Body fabric)
20,000 pcs (Collar & cuff)

VIYELLATEX GROUP
b) Dyeing Section 14-15 Ton per day
c) Garments Section 18 million pieces per year
11. Project cost: 20 million $
12. Different Departments: a) KNITTING SECTION:
 Knitting
 Inspection
b) DYEING SECTION:
 Batch section
 Dye house
 Dyeing lab.
 Quality control
 Finishing
c) GARMENTS SECTION:
 Merchandising
 Sample
d) MAINTENANCE SECTION:
 Electrical
 Mechanical
e) STORE SECTION
13.Supporting department:
a) Personnel administration
b) HRD
c) Marketing
d) Procurement
e) Finance and accounting
f) Security department
13. Total Manpower:
a) Knitting section 250
b) Dyeing Section Dyeing- 300
Finishing- 250

VIYELLATEX GROUP
c) Garments Section 3200
14. Major customers: a) Marks & Spencer
b) S. Oliver
c) ESPRIT
d) Tesco
e) Puma
g) GAP
h) G.Star
i) Wool worths
j) TU

VIYELLATEX GROUP
W
Maintenance
room
Maintenance
room
Maintenance
room
Washing
Ground
floor
L
I
F
T
L
I
F
T
L
I
F
T
L
I
F
T
2
1
3
4
7
6
5
EmergencyExitStairs
EmergencyExitStairs
Reception
room
IT, guest &
conference room
Office
Office
Product
Development
Office
Rest
room
Dinning and Prayer room
Work
shop
Sewing floor
Cutting
room
CAD
Room
Central store (Fabric
& accessories)
Sewing floor
Sewing floor
Medical
centre
Inspection
room
Finishing
section
Chemical
store
Raw
material
store
Garments
store
Child care
centre
ViyellaTex LTD
(Knitting)
ViyellaTex LTD
(Dyeing and
finishing)
Maintenance
manager
Lab
manager
TextileTesting
Corporation
1st
floor
Ground
Centralstore
Fashion
plastic &
package
LTD
ETPcontrol
centre
ETP
Boiler
room
Boiler
room
Substation &
maintenance
room
Cargo
lift
WTP Oxidation
plant
Generator
room
Chemical
room
Fashion plastic &
packaging sub station
room
RMS room
Security
room
Store
Bonded
ware
house
Generator room
Generator room
Garden & rainfall
Maingate
Pocket gate
Washing
Embroi
dery
Printing
YarnStore
1st
floor
NS

VIYELLATEX GROUP
Mohakhali
Airport
Uttara model
town
Tongi bus
station
Station road,
tongi
College
gate
Gazipura,
tongi
Baro
bari
Board
barzar
National
university
Ashulia
Bishwa
Estema
Shatrashta
College of
Textile
Technolog
y NS
Location Of The
VIYELLATEX Group
VIYELLATEX

VIYELLATEX GROUP
15. Physical Infrastructure:
The mill is built in such a way that there is possibility for further expansion of the mill.
The structure such as mill, office buildings, record rooms, guardrooms & dining room etc.
are made of solid hard concrete & brick mtls. . The whole area is surrounded by safety
brick wall .The main set up for m/c’s are built of corrugated iron & iron sheet, transparent
hard plastics with enough ventilation & scope for passing light & air.
Remarks:
VIYELLATEX LTD. is a well established knit composite industry. The industry
stands on industrial area of Gazipur. VIYELLATEX GROUP. is a Group of Companies, Viyella
spinning, Youngone’s fashion LTD, Viyella knitting and dyeing,. VIYELLATEX LTD. is going
to prove its own standard about product quality in world market as they know that their reputation
depends on its quality. VIYELLATEX LTD. is a profitable project and contributes the economy
of our country.

VIYELLATEX GROUP
MANPOWER MANAGEMENT
CHEPTER 02
VIYELLATEX GROUP

VIYELLATEX GROUP
Organogram of manpower:
Company Organogram
Finance
CHIEF EXECUTIVE OFFICER (CEO)
CHIEF OPERATING OFFICER (COO)
HEAD OF
PRODUCTI
ON
HEAD OF
MERCHAN
DISING
HEAD OF
COMMERCI
AL &
ACCOUNTS
HEAD OF
BU HRD
HEAD OF
QUALITY
ASSURAN
CE
HEAD OF
DESIGN &
PRODUCT
DEVELOP
MENT
HEAD OF
PLANNING
/ IE
HEAD OF ACCOUNTS & COMMERCIAL
ACCOUNTS DEPARTMENT COMMERCIAL DEPARTMENT
FAVP
(Preparation of Financial
Statement & Group Cheque Issue)
PRINCIPAL OFFICER
(Salary & Wages)
OFFICER
(Petty Cash &
Staff Salary)
IMPORT DIVISION
(In-Charge & FAVP)
EXPORT DIVISION
(In-Charge & FAVP)
PRINCIPAL OFFICER
Sr OFFICER SPO OFFICER
Jr OFFICER

VIYELLATEX GROUP
Organogram from knitting
Organogram of Dyeing
DGM/AGM
Manager / Asst. Manager
(Store)
Sr. Executive
/ Executive
Jr. Executive
(Yarn)
Jr. Executive
(Grey Fabric)
Store Asst.
(Yarn)
Store Asst.
(Grey Fabric)
Loader
(Yarn)
Batch
Helper/Loade
r
Manager/Asst. manager
(Technical)
Sr. Fitter / Fitter
Asst. Fitter
Servicing
man
Needle man
Servicing
helper
Manager / Asst. Manager
(Prodn
& Plan)
Knitting Master/
Executive (Flat)
Operator /
Asst. Operator
Sr. Fitter /
Fitter
Helper
Sr. Executive
(Prodn
,Plan & Sample)
Executive /Jr. Executive
(Prodn
, Plan & Sample)
Sr. Supervisor
/ Supervisor
Asst. Operator
Sr. Operator
/ Operator
Production Helper
Sample
supervisor
Sample asst
DGM/AGM
Manager
Planning
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor
Production
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor
Store
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor
Washing
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor

VIYELLATEX GROUP
Organogram of QAD & Finishing
Maintenance
DGM/AGM
Manager/Asst Manager
Sr.Executive/Executive
Finishing
Jr.Executive
Sr.Supervisor
/ Supervisor
Sr.operator
/Operator
Asst Operator
Prodn
Helper
Finished
fabric Store
Jr.Executive
Sr.Supervisor
/ Supervisor
Store Asst.
Loader
QAD
QAD(Knitting)
Jr.Executive
QAD(Dyeing)
Online
Sr.Supervisor
Superviso
r
Offline
Sr.Supervisor
Superviso
r
QC
AQC
Online
Sr.Supervisor
Superviso
r
Offline
Sr.Supervisor
Superviso
r
QC
AQC
QC
AQC
Electrician
Manager
Electrical engineerMechanical engineer
WelderMechanical feeder

VIYELLATEX GROUP
Management System:
 Intercom telephone
 Fax
 Written letters &
 Oral
Shift Change:
There are three shifts in the industry. So the shifts are changed at every 8 hours.
Shift Change/ for worker of Security:
A Shift – 06:00 – 14:00
B Shift – 14:00 – 22:00
C Shift – 22:00 – 06:00
General shift :
09:00 – 18:00
Office Time
09:00 – 18:00
Responsibilities of Production Officer:
1. To give dyeing program slip.
2. To match production sample with target shade.
3. To collect production sample for sample matching next production.
4. To observe dyed fabric during finishing running & also after finishing.
5. To identify disputed fabrics & report to P.M/G.M for necessary actions.
6. To discuss with P.M. about overall production if necessary.
7. To sign the store requisition & delivery challan in the absence of P.M.
8. Also to execute overall floor works.
9. To maintain loading/unloading khata.
10. Any other assignment given by higher authority.
Job Description of P.O & S.P.O:
Job title: Production officer & Senior Production officer
Report to: Production Manager
Purpose:
To control shift according to the plan made by the production manager
Territory: Dyeing section (major)
Batching and Finishing section (minor)
Nature and Scope:
Role within the organization:
Responsible for own shift production with good quality and minimum time.

VIYELLATEX GROUP
Environment:
Production officer has to work under huge stress. He has to work in acute heat
under physical and mental pressure. Also he has to work in acute heat all the year round.
Job Description of Production Officer:
Report To: Sr. production officer
Job Summary:
To plan, execute & follows up the production activities & control the quality production
with related activities.
Duties & Responsibilities:
 Overall supervision of dyeing, finishing production.
 Batch preparation & PH check.
 Dyes & chemical requisition issue & check.
 Write fabrics loading & loading time from m/c.
 Program making, sample checking, color management.
 Control the supervisors, operator, asst. operator & helpers of dyeing m/c.
 And also any other work as & when required by the management.
Job Description of Sr. Production Officer:
Report To: P.M (production)
Job Summary:
To plan, execute & follows up the production activities & control the quality production
with related activities.
Duties & Responsibilities:
 Overall supervision of dyeing, finishing production.
 Checks the different log books of different areas & report to management.
 Checks the sensitive parameters of different machine for smooth dyeing.
 Checks out the plan to control the best output from supervisor & workers.
 To trained up & motive the subordinates how to improve the quality production.
 Maintenance of machine & equipment. Any other works & when required by the
management.
 Control the supervisors, operator, asst. operator & helpers of dyeing m/c.
REMARKS:
The manpower management system VIYELLATEX GROUP. is well arranged. Every
officers & stuffs are responsible for their duty. But there are only six textile engineers in the
industry (5 for dyeing & 2 for Finishing). It is sufficient for fluent production. The efficiency
of the worker should be increased for more quality production.

VIYELLATEX GROUP
MECHINE DESCRIPTION
CHEPTER 03
VIYELLATEX GROUP

VIYELLATEX GROUP
KNITTING MACHINS

VIYELLATEX GROUP
Knitting
Knitting section is divided in four sections,
1. Inspection section
2. Flat knitting section
3. Circular Knitting section
4. Store section
1. Cloth Inspection Section:
In cloth inspection section two machines are available. Specification of those machines is
given below.
Type Cloth Inspection Machine
Manufacturer name Uzu fabric Inspection
Country Thailand
Model No. UZ 900.31
2. Flat Knitting Section:
Generally collar, cuff of knitted garments is produced in this section. In this section
there are 25 flat knitting machines, all of them are same type and also have same
specification. The specification of all machines is given below.
Type Automatic Flat knitting machine
Manufacturer name Precision Fukuhara Works Ltd.
Country Japan
Model No. M-100
Gauge G14
3. Circular Knitting Section:
This section contains 20 circular knitting machines. Circular knitting machines are
of different types, made by different manufacturer and also have different specifications. In
this section body fabric for knitted garments is produced. The different specifications of
different machines are given one after another
Machine no: 01
Machine type: Single jersey
Brand: Fukuhara (vxc-3s)
Origin: Kobe, Japan
Machine dia &Gauge: 30”; 24G
Extra cylinder: 30”; 20G
No of needle: 1860
No of feeder: 90
Machine no: 02
Origin: Kobe, Japan
Extra cylinder:
No of needle: 1932
No of feeder: 78

VIYELLATEX GROUP
Machine no: 03
Origin: Kobe ,Japan
Extra cylinder:
No of needle: 1932
No of feeder: 78
Machine no: 04
Origin: Kobe, Japan
Extra cylinder:
No of needle: 2268
No of feeder: 90
Machine no: 05
Brand: Pai Lung
Origin: Taiwan
No of needle: 2712
No of feeder: 108
Machine no: 06
Brand: Pai Lung
Origin: Taiwan
Machine dia &Gauge:25”;24G
No of needle: 1872
No of feeder: 74
Machine no: 07
Machine type: Single jersey(2 truck)
Brand: Pai Lung
Origin: Taiwan
No of needle: 1872
No of feeder: 74
Machine no: 08
Brand: Pai Lung
Origin: Taiwan
Extra cylinder: 30”;24G
No of needle: 2236
No of feeder: 90
Machine no: 09
Brand: Pai Lung
Origin: Taiwan
No of needle: 2256
No of feeder: 90
Machine no: 10
Brand: Fukuhara (v.c-3.25)
Origin: Kobe Japan
No of needle: 2268
No of feeder: 98
Machine no: 11
Brand: Fukuhara (B.c-3.25)
Origin: Kobe Japan
No of needle: 2268
No of feeder: 98
Machine no: 12
Origin: Kobe Japan
No of needle: 2268
No of feeder: 98

VIYELLATEX GROUP
Machine no: 13
Origin: Kobe Japan
No of needle: 2268
No of feeder: 98
Machine no: 14
Machine type: Fleece
Brand: Terrot
Origin: Germany
No of needle: 1872
No of feeder: 96
Machine no: 15
Machine type: Terrot
Brand: Terrot
Origin: Germany
No of needle: 1872
No of feeder: 96
Machine no: 16
Machine type: RibInterlock
Brand: Terrot
Origin: Germany
No of needle: 3368
No of feeder: 54
Machine no: 17
Machine type: Rib
Brand: Terrot
Origin: Germany
No of needle: 3840
No of feeder: 60
Machine no: 18
Machine type: Rib
Brand: Terrot
Origin: Germany
No of needle: 4080
No of feeder: 64
Machine no: 19
Machine type: RibInterlock
Brand: Terrot
Origin: Germany
No of needle: 4080
No of feeder: 64
Machine no: 20
Brand: Mayer & Cie
Origin: Germany
No of needle: 2640
No of feeder: 96
Machine no: 21
Brand: Mayer & Cie
Origin: Germany
No of needle: 2640
No of feeder: 96
Machine no: 22
Machine type: Rib
Brand: Fukuhara(V-ER-22)
Origin: Kobe Japan
No of needle: 4078
No of feeder: 64

VIYELLATEX GROUP
Machine no: 23
Machine type: Rib
Brand: Fukuhara (v.er-22)
Origin: Kobe Japan
No of needle: 4078
No of feeder: 64
Machine no: 24
Machine type: Rib
Brand: Fukuhara (v-er-22)
Origin: Kobe Japan
No of needle: 4078
No of feeder: 64
Machine no: 25
Machine type: Rib
Brand: Fukuhara (v-er-22)
Origin: Kobe Japan
No of needle: 4078
No of feeder: 64
Machine no: 26
Machine type: Rib
Brand: Pai Lung (pl-xrace)
Origin: Taiwan
Machine dia &Gauge:38”18G
No of needle: 2160
No of feeder: 76
Machine no: 27
Machine type: Rib
Brand: Pai Lung(pl-xr2bce)
Origin: Taiwan
No of needle: 2124
No of feeder: 76
Machine no: 28
Machine type: Rib
Brand: Pai Lung (pl-xr2bce)
Origin: Taiwan
No of needle: 2256
No of feeder: 76
Machine no: 29
Brand: Pai Lung (pl-xs3bace)
Origin: Taiwan
No of needle: 1800
No of feeder: 72
Machine no: 30
Brand: Pai Lung
Origin: Taiwan
Machine dia
&Gauge:24”;24G
No of needle: 1800
No of feeder: 72
Machine no: 31
Brand: Pai Lung
Origin: Taiwan
No of needle: 1944
No of feeder: 78
Machine no: 32
Machine type: Interlock
Brand: Pai Lung
Origin: Taiwan
No of needle: 2484
No of feeder: 72

VIYELLATEX GROUP
Machine No. 38
Type Fleece
Brand PAI LUNG.
Origin TAIWAN
Model No. PL-XF3B-LP/C.
Machine Dia 30”
Gauge 20G
Feeder No. 90
Machine No. 39
Type Single jersey
Brand PAI LUNG.
Origin TAIWAN.
Model No. PL-XS4B/A/CE.
Machine Dia 36”
Gauge 24G
Feeder No. 144
Machine No. 40
Type Single jersey.
Brand PAI LUNG.
Origin TAIWAN.
Model No. PL-XS4B/A/CE
Machine Dia 23”
Gauge 24G
Feeder No. 78
Machine No. 35
Type Auto striper Double jersey.
Brand PAI LUNG.
Origin TAIWAN.
Model No. PL-XDCS/6-U
Machine Dia 36”
Gauge 18G
Machine No. 41
Type Double jersey.
Brand PAI LUNG.
Origin TAIWAN.
Model No. PL-XRA-CE
Machine Dia 38”
Gauge 18G
Feeder No. 76
Machine No. 42
Type Double jersey.
Brand PAI LUNG.
Origin TAIWAN.
Model No. PL-XRA-CE
Machine Dia 38”
Gauge 18G
Feeder No. 76
Machine No. 37
Type Fleece
Brand PAI LUNG.
Origin TAIWAN
Model No. PL-XF3B-LP/C.
Machine Dia 30”
Gauge 20G
Feeder No. 90
Machine No. 36
Type Auto striper Double jersey.
Brand PAI LUNG.
Origin TAIWAN.
Model No. PL-XDCS/6-U
Machine Dia 36”
Gauge 18G
Machine no: 34
(Auto Stripe)(pl-xscs16)
Brand: Pai Lung
Origin: Taiwan
No of needle: 2256
No of feeder: 42x6
Machine no: 33
(Auto Stripe)(pl-xscs16)
Brand: Pai Lung
Origin: Taiwan
No of needle: 2256
No of feeder: 42x6

VIYELLATEX GROUP
DYEING MACHINS
FONG’S Dyeing m/c
Thies Dyeing m/c

VIYELLATEX GROUP
Dyeing
Flow chart of dyeing Section
Grey fabric from knitting section

Batching

Dyeing

Transfer to finishing
Flow chart of finishing Section
Finishing section
Open fabric Tube fabric
Slitting machine
Stentering
Compacting
machine
Final
inspection
Dewatering machine
Drying machine
Tube Compacting
machine
Final
inspection
Line Diagram of Jet Dyeing M/c

VIYELLATEX GROUP
Lay out plan of Dyeing section
Fongs-6 Thies-4Thies-5 Thies-3 Thies-1Thies-2 Fongs-3
FoThies
-5
Dewatering
M/c-1
Stenter (Bruckner)
Inspection
table
Chemical
Room
Planning & Dyeing Manager’s
Room
Sample-2
Fongs-5
Fongs-4
Production officer’s Table
Exit
Exit
Sample-1
Dewatering
Slitting&
Dewatering
M/c
Open C
Open Compactor- 1
Tube
Compactor- 2
Tube
Compactor-2
Inspection
table
Sueding
M/c
Raising
M/c-2
Raising
M/c-1
Turning
M/c

VIYELLATEX GROUP
No of Machine for Dyeing and Finishing Section:
Specification of Different Machines:
DYEING SECTION:
Dyeing Machine. Fongs-01,02,03:
Type Jet Dyeing Machine
Manufacturer name FONG’S
Country HONGKONG
Model No. ECO-38-2T
Year of manufacturing 2003
Temp. Range 00
-1400
C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 500 KG
Dyeing Machine. Fongs-04
Country HONGKONG
Model No. ECO-38-2T
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 1
Dyeing Section
1. Jet Dyeing Machine 13
2. Sample Dyeing Machine 02
Finishing Section
1. Super Slitter 01
2. Dewatering Machine 02
3. Stenter 02
4. Dryer 01
5. Tube compactor 02
6. Open width compactor 02
7. Raising Machine 02
8. Sueding Machine 01
9. Turning Machine 01
10. Slitting & Dewatering
Machine
01

VIYELLATEX GROUP
Country HONGKONG
Model No. ECO-38-2T
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 1
Country HONGKONG
Model No. ECO-38-2T
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 2
Dyeing Machine. New Fongs-01
Country HONGKONG
Model No. HSJ-3T
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 3
Dyeing Machine. New Fongs-01
Country HONGKONG
Model No. HSJ-4T

VIYELLATEX GROUP
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 4
Dyeing Machine. Thies-01
Manufacturer name THIES
Country Germany
Model No. D-48653
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 3
PermissibleWorkingPressure 0.35 MPa
Test Pressure 0.525 MPa
Country Germany
Model No. D-48653
Temp. Range 00
-1400
C
Used Utilities Water, Steam, Electricity,
Compressed Air
No. of Motor 7
No. of Nozzle 2
Country Germany
Model No. D-48653
Temp. Range 00
-1400
C
Used Utilities Water, Steam, Electricity, Compressed
Air
No. of Motor 7

VIYELLATEX GROUP
No. of Nozzle 1
Country Germany
Model No. D-48653
Temp. Range 00
-1400
C
No. of Motor 8
No. of Nozzle 4
Country Germany
Model No. D-48653
Temp. Range 00
-1400
C
No. of Motor 8
No. of Nozzle 4
Sample Dyeing Machine.01
Country Germany
Model No. MINISOFT
Temp. Range 00
-1400
C
No. of Motor 3
No. of Nozzle 1

VIYELLATEX GROUP
Sample Dyeing Machine.02
Country HONGKONG
Model No. ALLFIT-30
Temp. Range 00
-1350
C
No. of Motor 4
No. of Nozzle 1
FINISHING SECTION:
Finishing:
Textile finishing , in a restricted sense , is the term used for a series of processes
to which all bleached , dyed , printed and certain grey fabrics are subjected before
they are put on the market . In fact , finishing includes the final treatment of
every kind of fabric made from every kind of fiber .
Objective of finishing:
- Improving the appearance – Lustre , whiteness , etc .
- Improving the feel , which depends on the handle of the material and its
softness , suppleness , fullness , etc .
- Wearing qualities , non – soiling , anticrease , antishrink , comfort , etc .
- Special properties required for particular uses – water – proofing , flame –
proofing , etc. .
- Covering of the faults in the original cloth.
- Increasing the weight of the cloth.
Types of finishing:
1) Chemical finishing:
1) Chemical reaction of auxiliaries with fibers.
2) Application of the handle modifying products / additives.
2) Mechanical finishing:
 Mechanical treatment with machines.
Finishing effects:
 Easy – care
 Crease recovery.
 Dimensional stability.
 Good abrasion resistance.
 Improved tear strength.
 Good sewability
 Soft or stiff handle.
 Shine or luster

VIYELLATEX GROUP
FINISHING
MACHINS
(OPEN LINE)
Slitting,De-watering &
Detwisting m/c
Stenter
Raising m/c
Seuding m/c
Open Compactor

VIYELLATEX GROUP
Open fabric line for finishing
Slitting and dewatering machine
Machine specification:
Brand name: CORINO MACCHINE
Type/model no:
Company: Italy
Year: 2005
No of motor: 08
Function of the Machine:
 Used to remove excess water after pretreatment and dyeing
 To slit the tube fabric by the knife for opening of the fabric and ready for
stentering
 Delivered fabric is crease free state
 Before squeezing balloon is formed with the help of compressed air
passing by a nozzle or air sprayer
 It can control the diameter of fabric and GSM and shrinkage by over
feeding mechanism
 To impart soft finish to the fabric by using required softener.
Main parts of the machine:
- Squeeze roller (to remove water)
- Stretcher (to control width)
- Over feeding wheels (to control GSM)
- De-twisting device (To delivery the fabric roll in untwisted form)
- Folding device (to delivery the fabric in folded form)
- Squeezing roller
- Padder for softener
Controlling points or Control system:
1. Overfeed control
2. Pressure
3. Speed control
4. Width control
Power consumption:
Voltage: 400V
Frequency: 50Hz
Maximum power: 24kwatt
Manpower Required:
Worker: 02

VIYELLATEX GROUP
Production:
Capacity: 10 tones/shift
Actual production: 7 tones/shift.
Utility:
i) Water
ii) Electricity
iii) Compressed air or Processed air (to form the tube fabric into ballon with a
view to remove crease)
Feed roller pressure:
Bar PSI Kg Lbs
1 14.5 90 200
2 29 205 450
3 43.5 315 700
4 58 425 940
5 72.5 540 1200
6 87 650 1440
Mini
padder
De-twister
Rubber coated
padder
Wooden padder
Plaiter
Camera
Dancing roller
Dancing
roller
Fabric path of Slitting, De-watering &
De-twisting m/c
Feed
Delivery

VIYELLATEX GROUP
Work instruction:
Fabric Type Pad pressure Speed Over Feed
S/J 2.5 – 3 40 -50 40
PK 3 40 -50 40
1x1 Rib 3 -3.5 50 -60 25
2x2 Rib 3 – 3.5 60 40
P/I 3 – 3.5
Mer S/J 2 40 40
Mer PK 2.5 40 40
Mer 1x1 Rib 2.5 – 3 50 25
Mer 2x2 Rib 2.5 – 3 60 40
Mer P/I 2.5
Find out the limitations and faults of the machine and advise for removing these.
i) Workers does not record the pressure, in dia and out dia of different fabric in
record book
ii) Workers set the pressure of squeeze roller for different fabrics same. But
higher GSM fabric needs more pressure than lower GSM fabric. So removal
of excess water is not sufficient.
iii)
Stenter machine
Machine no. 01
Brand name: BRUCKNER +MAHLO
Type/model no: 72276-0463
Company:
Country: Germany
Year: 2004
Other specification:
Speed range:
15-30 m/min (for knit)
15-80m/min (woven)
Temperature range: 20-2500
C
No of motor in drying unit: 29
Total no of motor: 49
Maximum width = 102
Minimum width = 30
Steam pressure: 2 bar
Air pressure: 10 bar
Applied for: Open width fabric

VIYELLATEX GROUP
Machine no. 02
Mc specification:
Brand name: SUN SUPER.
Country: KOREA.
Speed range:
Max: 110m/min.
Use: 45 m/min.
Temperature range:
Max: 500 C
Use: 180 C (For heat set).
No of motor in drying unit:
Total no of motor:
Max dia: 295cm.
Min dia: 95cm.
Steam pressure: 2 bar
Air pressure: 10 bar
Applied for: Open width fabric
Fabric path of stenter
Overfeed & pinning
Fabric in the chain

VIYELLATEX GROUP
Extra attachment:
iv) Mahlo attachment for bowing control.
v) Selvedge gumming device
vi) Selvedge cutting device
i) Drying
ii) GSM control
iii) Width control
iv) Shrinkage control
v) Decrease sprirality
vi) Decrease Bowing effect
vii) Softener application
viii) Surface coating for Teflon finish
ix) Soil release chemical finish
x) Heat set for cotton lycra fabric
i) Feed zone
-Centering device
ii) Chemical padding zone
-Squeezing roller
-Chemical tray
iii) Bowing control zone
-Bowing roller (rubber roller, no of roller -2)
-Sensor (no of sensor -6)
-Uncurling roller
iv) Chain entry zone
-Uncurling device (both side of the chain entry)
-Sensor (both side of the chain entry)
-Brush roller (for attaching the fabric with the pin of the chain, no of
brush roller -4)
-Selvedge gumming device with gum box under the chain entry
v) Drying zone
-Gas rotamatic burner (10)
vi) Cooling zone
vii) Delivery zone
Chemical used:
Silicon softener (It is used to soft and slippery of the fabric)
Manpower Required:
Worker: 6
Production:
Actual production: 3.5-4.5 tones/shift.

VIYELLATEX GROUP
Heating arrangement:
No of Rotamatic burner: 10
There are 5 heating chamber in this machine. Each chamber has two burners which is
placed two sides of the machine.
Chamber Burner Burner
01 1A 1B
02 2A 2B
03 3A 3B
04 4A 4B
05 5A 5B
Temperature:
Maximum = 2500
C
Sample = 1100
C
Average = 130-1700
C
Utility:
i) Gas
ii) Electricity
iii) Compressed air.
Parameters used for different types of fabric:
BRUCKNER
Fabric Req.
GSM
Finish
GSM
R F B Temperature Speed
m/min
Over
feed
S/J 140 - 68” 71” 67” 140 14 60%
” 160 150/52 56” 64” 60” 150 20 10%
” 180 170/72 54” 56” 54.5” 110 12 60%
“ 190 188/90 58” 61” 57” 110 15 60%
H/J 280 270/75 64” 67” 62” 110 7 50%
Loop
back
280 255/60 74” 78” 75” 110 9 60%
Fleece 260 260/65 74” 80” 75” 110 9 60%
1×1 rib 240 224/26 72” 75” 74” 110 10 60%
Bolton
stripe
330 340/45 62” 67” 65” 130 10 50%
SUNSUPER
Fabric Req.
GSM
Finish
GSM
R B F Temperature Speed
m/min
Over
feed
S/J 190 178 58” 56” 60” 110 24 50%
S/J(c.v.c) 180 180 56” - 59” 110 35 50%
H/J 280 276 70” 72” 73” 120 18 50%
1*1 Rib 240 244 72” 73” 75” 120 18 40%
Bolton
stripe
330 335 62” 66” 70” 130 16 60%
Fleece 280 270 76” - 78” 110 16 50%

VIYELLATEX GROUP
Open compactor
Machine no. 01
Brand name: HELIOT International
Type/model no: HC2000GL
Company: France
No of motor: 08
Over feed = m/min
Machine speed = m/min
Speed range: 13-22m/min
Termperature range: 100-1400
C
Maximum width 86
Minimum width 36
Applied for: Open fabric
Left over feed: -20%+20%
Right over feed: -20%+60%
High production: -20%+60%
Front over feeding cylinder: -20%+60%
Middle belt: -20%+60%
Machine no. 02
Brand name: FERRARO
Type/model no: COMPTEX-RE 2800.
Company: ITALY.
No of motor: 17
Over feed = Max + 35%, Min -35%.
Machine speed = Max 32m/min, Min 4m/min.
C
Maximum width =240cm
Minimum width =100cm
Applied for: Open fabric
Left over feed: -20%+20%
Right over feed: -20%+60%
High production: -20%+60%
Front over feeding cylinder: -20%+60%
Middle belt: -20%+60%
1. To compact the fabric
2. To control the shrinkage
3. To maintain proper width and G.S.M
Heating system: Steam

VIYELLATEX GROUP
1. Heating chamber
2. Blower (2, one at the entry chain zone for uncurling and another at the
entry of compacting zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder (-40%+40%)
7. Belt cylinder (-40%+40%)
8. Uncurling device at entry of compacting zone.
9. sensor
10.brush roller
Additional attachment:
i) Selvedge cutting
ii) Selvedge safety
iii) Pinning safety
iv) Selvedge unrolling
v) Selvedge drying
vi) Steam zone heating
vii) Steam
Controlling points:
- Water pressure 2.5 lb
- Air pressure 4 lb
- Steam pressure 6 lb
Manpower Required: Worker: 06
Production: Capacity: 5 tones/shift or 10 tones/day
Utility: Steam Electricity, Compressed air.
Overfeed
roller
Steam
arrangement
Upper
shoe
Lower
shoe
Big
cylinder
Conveyor
belt
Fabric Path of Open Compactor
Feed
Delivery

VIYELLATEX GROUP
Types of
fabric
Buyer Color Over
feed
R GSM F
GSM
M/
C
dia(
cm)
R .
Dia
F dia Temp RP
M
Single
jersey
WW Blue 60% 170 58 59 1000
C 18
(Lycra)
ARCH
Black 60% 180 178 115 100 98 1100
C 15
(stripe)M
&S
Navy 60% 190 207 195 64 71 1100
C 18
11 Rib S O 0350 60% 210 205 210 74 75 1000
C 18
22 Rib
(lycra)
Tesco Black 60% 180 180 180 64 68 1100
C 18
Interlock Masco Khaki 60% 260 300 200 75 72 1100
C 18
Jack rib
(polyester)
Tesco Op
white
60% 190 188 190 64 66 1100
C 18
Polyester
fabric
Masco Khaki 60% 190 185 190 64 67 1100
C 20
Fleece WW Blue 60% 260 228 210 74 77.5 1100
C 18
Special finishing machine
Sueding
A sueder is sometimes referred to a s a sander since the machine consists of one or more
rolls covered with sand paper as the abrasive. Fabrics traveling over these rolls develop a
very low pile and the material's surface can be made to feel like suede leather. The hand will
depend on the fiber composition, the filament count in the yarn and the intensity with which
the fabric is worked.
Filament fabrics can be made to feel like a spun fabric and all fabrics will have a softer hand.
Sueding machine
Brand name: Lafer SPA
Type/model no: GSI106
Company: Italy
Year: 2002
No of motor: 08
Winch speed: 10-30m/min
Machine speed: 50m/min (max)
Drum speed: 30-35-50 rpm (Max 70)
Pile roller no: 06
Pile made of Plastic
Plaiter tension: 6kg
Taker in tension: 20kg

VIYELLATEX GROUP
Fabric return driver Tension: 25kg
Drum Tension: 50kg
Speed range: 10-40 m/min
No of cylinder/drum:
2 for double cylinder
1 for single cylinder
No of pin roller: 24 2 = 48
24 1= 24
Cylinder r.p.m (General): 100
Tension: 3 kg
Manpower Required:
Worker: 03
Production:
Actual production: 1.5-2 tones/shift.
Raising m/c:
In which process a layer of fibers lifting from the body of the fabric to achieve
soft and lofty effect on the surface is called raising.
Raising machine -1 (Single drum)
Type/model no: GRI 124C
Country: Italy
Year: 2002
FeedDelivery Front drag
roller
Rear drag
roller
Drum
Return drag
roller
Plaiter roller
Fabric path of Seuding m/c

VIYELLATEX GROUP
No of motor: 04
No of pile roller: 24
Machine speed: 50
Drum speed: Max 120
Manpower Required: Worker: 05
Production : Capacity: 2 tones/shift
Utility : Electricity, Compressed air.
Raising machine-2 (Double cylinder)
Type/model no: GRI 224A
Country: Italy
Year: 2003
No of cylinder: 2
No of pile roller: 24+24
Machine speed: 50
Drum speed: Max 120
No of motor: 05
Speed range: 20-30 m/min
No of cylinder/drum: 1
No of pin roller: 6
Cylinder r.p.m (General): 100
Tension: 3 kg
Production: Capacity: 5 tones/shift
Utility : Electricity, Compressed air.
Feed
Delivery
Pile
Counter pile
Front drag
roller
Rear drag
roller
Return drag roller
Plaiter roller
Fabric path of Raising m/c

VIYELLATEX GROUP
FINISHING
MACHINS
(OPEN LINE)
De-watering &
Detwisting m/c
Relaxed Dryer
Tube Compactor

VIYELLATEX GROUP
Tube fabric line for finishing
Dewatering machine -1
Dewatering Machine
No. of the machine 02
Manufacturer name Heliot International
Country France
Model No. EXP-24C
Speed 90 m/min
Used Utilities Water Electricity, Compressed Air
No. of Motor 06
Slitting machine
Sutter Slitter
Manufacturer name AKAB
Country Sweden
Model No. CR-2400
Used Utilities Electricity, Compressed Air
No. of Motor 03
De-twister
Rubber coated
padder
Fabric path De-watering & De-twisting m/c
Chemical Tank
Guide roller
Air passing
pipe
Conveyor belt
Feed
Delivery
Width controller

VIYELLATEX GROUP
Tensionless Dryer Machine
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
Brand name:HELIOT international
Serial no: D700HWT
Company: France
Temperature range: 110-1600
C
Each motor required 300 watt.
No of motor: 08
Worker: 04
1. Heating chamber (2)
2. Blower (8)
3. Synthetic blanket as a conveyor
4. Folder
5. Exhaust fan
Production:
Actual production: 8 -9 ton/shift.
Heating chamber: 3
No of rotamatic burner: 3
Heating system:
1. Gas fired
Temperature of the machine:
PV PV PV
129.50
C 1300
C 1350
C
SV SV SV
1300
C 1300
C 1350
C
Utility:
1. Gas (to make fire)
2. Electricity (to rum the machine)
3. Compressed air (to spread the fire)

VIYELLATEX GROUP
Types of
fabric
Buyer Batch Color In
dia
Out
dia
Overfeed Machin
e speed
Temperatu
re
Vibr
ation
Collar TESCO White 6 (m).
10(monito
r)
6 1300
C 120
5885 Blue 6 .10 7.0 1400
C Off
S.
Oliver
5843 0147 6 .10 4.0 1600
C Off
11 Rib 6.10 7.0 1300
C 120
TESCO 5870 White 36 34 6.10 7.5 1300
C 120
5874 Hela
pink
6.10 8.5 1400
C 120
5888 Black 38 36 6.10 7.0 1500
C 120
ESPRI
T
5836 Black 38 35 6.10 5.0 1600
C
22 Rib W.W 1480/06 Blue 6.10 5.0 1500
C 120
52 Rib M&S Sample Pink 6.10 5.0 1400
C 120
Interlock 1300
C 120
Single
lacost
TESCO 5882 RED 6.10 8.0 1400
C 120
Double
locost
EMA 5828 White 46 44 9.10 5 1400
C 120
Fabric path Dryer
Conveyor belt
Feed
Delivery
Conveyor belt
Feed roller
Vibrating roller
Burner

VIYELLATEX GROUP
Find out the limitations and faults of the machine and advise for removing these.
i) Selvedge drying system is not properly functioning.
ii) Maximum over feed of the machine is +60%.
iii) When the steam temperature is 1000
C-1200
C, then delivered fabric temperature is
45-500
C. But there is no cooling zone in this machine to reduce the excess
temperature. So a cooling zone in delivery zone can be attached.
Tube compactor machine -1,2
Brand name: HELIOT International
Type/model no: HCPPI
Company: France
No of motor: 07
Over feed = 40m/min
Machine speed = 25m/min
C
Maximum width 52
Minimum width 16
Applied for: Tube fabric
Manpower Required:
Worker: 06
Production:
Capacity: 5 tones/shift or 10 tones/day
Temperature: 1100
C
Utility:
Steam, Electricity, Compressed air.
Steam
arrangement
Upper
shoe
Lower
shoe
Big
cylinder
Fabric Path of Tube Compactor
Feed
Delivery
Feed roller

VIYELLATEX GROUP
100%
cotton
single
jersey
100%
cotton
11 rib
100%
cotton
pique
jersey
100%
cotton non
napped
fleece
65/35
C/P
napped
fleece
Cotton/
acrylic
napped
fleece
100%
cotton
interlock
Width required 60 cm 75 cm 88 cm 93 cm 68 cm 94cm 88 cm
Width at m/c outlet 62 77 90 95 70 95 90
Width at dryer outlet 57 70 84 90 59 87 80
HC99
Stretcher width on
HC99
65 79 93 97 71 98 93
Width at plimatic 62 77 90 95 70 95 90
Temp. of cylinder 1100
C 1100
C 1100
C 1100
C 1100
C 1000
C 1100
C
Air pressure at lower
conveyor
2,5b 2,5b 2,5b 2,5b 2,5b 2b 2,5b
Air pressure at upper
conveyor
3,5b 3,5b 4b 3,5b 3,5b 3b 4b
Eccentric adjust at
lower conveyor
5 5 5 5 5 4 5
Eccentric adjust at
upper conveyor
4 4 4 4 4 3 4
Teflon canvas at lower
conveyor
2 &3 4 4,5 4 4 4 4
Teflon canvas at upper
conveyor
2 &3 4 5 5 5 5 5
Steam 3
1
rotation
2
1
rotation
1
rotation
3
1
rotation
2
1
rotation
2
1
rotation
1 rotation
m/c speed 30m/
min
20-30
m/min
25-30
m/min
25-30
m/min
30m/min 25m/min 30m/min
Feeder speed Reads
3
Reads 5 Reads
6
Reads 5 Reads 6 Reads 5 Reads 6
LAB MACHINE SPECIFICATION:
A. CHEMICAL LAB:
1.
M/C Name Rota wash
Test Name Color fastness to washing
Test method ISO 105-C06, ISO-105-D02
Brand HEALINK
Manufacturer James H Heal co. ltd
Country/Origin England
2.
M/C Name Incubator
Test Name Color fastness to water, sea water, perspiration

VIYELLATEX GROUP
phenolic yellowing test
Test method ISO 105-E01, ISO 105-E02, ISO 105 E04 etc.
Brand HEALINK
3. (a,b)
M/C Name Electrolux Wascator FOM 71 CLS
Test Name Dimensional stability, spirality, appearance after
wash, DP Rating
Test method ISO 6330, BS EN ISO 26330
Brand HEALINK
Manufacturer SDL International
4. (a,b)
M/C Name AhibaNuance Lab. Dip DyeingMachine ECO
Test Name Lab. dip dyeing
Manufacturer Data color
Country/Origin U.S.A
5.
M/C Name Creda Dryer T520VW
Test Name Drying as per different types of test method
Country/Origin U.K
6.
M/C Name Electolux T4130
Test Name Fabric drying
7.
M/C Name Siemens
Test Name Fabric drying
Manufacturer Siemens
Country/Origin German
8.
M/C Name Perspirometer 290 (Acid and Alkali)
Brand HEALINK
9.
M/C Name Spray Rating Tester
Brand HEALINK
10.
M/C Name 78-1 Magnetic Stirrer
Test Name Stirring
Country/Origin China
11.

VIYELLATEX GROUP
M/C Name KERN Electronic Balance EG 300-3M
Test Name Take Measurement as per different method
Brand HEALINK
Manufacturer Kern & Sohn GmbH
Country/Origin Germany
12.
M/C Name Thermostatic water bath
Temp. range 0-1000
C
Country/Origin China
13.
M/C Name Digital Pipette
Test name Small amount of liquid chemical could be taken
accurately.
14.
M/C Name Digital pH mater
Test name Measure the pH
B. PHYSICAL LAB:
1.
M/C Name Orbitor Pilling & Snaging Tester
Test Name Pilling Resistance Test
Test method BS EN ISO 12945-1, BS 5811
Brand HEALINK
2.
M/C Name Crock Meter
Test Name Color fastness to Rubbing
Test method ISO 105-X12, BS EN ISO 105-X12
Brand HEALINK
3.
M/C Name Marks & Spencer Holoscope
Test name Measure the fabric appearance for pilling
4.
M/C Name Pilling assessment viewer
Test Name Measure the fabric appearance for pilling
Brand Verivide
Manufacturer Verivide ltd.
5.
M/C Name Megasol
Test Name Color fastness to light measurment
Test method ISO 105-B02, BS EN ISO 105-B02
Brand HEALINK

VIYELLATEX GROUP
Manufacturer James H. Heal & Co. Ltd
6.
M/C Name Tru Brust
Test Name Brusting Strength Test
Test method ISO 13938-2, EDNA 80.3-99,NextTest Method
22a, IWS Test Method .3
Brand HEALINK
Manufacturer James H. Heal & Co. Ltd
7.
M/C Name Yarn Grade Tester
Test Name Yarn grade assessment
Test method International method
Brand HEALINK
8.
M/C Name Button Tester
Test Name Button Strength Test
9.
M/C Name Ultra-test button tester (M&S)
Test Name Button Strength Test
Brand Mecmesin
Manufacturer Mecmesin ltd.
Country/Origin U.K
10.
M/C Name Spectrophotometer (SF 600 Plus CT)
Test Name Shade Matching & Recipe Formulation
Manufacturer Data color
Country/Origin U.S.A.
Software used Color Tool QC V 2.2, DCI Match
11.
M/C Name Thermo hygrograph
Test Name Measure the Temperature & Humidity
12.
M/C Name Spectralight lll
Test Name Assessing fastness rating
13.
M/C Name Verivide
Test Name Assessing fastness rating
REMARKS:
VIYELLATEX GROUP. is a well equipped industry. As the quality of the
machineries of dyeing, finishing & testing section are good, so the quality level of the
product is also good.

VIYELLATEX GROUP
RAW MATERILS
CHEPTER 04
VIYELLATEX GROUP

VIYELLATEX GROUP
Raw Material for Knitting
The raw material for knitting is the yarn. Different types of yarn of wide range of count are
used. In yarn store section we had the chance to know about different yarns of different
count used in VIYELLA TEX knitting. We also have known different yarn
manufacturer/suppliers name for this knitting section i.e. sources of yarn. Both carded and
combed yarn is used for knitting.
Generally used yarn and their count:
Cotton 24S
, 26S
, 28S
, 30S
, 32S
, 34S
, 40S
Polyester 75D, 100D
Spandex yarn 20D,40D, 70D
Grey Mélange (C_ 24S
, 26S
Ecru Mélange (C-85% V-15%) 24S
, 26S
, 28S
Anthra Mélange (C-65% V-35%) 24S
, 26S
, 28S
PC (65%Polyester & 35% cotton) 24S
, 26S
, 28S
, 30S
CVC 24S
, 26S
, 28S
, 30S
Count Type Composition Price/Kg
24S Carded
100% cotton
140/=
Combed 160/=
30S Carded
100% cotton
170/=
Combed 180/=
40S
Combed 185/=
100 D Polyester
75 D Polyester
28/1 CVC
40D LYCRA 600/=
70D LYCRA 600/=
20D LYCRA
40D LYCRA
Yarn Suppliers for VIYELLA TEX:
1. Prime Spinning Mill
2. Rk Spinning Mill
3. Jk Spinning Mill
4. Akij Spinning Mill
5. Pahartoli Spinning Mill
6. Youth Spinning Mill
7. Kader Spinning Mill
8. Silver Spinning Mill
9. Shamem Spinning Mill
10. Sinha Spinning Mill

VIYELLATEX GROUP
11. Msa Spinning Mill
12. Hanif Spinning Mill
13. S.Uddin Spinning Mill
14. Square
15. Roshwa Spinning Mill
Raw Material for Dyeing
VIYELLATEX LTD. is a knit composite textile industry. In the industry the raw materials
used for production are:
1. Grey fabrics
2. Dyes
3. Chemicals.
1. Grey Fabrics:
Following types of gray fabrics are dyed:
 Single jersey
 Single jersey with lycra
 Polo pique
 Single lacoste
 Fleece
 Interlock
 Interlock with lycra
 Rib
 Rib with lycra
 1Χ1 rib
 2Χ2 rib
 Different types of collar & cuff
2. Chemicals:
List of Chemicals Used In Viyellatex Group Ltd.
Acid
1. Acetic Acid
2. Hydrochloric Acid
Detergent
1. Felosan NOF
Washing Agent
1. Cibapon R
Levelling Agent
1. Cibacel DBC
Sequestering Agent
1. Invatex CS

VIYELLATEX GROUP
SALT
1. Gluber Salt
2. Common Salt
Whitening Agent
1. Uvitex BAM
2. Uvitex BHV
3. Hostalux ETBN (For polyester fabric)
4. Bluton BBV
Softener
1. Alkamine CWS
2. Sapamine FPG
3. Sapamine 544
4. Magasoft TET
5. Megasoft FMG (For White Fabric)
Fixing Agent
1. Sandofix EC
Reducing Agent
1. Hydrose
Bleaching Agent
1. H2O2
Enzyme
1. Bioace
2. Tinozyme 44L
Stabilizer
1. Tinoclarite CBB
Anticreasing Agent
1. Cibafuid C
PH
Controller
1. Acid
2. Neutracid RBT (Non volatile)
3. Soda Ash
4. Caustic
Per-oxide Killer
1. Invatex PC

VIYELLATEX GROUP
3. Dyes:
List of dyes used in VIYELLATEX LTD.
Sl. No. Name of the Dyes Type Source
01 Ciba Yellow FN2R Reactive Dye Swiss Color
02 Ciba Red FNR Reactive Dye Swiss Color
03 Ciba Red FN2BL Reactive Dye Swiss Color
04 Ciba Blue FNR Reactive Dye Swiss Color
05 Ciba Br. Blue FNG Reactive Dye Swiss Color
06 Ciba Red FN3F Reactive Dye Swiss Color
07 Ciba Yellow F4G Reactive Dye Swiss Color
08 Ciba Scarlet F3G Reactive Dye Swiss Color
09 Ciba Yellow WR Reactive Dye Swiss Color
10 Ciba Red WB Reactive Dye Swiss Color
11 Ciba Navy WB Reactive Dye Swiss Color
12 Ciba Dk. Blue WR Reactive Dye Swiss Color
13 Ciba Red HF Reactive Dye Swiss Color
14 Ciba Orange HR Reactive Dye Swiss Color
15 Ciba Navy H2G Reactive Dye Swiss Color
16 Ciba Black WHF Reactive Dye Swiss Color
17 Drim Yellow HFR Reactive Dye Clariant
18 Drim Red HF2B Reactive Dye Clariant
19 Drim Blue HFRL Reactive Dye Clariant
20 Drim Yellow CL2R Reactive Dye Clariant
21 Drim Red CL5B Reactive Dye Clariant
22 Drim Navy CLB Reactive Dye Clariant
23 Drim Orange CL3R Reactive Dye Clariant
24 Drim Yellow CL3GL Reactive Dye Clariant
25 Drim Turquis CLB Reactive Dye Clariant
26 Drim Turquis K2B Reactive Dye Clariant
27 Remazol Yellow RR Reactive Dye Dyestar
28 Remazol Red RR Reactive Dye Dyestar
29 Remazol Blue RR Reactive Dye Dyestar
30 Remazol Br Blue (RSPL) Reactive Dye Dyestar
31 Remazol Blue BB Reactive Dye Dyestar
32 Remazol T/Blue G Reactive Dye Dyestar
33 Remazol Yellow 3RS Reactive Dye Dyestar
34 Remazol Red 3BS Reactive Dye Dyestar
35 Dianx Yellow SEG Disperse Dychufix
36 Dianx Red CC Disperse Dychufix
37 Dianx Navy CC Disperse Dychufix

VIYELLATEX GROUP
38 Sunfix Yellow EXF Reactive Dye Sumitomo
39 Sunfix Red EXF Reactive Dye Sumitomo
40 Sunfix Blue EXF Reactive Dye Sumitomo
41 Sunfix Blue BRF Reactive Dye Sumitomo
42 Sunfix Yellow S3RD Reactive Dye Sumitomo
43 Sunfix Red S3BD Reactive Dye Sumitomo
44 Remazol Yellow GR Reactive Dye Dyestar
45 Remazol Red F3S Reactive Dye Dyestar
46 Remazol Navy Blue RGB Reactive Dye Dyestar
47 Remazol G. Yellow RNB Reactive Dye Dyestar
48 Bezactive Red VBN Reactive Dye Bezema
49 Bezactive Yellow V2R Reactive Dye Bezema
50 Foron Red SWF Reactive Dye N/A
51 Foron Navy SWF Reactive Dye N/A
52 Dianix Blue ER Disperse Dychufix
53 Dianix Black CCR Disperse Dychufix
54 Kemifix Yellow FRL Reactive Dye N/A
55 Kemifix Red 3BS Reactive Dye N/A
56 Kemifix Red F6B Reactive Dye N/A
57 Kemifix Yellow 4G Reactive Dye N/A
58 Kemifix Blue F2R Reactive Dye N/A
59 Kemifix Orange 2RL Reactive Dye N/A
60 Impozyn Black VB Reactive Dye Impo color
61 Impozyn Red 3BF Reactive Dye Impo color
62 Impozyn Yellow E3R Reactive Dye Impo color
63 Impozyn Blue V3R Reactive Dye Impo color
64 Impozyn T. Blue VG Reactive Dye Impo color
65 Impozyn Br. Orange V3R Reactive Dye Impo color
66 Tera Yellow W4G Disperse Swiss Color
67 Tera G. Yellow W3R Disperse Swiss Color
68 Tera Navy WRS Disperse Swiss Color
69 Tera Red W4BS Disperse Swiss Color
70 Tera Blue WBLS Disperse Swiss Color
71 Tera Black WNS Disperse Swiss Color
72 Tera Black BFE Disperse Swiss Color
73 Drimarin G. Yellow K2R Reactive Dye Clariant
74 Drimarin Blue CLBR Reactive Dye Clariant
75 Drimarin Blue K2RL Reactive Dye Clariant
76 Remazol Carbon RGB Reactive Dye Dyestar
77 Remazol Black B Reactive Dye Dyestar
78 Remazol Red RB Reactive Dye Dyestar

VIYELLATEX GROUP
79 Levafix Blue CA Reactive Dye Dyestar
80 Levafix Rubine CA Reactive Dye Dyestar
81 Levafix Amber CA Reactive Dye Dyestar
82 Ciba Yellow HG Reactive Dye Swiss Color
83 Ciba Blue HRN Reactive Dye Swiss Color
84 Ciba Red HBL Reactive Dye Swiss Color
85 Ciba Orange EBR Reactive Dye Swiss Color
86 Solacion Yellow HEXL Reactive Dye N/A
87 Solacion Red HEXL Reactive Dye N/A
88 Bezactive Turquis VGC Reactive Dye Bezema
89 Bezactive Red S2B Reactive Dye Bezema
Source:
Dyeing department of VIYELLATEX GROUP LTD. receive grey fabric from
knitting department of this company. According to buyer order, store officer receive the grey
fabric and he maintains the delivery of finished fabric.
Source of the Dyes of VIYELLATEX GROUP LTD. are Swiss Color, Dyestar,
Bezema, Clariant, Impo color etc.
Annual Requirements:
To determine annual requirements is very tuff. It mainly depends on the buyer order
and subcontract order. When the buyer order is large then the consumption is high and vice-
versa.
The annual requirements of grey fabric depend on the buyer order and the
requirements of dyes and chemicals depend on the colour depth.
Remarks:
For smooth running of a factory uninterrupted supply of raw materials is very
essential. As far as we saw the raw material control of VIYELLATEX GROUP. is good.

VIYELLATEX GROUP
PRODUCTION
PLANNING AND SEQUENCE OF OPERATION
CHEPTER 05
VIYELLATEX GROUP

VIYELLATEX GROUP
Sequence of Operation for Knit Dyeing:
Grey fabric inspection

Batching

Fabric turning

Loading to the m/c

Pre-treatment (Scouring & Bleaching)

Dyeing

Dewatering

Drying

Compacting & Calendaring

Final inspection & packing
Production Parameters:
1) PH
- During H2O2 bleaching PH
9.2-12
- During reactive dyeing PH
10.5-12.5
- During disperse dyeing PH
4.5-6.0
2) Temperature:
- For cotton scouring: 900
-950
C
- For cotton cold wash: 300
-400
C
- For cotton hot wash: 700
-800
C
- For cotton acid wash: 600
-700
C
- For cotton dyeing: 80-900
C (For hot brand)
600
C (For cold brand)
- Polyester dying: 1000
-1300
C
3) Time:
- For Scouring: 60-90 minutes
- For Disperses dyeing 60-90 minutes.
4) M: L ratio:
- For reactive dyeing M: 1 ratio maintained between 1:6 to 1:10.

VIYELLATEX GROUP
Description of Production Process:
Washing for colored fabrics:
 The colored fabrics, to be washed is loaded in the machine
 Required amount of water is taken.
 Felosan NOF (detergents) added & washing continued at 800
C for 20 minutes.
 Cold washing
Scouring-bleaching:
 Fabric, to be scoured is loaded in the machine
 Required amount of water is loaded
 Washing agent| detergent is added
 Steam pipes are on & scouring agents (i.e., caustic soda/ soda ash) added when the
temperature reaches at 700
C
 Then H202 is added.
 Temperature is then raised to 1050
C & the process is then carried out for 60-90
minutes depending on the requirements.
 The liquors are then drained.
 Then wash with Felosan NOF (detergent) at 980
C for 5 min.
 Then cold wash, at 350
-450
C & acid wash, at 600
-700
C is done.
Dyeing:
 After acid wash all liquors are drained out.
 Required amounts of water is taken
 Then leveling agents, anti-creasing agents, de-foaming agents are added according to
the requirements.
 Steam pipes are on & after 10-15 minutes dyes are added.
 Salts are added and runtime is 15-20 minutes.
 Then soda ash, after another 35minutes.
 Then the temperature is raised slowly up to the mark.
 The process is carried on & samples are taken after every 30-40 minutes to match
with the target shade. It continues until shade matching.
 If the sample is matched, then the liquor is drained out.
 Then cold wash at 350
-450
C.
 Wash with Cibapon R (Washing agent) for 5 minutes.
 Acid wash at 550
C is done.
 Fixing agent is added at 450
C for 15 minutes.
 Then softener is added at 450
C for 15 minutes.
Sample Of Dyeing

VIYELLATEX GROUP
Color Name Standard Recipe Sample

VIYELLATEX GROUP
Dyeing Curve:
Production Flow Chart:
Production flow chart for 100% cotton fabric:
Dyeing procedure for dark shade
Felosan NOF/Wetting agent = 0.5g/l
Kappazon H53NEU/Stabilizer (H2O2) = 0.5 g/l
Anticreasing agent = 1.0 g/l [Only for S/J]
60o
C x 5'
Caustic → 2 g/l
60o
C x 15'
Hydrogen peroxide → 2.5 g/l [Dosing 10']
(60o
C - 80o
c)
Temperature rise up to 105o
C
30'
Acetic acid → 1.0 g/l
600
C
900
C
&
10’
CBB
+
NOF
Caust
ic H2O2
1050
C
& 30’
700
C
600
C
980
C
&
10’
Drain
Drain
Acid PC
Acid Bioace
900
C
&
10’
CS
Drain
Drain
Drain
NOF
Scouring & Bleaching Curve
600
C
&
10’
550
C
&
30’
A. Acid
+C+DBC
Color Dosing
(20’)
Salt
Soda Dosing
(35’)
Check
Shade
Dyeing Curve
10
R
Acid Bioace
Drain
550
C
& 30’
Hot
Wash
450
C
& 30’
EC
450
C
& 30’
Acid Softener
Cold
Wash
Fabric
Unload
15’ 20’ 20’

VIYELLATEX GROUP
H2O2 killer → 0.5 g/l
60o
C x 10'
Acetic acid → 0.8 g/l (To control pH
= 4.5-5.5)
Enzyme → 1.5 g/l
55o
C x 45' - 60'
Kappaquest FE / Sequestering Agent → 0.35 g/l
90o
C x 5'
Sarabid LDR → 0.5 g/l (leveling agent)
60o
C x 5'
Gluber Salt (Runtime → 10')
60o
C x 10'
Dye stuff
60o
C x 35' Runtime 20'
Soda ash
60o
C x 40' Runtime 60'
Bath drop after shade matching
Hot rinse
60o
C x 10'
Soaping
80o
- 95o
C x 10'
Cold rinse
45o
C x 10'
Neutralize (Acetic acid = 0.5 g/l)
45o
C x 10'
Fixing
40o
C x 15'
Softening
Unload
Dyeing procedure for Light / Medium Shade

VIYELLATEX GROUP
Felosan NOF/ Wetting agent = 0.5 g/l
Kappazon H53NEU /H2O2 Stabilizer = 0.5 g/l
Anticreasing agent = 1.0 g/l
60o
x 5'
Caustic = 2 g/l
60o
C x 15' [Dossing]
Hydrogen peroxide (H2O2) = 2.5 g/l
(60o
- 80o
C)
Temp rise up to 105o
C & Run - 30'
Acetic acid = 1.0 g/l
H2O2 killer / Kappaquest FE = 0.5 g/l
60o
C x 10'
Acetic acid = 0.8 g/l [To control PH
- 4.5 - 5.5')
Enzyme = 1.5 g/l
55o
C x 45' - 60'
Sequestering agent = 0.35 g/l
90o
C x 5'
Sarabid LDR /Levelling agent = 0.5 g/l
Anticreasing - 0.5 g/l
60o
x 5'
Dye stuff
60o
x 35' - Run time - 20'
Glauber Salt
Dosing - 60o
x 10' - run time - 20'
Soda ash
60 x 40'
Hot rinse - 10' x 60o
C
Soaping
80o
- 90o
C x 10'
Neutralization / Acetic acid
45o
C x 10
Cold rinse - 45o
x 10'
Softening
Unload

VIYELLATEX GROUP
Dyeing Procedure for White Colour
Felosan NOF/wetting agent → 0.5 g/l
Kappazon H53NEU /Stabilizer → 0.5 g/l
Anticreasing agent → 1.0 g/l [Only for S/J]
Caustic → 3 g/l
60o
C x 15'
Hydrogen peroxide → 10.0 g/l
60o
C x 10'
Syno white 4BK/Optical brightener (60o
→ 80o
C)
105o
x 60'
NT x 10'
Acetic acid → 0.8 g/l [To Control PH
- 4.5 - 5.5]
Enzyme → 1.5 g/l
55o
C x 45' - 60'
Sequestering agent → 0.5 g/l
90o
C x 5'
Softener → 1.5 g/l
40o
C x 10'
N. Hot
Unload
Migration Dyeing procedure for dark, medium & light shade
Felosan NOF/wetting agent → 0.5 g/l
600
C
800
C 900
C
& 10’
10’
A. Acid
+C+DBC
Color Dosing
(20’)
Salt
Soda Dosing
(35’)
Check
Shade
Dyeing Curve
10’
R
Acid Bioace
Drain
550
C
& 30’
Hot
Wash
450
C
& 30’
EC
450
C
& 30’
Acid Softener
Cold
Wash
Fabric
Unload
15’ 20’ 40’

VIYELLATEX GROUP
Kappazon H53NEU /stabilizer (H2O2) → 0.5 g/l
Anticreasing → 1.0 g/l [Only for S/J]
60o
C x 5'
Caustic → 2 g/l
60o
C x 15'
Hydrogen peroxide → 2.5 g/l
(60o
C - 80o
C)
C
105o
C x 30'
Kappaquest FE /H2O2 killer → 0.5 g/l
60o
C x 10'
Acetic acid → 0.8 g/l [To control PH
= 4.5 - 5.5']
Enzyme → 1.5 g/l
55o
C x 45' - 60'
Sequestering agent → 0.35
90o
C x 5'
Sarabid LDR → 0.5 g/l
Anticreasing agent → 0.5 g/l [for S/J]
Dye stuff
60o
C x 35' → Run time - 20'
Glauber Salt [Run time 10']
60o
x10'
C [ Run time→ 20']
80o
C x 20'
cooling to 60o
C
soda ash
60o
C x 40' → Run time → 60'
Hot rinse
60o
x 10'
Soaping
80o
C - 95o
C x 10'
Cold rinse
40o
x 10'
Neutralize
45 o
x 10'
Fixing [ For medium & dark shade]
40 o
x 10'
Softening
Unload

VIYELLATEX GROUP
Production Flow Chart For 100% Polyester:
Fabric Load

Water Level – As Required

Raise temp to 600
C

Add Feloson NOF

Raise temp.to 900
C & run time 10 min

Drain


Raise temp. to 450
C

Add Neutracid RBT (Non volatile Acid) & runtime 10 min

Drain


Raise temp. to 450
C

Dye dosing for 10 min

Raise temp. to 1300
C & run for 45 min

Drain

Dyeing Curve
700
C
450
C
& 30’
Acid Softener
Cold
Wash
Fabric
Unload
1300
C
Color
Dosing
(10’)
Check
Shade
Acid
Wash
Drain
45’
Hydrose
+ Caustic
800
C
& 20’ Hot
Wash
450
C

VIYELLATEX GROUP
Water

Cooling at 700
C & sample cheek if shade ok then bath drop

Hydrose+ Caustic at 800
C for 20 min

Hot wash

Acetic wash at cold temp. for 10 min

Acetic Acid + Softener is added at 450
C & run for 10 min

Cold Wash

Fabric Unload
Production Flow Chart for CVC:
For CVC fabric dyeing, at first polyester part is dyed at 1300
C according to dyeing
procedure of 100% polyester dyeing. Then cotton part is first scoured & bleached. Then
cotton part is dyed according to dyeing procedure of 100% cotton dyeing.
Remarks:
VIYELLATEX GROUP., strictly follow up the production parameters like time,
temperature, M:L ratio, PH
etc. As they do some difficult shade, it takes more time for the
production of the batch and the dyeing process may vary from the dyeing flow chart for
different types of fabric & different types of shade. Considering these limitations the
Production Manager & the Senior Production Officer try their try their best to reduce the
production time.
QUALITY ASSURANCE SYSTEM
CHEPTER 06

VIYELLATEX GROUP
VIYELLATEX GROUP
The Quality assurance Department is assigned to maintain consistently uniform
quality of the material in process and various stages of its manufacturing. VIYELLATEX

VIYELLATEX GROUP
LTD is more about concern about quality. In this factory quality assurance is more preferred
than quality control, but both are in advancement.
After collecting fabric rolls from different m/cs, they are needed to be inspected or
assured required quality by the quality inspectors as if there were no big production
hampered and no complain from the buyers. Here are the details about it.
Objects of Quality Control:
1. Research.
2. Selection of raw materials.
3. Process control.
4. Process development.
5. Product testing.
6. Specification test
Scope for quality control, quality assurance and testing:
1. Testing lab
2. Machine auditing system
3. A good training system
4. Excellent analytical back up
5. Technical expertise

VIYELLATEX GROUP
WORKING PROCEDURE FOR LAB
SAMPLE IN (FABRICS)
Physical Test Wet Lab.
 Color fastness to light
 Bursting strength Color Fastness To Washing Dimensional Stability
 Pilling
 Crocking Prepare the sample
Pre-Production Sample Final Sample
Evaluate the Sample Wash the sample according to buyer measure
Test Testst
Report Making Tumble dry
Prepared the Report
Keep the sample Flat in conditioned temp
Pass Fail at least two hours before measure
Pass Fail
Delivery Refinish Measure the sample
Go for the final Refinish
Need to test again Prepared the Report
Need to test again
Pass Fail
Ready to deliver Refinish
Need to test again

VIYELLATEX GROUP
Quality Control in Grey Fabric Inspection:
Some Points Are Needed To Maintain For High Quality Fabric:
a) Brought good quality yarn.
b) Machines are oiled and greased accordingly.
c) G.S.M, Stitch length, Tensions are controlled accurately.
d) Machines are cleaned every shift and servicing is done after a month.
e) Grey Fabrics are checked by 4 point grading system.
List of Equipments:
In this factory VIYELLATEX this is the list of equipments to assure quality:-
1) Inspection m/c # 1
2) Inspection m/c #2
3) Scissors
4) Electronic balance
5) GSM cutter
6) Indication sticker
7) Measuring tape
Quality Assurance Procedure:
1) Body & Rib Inspection:
All rolls are kept in front of the inspection m/c time to time and are inspected over
the inspection m/c visually in a pre-set speed against light. For any major or minor
faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle
line, slubs etc are recorded in inspection report to classify the fabric based on the four
point system.
2) Collar & Cuff Inspection:
Collar& cuff are inspected visually under the light box, any major or minor faulty
collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round
problem etc properly counted and recorded.
Quality Standard:
VIYELLA TEX Ltd. maintains the ISO: 9002 standard in case of quality. Therefore,
the four point system is followed to inspect the body & rib fabric. The defects found and
points given against are recorded in the inspection sheet. Following table shows the four
point grading system followed by inspection at VIYELLA TEX Ltd.

VIYELLATEX GROUP
Following table shows common body and rib faults and response by inspection section at
VIYELLA TEX Ltd.:-
Four point grading system
Size of defects Penalty
3 inches or less 1 point
Over 3 inch but not over 6 inch 2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point
Rejection criteria for body & ribs
No. Faults Response
1. Needle mark Major needle line is rejected
2. Stripe Major needle line is rejected
3. Barre mark Rejected
4. Contamination & fly Approved for color but for white shed 1
point is assigned
5. Slubs 1 point
6. Thick thin place Reject
7. Birds eye 1 point
8. Pin holes 1 point
9. Wrong design Reject
10. Mixed yarn Discuss with manager
11. Sinker mark Major sinker mark is rejected.
12. Missing yarn Use 4 point
13. Holes Do
14. Oil line/stain Do
15. Chemical Do
16. Dirt stain Do
17. Crease line Do
18. Uneven tension Discuss with manager

VIYELLATEX GROUP
Following table shows common collar and cuff fault and response taken by inspection
section at VIYELLA TEX Ltd.:-
Rejection criteria for collar & cuff
No. Faults Response
1. Wrong ply Reject
2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7. Fly & contamination Acceptable for color but not for white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
15. Wrong tube Reject
Following table shows the acceptance calculation followed by the inspection section
at VIYELLA TEX Ltd.:-
Acceptance calculation
Factory: Roll yardage (A)
Total points founds(B)
Formula :
B
A X100 =points per 100 yard
Classification :
<= 40 points = A type
41-60 = B type
61-80 = C type
Above 80poin = Reject

VIYELLATEX GROUP
Quality Control in Dyeing And Finishing:
VIYELLATEX GROUP LTD. assures the quality of the products of dyeing section in the
following three steps:
1. In laboratory
2. In Dyeing section &
3. In Finishing Section
Procedures are described below:
In laboratory:
Swatch card from buyer according to their requirement
Recipe prediction for sample dyeing
Sample dyeing until matching with swatch card
Fastness & other tests of the fabric or yarn are done here.
In dyeing section:
According to the buyer’s sample, sample dyeing is done in sample dyeing machine
in dyeing shed & again matched with the approved sample.
If result is OK, then bulk production.
During dyeing, samples are taken until accurate shade matching. The interval may
be 30-40 minutes.
After dyeing sample is collected after softening matching is done.
Last of all, sample is collected after fixation & matched.
Then allowed the fabrics to be finished.
In finishing section:
By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
Then sampling is done for several times to test GSM, Shrinkage & fastness
properties.
Finally fabric is inspected & prepared for delivery.
Quality Standard:
VIYELLATEX GROUP LTD. follows the quality standard:
ISO-9002:2000.

VIYELLATEX GROUP
List of Equipments: -
In the Quality Assurance Department the followings equipments are used -
 Yarn Grade Tester
 78-1 Magnetic Stirrer
 KERN Electronic Balance
 Spray Rating Tester
 Incubator
 Iron
 Button Tester
 Ahiba Nuance Lab. Dip Dyeing Machine
 Thermostatic Water Bath
 Digital Pipette
 Creda Dryer
 Rota Wash
 Electrolux Washcator
 Orbitor Pilling & Snaging Tester
 Marks & Spencer Holoscope
 Tru Brust
 Crock Meter
 Push – pull tester
 Megasol (Light fastness tester)
 Spectro Photometer with software (Data Color)
 Thermo hygrograph
 PH
meter
Tests
There are two types of tests are done in Quality Assurance Department. They are –
1. Physical Tests
2. Chemical Tests
Physical Tests:
 Yarn Grade
 GSM test
 Shrinkage test
 Spirality test
 Tensile strength
 Abrasion resistance
 Pilling resistance

VIYELLATEX GROUP
 Button Strength Testing
 Lycra% determination
 Crease resistance
Chemical Tests:
 Fastness to washing.
 Fastness to light
 Fastness to actual laundering
 Fastness to sea water
 Fastness to water
 Fastness to perspiration
Fabric Inspection:
The inspection of fabric is a procedure by which the defects of fabric are identified
and fabric is classified according to degree or intensity of defects. The fabric inspection is
done for both grey and finished fabric.
Grey Fabric Inspection:
Grey fabric inspection is performed according to 4-point system.
Finished Fabric Inspection:
4 point numbering system is followed for finished fabric inspection. Defects found in
the final inspection:
1. Uneven shade
2. Oil spot
3. Neps
4. Crease mark
5. Machine Stoppage mark
6. Listing
7. Line mark
8. Pick missing
9. Double yarn
10. Dead cotton
11. Bowing
12. Fly yarn contamination
Procedure of the Different Tests:
Different types of fastness tests of the dyed fabric are done in quality control
department of the VIYELLATEX GROUP LTD. Different types of method (Standard or
buyer’s recommended) are followed for different types of tests. The process of the different
tests of fabrics & lab. dip dyeing is described in the following section:
Color Fastness Test Procedure
Color Fastness:

VIYELLATEX GROUP
The “color fastness” of a colored textile is defined as its resistance to these changes
when subjected to particulates of conditions. It follows that color fastness must be specified
in terms of these changes and expressed in terms of the magnitude.
1. Color Fastness to Wash Test
Required materials:
1. Sample size 40  100 mm
2. Multifiber at 40  100 mm
3. ECE detergent (WOB) – 4g/L
4. Sodium Perborate (Na2BO3.H2O2.3H2O2-1g/L) - 1g/L
5. Distilled water
6. Normal cold water
7. Steel balls
Required instrument:
1. Rota Wash
2. Scissor
3. Stitch machine
Procedure :
1. Cut sample & multifibre at 100  400 mm and then stitch.
2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the
sample.
For Marks & Spencer, the solution is taken by the following formula:
(Sample fabric + Multifibre weight)  50 ml
3. The sample is kept in 600
C for 30 minutes in Rota Wash Machine
4. Rinse the sample twice with cold water.
5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not
be more than 150°C.
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey
Scale & Staining Scale.
2. Color Fastness to Perspiration Test
Test specimen:
 Sample fabric – 50 mm  50 mm
 Multifibre fabric – 50 mm  100 mm
 Cut the multifibre into two piece
 Sandwich the test specimen between two piece of multifibre
Testing Solution:
1. Alkaline Solution:

VIYELLATEX GROUP
Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/L
NaCl – 5.00 g/L
Disodium hydrogen orthophosphate (Na2HPO4.2H2O) – 2.5 g/L
PH
– 8 (Adjust by 0.1 N NaOH)
2. Acidic Solution:
Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/L
NaCl – 5.00 g/L
Sodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.2 g/L
PH
– 5.5 (Adjust by 0.1 N NaOH)
Method:
- The composite specimen is put in a peri dish (2 specimen of a sample).
- Solution (Alkaline & Acidic) is taken in the two peri dish. Here, M:L is taken
1:20.
- Bubble is made out from the specimen by tapping.
- The specimen is put for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Peri dish with composite specimen & glass plate is placed into the incubator at
(372) 0
C for 4 hours.
- The specimen is dried (Temp  600
C)
Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
3. Color Fastness to Water Test
Test specimen:
 Sample fabric – 50 mm  50 mm
 Multifibre fabric – 50 mm  100 mm
 Cut the multifibre into two piece
 Sandwich the test specimen between two piece of multifibre
Testing Solution:
 Water is taken as required
Method:
- The composite specimen is put in a peri dish (2 specimen of a sample).
- Water is taken in the peri dish as required.
- Bubble is made out from the specimen by tapping.
- The specimen is put for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.

VIYELLATEX GROUP
- Excess solution is poured off.
- Peri dish with composite specimen & glass plate is placed into the incubator at
(372) 0
C for 4 hours.
- The specimen is dried (Temp  600
C)
Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
5. Color the Fastness to Rubbing (Dry & Wet) Test
Sample:
- Dyed fabric – 15 cm  5 cm
- White Test Cloth - 5 cm  5 cm
Procedure:
- White test cloth is put on to the grating and stag by steel wire.
- The sample is run twenty times manually for ten seconds. and the rubbing
fastness of the sample cloth and degree of staining is accessed.
- For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked
and squeeze. The wet rubbing cloth is placed on to the grating and stag with
stainless steel wire and run ten times manually then assess the staining on to the
rubbing cloth and the rubbing fastness of the sample cloth is accessed.
Report:
- Change of shade of the sample is measured with grey scale and degree of staining
of the white test cloth is measured by Staining Scale.
There are also some tests are done in the lab. And the process is described below-
A. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample:
 Two piece of 50 cm  50 cm fabric is taken for test.
Procedure:
a. Conditioning: Put the sample in table for 4 hrs for conditioning before starting
test.
b. Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample
(3 sides) by over lock sewing machine.
c. Put sample in washing machine and run according to buyer’s choice.
d. Drying: All Buyers’ requirement is tumble Dry except ECHO SCOURING is
flat dry.

VIYELLATEX GROUP
50 x 50 cm
Fig: Template
SHRINKAGE TEST CALCULATION:
Before wash – After wash
Shrinkage % = X 100
Before wash
Spirality test calculation:
S = (S1+S2) / 2
Spirality = (S+S  L)/100.
Suppose,
S1 = The right side distance of the specimen from the stitch line after
wash.
S2 = The left side distance of the specimen from the stitch line after
wash.
L = Length before wash
B. pH of a Dyed Fabric Test
Test specimen:
 2 gm of dyed fabric is taken.
 The fabric is cut into pieces of (0.5 cm  0.5 cm)
Procedure:
1. The sample is taken into conical flax.
2. 100 ml distilled water (slightly warm) is taken into the conical flax.
3. The conical flax is put on the Magnetic Stirrer for 30 minutes.
Report:
The PH
of the conical flax is measured by Digital PH
meter.
Lab. Dip Dyeing
Sample:
- Type - 100 % cotton fabric
- Weight – 5 gm
╬ ° ╬
35 x 35 cm
° °
╬ ° ╬

VIYELLATEX GROUP
Procedure:
- At first the recipe for the sample is calculated according to the sample weight.
- The fabric is kept in the dyeing chamber.
- Then the dyes, chemicals, salt & required amount of water is taken in that dyeing
chamber by digital pipeting on the basis of stock solution.
- Then the beaker is set into the lab. dip. dyeing machine for dyeing.
- The program for dyeing is started for 20 min at 400
C.
- After 20 min soda is added by pipeting.
- Then the dyeing program is set for 60 min at 600
C.
- When the dyeing time is finished the sample is taken out from the machine at
400
C.
- Then the sample is washed off. At first cold wash & then hot wash is done. After
it soaping is done.
- Then the sample is dried and compared with standard.
Recipe Curve:
600
C60 min
400
C20 min
Wash off
Dyes+Salt+Material Soda
+Water
Progressive Process For Lab. Dip. Dyeing
Recipe Calculation:
A dyeing recipe for purple color is given below:
Sample Weight – 5 gm
M : L – 1:10
Liquid Required – 50 c.c.
Sunfix Yellow S3RD – 9.3 c.c. (Shade – 1.86%)
Sunfix Red S3BD – 10.2 c.c. (Shade – 4.08%)
Sunfix Yellow S3RD – 9.3 c.c. (Shade – 1.86%)
Remazol Blue RR – 6.5 c.c. (Shade – 1.3%)
Salt (80 g/L) – 10 c.c. (40% stock)
Soda (20 g/L) – 2.5 c.c. (40% stock)
Water – 11.5 c.c.
Salt and soda is taken on the basis of the shade%. The salt and soda is used according to the
following table:

VIYELLATEX GROUP
Shade % Salt g/l Soda g/l
0.001-0.100 20 6
0.101-0.500 24 8
0.501-1.000 30 10
1.001-2.000 40 12
2.001-3.000 50 14
3.001-4.000 60 16
Above 4.000 80 20
Response of Q.C Officer:
Response to Q.C Faults:-
Faults Response
Yarn fault Inform yarn supplier
Knit fault Inform knitting department
Response to Machine Fault:-
Faults Response
Any electrical fault Inform electrical maintenance
Any mechanical fault Inform mechanical maintenance
Remarks:
VIYELLATEX GROUP. always aware about the quality of the product. The quality
of the product is always approved by the buyer. They follow the quality standard: ISO -
9002:2000. VIYELLATEX GROUP. is well equipped for checking the quality of the
product. They sent the quality report to the buyer time to time/batch to batch. We think as
VIYELLATEX GROUP. strictly meet up the quality level that’s why they are the only one
direct manufacture of Marks & Spencer garments.

VIYELLATEX GROUP
MAINTENANCE
CHEPTER 07
VIYELLATEX GROUP

VIYELLATEX GROUP
Maintenance:
Machine, buildings and other facilities are subjected to deterioration due to their
use and exposure to environmental condition. Process of deterioration, if unchecked,
culminates in rendering these service facilities unserviceable and brings them to a
standstill. In Industry, therefore has no choice but to attend them from time to time to
repair and recondition them so as to elongate their life to the extent it is economically
and physically possible to do so.
Objectives of Maintenance:
1. To keep the factory plants, equipments, machine tools in an optimum working
condition.
2. To ensure specified accuracy to product and time schedule of delivery to customer.
3. To keep the downtime of machines to the minimum thus to have control over the
production program.
4. To keep the production cycle within the stipulated range.
5. To modify the machine tools to meet the need for production
Maintenance of Machinery:
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time inspection
/ checking of facilities to uncover conditions that may lead to production break downs or
harmful description.
Break Down Maintenance:
In this case, repairs are made after the equipment is out of order and it can not perform its
normal functions.
Maintenance
Preventive Maintenance Break Down Maintenance
Electrical
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Mechanical
Maintenance

VIYELLATEX GROUP
Routine Maintenance:
Maintenance of different machines are prepared by expert engineer of maintenance
department. Normally in case of dyeing machine maintenance after 30 days complete
checking of different important parts are done.
Manpower Set-Up For Maintenance
 A Shift 6 AM - 2 PM
 B Shift 2 PM - 10 PM
 General Shift 9AM - 6 PM
Maintenance Manager
Mechanical Electrical
Mechanical In charge - 02 Electrical foreman
Diploma (Mechanical) - 02 Diploma (Electrical) – 02
Welder and fitter – 01 Electrician - 02
Fitter – 01
Maintenance Procedure:
Normally preventive maintenance should be done. During maintenance procedure following
points should be checked:
Maintenance of knitting machine/flat knitting machine:
SL.
No.
Items need to be checked & Serviced
1. Check and tightening all motor terminals.
2. Check and clean pressure sensor and tightening terminals
3. Clean the ventilation fans of panel board and circular fan on top of
machine.
4. Check and clean the interfacing and data cables.
5. Check and tightening the proximity switch terminals.
6. Inspection, cleaning and tightening all the terminals in the panel.
7. Check and tightening limit switch, safety door guard and the
emergency switch.
8. Functional test of the yarn detector.

VIYELLATEX GROUP
Maintenance of finishing department:
Equipment name:
Mahlo zone of stenter:
SL.
No.
Items need to be checked & Serviced
1. Check and tightening all motor terminals and clean the motor fan
(30days).
2. Check activity of wide and sensor and pneumatic regulator.
3. Check and clean pressure sensor and tightening terminals
4. Clean the A/C ventilation fans of panel board
5. Check the fan and the heat sink o the inverters in the panel board.
6. Check and tightening the edge sensors.
7. Check and tightening the photo sensor terminals.
8. Check and tightening the safety light barrier and tightening the
terminals.
9. Inspection, cleaning and tightening all the terminals in the panel.
10. Check and tightening limit switch, safety door guard and the
emergency switch.
Check List of Different Parts
Maintenance : Mechanical
Machine : Dyeing machine
SL. No. Items need to be checked & Serviced
1 Crease the m/c bearing.
2 Complete cleaning of machine.
3 Cleaning of drain valves, replace seals if required.
4 Check air supply filters, regulators auto drain seals
5 Clean filters element and blow out.
6 Greasing of unloading roller bearing.
7 Checking of oil level and bolts of unloading roller gearbox.
8 Checking of unloading roller coupling and packing.
9 Checking & cleaning (if required) of main vessel level indicator.
10 Check the oil level of pump bearing and refill if required.
11 Check the function of heat and cool modulating valves
12 Check all door seals.

VIYELLATEX GROUP
Maintenance : Electrical
Machine : Dyeing machine
SL. No. Items need to be checked & Serviced
1. Check & clean fluff and dirt at dirt at all motor fan covers.
2. Check all motor’s terminals
3. Check main panels (by using compressed air)
4. Check panel cooling fan & clean its filter
5. Clean main pump inverter and its cooling fan.
6. Check all circuit breaker, magnetic conductors and relays.
7. Check current setting of all circuit breaker & motor over load.
8. Visual checking of all power & control cables.
9. Check all pressure switches
10. Check calibration of main vessel & all addition tank
11. Check all pneumatic solenoids
12. Check calibration of heating/cooling modulating value
13. Check setting of tangle sensor.
14. Check setting & operation of lid safely switches.
15. Check all emergency switches
16. Check all indicating lamps
17. Check all on/off switches
18. Check all signal isolators.
Maintenance Tools & Equipments:
1. Combination tools / spanner
Function: Tightening & loosening of nuts & bolts.
2. Socket ratchet set
Function: Tightening of nuts & bolts.
3. Slide range
4. Monkey pliers
5. Pipe threat cutting tools
Function: To cut the threat in pipe.
6. Bearing puller
Function: To assist the opening of bearing from shaft.

VIYELLATEX GROUP
7. Pipe range
Function: Tightening & loosening of pipe joint.
8. Pipe cutting tools
Function: For pipe cutting.
9. Hole punch
Function: Punching the hole.
10. Divider
Function: For circle marking on metal & wood.
11. Easy opener
Function: To open the broken head bolt.
12. External threat die
Function: For external threat cutting.
13. Heavy scissor
Function: Cutting of gasket & steel sheet.
14. Oil can
Function: Oiling of moving parts.
15. Drill machine and drill bit.
Function: For drilling.
16. Grease gun
Function: For greasing of moving parts of m/c.
17. Grinding m/c
Function: For grinding & cutting of mild steel.
18. Welding m/c
Function: For welding & cutting.
19. Spirit leveler
Function: For perfect leveling.
20. File
Function: For smoothing the surface.
21. Hammer
Function: For scaling & right angling.
22. Circlip tools
Function: Circlip opening & closing.
23. Hacksaw blade
Function: For metal cutting.
24. Handsaw (wood)
Remarks:
Maintenance of m/c’s are very essential to prolong the m/c life and good maintenance is
important consideration. It is necessary to check that all routine maintenance is being done
regularly and properly otherwise efficiency of each department will be reduced.

VIYELLATEX GROUP
UTILITY SERVICES
CHEPTER 08
VIYELLATEX GROUP

VIYELLATEX GROUP
Introduction:
VIYELLATEX GROUP LTD. is a big project and so of course having a vast
project of utility service. Here the total account of utility facilities are available. The utilities
are
a) Water
b) Gas
c) Electricity
d) Compressed Air
e) Steam.
WATER
Water treatment plant:
(Water Softening Method – Base Exchange Process)
Source of water is deep tube well.
Production capacity – 80 m3
/hr = 1920000 liter/day
Actual Production – 1500000 liter/day
Required water - 1300000 liter/day
Technical
Details
Raw Water
tank
Filter Tank (1) Filter Tank (2) Hardness
Removing Tank
Size Length – 30´
Width - 15´
Height – 6’
Diameter – 6´
Height - 15´
Diameter – 6´
Height - 15´
Salt reqd:
190 kg/day/tank
Regeneration
time 1.30 hrCapacity 360 Ton
Source Natural source
Deep tube well
Raw Water
Tank
Filter Tank (1) Filter Tank (2)
ELECTRICITY
Gas Generator is used for supplying electricity for the dyeing, knitting & office of the
VIYELLATEX GROUP LTD.
Total power produced by Gas Generator – 945 KW = 1134 KVA
Factory (Dyeing & Knitting) Power Needed for Installation – About 1200 KW
Factory (Dyeing & Knitting) Power Needed at Running stage – About 720 KW
Power Needed for Office – About 250 KW
Specification of Gas Generator is given below:
Technical Details Generator Data
Type Gas Generator
Manufacturer Cummins Power Generation
No. of Gas Generator 03
Model No. 315 GFBA
Manufactured Country England

VIYELLATEX GROUP
Year of Construction 2002
Rated Power Prime
Rated 315 KW
Power Factor 0.8
Voltage 400
Rated Current (amp) 568
Frequency (Hz) 50
Rotating Speed (RPM) 1500
Battery Volts 24
Control System PCCP
Site altitude before derate 800 MASL
Site ambient temp. before derate 400
C
Source of Power used for Garments – DESA
Power Capacity – 750 KVA = 900 KW
There is a diesel Generator in the industry.
Capacity of Diesel Generator – 800 KW
Specification of Diesel Generator is given below:
Technical Details Generator Data
Type Diesel Generator
Manufacturer CATERPILLAR
No. of Diesel Generator 02
Model No. SR4B | SR4
Manufactured Country U.S.A.
Rated 649 H.P. or 484.0 KW
Rotating Speed (RPM) 1500
Voltage 400
Rated Current (amp) 723
Maximum Temp. 1050
C by Resistance
COMPRESSED AIR
Compressed air is produced by air compressor.
There are two air compressors for producing compressed air.

VIYELLATEX GROUP
Specification of the air compressor is given below:
Technical Details Air Compressor 1 Air Compressor 2
Type Atlas Copco Atlas Copco
Manufacturer Atlas Copco Airpower Atlas Copco Airpower
Model No. GA 30 GA 55
Manufacturer Country Belgium Belgium
Year of Construction 2002 2004
Maximum Working Pressure 10 bar 10 bar
Free air delivery 78 liter/sec 145 liter/sec
Nominal Shaft Power 30 KW 55 KW
Rotational Shaft Speed 3000 r/min 3000 r/min
Gross Weight 995 Kg 1550 Kg
STEAM
Steam is produce by Boiler.
From the Water Treatment Plant, water is stored in a reserve tank and from there water goes
to boiler & steam is produced.
Specification of the Boiler is given below:
Technical Details Boiler Data
Type Fire Tube Boiler
Manufacturer OMNICAL BORSIG ENERGY
Model No. DDHI 60 – 10
Manufacturer Country Germany
Thermal Capacity 3.9 MW
Maximum Steam Out 6 ton/hour
Maximum Working
Pressure
10 bar-g
Content up to NW 10940

VIYELLATEX GROUP
GAS
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section (Boiler- for heating water) from the
main line of the TITAS GAS LTD.
Sources of Utility:
Electricity : PDB & Generator
Steam : Boiler
Water : Pump
Compressed air : Compressor
Gas : TITAS GAS LTD.
Remarks:
As the biggest project the VIYELLATEX GROUP., so the vast utility systems.
There is a skill manpower group of engineers and other technical staffs to look after these
utility services. They have to remain aware of solution on a great sense of responsibility for
any type of problem due to utility supply.

VIYELLATEX GROUP
EFFLUENT TREATMENT PLANT
CHEPTER 09
VIYELLATEX GROUP

VIYELLATEX GROUP
The Effluent Treatment Plant:
The effluent generated from different sections of a textile mill must be treated before
they are discharged to environment. Various chemicals & physical means are introduced for
this purpose. The effluent treatment plant in VIYELLATEX GROUP. is chemical
biological combination process.
Objects:
This process is provided for treating the effluents of dyeing, printing,
finishing, weaving & thus allow to discharge effluent as per by World Bank dept of
environment of Bangladesh.
Requirement of discharge effluent as per World Bank:
PH
: 6 – 8
BOD : < 50
COD : < 250
SS : < 100
TDS : Not stated
Colour : Clear
Consumption of the chemical used:
Chemical Name Chemical Used
H2SO4 & HCl 25 Kg/day
Alam 250 Kg/day
Polymer 0.5 Kg/day
H3PO4 250 ml/day
Urea 3 Kg/day
Product Quality Check:
Following chemical tests are carried out to check the quality:
- BOD
- COD
- Total suspended solids
- Total dissolved solids
- Colour
- PH
Typical Output of the Plant:
Raw effluent colour Black
Raw effluent pH 11
Treated effluent colour Light greenish
Treated Effluent pH 6-6.5
Treated Effluent Temp 380
C

VIYELLATEX GROUP
Sketch of the ETP is given below:
Equalization
Tank Coagulant
Tank
Tube
Satalor
Erasion
Tank
Filter
Reserve
Tank
Circulation
Tank
Flow Chart of Effluent Treatment :
Raw effluent
Equalization Tank
Coagulant Tank
Tube Satalor
Aiartion tank
Circulation Tank
Reserve Tank
Filter
Sludge Separation:
Sludge of Tube Satalor
Sludge thickening plant
Sludge drying be

VIYELLATEX GROUP
STORE AND INVENTORY CONTROL
CHEPTER 10
VIYELLATEX GROUP

VIYELLATEX GROUP
Inventory Control:
Store is the place where every type of raw materials, spares, finished goods are kept
in proper system. Inventory control means the accurate calculation and data of every type of
raw materials spares and finished goods in time to time store 4 inventory control are
necessary, because –
1. To know about the required amount of raw material
2. To know about the job no – which would be processed
3. To be continued the production process
4. To find out the profit or loss of a company
5. Stock and stock value for consumption measuring
Frequency of Inventory Update:
- Monthly inventory control.
- Annual inventory control.
Scope of Inventory Control:
- Raw materials
 Dyes store.
 Other chemicals.
 Grey fabrics.
- Finished fabric.
- Spare parts.
- General store:
 Capital equipments.
 Accessories.
 Stationary.
 Maintenance parts.
Inventory System for Raw Material:-
 Raw materials partially received from production planning & directly from head office.
 Material receiving & inspection report (MRIR) is prepared. Received quantity is
mentioned and noted down.
 Submitted to Q.C. 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 are noted down.
In VIYELLATEX GROUP LTD. there are different inventory systems for different raw
materials.

VIYELLATEX GROUP
Grey Fabric Store:-
All the grey fabrics are stored in the fabric store near the batch section. Different types
of fabric are listed in the sheet according to fabric types, quantity and consumer’s
requirement. Fabrics GSM, shrinkage, diameter & other properties are also taken into
consideration. The batches are prepared by taking the required fabrics from the grey store.
Stages of Grey Fabric Inventory Control:
 After knitting production.
 Grey inspection.
 Warehouse.
 Batch preparation.
 Dye house.
Dyes And Chemicals:-
There is a different store for dyes and chemicals. Varies types of dyes and chemicals are
stored here according to dyes and chemicals companies. Different types of dyes and
chemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are also
included. Every day the sheet is updated and a copy of this sheet is supplied to the dyeing
manager, dye house and lab section.
Spares:-
In VIYELLATEX GROUP LTD. required amount of spears of different machines are
stored in the mechanical store room. All the spears are listed in a sheet which is controlled
by the mechanical & maintenance personnel. Spares are arranged in the store room
according to there size, quantity & requirements. There are shelf's in the store room to keep
the small spare parts.
Finished Goods:-
VIYELLATEX GROUP LTD. supplies its finished dyed fabrics to its garments
section. So, dyed finished fabrics are stored for short time in the finishing section. All the
delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics
diameter, buyer's name, Color & considering other technical parameters.
Stages of Finished Fabric Inventory Control:
 Finishing section.
 After final inspection.
 Warehouse.
Others:
There is a central store at VIYELLATEX. In that store the various types of
forms, papers; stationary & other necessary goods are kept.

VIYELLATEX GROUP
Inventory Procedure
 Bin Card
 Store Requisition
 Store Ledger Account
 Daily Inspection & Package Report
 Monthly Stock & Consumption Report
 Monthly L/C wise Delivery Report
 Received Delivery & Balance Stock
Remarks:-
VIYELLATEX GROUP. has individual stores for raw materials, finished goods etc.
There is not enough space to store the finished goods. It requires increasing the store area.
In VIYELLATEX GROUP. the store for inventory control is satisfactory. Sometime, they
fluctuate from ideal process otherwise they are ok.

VIYELLATEX GROUP
COSTING
CHEPTER 11
VIYELLATEX GROUP

VIYELLATEX GROUP
Introduction:
Costing is a process by which the setting price of a product is calculated. It is a very
important task for a factory which runs for business purposes.
And it is also strictly followed in the VIYELLATEX GROUP. Costing of the products
considering the raw materials expenditure, salary and wages of officers and workers,
distributions and advertisement expenses etc. all direct and indirect expenses is done in this
factory. It is determined by a troop of accountants with advice and consultancy of executive
director.
Costing Of the Product
The following points are considered for costing any dyed product in VIYELLATEX.
1. Total dyes & chemical cost
2. Total utility cost
3. Salary
4. Payment
5. Transport cost
6. Lunch
7. Entertainment cost
8. Miscellaneous cost
9. Government cash incentive
Price of the Product:
Generally price of product is determined by the required profit adding to the total
expenses. So,
Price of products= (Direct expenses + Indirect expenses + Factory
Overhead) + Required profit
Price Range of Different Products:
T-Shirt = $0.75 - $4.50 /Pcs
Polo Shirt =$2.00 - $6.50 /Pcs
Kids Wear ==$0.75- $2.15 /Pcs
Knitting Charge of Different Fabrics:
Fabric name Charge per
kg(Tk)
1. Single Jersey 09
2. Single Jersey with Lycra 30
3. Single locust PK 16
4. Double lacost PK 16
5. Single PK 16
6. Double PK 16
7. Rib 17

VIYELLATEX GROUP
8. Rib with Lycra 30
9. Interlock 25
10. Auto striper 80
11. Auto striper with Lycra 100
12. Fleece 22-25
Dyeing Charge of Different Fabrics:
Name of fabric process Charge per
kg(Tk)
1. White with Enzyme 35
2. White without Enzyme 30
3. Avg. color with Enzyme 85
4. Avg.color without Enzyme (Light&
med.)
75
5. Deep shed with Enzyme (Black) 110
6. Deep shed without Enzyme (Black) 95
7. Only wash (Tubular) 25
8. Only wash (Open) 45
9. Double dyeing (Face & Back) 115
Finishing Charge of Different Fabrics:
Name of fabric process Charge per
kg(Tk)
1. Slitting only 5
2. Stenter only 25
3. Compacting only 15
4. Stenter + Compacting 35
5. Stenter + Compacting+ wash 50
6. Tube Compacting 10
Costing Of the Product:
Let price of yarn is $ 3.00/ kg.
Process loss of yarn for knitting (10%) = $0.30
Knitting fabric cost = $3.30
Cost of dyes & chemicals = $2.50
Process loss for dyeing (12%) = $0.30
Dyed fabric cost = $ 6.10
Packing cost = $0.05
Production cost of fabric=$6.15

Industrial attachment of viyellatex group

Industrial attachment of viyellatex group

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