WELCOME TO THE
PRESENTATION
Bangladesh University of Textiles
Report on Industrial AttachmentAt
METRO KNITTING & DYEING MILLS LTD.(From 01 July to 31 August, 2012)
Supervising TeacherRASHEDA BEGUM DINA
(Lecturer)Dept. of Wet Processing Engineering
Bangladesh University of TextilesSubmitted by
SERIAL NO. NAME IDENTIFICATION NO.
01 UDAY RAY 2008-1-046
02 ELIAS KHALIL 2008-1-048
03 QMD. IMRAN HASSAN 2008-1-073
04 MD. SAMSUL ALAM 2008-1-104
Export Growth Turnover
Project Descriptionsister Concerns
• Metro Knitting &
Dyeing Mills Ltd
(Factory-2)
• Bea-Con Knitwear
Ltd
• Mercer Design Tex
Ltd
• KB Traders ltd
• AAA Textile Mills
Ltd
• Panam Agrovet Ltd
Company Name: METRO KNITTING & DYEING MILLS LTD.
Type: 100%Export oriented composite knit Dyeing Industry.Product Mix:
100% cotton100% polyesterNylonPolyester Cotton blendGray mélange (15% Viscose 85% cotton, 10% Viscose 90% cotton,30% Viscose 70% cotton) Ash mélange (1% Viscose 99% cotton)
Address: : Ramarbag, Kutubpur, Fatullah, Narayanganj-1400,Year of Establishment: 1st Sept. 2000 Website : http://www.metrokd.comDepartments : Knitting, Dyeing, Garments, Maintenance & Store
Man power Management(Dyeing Section)GENERAL MANAGER
SENIOR PRODUCTION MANAGER
PRODUCTION MANAGER
LAB (QAD)
IN-CHARGE
ASST. IN CHARGE
SR. SUPER VISOR
SUPER VISOR
ASST. SUPER VISOR
LAB (COLOR MATCH
ASST. MANAGER
TECHNICIAN
ASST. OFFICER
OFFICER
SENIOR OFFICER
DYEING
PRODUCTION
OFFICER
ASST. SUPERVIS
OR
SUPERVISOR
SHIFT IN-CHARGE
FLOOR IN-CHARGE
OPERATOR
HELPER
FINISHING
PRODUCTION
OFFICER
ASST. SUPERVIS
OR
SUPERVISOR
SHIFT IN-CHARGE
FLOOR IN-CHARGE
OPERATOR
HELPER
Machine Description
SCLAVOS DYEING MACHINEORIGIN : GREECEQUANTITY: 10MAXIMUM CAPACITY: 1500 KGMAX TEMPARATURE:142oCMAX NOZZLE: 6WORKING PRESSURE: 2.8 BAR
THIES Dyeing MachineOrigin: GermanyMaxm Temperature: 130-135oCLoading per nozzle: 250kgCapacity: 250-750kg
FONG DYEING MACHINEORIGIN:CHINA MAXTEMPERATURE: 140oCNO OF NOZZLE: 1~8
CIRCULAR KNITTING MACHINEBRAND: MAYER& CIEPAILUNG, JUINN LUNG, LISKYQUANTITY: 106
STENTER MACHINEBRAND: BRUCKNER ORIGIN: GERMANYSPEED: 4-100 M/MINPADDER PRESSURE: 0.7-10 BARMAX. PRODUCTION: UPTO 10 TON / MACHINE
COMPACTING MACHINE
BRAND: TUBETEX ORIGIN: USASPEED: 5-35M/MINMACHINE PRESSURE: 20-35 BARTEMPERATURE:90-120oC
GARMENTS MECHINERIESBRAND:JUKI, PEGASUS, YAMATOBROTHER, UZU, OSHIMA, TOYOLOCK, HASHIMALEEWAI, NISSINTOTAL :1229
Raw Materials
Types of raw material used:1. Yarn2. Fabric3. Dye stuff4. Chemical and auxiliaries
FABRICS USED COMMONLY•Single Jersey•Lycra Single Jersey •1x1 Rib•2x1 Rib•2x2 Rib•Fleece•Terry
Sources of yarn:
1. Cotton (Both Carded & Combed)- Loyal, Malek, N.ZJabber, KeyaS.Q Gill, Mix, Israq, Negreeka, Multizim 2. Polyester
- India 3. Mélange
- Shamim spinning mill- Prime spinning mills - Thermex spinning mill
4. Lycra- Korea, Vietnam, china
MOSTLY USED
CHEMICALS• Caustic Soda• Soda Ash • Hydrogen
Peroxide• Glauber Salt• Hydrose
COMMONLY
USED DYES
•Begacron (China)
•Novacron (China)
•Remazol
(Germany)
•Levafix
(Germany)
•Supra (India)
•Sumifix(China)
•Dianix (Germany)
•Terasil (China)
Production Planning, Sequence & Operations
Production per day: • Maximum Loading capacity 100% (11.36 tons)• Possible maximum loading 80% (9.088 tons)• Total production per days (3 shifts) = 9.088 x 2.5
(considering 2.5 batch in 3 shifts)= 22.72 tons
.
PH
• Scouring PH – 10.5-11
• During H2O2 bleaching PH 10.5-11
• Enzyme PH – 4.5• Before dyeing (Leveling) PH – 6.5• Salt PH – 7-8• During reactive dyeing PH 10.5-11.5• During disperse dyeing PH 4.5-6.0• Softener PH – 6.5
2) TemperatureFor cotton fabric scouring: 105ºC During NaOH addition 65oC During H2O2addition 70oC Peroxide killing at 80oC Sequestering at 90oC Bio-polishing at 55oCFor cotton dyeing: Low brand – 45oC Medium brand - 600C Hot brand – 80oCo Migration for turquoise color at – 90oCo Optical brightening agent (OBA) atb 80oCo Polyester dying: 1000-1300Co Softener at – 45oC
3) Time:-For white shade 4-5hrs-For 100% cotton 8-10hrs-For 100% polyester 5hrs-CVC 2 parts 13-14 hrs.
4) M: L ratio:-For reactive dyeing M: L ratio maintained within 1:6
Cycle Time 2-3 mins
Reel Speed 250-300 m/min
Dyeing Parameter
32%
30%
30%
3% 2% 1% 1% 1% 1 Uneven dyeing
2 Running shade
3 Dye spots
4 Batch to batch shade variation
5 Crease mark
6 Roll to Roll
7 Soda spot
8 Others
Dyeing Faults
Uneven Dyeing Crease Mark Dye Spot
Soda spot Hole Resist spot
Machine used in finishing section:•Dewatering machine •Slitting machine•Dryer•Compactor (Open/Tube)•Stenter•Raising machine•Sueding machine•Padder
Knit fabrics are finished in 2 forms 1.Tubular form2.Open form
Effects of Finishing-Easy care. -Crease recovery. -Dimensional stability. -Good abrasion resistance. -Improved tear strength. -Good sew ability.- Soft or stiff handle. -Shine or luster.
FinishingTypes of Finishing:1. Mechanical Finishing (Used to control dimension to improve appearance & handle)2. Chemical Finishing (Used to make glossy protection. To improve performance or serviceability)
Flow diagram of open & tube fabric finishing
Quality Assurance System
Quality Control system mainly two types: 1. Online QC
Raw material ControlProcess ControlLaboratory test
2. Offline QC A. Physical tests
GSM test Shrinkage test Spirality test Tensile strength Abrasion resistance Pilling resistance Button Strength Testing Crease resistance Dimensional stability Bursting strength test
B. Chemical TestColor Fastness to washing. Color Fastness to light. Color Fastness to Chlorinated water. Color Fastness to water spotting. Color Fastness to perspiration. Color Fastness to Sea-water. Fiber analysis. PH test. Spray test (water repellency
Fabric Inspection
Grey Fabric Inspection
Grey Fabric Inspection is performed
according to 4-point system.
Maintenance of MachinaryRoutine/Schedule
Preventive Breakdown
Maintenance Tools and their Functions
Name of the Tools
Functions
L-Key Loosen and tighten the screw
Air suctioner Clean machines by suctioning
Screw driver Loosen and tighten the screw
Spanner Loosen and tighten nut & bolts
Star driver Screw unlocking
Pliers Cutting, Holding, Joining of wire, Gripping
Pulley Key To loosen pulleys
Maintenance
Utilities
Types of Generator:A.Gas Generator (Running) 1.Brand: Perkins, England Capacity: 400 KW 2.Brand: Waukesh, USA Capacity: 900 KWB. Diesel Generator (Backup) Brand: Perkins, England Capacity: 200 KW
Fig:Gas generator 1
Source of utilities:Electricity : PDB & GeneratorSteam : BoilerWater : PumpGas : Titas gas Ltd
Utilities services available in Metro Industries Ltd
ElectricityWaterGasSteam
Gas generator 2
Diesel generator
Boiler Brand: COCHRAN , Scotland Maximum Temperature: 188 Maximum Steam Output: 10 ton/hr Steam pressure: 7.5 bar
Boiler
Store & Inventory Control
Objectives Financial activities Property protection Operating
Scope of Inventory Control
Grey Fabric Store
Dyes & Chemical
Stores
Spare Parts
Finished Goods Others
Effluent Treatment Plant
Metro has Combined Bio-chemical ETP in the factory premises. The output of the ETP is about -200CBM/Hr)
Chemical Name Chemical Used
H2SO4 & HCl 25 Kg/Day
Lime 250Kg/shift
Alum 250Kg/Day
Polyelectrolyte 1 Kg/day
H3PO4 1 Kg/shift
Urea 1 Kg/shift
Consumption of the chemical used
Types of ETP
Physio-Chemical Chemical-Biological Biological
Discharge water quality of Metro Industries:pH = 6-9BOD = 50 mg/ LCOD = 220 mg / LSuspended solid = 145 mg/LColor = color less.
Functions of different chemicals used in ETP:
H2SO4 & HCl:Neutralize the water from alkaline state.
Ferrous Sulphate & Lime: To remove the color of the effluent.
Alum & Polyelectrolyte: To agglomerate the smaller particles. For sedimentation of the smaller particle.
H3PO4/Urea: For increasing the production of the bacteria.
Dyeing Cost Along with Dyes and Chemical
Sl. No. Types Of Shade Type Of Finishing Price/Kg
1 Light Color Tube Finish 65 Tk2 Light Color Open Finish 75 Tk3 Medium Color Tube Finish 75 Tk4 Medium Color Open Finish 85 Tk5 Dark Color Tube Finish 85 Tk6 Dark Color Open Finish 95 Tk7 Black Color Or Extra Dark Tube Finish 110 Tk
8 Black Color Or Extra Dark Open Finish 125 Tk
9 Deep Black Or Deep Royal Tube Finish 115 Tk
10 Deep Black Or Deep Royal Open Finish 125 Tk
11 Only Wash Tube Finish 25 Tk12 Only Wash Open Finish 35 Tk13 White Tube Finish 40 Tk14 White Open Finish 50 Tk
Finishing Cost
Serial No.
Price quotation of finishing Price
1 ONLY STENTER 20 TK/KG2 ONLY OPEN COMPACTING 15 TK/KG3 STENTER + OPEN COMPACTING 30 TK/ KG4 ONLY TUBE DRY 8 TK/KG5 TUBE COMPACTING 8 TK/KG6 ONLY SUEDING 25 TK/KG7 SUEDING+ STENTER+ OPEN
COMPACTING55 TK/KG
8 ONLY BRUSH 15-20 TK/KG
Serial
No.Fabrication
Knitting Price(Tk./Kg)
1. Single Jersey 8-10
2. Lacoste/PK 14
3. Terry 14
4. Fleece 18-20
5. 1x1 Rib 14
6. Interlock 18
7.Single Jersey E.
Stripe100
8. Lacoste/PK E. Stripe 120
Cost Analysis
Knitting Cost
Exporting countries:GermanyNetherlandJapanUKSingaporeCanadaUSA
Marketing Activities
So, that was the very brief of our Industrial attachment program. It excludes so many subjects and facts. In this short presentation its very hard to include everything we did and learned in that program.
Thanks for giving us the opportunity to do this presentation.
Conclusion