Industrial report on dyeing-finishing section MKCL

Report on Industrial Attachment of dyeing & finishing section

At MEGHNA KNIT COMPOSITE LTD.

Prepared by

NAME DESIGNATION DEPARTMENT MOBILE NO MD. SIRAJUL HAQUE SAJIB Executive Dyeing finishing 01798035354 SHEK SADI Executive Dyeing finishing 01681714038 MOHAMMAD AL IMRAN Executive Dyeing finishing 01682608036

Submitted to:

MD. AMINUL ISLAM

B.Sc. in Textile Engineering (DU), MBA (IIUC)

Manager (Dyeing Finishing), MKC

[email protected]

Mobile no: 01758563556, 01912527128

mailto:[email protected]

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CONTENTS

Sl. No Content Pg. No

01. General information 03

02. Buyers 04

03. Physical infrastructure and organogram 05

04. Management system 06

05. Batching 07

06. Dyeing lab 08

07. Dyeing section 14

08. Dyeing curve of several dyeing process 17

09. Finishing section (Production and QC) 25

10. Quality Assurance system 29

11. Conclusion 32

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General information about MKC

Name of the Company Meghna Knit Composite Ltd. Type

100 % Export Oriented Composite knitwear Industry

Factory Address:

Gilarchala, Sreepur, Gazipur, Bangladesh.

Contact No +880-2-9854591-6 E-mail Address [email protected] Year of Establishment 2006 Business 100% export oriented knit fabrics

manufacture & readymade knit garments exporter

Products Knit Fabrics & Knit Garments No. Of employees (dyeing & finishing) 415 Legal Form of Company Private Limited Company.

Product mix

01. Single jersey

02. Lycra single jersey

03. Terry

04. Fleece

05. 1X1 Rib

06. 2X1 Rib

07. 2X2 Rib

08. 5X2 Rib

09. Interlock(Waffle)

10. Design S/J

Fabric quality

01. 100% Cotton

02. Modal Cotton –

03. Organic Cotton (Bio Cotton)

04. PIMA Cotton

05. CVC

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06. PC

07. 100% Viscose

08. Cotton Lycra

09. Grey Mélange

10. Ecru Mélange

11. Cotton slub

12. Yarn dyed

13. Organic slub

Buyers

Serial no Name of buyers Origin 01 Next United Kingdom 02 H&M Sweden 03 Marks & spencer(M&S) United Kingdom 04 Peek & Cloppenberg(P&C) Germany 05 Tesco PLC England 06 Cubus Norway 07 Mayoral United kingdom 08 Dressmann Norway 09 C&A Belgium 10 Decathlon France 11 RBSR BD 12 Multi Fabs BD 13 Park scene BD 14 Cross line BD 15 Shad fashion BD 16 Jumer Fashion BD 17 LC Waikiki Turkey

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Physical Infrastructure

Organogram of Dyeing and Finishing section

MKC

Knitiing

Dyeing & Finsishing

Production

Q.C

Garments

Admin

Maintenence

Marketing & merchandizing

GENERAL MANAGERPRODUCTION (01)

AGMPRODUCTION (01)

DYEING &FINISHING MANAGER(01)

Lab(AM & DM)

Batch(AM)

Dyeing(DM)

Finishing(AM)

Quality(Sr.Executive)

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Management System In MKC all the necessary administrative decisions are given my Managing Director which are rendered to all other officers by Executive Director and Technical Director. All the Management officials and staffs are highly skilled and dedicated to their work. So the management system of MKC is work efficient and regular. Shift Change: The industry has three shifts. They are: 1. Shift 01 Duration: 8 Hours.

2. Shift 02 Duration: 8 Hours.

3. Shift 03 Duration: 8 Hours. Workers get one-hour break time. Shift change depends on the work order and production. There is a supervisor in every shift who takes the working activities & understands his responsibilities from previous supervisor during shift change. Responsibilities of Production Officer: The responsibility of a Senior Production Officer / Production Officer is to control and supervise processes. They are also responsible to maintain a healthy working environment and maintain good relation with superior management officials and with the workers. It is a responsibility of a Senior Production Officer / Production Officer to achieve target production in required time. When any fault or defects is found in product, the blame goes to Senior Production Officer / Production Officer. A Senior Production Officer / Production Officer must find ways to minimize overhead expenditures and also try to make a batch more profitable. Being in-charge of the floor it is his responsibility that the production process is efficient and smooth.

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Batching

Batching is the receiving section of grey fabric and sending section of grey

fabric to the dyeing section which will dye. Batching is the process to get

ready the fabrics which should be dyed and processed for a particular lot of a

particular order.

Two types of Batching:

1. Solid

2. Assort

Batch contains body of garments as well as collar-cuffs according to the

design.

Required Quantity = 𝐵𝑎𝑡𝑐ℎ 𝑄𝑢𝑎𝑛𝑡𝑖𝑡𝑦

𝑇𝑜𝑡𝑎𝑙 𝑄𝑢𝑎𝑛𝑡𝑖𝑡𝑦× 𝐷𝑖𝑎 𝑄𝑢𝑎𝑛𝑡𝑖𝑡𝑦

For Solid batch only the fabrics of same diameter along with the collar/cuffs

will be considered. For Assort the fabrics of all diameters along with the

collar/cuffs will be considered.

Machine Used In the Batching Section

M/C Name: Air Turning Machine

No of M/C: 02

Company: DONGNAM Industrial Co., LTD. South Korea

M/C Name: Bag Sewing Machine

No of M/C: 02

Company: Hsing Cheng, Taiwan

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Dyeing Lab

SL No.

Machine Name Manufacturer Name Remarks

01. GyroWash James heal, UK Washing Machine

02. Wascator Electrolux, Sweden 03. Wascator Electrolux, Sweden 04. Dyna Wash James heal, UK 05. Siemens Siemens, Turkey 06. Electrolux Tumble Dryer Electrolux, Sewden

Dryer 07. Acudryer James heal, UK 09. Whirlpool Tumble Dryer USA 10. GSM Cutter Made in Bangladesh 11. Sewing M/C Single Needle 12. Sewing M/C Over lock 13. Shrinkage Template SDL, UK 14. Shrinkage Ruler SDL, UK 15. Incubator SDL, UK 16. Perspirometer (ISO &

AATCC) SDL, UK

17. Solution Stirrer Made in Korea 18. PH meter USA 19. Orbital Shaker (PH) Germany 20. Crocking Meter SDL, UK 21. Tru Burst James heal, UK 22. Titan James heal, UK 23. Orbitor Pilling M/C James heal, UK 24. Vervide Light Box Verivide, UK 25. Pilling Assessment

Viewer James heal, UK

26. Pilling Assessment Viewer

James heal, UK

27. Digital Weight Scale Ohaus, USA 28. Data Color China 29. IR dryer lab dyeing China 30. Ahiba lab dyeing USA 31. Mathis lab dyeing Switzerland 32. Water Heater Local

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Colorfastness to Rubbing

Test Specimen

Two pieces not less than 14cm × 5cm are required for dry rubbing and two for

wet rubbing. One specimen of each pair shall have the long direction parallel to

the wales (length) and the other parallel to the courses (width).

Test Procedure:

A. Dry rubbing

01. Lock the test specimen onto the base of the crock meter. The length or

width direction of the test specimen should be parallel to the direction in

which the rubbing is to be conducted.

02. Set a 5cm×5cm rubbing cloth on the figure of the crock meter by using

spiral clip. The weave of the test cloth should be parallel to the direction of

rubbing.

03. Lower the covered finger onto the test sample & make ten complete turns

of the crank, at the rate of one turn per second.

04. Remove rubbing cloth from the finger evaluate it for staining using grey

scale under standard light source (D65).

05. One test is done for lengthwise & another for widthwise.

B. Wet rubbing

01. All the process same as dry rubbing here rubbing cloth needs to be wetted

in distilled water& ensure 100% water take up (i.e. 1 gm. fabric weight

increased to 2.0 gm. after wetting).

02. Air dries the rubbing cloth at room temperature before evaluation.

Buyer’s Requirement

Buyer Dry Rubbing Wet Rubbing CUBUS 4(3-4) 2 H & M 4 2-3 Next 4 N/A C & A 4(3) 3-4(2) Tesco 4 3

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Colorfastness to Wash

Test Specimen

Cut out a specimen of 10 cm × 4 cm and make sure all colors are included in it.

Sew it along all four edges with the same size of multi-fiber fabric.

Test Procedure (Method Followed: ISO 105 C06 B2S)

1. Put the test specimen in a solution of 4g/L ECE Detergent & 1 g/L

Sodium Per borate with 25 steel balls at a ratio 1:50 and treated for 30

minutes at 500C.

2. Then Wash with distilled water for 1 minute.

3. Then wash with tap water for 1 minute.

4. Then dry in normal air.

5. Assess the change in shade & degree of staining with grey scale.

Buyer Requirement

Buyer Grading Washing CC, CS

4, 4-5 CUBUS

Color Staining

AC

3-4 Next CO 4.0

H & M NY 3.4 C & A PO 3.4

TESCO AC 4 Wo

Color Fastness to Perspiration

Test Specimen

Cut out a specimen of 10 cm × 4 cm and make sure all colors are included in it.

Sew it along all four edges with the same size of multi-fiber fabric.

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Reagent

Name Alkali Acid l-Histidine mono-hydrochloric mono-hydrate (C6H9O2N3HCl.H2O)

0.5 gm 0.5 gm

Sodium Chloride 5.0 gm 5.0 gm Disodium hydrogen orthophosphate dihydrate (Na2HPO4.2H2O)

2.5 gm 2.2 gm

Distilled Water 1000 ml

1000 ml

PH ( Adjust with 0.1N NaOH) 8.0 5.5

Test Procedure (Method Followed: ISO 105 E04: 1994)

1. Wet out the test specimen in perspiration solution at room temperature

, liquor ratio 1:50 and leave for 30 minutes

2. Pour off excess solution and place this composite test specimen

between two arylic plates under a pressure of 12.5 kPa and then place

in an oven for 4 hours at 37±20C.

3. Remove the specimen and hang to dry in warm air not exceeding 600C.

4. Evalute with grey scale.

Buyer Requirement

Buyer Grading Washing CC, CS

3-4, 4-5 Acid

Alkali

CUBUS Color Staining

AC

4 Next CO N/A H & M NY 3.4 C & A PO 3.4 TESCO AC -

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Dimensional Stability to Washing

Test Specimen

The minimum size for a stability square is 50 x 50cm. testing on smaller pieces

is not acceptable. Lay the fabric to relax for 4 hours on a bench in ambient

conditions so that it is smooth and tension free. Do not use the fabric within

5cm of the selvedge. Place the template on the fabric with the side of

the template parallel to the length (warp) direction. Mark the three width and

length marks in pairs 35cm apart, (see additional notes below for different

fabric types). Draw around the edge of the template, do not round off the

corners.

Draw an arrow outside the measurement area, to denote the length (warp)

direction prior to cutting from the main piece.

Template

Test Procedure

01. After 4 hours conditioning mark the fabric with template for both

(border to border & hole to hole).

02. Sew it along 3 side & one side is kept open in length side.

03. Treated with 25g/L Persil for 40 minute at buyer recommended

temperature.

http://garmentstech.com/wp-content/uploads/2014/01/Dimensional-stability-Sample-Marking.png

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04. Line dry.

05. Condition for 4 hours.

06. Measure (distance form hole to hole measured and average is taken).

Buyer requirements

Buyer Dimensional Stability to Washing (%)

Length (%) Width (%) Spirality (%)

CUBUS ±5 ±5 ≤5 NEXT S/J (-6), Rib (L-6 & W-8), Fleece (L-6 & W-8), Other Ly.(

L&W-5), Lycra S/J (L&W = -6) ≤5

H&M ±5 ±5 General ≤5 & Trouser ≤8

C&A -6.0, +2.0 -6.0, +2.0 Maximum 5 TESCO -7, +1 -9, +1 5

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Dyeing

Layout of dyeing section

Layout of finishing section

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Lists of machines in dyeing section

Lists of chemicals used in dyeing section

01. Anti-foaming agents i.e.: Anti formasol UDF

02. Detergents i.e.:Shunsol SCL

03. Anti-creasing agents i.e.:HK-208

04. Leveling agnets i.e.:Optavon4-UD

05. Stabilizers i.e.:Stabilizer SOF

06. Hydrogen peroxide killer i.e.:Bactosol SAP

07. Washing off agents i.e.:Persopon RSK

08. Enzyme i.e.:Mega PK 2

09. Brighteners i.e.:Syno white -4BK

10. Fixers i.e.:Albafix-ECO

11. Softeners i.e.:Sapamine-SCN

12. Silicon softeners i.e.:Megasoft-CEC, power soft

13. Neutralization agents i.e.:Invetex AC

Name of Machine Brand Origin Qty. No of nozzles Capacity

Dyeing (sample) Fong’s China 05 01 10 kg

Dyeing (sample) Fong’s China 02 01 30 kg

Dyeing (sample) Sclavos Greece 03 01 50kg

Dyeing m/c Fong’s China 02 01 250 kg

Dyeing m/c Fong’s China 01 02 500kg




Dyeing m/c Sclavos Greece 01 01 250 kg



Dyeing m/c Thies China 01 06 1500kg

Hydro m/c HzD-00 China 02 n/a

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14. Sequestering agents i.e.:Optavon SV

15. Teflon

16. Stiffening chemical i.e.:Polppred HNH

17. Finishing agents i.e.:Solusoft SIH

18. Anti-yellowing agents i.e.:Unidof APY

19. Caustic soda

20. Glober salt

21. Soda ASH

22. Acetic acid

23. Hydroze(BASF)

24. Hydrogen peroxide

25. Dyeing chemicals :

a. For natural fibers: Drimarine, Lavafix, Remazol, Sunfix,

sunzolNovacron, Avitera etc.

b. For polyester : Univadine(chemical), Foron, Terasil,

Coraline, Coralete lumi etc.

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Dyeing curve of several dyeing process in dyeing lab

01. CVC (Both Part Dyeing)

A. POLYESTER PART

Dyeing

1300C ×45 Min

Dye

1 2 3 700C 30’ BD

(600C × 10 Min)

PH = 4.5

1. Acetic –Acid

2. Levelling – DIF

3. Buffer –AB-45

B. COTTON PART

Demineralization

1 2 3 Demineralization (600C×10min)

BD

1. Detergent –SCL

2. Anti-Creasing –HK-208

3. Sequestering – 2UD

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Scouring & Bleaching

98oC

(Scouring & Bleaching) 1 hour

1 2 3 4 5 6 60oC

5min Bath Drain

H2O2 & Caustic

1. Anti-foaming –UDF

2. Detergent- SCL

3. Anti-creasing-HK-208

4. Sequestering -2UD

5. Levelling -PP

6. Stabilizer – SOF

Bio-Polishing

A. Acid (600C × 10min)

Peroxide Killer – SAP

(450C × 15 Min)

Acid + Enzyme

(550C × 1hr)

700C × 10’

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Dyeing

After-treatment

Neutralization

Acetic-Acid = 400C × 20 Min

Soaping (Depend on Shade)

Soaping –RD = 900C × 10 Min

Fixing (If Required)

Fixing – ECO = 400C × 20 Min

100% VISCOSE

Pretreatment

1 2 3 4 5 (900C × 30 Minutes)

M/C Temp. BD

1. Detergent-SCL

2. Anti-creasing – HK- 208


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4. Soda Ash

5. Oil remover – TLK

Neutralization

Acetic-ACID ( 600C × 20 Minutes)

Dyeing

10% 30% 60% 10% 30% 60%

Dye Salt Salt Salt Soda Soda Soda

1 2 3 4

600C × 15’

1hr 15’ 10’ 15’ 20’ 15’ 20’ 25’

M/C Temp.

PH = 6

1. Anti-Creasing-HK-208

2. Levelling –PP

3. Levelling ARI

4. Levelling E3R

After-treatment

Neutralization






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CVC (Polyester Part Dyeing) M:L = 1:10

98oC


1 2 3 4 5 6 60oC

5min Bath Drain

H2O2 & Caustic


2. Detergent- SCL



5. Levelling -PP


Bio-Polishing



(450C × 15 Min)

Acid + Enzyme

(550C × 1hr)

700C × 10’

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Dyeing

1300C ×45 Min

Dye

1 2 3 700C 30’ BD

(600C × 10 Min)

PH = 4.5

1. Acetic –Acid

2. Levelling – DIF

3. Buffer –AB-45

After treatment

Reduction Cleaning:

700C / 800C × 10 Min.

Caustic (1.5g/L)

Hydrose (1.5g/L)

Neutralization: 400C × 20 Min., Acetic Acid (1g/L)

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AVG. COLOR M: L = 1:10

Demineralization

1 2 3 Demineralization (600C×10min)

BD

1. Detergent –SCL

2. Anti-Creasing –HK-208


Scouring & Bleaching

98oC


1 2 3 4 5 6 60oC

5min Bath Drain

H2O2 & Caustic


2. Detergent- SCL



5. Levelling -PP


Page | 24

Bio-Polishing

After-treatment

Neutralization








(450C × 15 Min)

Acid + Enzyme

(550C × 1hr)

700C × 10’

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Finishing section (Production and QC)

List of machines in finishing section (production & Quality)

M/C#01: Slitting m/c

Brand: Bianco

Origin: Italy

No of m/cs: 03

Specification: Padder pressure up to 80 meter/min

Functions:

01. Open tubular fabric

02. Application of finishing chemicals in padder

03. Squeezing of excess water from fabric

M/C#02: Stenter machine

No of m/c: 3

Brand: Bruckner

Origin: Germany

Specification:

01. Bruckner 01: Chember-06

Blower-24

Burner-12

02. Bruckner02: Chember-08

Blower-32

Burner-16

03. Hasgroup03(TTM): Chember-08

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Blower-32

Burner-16

Functions of stenter m/c:

01. Heat setting

02. Drying

03. GSM control

04. Fabric width control

05. Dimensional stability

06. Application of softener

07. Chemical curing

08. Skew and bow control

09. Weft straightening

Parameters:

01. Temperature (can be raised up to 210 degree Celsius)

02. Time

03. Machine speed

04. Overfeed

05. Width of the fabric

06. GSM of the fabric

07. Padder pressure

M/C#3: Compactor machine

No of m/c: 02

Brand: Lafer

Origin: Italy

Functions of compactor m/c:

01. Shrinkage control

02. GSM control

03. Fabric width control

04. Dimensional stability

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05. Calendaring/ironing

Parameters:

01. Temperature (can be raised up to 210 degree Celsius)

02. Time

03. Machine speed

04. Overfeed

05. Width of the fabric

06. GSM of the fabric

M/C#4: Fabric inspection table

No of m/c: 04

Brand: UZu

Origin: Thailand

Functions of fabric inspection m/c:

01. Faults identification

02. Width checking

03. Shade matching

04. Final checking before sending to cutting

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Parts of machine to be maintained used in dyeing & finishing section

Mechanical:

01. Line clean m/c

02. Lubrication

03. Air pressure

04. All belt

05. Bearing

06. Gearbox

Electrical:

01. Inverter

02. Motor

03. Fabric lamp

04. Panel board

05. Auto stopper

06. Wearing and fuse

07. Electrical safety

08. PLC card

09. Circuit breaker

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QUALITY ASSURANCE SYSTEM

After collecting fabric rolls from different m/cs, they are 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. The quality assurance department is assigned to maintain consistently uniform quality of the material in process & various stages of its manufacturing. Objects of quality control 01. Process control 02. Process development 03. Product testing In Dyeing section:

01. After approval from the buyer, sample dyeing is done in dyeing m/c, in dyeing shed & again matched with the approved sample.

02. If result is OK, then balk production is commenced. 03. During dyeing process, before the final acid wash, samples are taken

and checked for accurate shade matching. 04. After dyeing sample is collected & matching is done. 05. Rubbing and wash fastness tests are carried out.

In finishing section:

01. Correctly dyed, after treated & matched fabrics are allowed for finishing.

02. By using a series of finishing machines correct width, softness & appearance are maintained according to requirements.

03. Then sampling is done several times to test GSM, Shrinkage & fastness properties.

04. Finally, fabric is inspected & prepared for delivery.

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Quality is specified on the basis of 4-points system Here is the point distribution for different kinds fault in this system: Up to 3” in length: 1 point 3” to 6” in length: 2 point 6” to 9” in length: 3 point Over 9” in length: 4 point Quality pts. / Per 100 square meter= 𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑖𝑛𝑡×𝐺𝑆𝑀/( Roll weigth×10)

Shade check: The shade achieved is to be checked several times while in process & at finished state to ensure the customers demand under recommended light source. Generally, the shade is checked at the following stage -After dyeing -After drying -After trial for finishing -After finishing

Grey Fabric Faults:

01. Hole

02. Barrie mark

03. Oil spot

04. Contamination of foreign particles

05. Bowing in case of stripe fabrics

06. Inadequate pressing

07. Unwanted marks on fabric

08. Pin holes

09. Sanforize pucker

10. Pressing producing shine on fabric

11. Folding defects

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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. Fly & contamination Acceptable for color but not for white 7. First round problem Reject 8. Uneven tension Discuss with manager 9. Missing yarn Reject 10. Crease line Reject 11. Rust line Reject 12. Oil Stripe Reject 13. Thick-thin Reject 14. Wrong tube Reject

Remedies:

01. Identical dyeing procedure should be followed for the same depth of the

Shade and batch.

02. Ensure proper heat setting for lycra/synthetic fabrics 03. The pH, hardness and sodium carbonate content of supply water should

check daily. 04. Proper machine speed in slitting m/c, stenter m/c and compactor m/c

Proper mixing of softener chemicals 05. Definite temperature maintenance for definite fabrics 06. Online gsm, fabric width check during passing through

sterner/compactor 07. Other finishing parameters such as shrinkage, spirality , bursting

Strength, phenolic test, fastness tests etc. should be checked during

operation to maintain desired quality of the fabric

Page | 32

Conclusion

Industrial attachment will give us our expected destiny of practical life. By the

completion of 1 week of Industrial attachment at MKC, we have got the

impression that the factory is one of the most modern export oriented knit

composite in Bangladesh. Though it was established only 10 years ago, it has

earned “very good reputations “for its best performance over many other

export oriented textile mills. During observations, following problems were

detected

01. During the transportation of the fabric on the dyeing floor & also during

the loading of the machine, fabrics are soiled by the contact with floor.

This makes the fabric/part of the fabric dirty.

02. It may require more dyeing/finishing agent or may create stain, less

finish requirements etc. making it faulty.

03. The- dyeing & finishing floor is watery most of the time. It should be

kept clean all the time.

04. Many time the dosing pipelines are clogged due to the careless dosing

of the chemicals. The supervisors should supervise the floor more

sincerely.

05. The machine stoppage time should be analyzed & minimized. The

maintenance should be carried out when the machine is out of action

(wherever possible).

During the observation period we have received co-operation & association

from the dyeing & finishing floor’s full & found almost all man, machines &

materials on appreciable working condition. All staffs & officers were very

sincere & devoted to their duties to achieve their goal.

Documents

Industrial report on dyeing-finishing section MKCL