PREPARED BY AL-AMIN KHAN.docx

TEX-426 & 428: INDUSTRIAL TRAINNING & PRACTICES

Department of Textile EngineeringOn

Aboni Textiles LimitedHemayetpur, Savar

Department of Textile EngineeringPRIMEASIA UNIVERSITY

Prepared By:MD. ALAMIN KHAN ID-101-196-041

ACKNOWLEDGEMENT

DAFFODIL INTERNATIONAL UNIVERSITY has given us the opportunity to perform the industrial attachment with Aboni Textile Limited (A concern of Babylon Group).We would like to convey our deep gratitude to our departmental head Prof. Dr. Md. MahbubulHaque for his throughout support without whose help it would not have possible to complete the training successfully. We are grateful toMd. Azharul Islam for supervising us to accomplish the attachment. May we also take the opportunity to express my sincerest gratitude toAboni Textile Limited (A concern of Babylon Group)management, and administration & personnel for their kind co-operation.Above all, we would like to acknowledge our deep debt to all teachers of our university especially of Fabric Manufacturing Technology department for their kind inspiration and help, which remain as the backdrop of all our efforts. Finally, we would like to acknowledge that we remain responsible for the inadequacies and errors, which may remain in the report undoubtedly.

INTRODUCTIONCHAPTER-1

INTRODUCTION:

By achieving practical knowledge it is possible to apply the theoretical knowledge in the technical field. For any technical education, practical experience is almost equally necessary in association with the theoretical knowledge. The industrial attachment is the most effective process of achieving the practical experience. It provides us sufficient practical knowledge about production management, productivity, evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory control, purchasing, utilities and Maintenance of machinery and their operation technique etc.

Industrial attachment is an essential part of four years B.Sc. in Textile Engineering as a course of Daffodil International University. We had the opportunity to perform the industrial attachment with ABONI TEXTILES LTD. During 45 days long attachment, we studied the man, machine, material aspects of the circular knitting section, knit dyeing section ,quality control section, planning section, grey fabric inspection. According to my studies there I have prepared the following report and would like to present.

CHAPTER-2

COMPANY PROFILE

Inside view

Outside view

Company ProfileSerial no.Subjectsdescription

1.NameAboni Textiles Ltd

2.Type100% Export Oriented Composite Knit Industry.

3.Legal Form of CompanyPrivate Limited Company.

4.Year of In corporation2001

6.Location

Hemayetpur, Savar,Dhaka, Bangladesh.

7.Certification & awardsB.S.C.IISO 9001:2000 OKO-TEX

8.

Production capacityProduction capacity per month (Garments) 78000 Doz. T shirt24000 Doz. Polo shirt17000 Doz. Sweat shirt / Jacket60000 Doz. Short / TrouserProduction capacity per month (Knitting Section) 1,50,000 Kgs Single Jersey / Pique1,00,000 Kgs Interlock1,00,000 Kgs Freeze1,00,000 Kgs RibProduction capacity per month (Dyeing Section)200 240 M. Tons

9.

Working Period

3(Three) shifts Per Day

Company DetailsPrimary Information

Company Name :ABONI TEXTILE LTD.

BKMEA Membership Number :624

Membership Type :Ordinary Member

Year of Registration :2002-03-13

Contact Information

Contact Person Name :MR. S. M. EMDADUL ISLAM

Contact Person Designation :Managing Director

Addresses :FactoryAddress :PLOT-169-171,UNION-TETULZHORAHAMAYETPUR,SAVARTelephone :88-02-8023495-6, 8013449Fax :88-02-7713502Office Address :2-3/1,DARUSSALAM ROAD,MIRPUR,DHAKATelephone :88-02-7713652Fax :88-02-8015128Email :[email protected] :www.babylongroup.com

Factory Information

Factory Category :B

Number of Machine :KNITTING : 68DYEING : 14

Production Capacity :300 TON/MONTH

Number of Employee (Workers) :Male: 500 | Female: 0 | Total :500

Yearly Turnover (In US$) :0

ABONI TEXTILE LTD is a sister concern group of Babylon Ltd. With a vision to transform the group into a self sufficient 21st century conglomerate, Babylon has diversified its products and services gradually and expanded to 18 strategic business units (SBU). All the units are controlled from the headquarter based in Dhaka which ensures integrated and smooth operation. It also enables Babylon to offer competitive price to its customers.

Babylons 18 strategic business units (SBU)are : Babylon Garments Ltd. Babylon Dresses Ltd. Suravee Garments Ltd. Aboni Fashions Ltd. Babylon Casual Wear Ltd. Aboni Knitwear Ltd. Aboni Textiles Ltd. Juniper Embroideries Ltd. Babylon Trims Ltd. Babylon Washing Ltd. Babylon Printers Ltd. TRENDZ (Local Retailing) Babylon Buying Services Ltd. Babylon Medical Services Babylon Outfit Ltd. Babylon Logistics Ltd. Babylon Products (Softy) Babylon Agriscience Ltd.BOARD OF DIRECTORS :Consists of the following members

1. Mr. Neesar Ahmed - In charge of IMPORTS & ADMINISTRATION2. Mr. Emdadul Islam - In charge of MARKETING & QUALITY CONTROL3. Mr. Moinul Ahsan - In charge of FINANCE4. Mr. Abidur Rahman - In charge of EXPORT & EMBROIDERY DIVISION5. Mr. Abdus Salam - In charge of BABYLON TRIMS LTD.

History of the Project Development:Aboni Textiles Ltd. a 100% export oriented composite knit textile unit established with the commitment to contribute to the Global needs for knit and casual clothing. Aiming at the context of the changing Global demand pattern, international environment on trade specially the withdrawal of quota system. The project is comprising with the Knitting, Dyeing and Ready-made Garments production available from one stop service. We ensure to supply of finished RMG all from one source, in time delivery and complying quality. The machines and equipments setup for these projects are procured from world-class brand, names renowned for their high quality, product integrity and dependable production.The Project is established in 2001. The manpower engaged in the Projects all highly skilled, purely professional, and vastly experienced. The unique combination of organized Managerial and Technical team in one hand and latest, advanced and balanced technology on the other hand made the project on of the top to be referred in this field in the Country. The best use of continuous development of Human Resources by providing them International Standard Environment and equal opportunity is the keys for achieving comprehensive competence in all the level.Aboni Textiles Ltd. has been established with the objective and vision to meet the needs of 21st century of world wide knit apparels market from one stop service being committed to On-time Delivery, Short Lead Time, Quality Assurance, Price Affordability and Social AccountabilityMission & vision of the company:Aboni Textiles Ltd. is a prominent developing composite Knit Garments in Bangladesh. Started its journey with circular knitting section in the year of 2001. As its 2nd phase Dyeing Section started in 2002 with the capacity of 8,000-10,000kg per day. And in the end of 2008 Garments Division commenced with 12 lines. All the above three divisions Knitting, Dyeing and Sewing are located in the same premises of about 3 acres land at hemayetpur, savar,Dhaka, Bangladesh. Its unic management body with experienced & qualified personals aim to establish the company as a brand name of top class Garments manufacturer in Bangladesh.

Different Department:

Knitting Dyeing (Knit). Finishing Garments. Washing

Supporting Department:

Personnel department Marketing and Merchandising Utility Human resource Department Accounting and financing

Major buyers of ABONI TEXTILE LTD:UK - TESCO , NEW LOOK .France - JULES, KIABI , MONOPRIX, CAMAIEU.Sweden - H & MSpain - ZARAItaly - TRR.

Capacity of ABONI TEXTILE LTD:The knit textile project has been designed with all European best Machinery and Technical know-how. The current capacity of the project is 15.0 tons per day for Knitting, 12.0 tons per day for Dyeing & 18 tons per day for Finishing. This project is having both tubular and with open-width facility.A modern and efficient composite knit textile industry equipped with hi-tech European Knitting, Dyeing, and Finishing Machinery. Aboni offers various types of high quality tubular fabrics including interlock, single jersey, pique polo, lacoste, rib, lycra rib, flat knit collar / cuff and many other varieties of structured fabrics and fashionable garments.Aboni now also offers stentering, compacting, and calendaring of open width fabrics and is equipped with 100% Cotton, T/C, CVC, Polyester & Spandex mixed fabric finishing facilities.Location Of ABONI TEXTILE LTD In Google Map:

Image-Location of ABONI TEXTILE LTD

CHAPTER-3

LAYOUT OF THE COMPANY

Amtoli BazarAJI groupDhaka Aricha Main RoadHallmark groupAmin BazarENWSAboni Textile LtdAboni fashion LtdButton Tex LtdAKH groupAboni Textiles Ltd. Location layoutSadat Composite Knit Industries LtdSadat Composite Knit Industries LtdSadat Composite Knit Industries Ltd, LOCATION LAYOUT

CHAPTER-4HUMAN RESOURCE MANAGEMENT

A. Recruitment Policy: .Recruitment is done as per following systems. Serving notice/poster in important locations. Personal contacts by own employees. Head hunting for manager/executive

B. Selection: During the selection of the workers following factors are considered: Good physical appearance/fitness Age 18 years minimum must be supported by certificate from educational institution or local govt. authorities and confirmed by medical officer. Educational qualification as per job profile. Skill ness (practical for operators). Wages/salary negotiation. Joining date. C. Joining: Selected workers/trainees submit the followings to personal department on joining: Prescribed application form duly filled. Two passport size photographs. Educational certificate. Experience certificate (if any). Medical fitness certificate mentioning age. D. Service Confirmation: On completion of 3 months satisfactory job performance, company confirms the employees' service permanently. Trainees who fail to show satisfactory performance within this time his/her apprenticeship period are generally extended for another one month. If he/she cannot cope-up within this given period then his/her service is terminated.E. Daily Working Hours and Over Times: Eight hours a day from 8.00 am to 5.00 pm with one hour lunch break. Maximum two hours overtime per day (maximum 12 hours per week) with one-hour Tiffin break in the afternoon/evening. Friday is weekly holiday.F. Medical: Medical facilities are as follows: Each worker provided medical allowance @ Tk.200/= per month. Company also provides treatment with experience doctors. Company also provides medicine as required. First Aid facilities with trained first aider are available for each employee. Accident register for injured person is being maintained.

G. First Aid Box: Each floor has been provided with sufficient first aid box with following items: Pain relief tablets (Paracitamol). Nix. Or-Saline. Antiseptic cleaner (Savlon). Roller bandages Surgical gloves Surgical gauze. Cotton. Surgical scissors. Tourniquet. Adhesive tape (plasters). Antibacterial ointment sterile (Savlon cream).

OTHER FACILITIES:A. Salary & Wages: Salary and wages are paid to the staff and workers as per gazette notification of the government of Bangladesh. Payment of salary and wages are made regularly on 1st of each month. In the salary sheet basic salary, house rent, medical allowance and gross salary are shown separately for each employee.

B. Overtime: (1) Overtime is calculated on the basis of double the basic salary calculation of over time per hour is.Basic salary x 2 26 (days) x 8 (hours) (2) Payment of overtime is made of 1st date of each month. C. Bonus: Two festival bonus equivalents to two month basic salary are paid to each employee, Who has completed one year of service.D. Leave:(1) Casual: All employees enjoy 10 days casual leave in a year with full salary/wages.(2) Sick Leave: All staff & workers are entitle 7 days sick leave upon submission of medical certificate.(3) Maternity Leave: Female employees are entitled to enjoy 12 weeks (6 weeks before & 6 weeks after delivery) maternity leave with 100% salary/wages.(4) Earn Leave: For adult worker, 1 day leave for 22 days of work (but they have to work minimum 1 year for the entitlement).(5) Festival Leave: 10 days per calendar year.MANAGEMENT SYSTEM: Buyer sample is send to G.M or merchandising manager. Marching is done under lab manager. Sample is prepared by asst. dyeing manager. Sample is send to the buyer for approval. Approved sample is returned and taken as STD. sample for bulk production. Dyeing manager gives responsibilities to asst. dyeing manager. Then shift in-charge with the supervisors start bulk production. On line and off line quality check is done by lab in-charge and asst. dyeing manager. After dyeing asst. manager (finishing) controls the finishing process with the supervision of shift in-charge. Finally G.M checks the result with dyeing manager and decision is taken for delivery. SHIFTING:In Aboni Textiles Ltd the whole day production time is divided into 3 shifts. Per shift Consists of 12hours.

ShiftDuration

A8.00 AM-2.00PM

B2.00PM-10.00PM

c10.00PM-8.00AM

DUTIES & RESPONSIBILITY OF DIFFERENT POST:

Managing Director:

To deal with the buyer and merchandiser. To set up price for the product. To plan apply and control all administrative functions. To follow up the instruction of managing director and chairman.

GM in Dyeing and Finishing Section: Overall supervision of dyeing and finishing section. Check the sensitive parameters of different machines for smooth dyeing. Check the different log books and report to management. Check the plan to control the best output. To trained and motive the subordinates how to improve the quality production. Control the Manager, Asst. Manager, Senior Production Officer, Production Officer, in -charge, supervisor, of dyeing and finishing section

Deputy General Manager (DGM) production:

Overall supervision of dyeing and finishing section. Check the sensitive parameters of different machines for smooth dyeing. Check the different log books in different areas and report to management. Check the plan to control the best output To trained and motive the subordinates how to improve the quality production. Control the supervisor, operator, asst. operator and helper of dyeing machine. Any other work as and when required.

Manager:

To supervise the personal working under him To plan the sequence of production To arrange necessary raw materials for the production problems. To find out the possible reasons which are responsible for less production? To follow up the instruction of Managing Director and Executive Director as well.

Senior Executive:

Overall supervision of dyeing and finishing section. Batch preparation and pH check. Dyes and chemicals requisition issue and check Write loading/unloading time from machine. Program making, sample checking color measurement. Control the supervisor, operator, asst. operator and helper of dyeing machine. Any other work as and when required.Executive: To collect the necessary information and infrastructure from the previous shift for the smooth running of the section. To match production sample with target shade. To match production sample lot sample matching next production. To observed dyed fabric during finishing running and also after finishing process. To identify disputed fabrics and report to PM/GM for necessary action. To discuss with PM about overall production if necessary. T sign the store requisition and delivery challenge in the absence of PM To execute the overall floor work. To maintain loading/unloading paper.

Shift In charge:

To follow the workers movement. Should discuss with the production Officer about what is happening. To maintain the production sequence. To check the sample at certain time interval.

CHAPTER-5

PRODUCTION PLANNING & CONTROL

Basic Procedure of Production Planning &Control:A planned work brings success. Without planning nothing is complete within the required time. So planning has its own importance which is intolerable. Planning gives a scheduled task and control completes it successfully. But production planning and control is not an easy task. Its basic working procedure is as follows- Taking order form marketing division , Analyzing the orders Planning for knitting the fabric Planning for dyeing the fabric Planning for finishing the fabric

It is only a basic procedure. It may change according to the type of order. Sometimes the order is planned only for finishing the materials or only for dyeing the goods. Then some steps are minimizing for planning. Taking order from the marketing division:

ATL marketing division supplied fabric orders to the planning and control division by a specific format. Analyzing the orders:

After getting the fabric order, this section analyzes the orders according to buyers order quantity, type of orders (i.e. type of fabric, color to be dyed etc.) delivery date etc. This section plans for required quantity of fabric to be knitted, knitting balance, fabric to be dyed, dyeing balance RFD (ready for delivery), RFD balance, delivery fabric & delivery balance. Planning for knitting:

This section plans for knitting production. It selects m/c for knitting the fabric, no of m/c to be used, type of yarn used, from which source of yarn will be collected, required GSM, width etc. It also gives delivery date of knitted fabric. Planning for dyeing of the fabric:

Production planning for dyeing is called "Batch Plan". Batch plan is prepared according to m/c capacity, no. of nozzle batch no, fabric construction, color, width, GSM and priority of delivery etc. and written in a batch card. Planning for finishing of the fabric:

Finishing schedule is same as dyeing. After dyeing, materials go to the finishing section with the batch plan. The fabric can be finished in the open line finish or tube line finish. Finishing line will be selected according to the type of the fabric to be finished. Finishing data is written to the batch card and is informed to the planning section. However this section always forces to all the departments to finish all the workwithin the delivery time given by the buyers. Thus, it plays a very important role in the success of the company.

CHAPTER-6

KNITTING SECTION

Knitting:. Knitting is the method of creating fabric by transforming continuous strands of yarn into a series of interlocking loops, each row of such loops hanging from the one immediately preceding it. The basic element of a knit fabric structure is the loop intermeshed with the loops adjacent to it on both sides & above and below it. Knitted fabrics are two types. One is weft & another is warp. ATL produces weft knit fabrics. Classification of knitting: Knitting warp knitting weft knitting

Circular/tubular knitting Flat knitting

Single jersey Double jersey Example:1. Lacose 2. pk 3. Fleece Rib Purl Interlock4. Tery fleece

Layout Plan Of Knitting Floor:

Features of Knitting Machine:A knitting machine is an apparatus for applying mechanical movement either hand or power driven, to primary knitting element in order to produce knitted structure from yarn. The machine incorporates and coordinates the action of a number of mechanism and device each performing specific function, which contributes toward the efficiency of the knitting action.

The main features of a knitting machine are given below: The frame, normally free standing and either circular or other shape according to needle bed. The machine control and drive system The yarn supply system The knitting system The fabric take-down mechanism The quality control system The stop motion mechanism

Machine List Of Knitting Section In ABONI TEXTILE LTD: Machine name Machine Quantity

Circular Knitting(Single jersey) m/c 30

Circular Knitting(Rib+Interlock) m/c19

V-bed Knitting m/c18

Grey Fabric Inspection m/c03

Types of weft knitting m/c Circular knitting m/c Flat bed knitting m/cS/LBrand namePai lung

01Cylinder dia42,36

02Feeders84f

03Gauge(NPI)18g,28g

04Needles2376,3168

05RPM21

06OriginTAIWAN

07m/c typeRib

Specification Of Pai Lung Circular Knitting M/C:

Specification of FUKAHAMA circular knitting m/c:

01Brand nameFUKAHAMA

02Cylinder dia38

03Feeders76

04Needles2148T

05OriginJAPAN

06m/c typeSingle jersey

07Gauge(NPI)18G

08RPM23

Specification Of JIUNN LONG Circular Knitting M/C:

01Brand nameJIUNN LUNG

02Cylinder dia32,42,38,36

03Feeders96F,84F,114F,

04Gauge(NPI)24G,18G,24G,24G

05Needles2400T,2484T,2880T,2212T

06RPM21,18

07OriginTAIWAN

08m/c typeSingle jersey, Rib

Specification Of MAYER & CIE Circular Knitting M/C:

01Brand nameMAYER & CIE

02Cylinder dia26

03Feeders24

04Needles2268T

05OriginGermany

06m/c typeSingle jersey

07Gauge(NPI)27G

08RPM18

Circular knitting machine details:

Machine parts :

NEEDLENeedle is the primary knitting element. It is a thin metal bar.

Needle is used to produce a loop.

SINKERSinker is the second primary knitting element. It is a thin metal plate.

Functions of sinker are Holding down Knocking over Loop formation.

KNITTING CAMCam is the device which converts rotary machine drive into a suitable reciprocation action for the needle.Knitting cams (raising) are three types. These are:i. Knit camii. Tuck camiii. Miss cam

KNIT CAM:

It is used to produce a knit loop.

TUCK CAM

It is used to produce a tuck loop.

MISS CAM

It is used to produce a miss loop.

CAM BOX:

Function of cam box is to set cam on the slider.VDQ PULLEY:

VDQ pulley is used to control the GSM & SL.

MEMMINGER POSITIVE FEEDER:

It is used to apply positive feed of the yarn.

OILING POINT:

It is used to pass oil into the needle.

AIR PIPE:

It is used to flow air into the cam and needle.LYCRA FEEDING DEVICE:

Lycra feeding device is used to apply positive feed of the spandex.

Main features of flat bed knitting machine: Flat bed machine has two stationary needle beds Latch needles are used Angular cam system is used Separate cam system for each needle bed

Specification Of Flat Bed Knitting Machine:01BrandKAUO HENG

02ModelKH-313

03Gauge14

04OriginTAIWAN

05Dia54

06Total no. Of machine18

Sequence of operations in knitting section:

Sample fabric

Design analysis

Setting the machine for the specific design

Production

Quality control

Send to batch section

Comparison between basic structures of weft knitted fabric:

Structure Properties PlainRib Interlock

AppearanceDifferent on face & backSame on both sidesSame on both sides

UnrovingEither endOnly from end knitted lastOnly from end knitted last

CurlingTendency to curlNo tendency to curlNo tendency to curl

Thickness & warmthThicker & warmer than plain woven made from same yarnMuch thicker & warmer than plainVery much thicker & warmer than plain

End-uses

Ladies stockings, fine cardigans, dresses, base fabric for coating

Socks, cuffs, waistbands, collars,Underwear, knitwear.

Underwear, shirts,Suits, sportswear, Dresses.

Types of Fabric Knitted In Aboni Textiles Ltd:Single Jersey

Single Jersey: Single Jersey (Lycra) Single Jersey (Auto Stripe)

Pique

Pique Pique (Auto Stripe)

Interlock

Interlock Interlock D/N (Cotton) Interlock D/N (Polyester)

Rib

Rib: Any Drop Needle Rib Elasten

Lacoste Single Lacoste Double Lacoste

Types of yarns used in Aboni Textiles Ltd:Type of yarnCount

Cotton20S ,24S, 26S, 28S, 30S, 32S, 34S, 36S ,40S

Polyester70D, 100D,150D

Spandex yarn20D,40D, 70D

PC (65%Polyester & 35% cotton)24S, 26S, 28S, 30S

CVC(60% Polyester & 40% Cotton) 24S, 26S, 28S, 30S

Typical knitting calculations:The calculations which are frequently used in the knitting section are discussed below: Gauge (G): Number of needles per inch. Total needles: Machine diameter Gauge3.416. Feeders of Single Jersey: Machine diameter3. Feeders of Double Jersey: Machine diameter2. Production Calculation per shift (kilograms):

Important parameter& their effect in fabric production:

Stitch length-

Stitch length increase, GSM decrease. Stitch length decrease ,GSM increase

GSM

Grey GSM should be less than finished GSM GSM increase with decrease of stitch length and it is adjusted by Variable Dia Quality (VDQ) pulley. Color If shrinkage increase then GSM increase.

Count GSM depends on yarn count

Gauge

If gauge decrease then stitch length increase.

Feeder

Production increase with increase of number of feeder.

Design

Cam setting Set of needle Size of loop shape.

Greige fabric inspection:Most of the knitting factories follow 4-point grading system for quality standard. Though AKL is a 100% export oriented sub-contracting factory but they do not follow any standard system like 4-point or 10-point system.AKL standardize their products by checking of their skilled inspection team, visual inspection of every product if any problem is occurred & negotiation with buyers. But some officials of AKL suggest 4-point grading system with big problem in product; but it is rare case.

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

Faults and their causes in knitting:-Defects

Causes

Star mark

Un-effectiveness or buckling of latch of needle.Low GSM.Yarn tension variation.

HoleWrong stitch attachment.Yarn breakage.Yarn tension variation.Defective needle.Thick-thin place in the yarn.

Set-up

Yarn breakage.

Needle markNeedles hook breakage.Needle latch breakage.Dirt in needle slot.Needle line.

BarrieImproper cam setting.Bad yarn.Needle to loose or tight in trick.Count variation in same lot. Lot mistake.Low tensioned yarn.Old produced yarn.Faulty yarn.

Oil markExcess oil or grease use in the machine.Poor quality lubricant.Mixing of lubricant.Leakage in oiling system.

Drop stitchesFaulty needle.Wrong setting of yarn feeder.Improper yarn feeding.

Wheel free & belt freeUnlocking the wheel lock.Raising the wheel to upper collection.

Slubs

Poor yarn quality.Poor air circulating system. Fly formation of yarn.

Packy

Thicked yarn.

Black spot

Late servicing of m/c

LoopYarn tension variation.Needle drop.Low SL.

Yarn contra

Storage of dust during yarn feeding.

Lycra drop Wrong setting of needle.Dusted yarn.

Lycra out

Breakage of yarn.Dusted yarn.

GSM variationWrong setting of VDQ pulley.Wrong selection of yarn count.Tension variation in yarn.

Count variationDifferent count in same lot.Different yarn quality in same order.Long storaged yarn.

Design variation

Stripe variation in the machine.Wrong cam arrangement.

Batching :Batching is the process to get ready the fabrics for wet processing like scouring, bleaching, dyeing, finishing, washing, heat setting etc.Where the greige fabric are visually Inspected & divided into different batches. It is a part of dyeing process & it is done to feed the dyeing machines for fabric dyeing. The main function of batching section is to prepare the batch for dyeing according to machine capacity, order and emergency. This section receive the grey fabric from knitting section and make batch according to order for particular shade. Then this batch delivers to dyeing section for dyeing. The main Function of Batch section: To receive the grey fabric roll form knitting section. Turn the few selected the gray fabric using air turning machine . Prepare the batch card for dyeing machine depending on the following criteria: Buyer order sheet Individual Machine capacity & performance Dyeing shade ( light or dark, color or white) Types of fabric & fabric construction. Either Emergency order or not. To send the grey fabric to the dyeing floor with batch card.

Objects of Batching: To use maximum capacity of existing dyeing m/c. To minimize the washing time or preparation time & m/c stoppage time. To keep the no. of batch as less as possible for same shade. To use a particular m/c for dyeing same shade.

Batch calculation:

Equation for rope length: Dia quantity

Example:Let, machine capacity 500KgGiven DiaQuantity 45866 49 4688 51 2545

Calculation:Total quantity = 866+4688+2545=8099No. of batch = 8099500=17For 45 Dia, 866 = 54KgFor 49 Dia, 4688 = 290KgFor 51 Dia, 2545 = 158KgEquation for collar program Dia quantity per batchAvailable m/c in batch floor:

Machine Name : Air Turning M/CNo. of M/c : 01Origin : KOREAN

Air turning m/c function: For Reversing the Circular Knitted Fabrics The Machine is used to reverse the knitted face to back and back to face. The Machine has capacity blower pipe, fabric turning pipe, roller and folding parts. Process of fabric turning: Turn right the blower pipe. Insert the one end of fabric to fablic turning pipe. Switch on. Fabric moves to left side of turning pipe. Bring back the blower pipe. fabric will be entered to lnside of turning pipe and at the same time blower direction will be changed. Fabric will be reversed and folded automaticallyBatch Management

Checking point before Operation:1. Availability of required manpower.2. Availability of key accessories & other required materials.3. Availability of power.4. Check order no. & customers name of the batch/job card.5. Check types, quality, quantity,& other specification on the batch/job card.6. Check fabric & yarn quality & quantity while receiving goods from inspection.7. Check machine wise production plan to set priority.Operation Procedure:

1. Check production plan to set the priority2. Select 7-8 batches/shift to prepare

3. Consult with previous shift stuff to get the required information about the batches4. Check batch card & job card specification(e.g.-Yarn type, quality, weight etc) for fabric & collars/cuffs respectively5. Calculate number of batches, nozzles & rolls to be prepared for each order & specify on the batch & job card. One should be very careful while calculating & entering such data on these cards.6. Start batching operation & check the following information-7. Machine no8. Number of nozzle to be prepared9. Order no.10. Customer number11. GSM12. Width13. Lot no.14. Turning required or not15. Special instruction(if any)16. Prepare the body fabric of specified weight. This weight must be accurate & each nozzle of same batch must weight equal to ensure even dyeing.17. Calculate the number of collar/cuffs & attach the collars& cuffs with the body fabric18. Write down the weight of each roll on the back of batch card19. Check hole mark in each roll for identification20. Turn the roll(if required)21. Calculate the total weight very carefully & write it down in the specific area of the batch card22. After completation of one batch, write OK as comments at the notes section of batch card & send the batch along with the card to the dyeing section.

Lab dip:A lab dip is a swatch of fabric test dyed to hit a color standard. Several lab dips may besubmittedfor feedback until the standard is achieved and the lab dip is approved. Lab dips are reviewed in a "light box".Lab dips are doneto provide a visual aid on how a color will look when it is dyed. Actual production sample will vary from the lab dip that is provided.It is not possible to lab dip enough fabric for a sample cap or garment. When the goods are dyed in a real production run, the conditions are dramatically different from the laboratory. Production will not begin on fabric unless a lab dip is approved or the customer waives the lab dip process. Once a lab dip is approved, we will dye only to the lab dip approved.OBJECTS OF LABDIP To know about the shade % of fabric for sample dyeing. To calculate revise recipe for sample dyeing. To compare dyed sample with swatch by light box spectroflash. Finally approved lab dip(Grade: A B C)

Lab dip preparation:

Receiving buyer swatch

Take Spectrophotometer reading

Start up recipe(DCI match) software/Using color tools software

DCI match software is given recipe

Digital/Manual Pipatting

Fabric sample Pot dyeing

Unload

Normal wash

Acid wash

Hot wash

Cold rinsing

DryingAvailable machine of Dyeing Lab:S/LM/C NAMETYPE

01Manual twist testerYarn twist testing

02Motorised crock meterRubbing fastness testing

03Digital pilling testerPilling testing

04Incubator

Colorfastness to water

05Indesit drayerTumble dryer

06Electrolux dryerdryer

07Washcator washing

08Electrolux WashcatorDimensional stability

09Electrolux washing m/cwashing

10AHIBA top speed 2Sample dyeing

11AHIBA nuanceSample dyeing

12Rapid Eco dryerdryer

13SpectrophotometerRecipe making

14Digital Ph meterPh & temp measuring

15Digital pipetteAutomatically pipetting

16Vervide cac-60Color matching cabinet

17Manual wrap reel m/cCount measurement

The flowing equation are used in lab: This eqation are given below:

Recipe % Sample Weight Dye Solution = (cc). Stock solution %

( Recipe % Liquor) Salt = (gram per liter). 1000

(Recipe % 100 Liquor) Soda Solution = (cc). (1000Stock solution %) Lab liquor ratio - 1:8 Topping fabric sample Lab liquor ratio - 1:13

COLOR MASUREMENT SYSTEM:There are two ways for color measuring system of standard sample. This are 1. Manual method 2. Computer color matching system(CCMS)1.Manual Method: In this method,at first we need to see the sample fabric is either dark or lighter,then which tone is present either yellowish or blueish tone ,then based on assumption increase or decrease shade % .Sometimes standard sample is measured by comparing it with previously produced samples of different tri-chromatic color combination. The sample with which the color of the std. matched, that sample color recipe is being taken for shade matching. This methods accuracy completely depends on the vision of the experience person.

2. Computer Color Matching System(Ccms): The instrumental method is more reliable if it is operated accurately to do the work of color measurement. Spectrophotometer interfaced with a PC is used for shade matching. This instrument works with the principle of reflectance measurement of light at different wave length. When the standard sample is being subjected under spectrophotometer, then the instrument suggest a recipe with required tri-chromatic colors within the tolerance limit of color difference. In this way, color measurement of the standard sample is carried out for the purpose of shade matching.Spectrophotometric measurement: Color fastness is usually assessed separately with respect to: It is an alternative to the visual method of assessment by Grey Scale. The color of the specimen which has been subjected to the color fastness test and the color of an original specimen are measured instrumentally by spectrophotometric measurement.

The CIE LAB coordinates for lightness L*, chroma C* and hue H* for both specimens are measured.

The total color difference value AE* which is the function of AL *, AC*, AH * are calculated and converted to a Grey, Scale by means of a series of equations or by the following table

Functions of spectrophotometer: Color difference Metamerism Pass/fail operation Fastness rating Shade library Cost comparison Color match production Reflectance curve.

Sequence Of Dyeing Polyester Part In Lab:Color dosing

Water dosing

Levelling/dispersing dosing(1 g/l)

Ph buffer/Acid dosing (1g/l)

Fabric load in pot

Pot load in m/c

As reqd temp (130*45)

Pot unload from m/c (45)

R/c (80*20)with caustic 2 g/l ,hydrose 2 g/l

Hot wash (90*10)

Acid wash (0.8g/l)normal temp

Cold wash (Rinse)

Dry sampleSequence of dyeing cotton part in lab:

Digital pippeting procedure: Dont use less than 1 cc in digital pipette. Always try to avoid 2%,4% & other big % of stock solution . Always try to meet total volume (40ml) with solid salt,if needed 2%,4% & others % of stock solution then make required % of stock solution. Always try to use same stock solution for same shade & its stricklt controlled. Always try to use same fabric & yarn lot for same shade.

Purity test of NaoH (%) Dissolve 1 gm of soda ash in distrilled water in a 100ml measuring flask. Making the volume up to the mark. Filled the burette with 0.1 M HCL solution with the help of funnel. Note down the initial reading of burette. Pipette out 10 ml of soda ash solution & transfer in the titration flask. Add 1-2 drops of methyl orange as indicator . Add 0.1 M HCL solution from the burette drop wise with constant shaking until color change from orange to red. Note the final reading of the burette. Purity Percentage of Na2co3= 5.3*burette reading =x%

58 | Page

LAYOUT PLAN OF DYEING FLOOR:

CAPACITY CHART:

MACHINE NUMBERTOTAL CAPACIY

HT-3540KG

HT-2360KG

HT-1180KG

HT-4450KG

DM-3600KG

DM-4A600KG

DM-4B600KG

DM-4C600KG

HT-5750KG

DM-6900KG

KOREAN150KG

HT-B(sample dyeing machine)50KG

HT-S/1(sample dyeing machine)25KG



S/W-1(sample dyeing machine)30KG

Dyeing Machine Specification:

Machine Quantity:MACHINE TYPEQUANTITY

SCLAVOS04

DILMENLER07

KOREAN01

LONGCASE01

Specification of SCLAVOS dyeing machine:M/c NameSCLAVOS

No. of Nozzle03

Total Capacity540Kg

Maximum work pressure (bar)2.8

Maximum work temperature (C)140

Types Twin soft flow system

Built Year2005

OriginAthence Greece

Specification of DILMENLER dyeing machine:M/c NameDILMENLER

No. of Nozzle06

Total Capacity900Kg

Maximum work pressure (bar).5


Types Winch dyeing

Built Year2005

OriginTurkey

Specification of BENEKS dyeing machine:M/c NameBENEKS

No. of Nozzle02

Total Capacity25Kg

Maximum work pressure (bar)1.5


Types Winch dyeing

Built Year2010

OriginTurkey

Dyeing Process Definition:

Pretreatment is carried out before dyeing to remove oil, waxes, and fats, naturalColoring matters and all other impurities and to ensure proper dyeing.Scouring: Gray fabrics contain fats, waxes, and other impurities. The absorbency of the fabric is adversely affected due the presence of these impurities .this leads to improper dyeing, printing and finishing in the subsequent process. These impurities are removed from the fabric by a chemical treatment. This chemical treatment is called scouring process.

Bleaching: Bleaching is the process for removing natural nitrogenous coloring matter, i.e. dust ,husk, broken seeds, protein, leaf , etc from the fabric and make it white by oxidizing or chemical treatment .

Scouring & bleaching Objects:

To remove fats, wax, impurities from the fabrics. To increase absorbency of fabric To remove natural coloring materials, dirt, dust, broken seed by oxidizing of chemical treatment To obtain pure & permanent color. To whiten the fabric. To impart wet ability of the fabric which is necessary for further treatment and in domestic uses. It helps to produce even shade during dyeing operation.

Washing: Washing is a process to remove waxes, fats, or to increase absorbency of the fabric by chemical treatment. Washing process specially used only for TC and TTC dark color shade.

Some Important Point for Dyeing:

Stripping=When it is impossible to control the levelness need to remove all colors from the fabric is called stripping.

Re dyeing = After stripping Process fabric is dyed again. Stripping is the part of re dyeing process.Addition= with out dropping Bath color is added to bath.

Topping= Hot wash, neutralization, then again dyeing process is performed.

Calculation Of reel Speed & Cycle Time: Reel Speed= Batch Weight*1000 Dia (Inch)*0.254*G.S.M*No Of Nozzle*Cycle Time Cycle Time= Batch Weight*1000 Dia (Inch)*0.254*G.S.M*No Of Nozzle* Reel Speed

Effect of Cycle Time:

When Cycle Time Increase Then increase Uneven Shade, Running Mark When Cycle Time decrease Then Color pick up low

Bulk Production Operation procedure: Process Sequence:

I. PretreatmentII. EnzymeIII. DyeingIV. WashingV. Softening Fixing

Chemical used In Aboni Textiles Ltd:Serial NoChemical NameBrand Name

01DetergentDFW,RWD

02Sequestering agent1090

03StabilizerSIF

04Anti-creasing agentCA

05Caustic SodaNaOH

06Bleaching agent/Oxidizing agentH2O2 50%

07Peroxide KillerVHK

08AceticAcid/NeutralizationCH3COOH,Green-acetic acid

09EnzymeMataenzyme-E

10Leveling agentDLR

11Glauber SaltNa2SO4

12Soda AshNa2CO3

13Soaping/Washing AgentDSP

14SoftenerNISB,OFS,CSIL,SCH

15Fixing AgentOptifix-EC, GG-100

16OBAG.CO3

17Reducing AgentHydrose powder BASF

Dyes Used in Aboni Textiles Ltd:

Sl. NoDyes Brand

1Matex

2Remazol

3Novacron

5Ciba

Different Types of Dyeing Process:

BASIC COTTON DYEING PROCESS:1. Scouring & bleaching process:

Chemical used: Detergent-1.5gm/l Oil spot remover-0.75 gm/l Sequestering agent-1.0 gm/l Anti crease-1.0 gm/l Anti foam-0.2 gm/l Causting-3.0 gm/l Sif-0.6 gm/l H2o2-6.0 gm/l

PROCESS: Detergent, oil spot remover, sequestering agent, anti crease, anti foam apply into the machine.

D/t: 2-3 minTemp: 50c

causting d/t: 10minTemp: 60c, steam up 70c h2o2D/t: 10 minTemp: 98cTotal r/t: 60 min. after this time cooling the machine 70 and cut a sample for check the scouring rate.

DRAIN THE WATER AND TAKE NEW WATER

2. NORMAL HOT WASH

D/t: 10minTemp: 80-90ccooling 70c


3. COLD WASH D/t: 10minTemp: 70c DRAIN THE WATER AND TAKE NEW WATER

4. NEUTRALIZTION PROCESS:

CHEMICAL USED: H2o2 killer (vhk)-0.6 gm/l acide (as)-0.5 gm/l detergent (dfw)-0.2 gm/l

PROCESS: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t:2-3 minR/t: 10 minTemperature: 60c*ph must be check.


5. COLD WASH D/T: 10MIN TEMP: 70C


6. ENGYME:

Engyme (ds)-1.0 gm/Process: the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 50 minTemperature: 55-75c


7. COLD WASHD/t: 10minTemp: 70c DRAIN THE WATER AND TAKE NEW WATER

Ph and hardness check.ph-6-6.5 for cotton

8. DYEING PROCESS: Levelling agent (dlr)-1.0 gm/l sequestering agent (1090)-0.50 gm/l anti crease (ca)-1.0 gm/l acide (as) - 0.10 gm/l anti foam-0.20 gm/l

D/t:2-3 minR/t: 10 min Temperature: 60c (light shade) 40c (deep shade)Dyes:----------------------Deep shade:D/t: 20minR/t: 10 minTemperature: 40c (deep shade)Light shade:D/t: 30 minR/t: 20 minTemperature: 60c (light shade)

Sequestering agent (1090)-0.10 gm/lSoda-20 gm/lGlubal salt- gm/l

Process: glubal salt apply to the m/c in 3 times equaly.each time-D/t: 10minR/t: 10 minFinal r/t: 30 minThen salt sample check.if ok then

Soda:D/t: 40minR/t: 20minTemp: 40Again sample check.if ok.

DRAINS THE WATER AND TAKES NEW WATER

9 .COLD WASH:APPLY NORMAL WSAH TO THE FABRIC.TEMP: 70CR/T: 10 MIN (LIGHT) 20 MIN (DEEP)

DRAIN THE WATER AND TAKE NEW

10. NEUTRALIZATION:DETERGENT (DFW)-0.5 gm/LACIDE (AS)-1.0 gm/L

PROCESS: MIXING THE ENTIRE CHEMICAL IN THE BLANKET THEN DOSSING THE CHEMICAL INTO THE MACHINE.D/T:2-3 MINR/T:20 MINTEMPERATURE: 50C


11. SOAPING: SOAP (DSP)-0.5 gm/L CLEAR-0.3 gm/L CSC-0.5 gm/L

PROCESS: MIXING THE ENTIRE CHEMICAL IN THE BLANKET THEN DOSSING THE CHEMICAL INTO THE MACHINE.D/T: 2-3 MINR/T: 15 MINTEMPERATURE: 50C DRAIN THE WATER AND TAKE NEW WATER

12. SOFTENER: SOFTENER-0.5 gm/L SEQUESTERING AGENT (1090)-0.10 gm/L ACIDE-(CN)-0.10 gm/L

PROCESS: MIXING THE ENTIRE CHEMICAL IN THE BLANKET THEN DOSSING THE CHEMICAL INTO THE MACHINE.D/T: 2-3 MINR/T: 15 MINTEMPERATURE: 50C UNLOAD PROCESS NAME: 100% COTTON WHITE PROCESS:1. LOADING HOT:

Detergent (AFD) - 0.5 gm/L Oil spot remover (OSR) - 0.5 gm/L Anti crease (CA) - 0.5 gm/L AF-9.0 gm/L

TEMPERATURE & TIME: 80C&15minPROCESS: Take required amount of water in the m/c and add chemical and run 15min. after drain and fill water2. SCOURING & BLEACHING&WHITENING PROCESS: Detergent (RWD)-1.0 gm/L Anti crease (CA) - 0.6 gm/L Sequestering agent (FE+)-0.5 gm/L Anti foam (Mx jet) - 0.3 gm/L Caustic-2.0 gm/L SIF-8.0 gm/L H2O2-0.23 gm/LWhite COB-0.23%Sky BVB-0.161%

TEMPERATURE & TIME: 100C&50minPROCESS: Take required amount of water in the m/c and add chemical (RWD, ,CA FE+,MX,SIF)And dosing the caustic 40 min at 60-65 c and dosing the H2O2 5min .run the machine 20 min and then dosing the COB,BVB and run the machine 50 min .sample check if ok then drain water and take new water.3. NORMAL HOT:Sequestering agent (FE+)-0.5 gm/LTEMPERATURE & TIME: 90C&10min

PROCESS: Take required amount of water in the m/c and run the machine 10 min .finally drain the water and take new water in the machine.

1. NUTRALIZATION PROCESS:

Acid (As)-0.3%Sequestering agent (FE+)-0.5 gm/L

TEMPERATURE & TIME: cold&10min

PROCESS: Take required amount of water in the m/c and add chemical)And run the machine 10 min and drain water and take new water.

6. ENZYME WASH:

ENZYME (Bio-f)-1.0gm/LTEMPERATURE & TIME: 55C&40min

PROCESS: Take required amount of water in the m/c and add chemicalAnd run the machine 40 min at 55 temp and sample check if ok then drain water. UNLOAD

TURQUISE COLOUR (COTTON):

Load water according to the receipe

Load fabric to the selected machine

oil spot remover (osr) -0.5gm/lDetergent (rwd)-0.5 gm/lSequestering agent (1090)-0.5 gm/l

Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 10 mintemperature: 80c

Drain all the chemical and again fill the water

Oil spot remover (osr) -0.75 gm/l Detergent (rwd)-1.5 gm/l Anti crease (ca)-1.0 gm/l Sequestering agent (fe+)-1.0 gm/l Anti foaming agent (mx)-0.5 gm/l Caustic-3.0 gm/l H2o2-6.0 gm/l Sif-0.6 gm/l

Test the scouring by absorbancy test.if ok then-Process: mixing the entire chemical (rwd, osr, ca, fe, mx) in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 5 minTemperature: 50c

Caustic:D/t: 10R/t: 5Temp: 60cH2o2& sif:Take cold water 100l and mixing the chemical.D/t: 5 minR/t: 10minTemp: 70cFinal temperature: 100cR/t: 60 minThen cooling the temp and cut the sample.

Drain the entire chemical and again fill the water.

apply normal hot to the fabric. temp: 90c r/t: 10

Drain the water and again fill the water.

Apply normal wsah to the fabric.Temp: 50cr/t: 5-10

Drain the water and again fill the water

H2o2 killer (vhk)-0.6Acide (as)-0.5Detergent (dfw)-0.2

Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 10 minTemperature: 60c*ph must be check

As-0.1Engyme (ds)-0.5Dfw-0.3

Process: the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 50 minTemperature: 55cPh-4.5

Apply normal hot to the fabric with sequestering agent. (0.5 gm/l).Temp: 70cR/t: 10Ph-4.5 & hardness check

drain the water and again fill the water

Levelling agent (dlr)-2.0 gm/l ,Dba-1.0 gm/lSequestering agent (1090)-0.50 gm/lAnti foam-0.20 gm/lAcide (as)-0.10 gm/l

Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 10 minTemperature: 40c

Turquise color dye80*90*80Process: mixing the dye in the blanket about 5 min.D/t: 30minTemp: 80cR/t: 20 min

Sequestering agent (1090)-0.10 gm/l Glubal salt-60 gm/l Soda-20 gm/l

Process: glubal salt apply to the m/c in 3 times equaly.each time-D/t: 10minR/t: 30 min, temp-90cThen salt sample check.if ok thenCooling..60c

Soda:D/t: 40minR/t: 20minTemp: 80(steam up 60 to 80c)Again sample check.if ok

drain the water and again fill the water

Apply normal wsah to the fabric.Temp: 70cR/t: 5-10


Neutralization:

Detergent (dfw)-0.3Acide (as)-0.4Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 20 mintemperature: 50c


Soaping: Soap (dsp)-0.5 Clear-0.3 Csc-0.5(only for turquise)



Softener-0.5 Sequestering agent (1090)-0.10 Acide-(cn)-0.10

Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 15 minTemperature: 50c UNLOAD

POLYESTER COTTON FABRIC DYING PROCESS:

1. Loading : Detergent (AFD) - 0.5 gm/L Oil spot remover (OSR) - 0.5 gm/L Anti crease (CA) - 0.5 gm/L AF-9.0 gm/L Temperature & time: 80c&15min

PROCESS: Take required amount of water in the m/c and add chemical and run 15min. after drain and fill water2. Scouring & bleaching & whitening process: Detergent (RWD)-1.0 gm/L Anti crease (CA) - 0.6 gm/L Sequestering agent (FE+)-0.5 gm/L Anti foam (Mx jet) - 0.3 gm/L Caustic-2.0 gm/L SIF-8.0 gm/L H2O2-0.23 gm/L White COB-0.23% Sky BVB-0.161% Temperature & time: 100c&50min

PROCESS: Take required amount of water in the m/c and add chemical (RWD, ,CA FE+,MX,SIF)And dosing the caustic 40 min at 60-65 c and dosing the H2O2 5min .run the machine 50 min .sample check if ok then drain water and take new water.

3. NORMAL HOT:Sequestering agent (FE+)-0.5 gm/LTEMPERATURE & TIME: 90C&10min

PROCESS: Take required amount of water in the m/c and run the machine 10 min .finally drain the water and take new water in the machine.4. ENZYME WASH:

ENZYME (Bio-f)-1.0gm/LTEMPERATURE & TIME: 55C&40min

PROCESS: Take required amount of water in the m/c and add chemicalAnd run the machine 40 min at 55 temp and sample check if ok then drain water.

5. COLD WASH:

TEMP: normalR/T: 5(2 times)

6. POLYESTER PART DYEING:

DCP-2.0 gm/LSequestering agent (1090)-0.5 gm/LACID (As)-0.3 gm/LBD-1.5 gm/LDYES: --------------%

PROCESS:Leveling chemical dosing at 40cColor dosing at 60c, D/T: 20minR/T: 5, pH-4.0Temperature up 60-100 at 2c/minTemperature up 100-130 at 1c/minTemperature down130-100 at 1c/minTemperature down 100-60 at 2c/min After that we need to check the sample .if ok then we move to next step.7. REDUCTION CLEARING: DETERGENT (RWD)-2.0gm/L CAUSTIC-3.0gm/L HYDROSE-1.0 gm/L

PROCESS: this process is done for the removing extra dyes which are staying the surface of the fabric specially cotton part.8. NORMAL HOT:Temp: 80cR/t: 109. NUTRALIZATION PROCESS: Acid (As)-0.3% Sequestering agent (FE+)-0.5 gm/L Temperature & time: cold&10min

PROCESS: Take required amount of water in the m/c and add chemical)And run the machine 10 min and drain water and take new water.10. COLD WASH: TEMP: normalR/T: 5(2 times)

11. COTTON DYEING PROCESS:

Levelling agent (dlr)-1.0 gm/l sequestering agent (1090)-0.50 gm/l anti crease (ca)-1.0 gm/l acide (as) - 0.10 gm/l anti foam-0.20 gm/l

D/t:2-3 minR/t: 10 minTemperature: 60c (light shade) 40c (deep shade)Dyes: ----------------------Deep shade:D/t: 20minR/t: 10 minTemperature: 40c (deep shade)Light shade:D/t: 30 minR/t: 20 minTemperature: 60c (light shade)

Sequestering agent (1090)-0.10 gm/lSoda-20 gm/lGlubal salt- gm/l

Process: glubal salt apply to the m/c in 3 times equaly.each time-D/t: 10minR/t: 10 minFinal r/t: 30 minThen salt sample check.if ok thenSoda:D/t: 40minR/t: 20minTemp: 40Again sample check.if ok

12 .cold wash:Apply normal wsah to the fabric.Temp: 70cR/t: 10 min (light) 20 min (deep) 13. Neutralization:Detergent (dfw)-0.5 gm/lAcide (as)-1.0 gm/l

Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t:2-3 minR/t:20 minTemperature: 50c14. Soaping: soap (dsp)-0.5 gm/l clear-0.3 gm/l csc-0.5 gm/l

Process: mixing the entire chemical in the blanket then dossing the chemical into the machine.D/t: 2-3 minR/t: 15 minTemperature: 50c15. Softener: softener-0.5 gm/l sequestering agent (1090)-0.10 gm/l acide-(cn)-0.10 gm/l


UNLOAD

DYEING PARAMETERS:PH Levels for Different Stages Of Cotton Dyeing:

Initial Bath pH 6.5~7.0. Before Enzyme, bath pH 4.5~4.7. After Enzyme pH 5.5~6.0. Scouring & Bleaching, bath pH 10.0~10.5. After Scouring & Bleaching, pH 8.5~9.0. After Adding Dyes, pH 6.2~6.35. After Addition of Salt, pH 7.5~8.0. After Addition of Soda, pH 10.5~11.0. Before Softener, bath pH 7.2~7.8. After Softener Addition, bath pH 6.5~6.8.

Ph Levels For Different Stages Of Polyester Dyeing:Initial bath pH 6.5~7.0. Scouring, bath pH 10.0~11.5. After Scouring, bath pH 8.5~9.0.After Addition of Colors, bath pH 4.2~4.3. During Reduction Clearing, bath pH 10.5~11.5. Before Softener, bath pH 6.3~6.8.

Common dyeing faults with their remedies:

1. Crease mark:Causes: Poor opening of the fabric rope Shock cooling of synthetic material If pump pressure & reel speed is not equal Due to high speed m/c running

Remedies: maintaining proper reel sped & pump speed. Lower rate rising and cooling the temperature Reducing the m/c load Higher liquor ratio

2. Uneven dyeing:Causes: Uneven pretreatment (uneven scouring & bleaching). Improper color dosing. Using dyes of high fixation property. Uneven heat-setting in case of synthetic fibers. Lack of control on dyeing m/cRemedies: By ensuring even pretreatment. By ensuring even heat-setting in case of synthetic fibers. Proper dosing of dyes and chemicals. Proper controlling of dyeing m/c

3. Batch to Batch Shade variation: Causes: Fluctuation of Temperature. Improper dosing time of dyes & chemicals. Batch to batch weight variation of dyes and chemicals. Dyes lot variation. Improper reel speed, pump speed, liquor ratio. Improper pretreatment. Remedies: Use standard dyes and chemicals. Maintain the same liquor ratio. Follow the standard pretreatment procedure. Maintain the same dyeing cycle. Identical dyeing procedure should be followed for the same depth of the Shade. Make sure that the operators add the right bulk chemicals at the same time and temperature in the process. The pH, hardness and sodium carbonate content of supply water should check daily.

4. Patchy dyeing effect:Causes: Entanglement of fabric. Faulty injection of alkali. Improper addition of color. Due to hardness of water. Due to improper salt addition. Dye migration during intermediate dyeing. Uneven heat in the machine, etc.Remedies: By ensuring proper pretreatment. Proper dosing of dyes and chemicals. Heat should be same throughout the dye liquor. Proper salt addition.

5. Roll to roll variation or Meter to Meter variation:Causes: Poor migration property of dyes. Improper dyes solubility. Hardness of water. Faulty m/c speed, etc

Remedies: Use standard dyes and chemicals. Proper m/c speed. Use of soft water

6. Dye spot:Causes: Improper Dissolving of dye particle in bath. Improper Dissolving of caustic soda particle in bath.Remedies: By proper dissolving of dyes & chemicals By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the . large un-dissolved particles are removed 7. Wrinkle mark:Causes: Poor opening of the fabric rope Shock cooling of synthetic material High temperature entanglement of the fabricRemedies: Maintaining proper reel sped & pump speed. Lower rate rising and cooling the temperature Higher liquor ratio8. Softener Mark:Causes: Improper mixing of the Softener. Improper running time of the fabric during application of softener. Entanglement of the fabric during application of softenerRemedies: Maintaining proper reel sped & pump speed. Proper Mixing of the softener before addition. Prevent the entanglement of the fabric during application of softener

FINISHING SECTION:Finishing is the general term for a multitude of processes and treatments which a fabric may undergo after it has been made (woven or knitted) and coloured (dyed or printed). It is the final processing of the cloth and its purpose is to make the fabric suitable for its intended end use. Finishing is the final processing before the fabric is cut into apparel or made into any articles of textiles.In order to impart the required functional properties to the fiber or fabric, it is customary to subject the material to different types of physical and chemical treatments. For example, wash and wear finish for a cotton fabric is necessary to make it crease-free or wrinkle-free. In a similar way, mercerising, singeing, flame retardant, water repellent, waterproof, anti-static and peach finishing achieve various fabric properties desired by consumers.The use of 100% synthetic textiles has increased considerably since the development of textured yarns made of filaments, and the growing production of knit goods. The use of open weave has enabled production of lighter, breathable, fabrics to ensure better wearing comfort.

Object of finishing: Finishing is done to improve following things:- To improve the attractiveness. To improve appearance. To improve properties. To improve quality To improve of dyed and printed fabric. To reduce crimp. To reduce wrinkle. To reduce shrinkage. To reduce loss of strength. To improve lusture. To improve handle. To improve service ability.LAYOUT PLAN OF FINISHING FLOOR:

Flow chart of finishing section:

Open fabric Tube fabric Slitting machine Dewatering machineStenteringDrying Machine Open Compacting m/cTube compacting machineFinal inspectionInspectionFinal inspection Dyed fabric

Avaliable machine in finisfing floor:S/LMachine nameNo. of machineBrandOrigin

01De-Watering01Santex Switzerland

02Slitting01CorinoItaly

03stenter01Unitech Italy

04open compector01LafarItaly

05tube compector01SantexSwitzerland

06dryer02- Santex- Unitech-Switzerland-Italy

07bag-sewing 01localLocal

08hydroextractor01DilmenlerTurkey

De-watering machine:After dyeing process from the dyeing machine then the fabrics arc ready for dc-watering. This is the process to remove the water from the fabric partially by squeezing. This is the main function of the squeezing machine. But here also control the some important factor of the fabric quality.The basic function of the squeezing m/c: To remove the excess water from the dyed fabric. To control the length of the fabric. To control the spirality of the fabric. To control the width of the fabric. To increase the softness of the fabric. To remove the crease mark of the fabric.

M/C Specification:

Brand NameSantex

CompanySantex ag

ModelSth

OriginSwitzerland

Electr. Voltage400 v

working Speed40~ 60 m/min

Year of Manufacture2004

Overfeed Range-5% to +10%

M/C Parts:1) Spreader To open the fabric from the rope position.2) Hand wheel it is used for guide spreader.3) Water tank To store the water and fall into the Fabric in rings form.4) Over feed G.S.M control.5) Turn tube fabric rotation is controlled by it .feed the fabric into spreader 6) Densing roller Help to remove the crease mark.7) Air pressure Open the tube fabric to remove the crease mark.8) Padding roller 2 Seta) Front roller - After squeezer water contain 20%b) Back roller - After squeezer water contain 30% 9)security shield Automatic system to ensure the security of padder. Padding roller pressure capacity-6bar Maximum apply-4bar. Normally applied-2 bar

Controlling point:1. Speed: As much as possible (40-60 m/min). Higher the GSM lower the speed.2. Over feed: As required. Higher the GSM higher the over feed.3. Padder pressure: 2-2.5 bar as required. Higher the GSM lower the padder pressure.4. Width: Fabric width is adjusted as per required width.

SLITTING MACHINE:Slitting machine is used for removing excess water from tube fabric or open fabric .That is applied by cutting the tubular fabric into open wide fabric.The basic function of the slitting m/c: To open the tube fabric according to specific needle mark. To remove the excess water from fabric. To remove the crease marks.

Machine nameSlitting machine

brandCorino

Year2004

Model177/04

Maximum pressure8 bar

Maximum working speed80-85 m/min

M/C Parts: Twist detector- detect the twist of fabric which is in rope form. Cutting knife/device - cutting the fabric according to specific needle mark. Ring use to help the cutting process. Sensor Identify the specific wales line .makes sense for it. Guide roller after slitting ,plaiting of the fabric to plaiting . Plaiting - open fabric is make plait by plaiting. Padder- to remove the required exact water.

Controlling point: Maintain fabric expanding shape to keep minimum dia of (1*1)Rib, (2*1)Rib,(2*2)Rib fabric, otherwise after slitting fabric dia increased. Speed -The speed should be optimum (30-80 m/min).More speed,less remove of water. Pressure: The padder pressure should be according to requirement. Although ATL normally used 2 to 2.5 bar at front padder. Hairiness remove Remove hairiness of fabric otherwise it may causes uneven padder pressure.

DRYER:Drying is defined as a process where the liquid portion is evaporated from the fabric. After de-watering then the fabric through the dryer.The basic function of the dryer m/c: To dry the fabric by using steam or gas blower To control the vibration which increase the G.S.M. To control the overfeed system.

Specification of santex ag:Brand NameSantex AG

CompanySantex AG


OriginSwitzerland

TypeSantashrink 2K/240, IRGF1 ,GAS

ModelCH-9555, Tobel

Max. Working Speed30 m/min

Min. working Speed3 m/min

Max. Temperature1850C

No. of Burner 02

Overfeed Range0% to -25%

No. of Chamber02

Specification of UNITECH :Brand NameUNITECH dryer

CompanyUNITECH co Ltd


OriginItaly

TypeDF-3K-260

ModelGold evo 3

No. of Chamber03

Burner03

M/C Parts: Conveyor net Chamber Burner Exhaust air fan Over feed roller Filter net Fan Nozzle

Controlling point of SANTEX dryer for open fabric:S/LColorTemp()VibrationSpeed(m/min)Overfeed(%)

01Black15040025-3020-25

02Average color14040020-2520-25

03White12040020-2520-25

04polyester110-12040025-30

Controlling point of dryer for tube fabric:S/LColor/GSMTemp()Speed(m/min)

01White1405.5

02Average color1606.6-7

03Black1708-9

042201505.5-6

051801607-8

Controlling point of santex dryer for collar fabric:S/LColorTemp()Overfeed(%)

01Scouring16020

02White14020

03Pale/light15020

04Deep/dark shade16020

Never dry coller/cuff in dryer second times otherwise shade is not matched. Vibration roller increase GSM ,its speed kept down between (400-600) according to buyer requirement.Following things are also considered incase of Dryer machine: If fabric is redder than the standard one, then reduce the temperature. If fabric is more Yellowier than the standard one, then increase the temperature. If fabric is more Bluer than the standard one, then increase the temperature.

Stenter machine:A machine or apparatus for stretching or stentering fabrics. The purpose of the stenter machine is to bringing the length and width to pre determine dimensions and also for heat setting and it is used for applying finishing chemicals and also shade variation is adjusted. The main function of the stenter is to stretch the fabric width wise and to recover the uniform width.Stenter consists of three parts:

Functions of Stenter Machines: Heat setting is done by the stenter for lycra fabric, synthetic and blended fabric. Width of the fabric is controlled by the stenter. Finishing chemical apply on fabric by the stenter. Loop of the knit fabric is controlled. Moisture of the fabric is controlled by the stenter. Spirility controlled by the stenter. GSM of the fabric is controlled by stenter. Fabric is dried by the stentering process. Shrinkage property of the fabric is controlled. Curing treatment for resin, water repellent fabric is done by the stenter.

Specification of UNITECH stenter machine:Brand nameUNITECH

Serial no.A5040158

OrigionItaly

Year2004

Speed range(7-150)m/min

Temp range(70-210)

Chamber06

Fabric width range(114-250)cm

Air pressure3 bar

Burner06

Extra attachmentMATLo

Used utiliesGas,Air,Electricity

M/C Parts: Padders Weft straighter(mATLo) Burners Heat recovery Attraction rollers Circulating fans. Clips Pins I.R Nozzle Chain arrangement Blower Exhaust air fan Over feed roller

Controlling point of UNITECH dryer for open fabric:Pressure in padder:White3.0 bar

Color2.5 bar

Heat setting3.5 bar

If softenter is used in dyeing machine ,then padder pressure in stenter machine 3 bar. If softenter is used in stenter machine padder pressure 2.5 bar

STANDARD OPERATING PARAMETER FOR DIFFERENT FABRIC IN STENTER:

Fabric TypeGSMDiaTempOver FeedPadder PressueSpeed (rpm)Blower rpm

Single jersey115-1502+110-14040-45% 2 bar30-351100-1300

Single jersey160-2202+120-17040-45%2.5 bar25-301200-1400

Lycra Single jersey160-2004+130-16050% 2 bar25-301200-1400

Lycra Single jersey200-2504+140-16050% 2 bar24-281200-1400

Pique160-2003+130-16040-45%1.5-2bar25-301200-1400

Lycra Pique190-2204+130-16050% 2 bar20-251200-1400

Fleece/Terry260-3004+140-17040-45% 2 bar20-251300-1400

1x1 Rib160-2202+130-16045% 2 bar24-281300-1400

2x2 Rib190-2202+140-16045% 2 bar20-251200-1400

Interlock190-2203+130-16050% 2 bar20-251200-1400

COMPACTOR MACHINE:Compactor is a textile finishing machine which is designed specially for compacting 100% cotton knitted fabric like jersey, pique, interlock, plush, rib and sinker etc. as well as cotton blended fabric in rope form, changing the loft and dimensional stability of the fabric and presenting it to plaited form. Fitted with two felt compacting units which makes it to obtain top quality fabric, with minimized shrinking nature and a soft fluffy hand.

Functions of compactor Machines: GSM control Control shrinkage Twisting control Increase smoothness of fabric Heat setting is done of fabric Shade match control.

Types of Compactor Machine: Compactor machines are two types. They are- 1. Tube compactor2. Open compactor

Specification of Tube Compactor Machine:Brand nameSantex ag

year2001

Manufacturing countryItaly

Speed range25-45 m/min

Temperature110-150

Used utilitiesElectricity, Compress air, Steam

modelSTS(Santaspread)

Maximum width50

Minimum width17

Applied forTube fabric

Specification of open Compactor Machine:

Brand nameLafer

year2004

Manufacturing countryItaly

Speed range8-45 m/min

Temperature20-150

Used utilitiesElectricity, Compress air, Steam

modelSPA

Over feed range(50-100)m/min

Applied foropen fabric

M/C Parts: Over feed roller. Steam sprayers. Expander. Cylinder Blanket Teflon covers. Tension roller Sensor roller Temperature roller Cold roller

Controlling point of compactor for open fabric:

S/LColorTemp()SpeedOverfeed (%)Finish diaCompaction (%)

01Black140-1503510070.5-715

02Average color140-1503510070.5-715

03White140-1503510070.5-717

S/LFabric styleOverfeed(%)Compaction(%)

01S/j126-7

02(1*1)Rib125-6

03Single/double lacoste20-228-10

GSM steam speed tension overfeed GSM steam speed tension overfeed

Quality Control:Quality control is concerned with the evaluation of test data and its application to control of the textile process, raw materials, intermediate products and final products. It is concerned not only with quality level and cost of maintaining this quality level but also concerned with the presentation of tangible values to measure quality and changes in quality. In order to control quality one must know about the consumers expectations.

Process Flow Chart of Final Inspection:

At first check the shade as per buyer standard with dimensional stability from lab.

Secondly check dia / width fabric weight or G.S.M

Thirdly check fabric surface or appearance as per buyer standard.

The every roll with every meter check (as per four (04) point system)

Make a report.

Send to the buyer

If OK then ready for delivery.

If not OK then identify the fault.

If it is knitting fault then inform the knitting department by job card and mail, & requested the fabric for replacement.

If it is dyeing fault, then give job card to dyeing department correction. And if is not reprocess able then reject the fabric & inform the dyeing department to replace the rejected quantity

List of Equipments:1. Computer 2. Light box3. Electric Heater4. Sample Dyeing M/C5. Electrical Balance 6. PH meter7. G S M Cutter8. Washing M/ C9. Shrinkage & spirality measurement instrument

Objectives of quality Control: Selection of raw materials Specification test Product testing. To ensure the product desired quality. To fulfill requirements for quality. Process control and development To control and different techniques will be required by different conditions. Quality assurance and so on. To evaluate accurately of the end product. To research and development Quality assurance and so on.

Quality Management system:

Quality assurance procedure may be provided by the following two major parts-

Quality control

On Line TestOff Line Test

Physical TestsChemical TestsOn Line Test: Fabric GSM control Grey Fabric Inspection with 4 point system Diameter and Width control Shade Check; Bias and Bowing; Visual appearance (Enzyme performance); Stripe.Off Line Test:Off line quality are divided into two groups-Physical Tests and Chemical Tests.

TEXTILE TESTING FOR KNIT FABRIC:COLOR FASTNESS TEST:1. Color fastness to washing2. Color fastness to rubbing/crocking3. Color fastness to perspiration4. Color fastness to water5. Color fastness to sea water6. Color fastness to light7. Color fastness to saliva8. Color fastness to saliva & perspiration9. Color fastness to phenolic yellowing

SHRINKAGE & RELATED TEST:1. Dimensional stability to washing-2. spirality/skewness-FABRIC/GARMENTS PERFORMANCE TEST:1. Pilling resistance, ICI BOX2. Abrasion resistance (martindale method)3. Pilling resistance (martindale method)4. Elongation & modulus5. Stretchability of narrow fabric6. Stretch & recovery7. spandez/lycra slippage(flex test)ANALYTICAL TEST:1. PH valueCONSTRUCTION ANALYSIS:1. Fabric weight2. Stitch density3. Fabric widthFABRIC/GARMENTS STRENGTH TEST:1. tensile strength 2. Bursting strength- 3. Seam performance4. Tearing strength

YARN TEST:1. twist2. Yarn appearance3. Yarn count4. Tensile strength 5. Tensile strength OTHER TEST:1. General appearanceQuality Control Flow Chart:

Yarn receiving

Sample Knitting BatchingDyeing (Check shade & Faults)

Dewatering

Drying (Check diameter, Pretreatment, Shrinkage Spirality and GSM)Compacting

Final inspection

If sample OK go for bulk production

Quality assurance:Quality assurance is defined as all those possible planned and systematic actions necessary to provide adequate confidence than a product or service will satisfy given requirements for quality. The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing.

Quality assurance at different stage:Assures the quality of the products of dyeing section in the following three steps: In laboratory In dyeing section & 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 buyers 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.

List of equipments:

In the quality assurance Department the followings equipments are used- Electronics Balance Iron Lab. Dyeing Machine Rota Wash Crock Meter Spectro-photometer with software (Data Color) PH meter

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 gray 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: Uneven shade Oil spot Neps Crease mark Machine Stoppage mark Listing Line mark Pick missing Double yarn Dead cotton Bowing Fly yarn contamination

Some test procedure are given below

G S M Test:GSM is the most important factor. There is a G S M Cutter. The Sample is cut then weighted in the electronic balance. The reading is then (in gm) from the balance, multiplied by 100, to get Value of G S M.

Finished Fabric dia:In Knit, dyeing finishing, finished diameter is Very important factor. It should be kept as the buyer requirements. Simply a measuring tape measures it. Finished diameter is controlled at compacting m/c.Color Fastness to Rubbing:Rubbing fastness is the resistance to color fading of dyed textile, when rubbing against a rough surface.Process The test specimen size 15cm x 15cm are taken Then place on the cork meter. (5cmx5cm) Cotton, desized, bleased but without finished fabric is attached to the cork meter finger. Rubbing 10 minutes at 10 second. Rubbings are test in two conditions.1. Dry condition and2. Wet condition Here gray scales are used and grade the fabric rubbing fastness according to the gray scale.

Color fastness to washThe resistance to color loss of any dyed or printed material during wash.

Chemical:

ECE Detergent4gm/l Sodium per-borate1gm/l Time 30 mine Temperature 60C Steel balls 25 Solution of chemical 150 ml (From 1 litter ECE or Sodium per-borate)

Required materials: Sample size 40 x 10 cm Multi-fiber at 40 x 10 cm ECE detergent (WOB)-4g/L Sodium Per-borate (Na2BO3.H2O2-1g/L)-1g/L Distilled water Normal cold water

Required instrument: Rota wash Scissor Stitch machine

Process:

The cut sample sized 4cmx10cm. Attach the multi-fiber with the sample. Sample immersed in 150ml solution of ECE or Sodium per-borate and put into the Rota wash m/c for 30 mine at 60C After that dry on oven. Here gray scale is used to measurement.

Changing After wash and before wash the sample.

Staining Color bled from sample to multi-fiber

Color fastness to light:

Purpose:Light fastness is the test design to evaluate the laundering fastness test of dyeing, Pigment which re to be made in comparison of result obtained on many test pieces treated under light.

Method: ISO

Apparatus: 1. Light fastness tester & blue scale2. Scale3. Scissor 4. Hard paper5. 4cm X 2cm

Process: Cut the sample specimen into (4X2) cm Stay the sample into the sun test m/c for 20 hour. Finally measure the color change with blue wool scale. Expectable value (5-8)

StandardRating

8Fast

7Fast

6Average

5Average

4Average

3Average

2Not fast

1Not fast

Result:The test result of light fastness test is equivalent to the class of standard 6.So we can say that the color fastness of dyed fabric is averShrinkage test:M/C Name:Washing m/cTemperature40 CTime(37-40) minutesWater amount20 litters

Chemical:

ECE Detergent20,40,50gm/l (According to the buyer requirement)

Sodium per-borate5.10gm/lProcess: At first wash the fabric sample in washing m/c with require chemical at 40C on (37-40) mine. After that dry the fabric in oven in required temperature. Before washing the fabric are marked with tame plate or measuring tape. After washing find out the length, chest, salvage or spirality change.

After wash Before washLengthwise: = ---------------------------------- 100 Before wash

After wash Before washWidth wise:= --------------------------------------- 100 Before wash

Maintenance:Maintenance is a process by which equipment is looked after in such a way that trouble free. Service and increased machine life can be ensured and specific product quality required by the customers is sustained. On time maintenance increase m/c lifetime & ensures trouble free services. Maintenance of machineries is very important for any type of industries and it is must for a knit composite factory. All machines and machine parts of knitting, dyeing and garments are maintained with extreme care. Because production quality and quantity, both depends on the maintenance with regularity.Objective of Maintenance: To keep the factory plants, equipments, machines. Tools in an optimum working condition. To ensure specified accuracy to product & time schedule of delivery to customer. To keep the machine down time to minimum thus to have control over the production program. To keep the production cycle within the stipulated range. To modify the machine settings to meet the need for the production.

Maintenance of Machinery:

MainenancePreventive MaintenanceBreak Down MaintenanceMechanicalMaintenanceElectricalMaintenanceMechanicalMa

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