Final industrial report (SQUARE Textiles Limited)

Introduction Industrial attachment is an essential part of four years course of B.Sc. in Textile

Engineering Bangladesh University of Textiles. I had the opportunity to perform the industrial

attachment at SQUARE TEXTILES Ltd. During 2 months long attachment, I studied the man,

machine, material aspects, quality control section, planning section, utility section, maintenance

section of the mill. There I learn about how a factory runs smoothly. How an administration

should be in factory also its environment how it affects workers work mentality. At SQUARE we

acquire our required knowledge about different yarn production process and Quality control,

From its raw material to dispatch. Various kind of yarn like normal card , normal comb, rotor

yarn, siro, inject, mélange , compact, organic, PC, CVC, white, double yarn, neppy, core spun,

slub yarn.Which gives us vast practical knowledge as a student of Yarn Manufacturing

Engineering .There I saw modern equipment of quality control like HVI, USTER, AFIS,

Tensojet, Autostretch 5C, Mesdanlab, NTDA. There I learn about different M/C and its

maintenance which is very much helpful to avoid Industrial Hazards. I also saw safety

measurement taken at the factory.

By achieving practical knowledge it is possible to apply the theoretical knowledge in the

Engineering field. For any Engineering study, practical experience is almost equally necessary in

organization with the theoretical knowledge. The industrial attachment is the most effectual

process of achieving the practical experience. It provides me 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.

According to my studies there I have prepared the following report and would like to

present.

1 SQUARE TEXTILES LTD

PROJECT DESCRIPTION

2.1. Project:

Name of the Project: Square Textiles Ltd. & Square Yarns Ltd.

Type: 100% Cotton and blend Yarn Manufacturing.

Year of Establishment:

There are 4 Unit which are situated inside the factory .They were established in different time.

Unit-01: 1995

Unit-02: 1998

Unit-03: 2000

SYL : 2006.

Address:Corporate Office:

Square Centre

48, Mohalhali Commercial Area

Tel: 02-8817729-38 & 02-8827729-38

Email: [email protected]

Factory:Vill-Saradaganj, Post-Kasimpur, Thana: GazipurSadar

Dist: Gazipur

Tel: 02-7701232, Fax: 02-7701321

Head Office:Mascot Plaza (10thFioor), 107/A, Sonargoan Janapath Road, Sector-07,

Uttara , Dhaka-1230.

Tel:02-8916163-65,02-8951101-8, Fax: 02-8916520.


tel:02-8916163-65,02-8951101-8

mailto:[email protected]

Fig : 2.1 Location map of Square Textiles


Sponsors:

• Samuel S. Chowdhury, Chairman.

• Mrs. Ratnapatra, Vice Chairman

• Tapan Chowdhury, Managing Director.

• Mrs. Anita Chowdhury,Director

• AnjanChowdhury, Managing Director.

Banks:

1. Standard Chartered Bank

SCB House, 67 Gulshan Avenue

Dhaka.

2. Bank Al Falah Limited

5, Rajuk Avenue, Dhaka

3. HSBC Ltd.

Anchor Tower

1/1 –B Sonargaon Road, Dhaka

Insurers

1. Pioneer Insurance Co, Ltd.

10, Dilkusha C/A

Dhaka.

2. Pragati Insurance Co. Ltd.

20-21, Kawran Bazar

Dhaka

Listing

1. Dhaka Stock Exchange (DSE)

2. Chittagong Stock Exchange (CSE


Fig: 2.2. Master plan of STxL


2.2. Product Mix:

Unit -01:

Card Hosiery & Comb Hosiery, organic, siro, slub, melange, inject, 100%

manmade(viscose ,modal , polyester).

Unit -02:

Card Hosiery & Comb Hosiery, compact, organic & rotor card woven.

Unit -03:

Rotor Card Woven, knit slub

SYL:

Blended (PC, CVC, melange, combed), double yarn, neppy, 100% polyester

Number of Spindle

Unit 1: 36288

Unit 2: 23184

Unit 3: 3192

SYL: 31248

2.3. DIFFERENT DEPARTMENT:

Department

Production Department.

Quality Assurance

Department.

Utility Department

Maintenance Department

HR &Administration

Department

Civil Department

Store Department

IT Department

Marketing Sales Department

Planning &Procurement

Department

Finance & Accounti

Remarks:

Square Yarns Limited is a well known export oriented spinning industry in our country.

They process many goods and their project is a big amount.


Manpower Management

3.1. Manpower management is the means of manpower control to ensure the most

efficient and economical use of available manpower.

Manpower Planning which is also called as Human Resource Planning consists of putting

right number of people, right kind of people at the right place, right time, doing the right things

for which they are suited for the achievement of goals of the organization. Human Resource

Planning has got an important place in the arena of industrialization. Human Resource Planning

has to be a systems approach and is carried out in a set procedure. The procedure is as follows:

Analyzing the current manpower inventory

Making future manpower forecasts

Developing employment programmes

Design training programme 3.2. Management System

Definition:

A management system is the framework of processes and procedures used to ensure that an

organization can fulfill all tasks required to achieve its objectives.

For example, an environmental management system enables organizations to improve their

environmental performance through a process of continuous improvement. An oversimplification

is "Plan, Do, Check, Act". A more complete system would include accountability (an assignment

of personal responsibility) and a schedule for activities to be completed, as well as auditing tools

to implement corrective actions in addition to scheduled activities, creating an upward spiral of

continuous improvement.

Table: 3.1 Organogram of different section

Adminstra

tion

Production Quality Utility Maintenance


http://en.wikipedia.org/wiki/PDCA

http://en.wikipedia.org/wiki/Organization

http://en.wikipedia.org/wiki/Procedure_(term)

http://en.wikipedia.org/wiki/Business_process

M.D G.M. A.G.M D.G.M Manager

E.D D.G.M Sr.Manager Sr. Manager Asst.

Manager

D.G.M A.G.M Manager Asst.

Manager

Sr. Executive

Factory

Manager

Sr.

Manager

Asst.

Manager

Sr. Executive Executive

Sr. Manager Asst.

Manager

Sr.executive Executive Sr.

maintenance

officer

Asst. Manager Sr.executiv

e

Executive Sr.asst.

officer

Maintenance

officer

Executive Sr.

Prodution

officer

Qua;ity

Officer

Asst. Officer Assit. Officer

Officer Production

officer

Sr.

Asst.Officer

Utility officer

Junior officer Worker Asst. officer

Sr. officer asst Lab assistant

Officer asst.

3.2. Organogram of different section


3.4. Management Apparatus in STxL

Board of Directors:Mr. Samuel S. Chowdhury Chairman

Mrs. RatnaPatra Vice Chairman

Mr. TapanChowdhury Managing Director

Mrs. Anita Chowdhury Director

Mr. AnjanChowdhury Director

Mr. M. Sekander Ali Independent Director

Mr. Syed AfzalHasanUddin Independent Director

Audit Committee:

Mr. M. Sekander Ali Chairman

Mrs. RatnaPatra Member

Mr. AnjanChowdhury Member

Management Committee

Mr. Tapan Chowdhury Chairman

Mr. Anjan Chowdhury Member

Mr. Mostaque Ahmed Siddiqui Member

Mr. Md. Kabir Reza Member

Mr. Md. AlamgirHossain Member

Company Secretary

Mr. KhandakerHabibuzzaman


Management Team

Mr. Mostaque Ahmed Siddiqui Chief Operating Officer

Mr. Md. AlamgirHossain Chief Financial Officer

Mr. Md. AbdurRashi Head of Factory

Mr. Md. Idris Ali Head of Utility

Mr. MajiburRahmanBhuiyan Head of Internal Audit

Mr. Sayeed Ahmed Chowdhury Head of Procurement & Planning

Mr. Mohammad Shohel Anwar Head of Quality Assurance

Mr. Md. NaziburRahman Head of Marketing

Mr. Md. Adam Ali Khondoker Head of HR & Admin

Mr. Tazul Islam Head of Maintenance

Auditors

M/s. Das Chowdhury Dutta & Co.

Chartered Accountants

Well Tower, 1st Floor, Flat-A/1

12/APuranaPaltan Line, Dhaka

In SQUARE TEXTILES LTD. the management system is

Intercom telephone

Fax and E-mail

Written letters and

Oral

Shift Change:

There are three shifts in the industry. So the shifts are changed after 8 hours. There are

A shift: 6:00 am to 2:00pm

B shift: 2:00pm to 10:00pm

C shift: 10:00pm to 6:00am

General shift: 8:00am to 5:00pm


3.5. Responsibilities of a Production Officer:

In the Back Process:

A production officer should enter the mill before 15 minutes of the shift starting for taking

over the shift. He needs to look at and assure the following things:

Stock of Mixing and Stock of Lack

Availability of Stock for the next shift

Humidity and Temperature

Doffer speed of Carding to face the shortage of feed material of the next process

Carding and Simplex should be in running condition always to ensure the feed material of

next process

3.6. Manpower arrangement in different section (unit-01)Section designation No of

machine

Shift Total

G A B C

Mixing Mixing man 4 59 59

FDP operator 4 - 5 5 5 15

Blow room operator 2 - 4 4 4 12

Carding operator 20 - 3 3 2 8

Drawing operator 15 - 5 5 6 16

Unilap operator 2 - 1 1 2 4

Comber operator 12 - 3 3 2 8

Simplex operator 8 - 7 7 6 20

Ring(male)

Ring(female)

Doffer

operator

72 - 39

50

39

51

38

51

116

152

Winding(male)

Winding(female)

B.shorter

operator

12 - 16

47

16

47

16

47

48

140

Packing(male) - 2 2 2 6

Packing(female) - 5 4 5 14

Table: 3.2

3.7. Training & Development


Training is the process of enhancing the skill, capabilities and knowledge of employees

for doing a particular job. Training process moulds the thinking of employees and leads

to quality performance of employees.

Training is crucial for organizational development and success .The benefits of training

can be summed up as Improves morale of employees ,less supervision ,fewer

accidents ,chances of promotion, increase productivity. SQUARE TEXTILES LTD

company is following the above theme for training & development .

3.8. Remuneration

Remuneration provides basic attraction to an employee to perform job efficiently and

perfectly. Salaries constitute an important source of income and determine their standard of

living. In Square Textiles Limited , employees get a standard figure of salary. They got their

salaries at the beginning of the month.

Remarks:

Manpower Planning is a two-phased process because manpower planning not only

analyses the current human resources but also makes manpower forecasts and thereby draw

employment programs. Manpower Planning is advantageous to firm. By using a proven

management system one can able to continually renew his mission, strategies, operations and

service levels.


Machine Description

4.1. Machine :

A machine is a device that applies force, changes the direction of a force, or changes the

strength of a force, in order to perform a task, generally involving work done on a load .

Machines are often designed to yield a highmechanical advantage to reduce the effort needed to

do that work.

A simple machine is a wheel, a lever, or an inclined plane. All other machines can be built

using combinations of these simple machines; for example, a drill uses a combination of gears

(wheels) to drive helical inclined planes (the drill-bit) to split a material and carve a hole in it

"Machines are worshipped because they are beautiful and valued because they confer power;

they are hated because they are hideous and loathed because they impose slavery" [Bertrand

Russell Sceptical Essays: Machines and the Emotions]

Machine description: square Textiles Ltd. use Rieter blow room line. The figure of the blow room line of the mill is given below-

Fig 4.1 : Rieter Blow Room Line


4.2. Machine description:

Square Textiles Ltd. use Rieter blow room line. The figure of the blow room line of the mill is

given below-

4.2.1. Blowroom:

4.2.1.1. Unifloc:

The foundations for yarn quality and thus the quality of the textile end product are laid in the

blow room process. Square uses unifloc A10 for unit-1 & unit-2 and unifloc A11 for unit-3 &

syl. The Unifloc A10 &A 11 processes the fiber material gently and efficiently into micro tufts,

from which impurities can be removed very readily in the subsequent processes. This effectively

supports the quality and economic efficiency of yarn manufacture.

Table 4.1

MODEL A10 A11

BRAND RIETER RIETER

ORIGIN SWITZERLAND SWITZERLAND

PRODUCTIO

N

1100 Kg/hr 1200 kg/hr

m/c speed 5-20 m/min 5-20 m/min

Take up depth 4-10 mm 4-10 mm


Fig 4.2: UNIFLOC A11

4.2.1.2. Uniclean:Square mainly uses B10 and B11 type machine. The UNICLEAN pre-cleaner cleans the micro

tufts in the first cleaning stage immediately after the Unifloc . This enables machine output of up

to 1100 kg/h to be achieved. Cleaning is performed without nipping and is therefore very gentle

to the fibers and at the same time efficient. This ensures a high level of raw material utilization.

M/C specification of B11 model is given below:


Table 4.2

Fig 4.3 : UNICLEAN B114.2.1.3. Unimix:


Model B11Brand RIETEROrigin SwitzerlandCleaning intensity

0-1

Relative waste amount

1-10

Production 1100 kg/hr

The mixing machine guarantees homogeneous, intimate mixing of the bale feed in a minimum of

space, even with unfavorable bale lay-down. The unique 3-point mixing process is equally

suitable for cotton and man-made fibers. 6 mixing chambers ensure not only effective mixing,

but also high production performance. The large storage volume of the Unimix provides the ideal

preconditions for a high degree of operating autonomy in the blow room.

Table 4.3Model B7/3 B70

Brand Reiter Reiter

Origin Switzerland Switzerland

Production 500 kg/hr 500 kg/hr

Mfg year 1996 2006

Effeciency 75% 80%

Fig 4.4 : UNIMIX B70

4.2.1.4. Uniflex :


Thus a very homogeneous batting laydown is formed both lengthwise and crosswise. The

adjustable chute depth determines the lap weight required depending on production and type of

fiber. The material is carried further by a perforated drum and a plain drum. The machine is

equipped with automatic lap intake, thus no manual intervention is needed when starting up the

fine cleaner. The feed roll supplies the material to the opening cylinder. The opening cylinder,

which is available in different versions depending on the requirements of the material, takes over

the material. The spinner can set the rotation speed of the opening cylinder according to his

objectives and raw material.

Table 4.4

Fig 4.5: UNIFLEX B60

4.2.1.5. THE COTTON SHORTER


Model B50 B60 LB5/6Brand RIETER RIETER LAKSHMIOrigin Switzerland Switzerland IndiaMfg year 1996 2006 1996Production 450 kg/hr 500 kg/hr 450 kg/hrEfficiency 75% 80% 75%

The cotton shorter in general detects differentiation in color, regardless of the material.

Therefore paper, tar, dark cotton tufts, colored synthetic material are recognized with high

accuracy.

Due to the color differentiation of cotton, The cotton shorter automatically recognizes and

optimizes after machine start the color grade of the cotton tufts. Hence, even contamination with

a similar color like the cotton tufts will be detected and ejected.

Table: 4.5

Model Sp-Fpu HRS-120 ED-351-

1200T

Brand Truttzschler loptex Jossi

Origin Germany Ittaly Switzerland

Mfg year 2012 2011 2006

production 400 kg/hr 400 kg/hr 400 kg/hr

Fig 4.6 : SP-FPU

4.2.1.6. Condenser :


Furthermore, the condensing process enables yarn hairiness to be reduced quite dramatically,

especially of hairs longer than 2 mm (Fig. 75), i.e. those hairs which cause the main problems in

downstream processing.

The condensing process also enables the abrasion resistance of the yarns to be improved.

This not only results in much better yarn abrasion test values, but also considerably reduces

deterioration in yarn quality during winding. All these quality advantages can be exploited by

spinning mill operators. In most cases even yarn twist can be reduced, resulting in higher

delivery speeds on the spinning machine.


Table :4.6

Model LA5/6 A20 A21

Brand LAKSHMI RIETER RIETER

Origin India Switzerland Switzerland

Fig 4.7 : Condenser-A21

4.2.2. Carding Machine

Carding may be defined as the reduction of an entangled mass of fires to a filmy wed by working

between two closely spaced, relatively moving surface clothed with sharp wire point. It is the

heart of spinning.

Table: 4.7


Model C50 C51 C60

Brand RIETER RIETER RIETER

Origin Switzerland Switzerland Switzerland

Production

Cylinder

speed

Rpm 473 rpm 504 rpm

Flat speed 0.29

m/min

0.29 m/min 0.22 m/min

Gauge of carding m/c

Feed plate to feed r/r = .15mm

Feed R/r to licker in = .9mm

Licker in to first knife = .35mm

Licker in to 2nd knife = .45mm

Linker in to cylinder = .25mm

stationary back to cylinder = 0 .35mm

Flat to cylinder = .35/.35/.3/.3/.3mm

Front plate to cylinder= 1mm

Back(top) plate to cylinder = 1.2mm

Front stationary to cylinder = .3/.3

Front knife = .3mm

Doffer to cylinder = .175mm

Doffer to stripping R/r = .15mm

Stripping R/r to delivery R/r = .15mm

Delivery to delivery R/r= .15-.125mm

Cleaning brush of flat = .15mm

Licker in dia = 253mm

Cylinder dia = 1290mm

Doffer dia = 500mm


Fig 4.8 : carding m/c C 60


4.2.3. Breaker Draw Frame

Modern high-performance draw frames are currently equipped with highly efficient extraction

systems which reliable remove a substantial proportion of the dust still present in the fiber

material. Dust, fiber fragments and trash are effectively separated from the fibers by fiber/fiber

friction during the drafting process in the draw frame and can thus very easily be removed by the

extraction system

Table: 4.8Model SB-2 RSB-1 RSB-951 SB-D-10 SB-D-40

Brand RIETER RIETER RIETER RIETER RIETER

Origin Switzerland Switzerland Switzerland Switzerland Switzerland

Drafting 4 over 3 4 over 3 4 over 3 4 over 3 4 over 3

Doublingrati 5:1 8:1 8:1 6:1 6:1

Fig 4.9: Breaker Draw Frame


4.2.4. Finisher Draw Frame :

Modern high-performance draw frames are currently equipped with highly efficient extraction

systems which reliable remove a substantial proportion of the dust still present in the fiber

material. Dust, fiber fragments and trash are effectively separated from the fibers by fiber/fiber.

Table: 4.9

Fig 4.10 : finisher Draw Frame


Model RSB-1 SB-2 RSB-D40 RSB-D45

Brand RIETER RIETER RIETER RIETER

Origin Switzerland Switzerland Switzerland Switzerland

Doubling 8:1 5:1 8:1 8:1

Delivery 700 650 700 700

Bottom R/r

dia

F-40mm,

M-30mm,

B-30mm

F-40mm,

M-30mm,

B-30mm

F-40mm,

M-30mm,

B-30mm

F-40mm,

M-30mm,

B-30mm

4.2.5. Unilap: A machine which produce lap from sliver.

Table: 4.10

Fig 4.11: UNILAP E 5/3


Model E5/3 E30 E32



Delivery

speed

100m/min 100m/min 100m/min

Doubling 24 24 24

Drafting R/r 30mm 30mm 30mm

Calendar R/r 50mm 50mm 50mm

4.2.6. Comber:Combing may be defined as the removals of short fibers, neps, and remaining impurities of

card sliver by using comber machine.

Table: 4.11

Model E60H E62 E65



Feed/nip 360

Nip/min 5mm

Doubling 08 08 08

Drafting sys 3over3 3over3 3over3

Noil % 8-15 8-15 8-15

Lap length 230mm

Lap wt 1000gr/yds

Delivery/ m/c 01 01 01

Efficiency 90% 90% 90%

OTHER SPECIFICAION

Comber brush dia: 85-110mm

Detaching R/r dia: 23-24.5mm

Delivery R/r dia: 45mm

Funnel: 3.5-7 mm(inner dia)

Calendar R/r dia: 45mm

Feed amount teeth: 17-22

Drafting R/r: 42-45mm

Fig 4.12 : comber m/c


4.2.7. Simplex: Simplex is the machine involved next to the drawing operation, where the sliver

is subjected to one or more attenuating process and the attenuated sliver receives a small amount

of twist and is then wound on a bobbin.

Fig 4.13: Simplex Electrojet


SPECIFICAION OF SIMPLEX

Table: 4.12


Model FL-16 FL-100 ELECTROJET

Brand TOYOTA Marubeni

Corporation

Tokyo

Electrojet

Origin Japan Japan Spain

Flyer rpm 1100 1100 1100

No. of flyer 120 120 120


Full bobbin dia 152mm 152mm 152mm

Top R/r dia 19mm 19mm 28.5mm

Bottom R/r d 28.5mm 28.5mm 28.5mm

Condenser 12-15mm 12-15mm 12-15mm

Apron (top) 38.8x40x1.4

mm

38.8 x 40 x1.4 mm 38.8 x 40 x1.4 mm

Apron(bottom) 37 x 40 x 1 mm 37 x 40 x 1 mm 37 x 40 x 1 mm

Wighting arm TexpartsPK-

1500-110938

Texparts PK-1500-

110938

Texparts PK-1500-

110938

4.2.8. Ring Frame:

It is the final step of produce yarn. Where feed material is roving and final product is yarn.

the main operation are involved in there are creeling, drafting, twisting, winding, building,

doffing, etc

Table : 4.13

Fig 4.14 : Ring m/c


Model FA-507A RX-240 LR60/AX

Brand ERFANJI TOYOTA LAKSHMI

Origin China Japan India

Spindle speed 18000rpm 18000rpm 18000rpm

No. of

spindle

128 128 120


OTHER SPECIFICATION:

Spindle to spindle distance: 70mm

Spindle wharve: 18.5mm dia

Spindle dia:

Cot R/r dia: 27-29mm

Arbar: 25mm

Creel: 27mm

Bottom R/r: 27mm(all)

Ballon control ring: 46mm

Ring cup: 38-40mm

Tin pulley: 200mm

Juki pulley: 70mm

Tap length: 2455mm

Tap thickness: 0.7mm

Bottom shaft: 40mm

Flange width: 1.5mm

Front to middle R/r dist.: 45mm

Middle to back R/r dist.: 57mm

Lappet hook dia: 3mm

Roller pressure: It may be different types. These are below-

Traveler number: It may be different types. These are below-


Front Middle Back

Green 14 kg 10 kg 12 kg

Red 18 kg 14 kg 16 kg

Black 10 kg 10 kg 10kg

arn count Tr. No. M/c speed

36/1 CH 4/0 16500

30/1 CH 3/0 17500

32/1 KH 3/0 17500

30/1 KH 3/0 15100

26/1 KH 2/0 16500

18/1 CH 1/0 16000

20/1 KH 1/0 16000

Spacer of ring frame:


Spacer is important parts of ring frame . it is place between middle of top and bottom

apron. It creates gap between two apron.

Selection of spacer:

For same count different color spacer is used then check performance (ends break rate,

quality criteria ) .Select spacer for this count which show opimum performance.

Ring cops:

Ring bobbin is a importants parts of ring frame.Yarn are winding here, so for better winding

it is important.

Colour of ring cops:

For separation of count different color of ring cops are used.

o Red old

o Red new

o Yellow old

o Yellow new

o Teya

o Green

o Chocklate

o Orange

o Black

o Sky

o Light blue

o Deep blue

o Ash

o Firoza


Spacer colour Spacer size (mm)

Red 1.8

Yellow 2.2

Lilac 2.5

White 2.8

Black 3.8

Beige 4.8

Green 5.5


4.2.9. Winding m/c:It is used for re-wounding of yarn into required suitable package.

Table: 4.14

Model AC

338

Savio

polar

Murat

ec

Orion

M

Brand Schlaf

thorst

Savio

polar

Murat

ec

Origin Germ

any

Ittaly Japan Ittaly

No. of

drum

60 64 60

Drum

speed

Splici

ng sys

Auto

matic

Auto

matic

Auto

matic

Auto

matic

Effici

ency

60% 65% 65% 60%


Fig 4.15: winding m/c


4.2.10. Rotor frame:The rotor spinning machine is the first final spinning machine to be practically fully

automated. Rotor spinning frame is a double sided spinning machine and works

according to the open end processing. The machine works with a discontinuous process.

The rotor spinning machine is also an excellent recycling device.

Table: 4.15

Model BT-

903

Autoc

oro

288

Autoc

oro

360

Brand RIET

ER

Schlaf

thorst

Schlaf

thorst

Origin Switz

erland

Germ

any

Germ

any


Fig 4.16 : Autocoro AC-288


Main parts of Auto coro:

1) Drive unit

2) M/c section

3) End unit

4) Spinning position

5) Spin box

6) Automatic piecer carriage

7) Pacakage doffer top cone

8) Starter supply carriage

9) Starter winder

1)Drive unit:

Informater

Corolab control component

Yarn guide drive

Left hand rotor drive

Combing roller drive

Auxiliary shaft drive

Changing gear drive

M/c control component

Frequency convertor

Starter winder

3)End unit:

Suction generator

Right hand motor

Trash removal drive

Package conveyor drive

Auxiliary yarn guide drive

5)Spin box:

Sliver feeding

Combing roller

Rotor

Take up drive


Other parts of Auto coro:

Naval

Coupling gear

Flexible coupling

Adapter

Washer

O.ring

Torque stop

Twin disc

Drum drive

Rotor type:

There are different type of rotor are used for different yarn count

Table: 4.16

Rotor type Count (Ne)T-533 12-14, SlubT-540 7-10TT-540 7-16, SlubT-546 6

Material passage:

Sliver can

pre condenser

condenser

feed roller

combing roller

fibre channel

adapter

naval

rotor

take up device


4.3. Heat setting:

This machine is used for increasing yarn moisture content. In Square Yarns Limited, There have

only one machine for doing this.

Machine name Heat setting

Brand name Elgi Electric

Origin India

Main specification:

Heat set time 55 minute

Temperature 600c

Pressure 5 kg/cm2

Fig 4.16 : Heat Setting Machine


4.4. Machineries: Machineries used in square Textiles Ltd. For processing fibres into yarn are:

Table 4.17: Machinery Of Unit-1

Sl. Machine Name Type/Model

Installation Date

Quantity Mfg. By

1 Unifloc A 10 1996 1 Rieter Machinery Ltd.

Switzerland.2 Uniclean B 10 1996 1

3 Cotton Sorter SP-FPU 2012 1 Truttzschler,Germany

4 Unimix B 7/3 1996 3 Rieter Machinery Ltd.

Switzerland.5 Uniflex B 50 1996 2

6 Condenser LA 5/6 2007 1 Lakshmi,india7 MBO LB

3/6R1996 1

8 Carding C50 1997 19

Rieter Machinery Ltd.

Switzerland

9 Carding C51 2000 110 Breaker Draw

FrameSB2 1996 1

11 Breaker Draw Frame

SB951 1996 3


RSB1 1996 1


SB D40 2006 1

14 Unilap E 5/3 1996 115 Unilap E 32 2000 116 Comber E 60H 1996 617 Comber E -62 1996 418 Comber E-65 2006 219 Finisher Draw

FrameRSB

D402006 6

20 Simplex FL 16 1995 821 Ring Frame FA507

A1995 72 ERFANAJI, China

22 Winding Machine

Autoconer 338

1996 5 Schlafhorst, Germany

23 Winding Machine

Savio Polar 2012 6 Savio Polar , Ittaly

24 Winding Muratac 2002 1 Muratac , Japan


Machine

Table 4.18 : Machinery Of Unit-2

Sl. No.

Machine Name Type/Model

Installation Date Quantity

Mfg. By

1 Unifloc A 10 1998 1 Rieter Machinery Ltd.Switzerland.

2 Uniclean B 11 1998 1

3 Verio Clean LB 9/2 19/7/12 from unit 2 1 Lakshmi,india4 Cotton

Sorter(Loptex)HRS12

016/11/11 1 Ittaly

5 Cotton Sorter SP-FPU 23/5/12 1 Truttzschler,Germany

6 Cotton Sorter Vetal Scan 9/10/12 from U-3 1 Lakskmi,India7 Unimix B 7/3 1998 3

Rieter Machinery Ltd.Switzerland.

8 Uniflex B 60 1998 29 Finecleaner B 50 9/10/12 from U-3 110 Mixing Bale

OpenerB ¾ 1998 1

11 Condenser A 21 27/2/13 112 Carding C51 1998/A18,2000/

A19,200215

13 Carding C51H 1998 414 Aerofeed A70 1998/A18,2000/

A19,200219


SB2 1998 2

16 Finisher Draw Frame

RSB-D30 1998/2001 6


RSB-1 1996 1


RSB-D45 A1-13/3/13 from U-4 2

19 Unilap E 30 1998 120 Unilap E 32 1/5/10 From U-4 121 Comber E65 2009 7


A1&A2,4 /7/11 From U-4

22 Comber E62 2006 A8&A9-9/7/12From U-1

4

23 Comber E60H 1998 324 Simplex FL 100 19998 A5-2007,A6-

20086 Marubeni

Corporation Tokyo,Japan

25 Ring Frame LR60/AX

A1-11/9/12& A2-04/9/12

2 LMW,India

26 Ring Frame RX-240 1998 21 Toyota, Japan27 Rotor BT 903 1998 4 RIETER

ElitexCzeck Republic

28 Autoconer AC 338

1998 6 W.Schlafhorst AG.&CO.Germany

Table 4.19 : Machinery Of Unit-3

Sl.

No.

Machine

Name

Type/Model Installati

on Date

Quantit

y

Mfg. By

1 Unifloc A 11 2000 1 Rieter Machinery Ltd.

Switzerland.2 Uniclean B 11 2000 1

3 Cotton

Sorter

ED-351-

1200T

2006 2 JOSSI,Switzerland

4 Unimix B 7/3 2000 2

Rieter Machinery Ltd.

Switzerland.

5 Uniflex B 50 2000 3

6 Condenser A 20 2000 2

7 Condenser A 21 2006 1

8 MBO B 7/3 2000 1

9 Carding C51-H 2000 15

10 Breaker Draw

Frame

SB D10 2000 6

11 Finisher draw

Frame

RSB

D30

2000 7

12 Finisher draw

Frame

RSB

D45

2011 1


13 Rotor Autocoro

288

2000 10 W.Schlafhorst AG.&CO.

Germany

14 Rotor Autocoro36

0

2002 1

Table 4.20 : Machinery of SYL

Sl. No.

Machine Name

Type/Model

Installation

Date

Quantity

Mfg. By

1 Unifloc A 11 2006 1


2 Uniclean B 11 2006 1

3 Unimix B70 2006 2

4 Uniflex B 60 2006 3

5 Cotton Shorter ED-351-1200T

2006 3 JOSSI,Switzerland.

6 Condenser A 21 2006 1 Rieter Machinery Ltd. Switzerland.

7 MBO 1 Laxmi,India.

8 Card C50 2006 14 Rieter Machinery Ltd. Switzerland.



10 Unilap E32 2006 2

11 Comber E60H 2006 8



RSB D40 2006 6

13 Simplex Rovemati CAF

2007 7 Electrojet ,Spain.

14 Ring Frame LR 6/A 2006 26 Laxmi,India.

15 Ring Frame EJM138JLA 2006 5 Erfangi,Shanhai,China.

16 Winding Machine

Orion M 2009 3 Savio,Ittaly.

17 Winding Machine

Autoconer,AC 338

2009 6 W.Schlafhorst AG.&CO.Germany.

Remarks: Square Textiles Ltd. Uses modern machines for thinking of quality. They also have a

developed testing laboratory equipped with latest developed m/cs

Raw materials

5.1. Raw material: A raw material is the basic material from which a good product is

manufactured or made, frequently used with an extended meaning Raw material is goods or

products which are used in manufacturing or unprocessed products which are used in the creation

of some final product. For example, the term is used to denote material that came from natureand

is in an unprocessed or minimally processed state, a raw material is the wood that is used to

make furniture, fibers to make yarn etc.

5.2. Raw material used in STxL

1.Naturalfibre

Cotton

Flax

Pima

CIMA

BCI

Organic

2.Regenerated cellulose

Viscose

Modal

Tencile

Excel

Promodal

Micromodal

3.Man madefibre

Polyester


http://en.wikipedia.org/wiki/Nature

Lyra

PVA

Acrylic

5.3. Name of fibre importer country

1.Cottonfibre

U.S.A

Brazil

Argentina

Mexico

India

Pakistan

CIS

Africa

Arbia

Cotton Supplier

Delco international

Sunny texim

Dewou international

Olam international

Cargil cotton

Four star group

Man madefibre

China

Korea

Malaysia

Indonesia

Thiland

5.4. Weight of Different cotton bales

Table: 5.1

Name of origin Weight in kg

U.S.A 230 -250

C.I.S 230 -250


Brazil 230 -250

Organic 230 -250

PIMA 230 -250

India 150 -160

5.5. Description of Cotton bale: Normally cotton bale contains cotton fibers, without

cotton fibers cotton bale also contains some contaminations. Following information is found in a

bale-

Binding material used for bales: Steel wire

No of binder: 10

Bale size: 95 cm x 80 cm x 59 cm

Bale weight: 220 kg

Tare weight: 2.6 kg

Bale loading & unloading system: It is done by FORKLIFT.

Capacity of raw cotton go down:20000-40000 bales

Bales used in per lay down: 28 bales

Bales consumption/day: 84 /unit

5.6. Contaminations of raw cotton : In raw cotton without cotton fibre all the material present

is called contamination.The contamination present in the raw cotton is given below:

• Black cotton • Wooden piece


• Piece of cotton cloth

• Color thread

• Piece of polythene

• Piece of white cloth

• Piece of plastic

• Polypropylene

• Bale covering cloth

• Color cotton

• Jute

• Hair and Wool

• Others

5.7. BALE FORMATION AT MILL:

Cotton fiber originated from seed, which is called seed cotton. In cotton plant several cotton pot

or ball produced. Cotton growing origins are USA, CIS countries, Egypt, Africa, Australia,

China and also India and Pakistan. In our country cotton is mainly imported from huge cotton

grower USA, CIS, Australia, Africa, Egypt etc. because cotton of India and Pakistan fails to meet

our demand from view of quality and quantity. During harvesting seed cotton pots are collected

from the plant which is known as picking of cotton. Picking can be done manually and

mechanically. Manual picking can ensure cotton pot selection, segregation and collection

separately. So manual picked cotton is less trashy but collection/production is very low. Again in

mechanical picking, production rate is very high but have no choice. Big cotton growing

countries like USA use mechanical picking which in the other hand reduce cost of cotton. After

picking seed cottons, fibers are separated from seed by ginning machine for subsequent

processing. Seedless cotton fibres are then compressed to bales of around 500 lbs for easy

shipment to users. Seed cotton process flow and a typical bale size (95cm*59 cm*80 cm)is

shown as below. inSquar Textiles Ltd.J-34(Indian) cotton is used.

Spinning mill purchase those cotton bales under contract of some fibre property like fibre length,

fineness, strength, trash content etc. But modern spinning mills test all fiber properties for each

and every bale under Id. no. prior use taking representative samples of about 4 ounces from both


side of each bale. For this, thousands of bales need to be tested within very short time where HVI

has no alternatives. HVI i.e. High Volume Instrument offers all possible fibre property tests at a

very high speed.

5.8. BALE MANAGEMENT:

Bale Management is a process of inventory control and selection of Bales of Fibers according to

their properties and also to mix the Fibers homogeneously to get consistent production and

quality of yarn, which is extremely important for production of knitted yarn. For Bale

Management, all of the Bale samples are tested and Bales with almost similar category are

arranged for homogeneous mixing.

5.9. Procedure of Bale Management:

Step-1: Bales provided by the vendor, are received in the plant, and Identification number is

given on each Bale, sample is taken from each of the Bale for testing, a number is added to each

similar to that provided on the bales. The bales are stacked in the storehouse.

Step-2:100% of the bale samples are tested on the fineness tester.

Step-3: A status report is prepared based on the MIC value of the tested sample.

Step-4:Range of MIC values are selected for specific count of Yarn. Generally MIC value 4.0 to

4.5 consider for hosiery .

Step-5:Production Department prepares a table for the Bales of similar category to be mixed.

Step-6:Bales are then transferred to Blow room Line, placed horizontally and mixing is done by

manually(stack mixing).

5.10. Quality of raw material:

Quality of cotton fiber is given below-

Table 5.2: Properties of cotton fiber


R/C Type Mic Mat Len SC

I

Str Unf SFI Eln

g

CG Rd +b Moist.

Indian 4.12 0.88 25.67 133 29.4 80.

2

11.2 6.0 31-3 68.

0

8.8 6.2

CIS 4.58 0.90 28.11 135 31.2 82.

8

8.9 5.6 21-3 79.

1

9.2 6.5

USA 3.97 0.88 29.56 149 34.0 83.

7

8.1 6.6 43-3 69.

4

8.9 8.3

Remarks: Raw materials of any process are very important. Because the quality of final product depends on the raw materials. For this reason better quality raw materials should be selected. For smooth running of a factory uninterrupted supply of raw materials is very essential.

Production Planning And Sequences And Operations

6.1. Production planning:

Production planning is the manufacturing process of preparing and producing goods and

services for use by consumers and other businesses. Depending on the size of the company,

production planning can be a detailed and lengthy process. Production planning has evolved over

the past several decades as business technology has increased the amount of information

businesses can use for production planning. This information has led companies to create

detailed production planning, which includes the use of schedules and electronic information for

producing goods and services.

The administrative process that takes place within a manufacturing business and which

involves making sure that sufficient raw materials, staff and other necessary items are procured


and ready to create finished products according to the schedule specified. Atypical large

manufacturing business engaging in production planning will aim to maximize profitability

while maintaining a satisfied consumer base.

The function of a manufacturing enterprise responsible for the efficient planning, scheduling,

and coordination of all production activities. The planning phase involves forecasting demand

and translating the demand forecast into a production plan that optimizes the company's

objective, which is usually to maximize profit while in some way optimizing customer

satisfaction. These twin objectives are not always synonymous. During the scheduling phase the

production plan is translated into a detailed, usually day-by-day, schedule of products to be

made. During the coordination phase actual product output is compared with scheduled product

output, and this information is used to adjust production plans and production schedules.

If the production or manufacturing process is viewed as an input-output process, then the

production planning function can be viewed as a control process with feedback .The control is in

The form of schedules and plans, while the feedback results from the comparison of the

production reports with the production schedules.

6.2. Flow Chart of Carded, Combed and Rotor Yarn Manufacturing process:

A flowchart is some such pictures from which it is understood that to solve the problem how

successively we have to move forward. The flowchart of carded, combed and rotor yarn

manufacturing process is given below:

Carded (Ring) Combed (Ring) Rotor


Carding

Breaker Draw Frame Breaker Draw FrameBreaker Draw Frame

CardingCarding

Blow Room Rooomroom

Blow Room Rooomroo

Blow Room Rooomroo

Table 6.1Process flow chart of PC(KH), CVC (KH) and Melange yarn:

PC(KH) CVC (KH) MELANGEHand mixing Hand mixing Hand mixing

MBO MBO MBO

Uniclean Uniclean Uniclean

Unimix Unimix Unimix

Uniflex Uniflex Uniflex

Condenser Condenser Condenser

Carding Carding Carding

Breaker Drawing Breaker Drawing Breaker Drawing

Finisher Drawing Finisher Drawing Finisher Drawing

Simplex Simplex Simplex


Marketing

Winding

Heat Set /Conditioning

Packing

Ring

Packing

Simplex

Marketing

Finisher Draw frame

Marketing

Finisher Draw frame

Packing

Unilap

Finisher Draw frame

Simplex

Ring

Rotor

Winding


comber


Ring Ring Ring

Winding Winding Winding

Heat Setting Heat Setting Heat Setting

Packing Packing Packing

Core Spun Yarn:

Core spun yarn are consist of two portion one is core portion and another is sheath portion.

Normally sheath are consist of natural or manmade fibre and core is consist of filament or

elastomeric fibre. Normally we use Lycra as an elastomeric fibre.

Process Sequence of core spun yarn :

This process is as like as ring yarn but here core portion like lycra introduces in ring

section at front zone.

Table 6.2 :core draftCount (Denier ) Core Draft

40 3.2-3.5

70 3.5-3.8

Compact Yarn:Compact Yarn is a yarn which has lower hairiness means there is less no of protruded fibre

and C.S.P is higher compare to normal yarn .

Process Sequence of Compact yarn:

This process is as like as ring yarn but here after front roller of ring frame extra Elite

unit is introduced. By this triangles are reduced and maximum fibre are participate during

twisting which reduced the hairiness.

Specification of Elite unit :


Elite Cot dia : 37 mm

Front Cot to Elite cot : 1.88mm

Latice apron length: 39mm (Susan)

Compact Spinning angle: 00/900

Elite air suction: 36 P.S.I

SlUB Yarn:

Slub yarn is a yarn which has various thickness at its length.

Process of producing slub yarn:

It is same as Ring yarn production but here SERVO motor is introduced in ring frame which

control the feed roller speed. Its creates various speed to the feed roller which various draft. It is

the reason for its different thickness

Point should be considered during Slub attachment:

1) Slub length

2) Slub dia

3) Interval length

How can we measure slub dia:

If slub length is 5 cm . Then we cut 10 slub parts length 4 cm (for actual length) and 10

sample for interval length. Then we weight individual sample . If slub sample weight is two

times than interval sample then it is called Slub dia two times .

NOTE: Slub count determined including both slub and interval yarn

Table 6.3 : Slub Attachment

Count Slub

Length

(cm)

Interval

Length(cm)

Dia% T.M

Weaving Slub

10 2.5-5.5 40-60 1.60 5.12

20 3-5 10-25 1.75 5.02

Knit Slub

24 3.5-6.0 25-40 2.0 4.3


30 3.5-6.0 20-60 2.0 4.55

Process mapping :

Process mapping means how a new process are running in the production floor.For

separation of different process different color can and bobbin brand, cops are used.

Flow chart of process mappingName of m/c Remark

Blow room Line -1

Carding 8-14, green elastic of can brand

Breaker draw frame 1-2, red elastic brand

Unilap 1, require blue mark

Comber 7-14, light blue elastic

Finisher draw frame 4-5, light blue elastic

Simplex With out cap

Ring frame 1-11, red cops

Winding 7 (1-26 head), with steaker


6.3. Production Parameters:

Production parameter of different machine is given below-

Blow room Line:

No. of blow room line = 3 ( U-1,U-2,U-3,U-4)

In every unit there are two line starts with unifloc and the third line is start with Mixing Bale

Opener

Production Capacity of Blow room:

Line 1 :500 – 600 kg per hour

Line 2 : 500 – 600 kg per hour

Cleaning efficiency of Blow room : 75%

Wastage : 4%

6.4. Process parameter for different process running in different Unit:

In Unit-1 mainly 100% cotton, Blended (e.g. 50% modal+50% Cotton), 100% Moadal, 100%

polyester

In Unit-2 mainly 100% cotton, Rotor (OE,super,normal,knitting)

In Unit-3 mainly Rotor (OE,super,normal,knitting)

In Unit-4 mainly Blended (PC, CVC, PV),100% viscose , Cotton Millange, Grey Millange

produced


Process parameter for different process running in different Unit is discussed Below

Process Parameter (cotton) Table 6.4:

M/C Parameters Setting Stxl unit-1 Stxl unit -2 SYL

Uniclean

Cleaning Intensity 0.7 0.5 0.5Relative Waste Amount 8 6 6

Uniflex Cleaning Intensity - 0.6 0.3Relative Waste Amount - 7 6

Carding Sliver Ktex 5.2 5.2 7.5Delivery Speed 54.6kg/hr 54.6kg/hr 75kg/hrCylinder Speed 480 480 850L-in Speed 1500 1500 1400Flat Speed 0.24 0.23 0.37Gauge 0.25/0.225/0.20 0.25/0.225/0.20 0.25/0.225/0.20

SB2/Breaker

Sliver Ktex 4.9 4.9 4.9Delivery Speed 750 750 700Zone Setting 39/44 39/42 39/44Condenser 4.2 4.6 4.6Web Funnel 8 11 8

Unilap Sliver ktex 80 75 75Delivery Speed 100 120 120Zone Setting 44/48 42/44/46 45/48

comber Sliver ktex 4.9 4.9 4.9Main Distance 42 41 45/50Nip/min 300 350 400Feed/Nip 4.7 4.7 4.7

Finisher Sliver Ktex 4.9 4.9 4.82Delivery Speed 500(c)/650(k) 450 500Zone Setting 39/45 40/44 40/45Web Funnel 4.2 4.2 4.2Condenser 8 10 8Scanning Roller Load 320/320/320/200 120 6mbar/120

Simplex Roving Hank 0.69 0.8 0.79TPI 1.05 1.07 47(TPM)Spacer Green Cream CreamDelivery Speed 1050 1050 1000Zone Setting 37.5/49.5/55.5& 37.5/49.5/54 48/50/54Back draft 1.19 1.19 1.17Arm Pressure Red Green Green

Ring Zone Setting 44/54 44/54 44/57&42.5/60Back draft 1.30 1.29 1.3&1.24T.M/TPI(30Ne) 3.64 6.64 3.75&6.65Arm Pressure Green Green Green


Process Parameter (Modal/Viscose) Unit-1Table 6.5 :

M/C Parameters Setting100% Modal/Viscose 50% Modal/Viscose

Varioclean Grid bar setting 5/5/5/5 9/9/9/9Opening roller RPM 800/600 700

Grid Bar Angle

MBO 1 3Unimix 2 3

Carding Sliver Ktex 6.5 4.9Delivery Speed 35kg/hr 45kg/hrCylinder Speed 390/300 480

L-in Speed 980/450 1500Flat Speed 0.24 0.24

Gauge 0.25/0.25/0.25/0.30/0.30 0.25/0.225/0.20SB2/Breaker

Sliver Ktex 4.9 4.9Delivery Speed 500 500Zone Setting 46/46 46/46

Condenser 4.6 4.6Web Funnel 11 11

Unilap Sliver ktex - -Delivery Speed - -

Zone Setting - -Comber Sliver ktex - -

Main Distance - -Nip/min - -Feed/Nip - -

Finisher Sliver Ktex 4.9 4.9Delivery Speed 500 500

Zone Setting 45/49 45/49Web Funnel 10 10Condenser 4.6 4.6

Scanning Roller Load 380/380/320/200 380/380/320/200Simplex Roving Hank 0.90 0.90

TPI 0.766 0.908Spacer Blue Green

Delivery Speed 1050 1050Zone Setting 40.5/49.5/60.5 40.5/49.5/60.5Back draft 1.26 1.19

Arm Pressure Red RedRing Zone Setting 44/54 44/54

Back draft 1.39 1.30T.M/TPI(30Ne) 3.40 3.70Arm Pressure Green Green


Parameters For Winding Speed (m/min)

Table 6.6 :

Count(Ne) Normal/Blended:Process : 100% Cotton+Blended Modal,Viscose

Slub :Cotton+BlendedSlub

100% Modal/Viscose

Lycra Yarn

7 850 800 800 8009-10 1000 850 950 90012-14 1100 950 1050 950&1000(14Ne)

16 1300 1050 1250 100018 1400 1100 1350 1050

20-22 1450 1150 1400 110024-26 1550 1200 1500 1100

28&above 1600 1200 1550 1100

Yarn Tension Control in winding M/C

Table 6.7 :

Process Count(Ne) Pressure Min. Pressure Doffing Cycle Tension

PC/CVC/100% cotton

7 54 24 2010-16 52 22 2018-20 42 16 2022-38 35 12 2040-60 35 5 20

MH/CM 10-16 52 22 2018-20 42 16 2022-38 40 15 20

40&above 15 5 20PV/PVC 10-18 30 10 20

20-40 25 8 20100% PSF 10-18 30 10 20

20-40 20 7 20


6.5. Attachment For Diversified Product:

( 1) Slub attachment:

( a) R/F-01 , ( 8-24 ) , ( 47-48 ) , ( 51-53 ) => Bea Electronics ( b) R/F-( 25-28) , ( 39-45 )=>Caipo,Itali( c ) R/F-(49-50)=>Pinter, Spain

Total Slub Attachment=> 23+12+2=37

( 2 ) Core Yarn Attachment:

( a ) R/F-( 25-26 ) , (29-32)=>Capio,Ittali( b ) R/F-( 25-28)=>Pinter, Spain

Total Lycra (Core ) Attachment=> 6=6=12

( 3 )Lycra (Core ) Slub Attachment:

( a ) R/F-( 25-26 ) =>Capio,Ittali

(4 ) Inject Yarn Attachment:

R/F- ( 01-07)=> Bea Electronics , India

(5 ) Inject Slub Attachment:

R/F-01 Bea Electronics,India

( 6 ) Siro : R/F : 57

6.6. Production planning:


For production of 25 ton 30 Ne carded cotton yarn firstly it is required to take 29.0699 ton raw

cotton. Because 3o Ne carded yarn production 14 % wastage will occur. As each bale weight is

220 kg so 132.13 bales are required for this amount of yarn production. In Square Textiles Ltd.

each lay down contains 20 bales. So 6.6 ~7 lay down is required. Square Textiles Ltd. produce

20 ton/day, so 30 hours is required to produce 25 ton yarn.

6.7. Description of production process:

First the raw materials of the final product are taken. If mixing is necessary it is done. If

carded yarn is produced then the raw materials is passed through the blow room line m/c, carding

m/c, breaker draw frame, finisher draw frame m/c, simplex m/c, ring frame m/c and finally

winding m/c. Then the yarn is conditioned by Heat set m/c .If combed yarn is produced then two

extra m/c named Lap former m/c & Comber m/c is used between breaker and finisher draw

frame m/c in the carded process.

Monthly average production: 577748 Kg/Month

Monthly efficiency: 85%

Remarks: Production rate of any mill is important. Because the economic condition of the mill

depends on the production rate.


Quality Assurance System

7.1. Quality assurance

The quality of yarn produced should conform to the quality norms specified by the customer. It

is equally important that:

Quality assurance (QA) refers to the systematic activities implemented in a quality system so that

quality requirements for a product or service will be fulfilled. It is the systematic measurement,

comparison with a standard, monitoring of processes and an associated feedback loop that

confers error prevention. This can be contrasted with quality control, which is focused on process

outputs.

7.2. Quality Assurance Procedure:

Two principles included in QA are: "Fit for purpose", the product should be suitable for the

intended purpose; and "Right first time", mistakes should be eliminated. QA includes

management of thequality of raw materials, assemblies, products and components, services

related to production, and management, production and inspection processes.

this should be achieved without making any compromise in productivity, which otherwise affects

the yarn costing. Quality Control is concerned with sampling, specifications and testing as well

as the organization, documentation and release procedures which ensure that the necessary and

relevant tests are carried out, and that materials are not released for use, nor products released for

sale or supply, until their quality has been judged satisfactory. The Quality Control Department

as a whole will also have other duties, such as to establish, validate and implement all quality

control procedures, keep the reference samples of materials and products, ensure the correct

labeling of containers of materials and products, ensure the monitoring of the stability of the

products, participate in the investigation of complaints related to the quality of the product, etc.

All these operations should be carried out in accordance with written procedures and, where

necessary, recorded


7.3. Controlling quality:

i) Cotton & Raw Material Testing (Bale Management)

Cotton samples received will be tested against mill norms and a decision regarding purchase of

the lot or rejection will be taken. Lots which fulfill the quality norms will be purchased, and

100% testing of the bales from the lot will be carried out Bale Management should be strictly

followed.

ii) In-Process Testing & Process Optimization

In-process material at every process stage must be checked and wherever deviations are

observed, the process must be optimized by conducting trials.

iii) Finished Product Testing

Before the final product is being dispatched to the customer, the same should be checked against

the norms specified by customer. Non-conforming product must be packed separately and given

separate lot/batch number.

iv) Calibration of Testing Equipment

To arrive at reliable results, the testing instruments must be calibrated (Internally or by service

engineer as the case may be) as per the prescribed method and schedule.

There are four unit known as STxl 1; STxl 2; STxl 3; &SYL.The 1 st three unit STxl 1; STxl

2; STxl 3; which are certified by ISO 9001.


7.4. Quality control equipment:List of quality control equipment is given below-

Table no. 7.1 :

List of quality control equipment

Serial

no.

Machines name Quantity Manufacturer WORK

01. Uster HVI Spectrum 1 Uster Technologies,

Switzerland

Raw cotton inspectionSCI; Mic;SFI;Str;Elg;Rd; +b; C Grade; Trcnt

02. Uster HVI 900

(Zellewegeruster)

1 Uster Technologies,

Switzerland

Upgrade version of (1); maturity & moisture extra

03. Uster tester 5 1 Uster Technologies,

Switzerland

Yarn & sliver inspection;

Unevenness ; thick thin; hairiness; neps

04. Covatest (techno textile

testing technology)

1 Germany Same as uster 5

05. Uster AFIS Pro 1 Switzerland Raw material & sliver inspection Upgrade version of UsterAfis ; length; UQL(w)mm; SFC; spun length; (2.5%, 5%); IFC; maturity; Nep; SCN; NRE; TRASH

06. Uster AFIS 1 Switzerland SAME as 5

07. Dynajet(textechno 1 Germany Yarn’s weak point


textile testing

technology)

test

08. Ustertensojet 1 Switzerland Single yarn strength tester

Tenacity ;elongation; breaking force

09. Zweigle G566” 1 Switzerland Yarn inspection Full COPS Hairiness

10 Eureka EY12 (Eureka

Precision Instrument

Company)

1 South India Warp reel ;yarn count

11. Mesdanlab 1 Italy Yarn twist tester

12. NTDA (MAG SITRA

Ele Trash)

1 Germany Raw material inspection

Neps; Trash; Dust analyse

13. Board Wrapping

(MAG)

1 India Same as 10

14. Auto stretch 5C 1 India Yarn lea strength

15. HVI Rapid

Conditioning Cabinet

(SDL)

1 Switzerland Raw material inspection

Cotton conditioning

Table 7.2 :Quality control system;


PROCESSING STAGE

ONLINE QUALITY CONTROL

OFFLINE QUALITY CONTROL

EQUIPMENTS

RAW COTTON

VARIOUS FIBER PROPERTIES

HVI SPECTROGRUM: SHORT FIBRE%,NEPS,UM%,PERIODIC VARIATION AFIS.,AFIS PRO,

BLOW ROOM

FIBER CLEANING EFFICIENCY

CARDING SLIVER WT/YD,CV% SHORT FIBER%,NEPS,UM%,PERIODIC VARIATION

AFIS, AFIS PRO,USTER TESTER 5

DRAWING SLIVER WT/YD,CV%,SPECTROGRAM

NEPS,UM%,PERIODIC VARIATION,SPECTROGRAM

AFIS.,AFIS PRO,USTER TESTER 5

LAP FORMER

LAP WT/YD,NEPS AFIS.,AFIS PRO

COMBER SLIVER WT/YD,CV%,SPECTROGRAM,

NEPS,COMBER WASTE%

AFIS.,AFIS PRO,USTER TESTER 5

ROVING FRAME

CV%,SPECTROGRAM USTER TESTER 5

RING FRAME

HAIRINESS AAND BALLON SHAPE

SPECTROGRAM YARN COUNT,U%,CV%, NEPS,THICK,THIN

USTER TESTER 5,WRAP REEL & BALANCE

WINDING SHORT THICK,LONG THICK,NEPS,COUNT VARIATION,CLASSIMATE FAULT

U%,CV% USTER TESTER 5

PACKING CARTOON WEIGHTENING BALANCE

7.6. There is four minilab at each unit. Here is the list of the equipment


Unit 11. Eureka ( warp reel)

2. Optical yarn reader (Sub meter, thick, thin)

3. Fabric inspection

4. Fibro block(roving, sliver length measurement)

5. Merlin-spa 1803 ( spindle 18,lycra attachment)

Unit 2

1. Eureka (warp reel)

2. Fibro block ( sliver, roving length measurement)

Unit 3

1. Eureka (sliver, roving length measurement)

2. Eureka (warp reel)

3. Zwigle ( Germany, Type G-585/1 sub test)

Unit 4

1. Eureka ( sliver, roving length measurement)

2. Ele warp 10 ( warp reel, yarn count test)

3. Fibro block (India) ( roving , sliver length measurement)

4. MAG (solvics)

5. Statex ( Auto twist tester)

7.7. USTER HVI SPECTRUM:

1)Name of the equipment: Uster high volume instrument(HVI)

2)Objectives: To measure


MIC,length,maturity,strength,SFI,elongation,moisture,Rd,+b,colorgrade,trash area, trash

grade,uv.

3)Testing type

a)System testing

b)Module testing

Length and strength module

Micronaire module

color and trash module

4)Operating procedure:

a)Switch on the power of the machine.

b)Calibrate the color,mic, length, trash.

c)At first mic of the fibre sample is carried out followed by the color, length strengtest.

d) The print out of test result is obtained.

5) Pocedure method:

(1) Visual inspection of the printed individual and summery results.

(2) Bale management is carried out with Bias from these results.

Details about three modules:

a) Micronaire module:

I. Working principle- Air flow method

Fiber thickness, inter space, air pass, mic , fineness

II. Sample weight- 8.5 to 11.5 gm.

III. Application range of mic- 2 to 7

7.8. Color and trash module-

Working principle- Electro optical method

Colour grade is determined by combination of Rd and +b.


Rd-: Expresses degree of brightness

More Rd more brightness

Application range of Rd- 35 to

90%

+b:-

Express degree of yellowness

More +b more white cotton

Application range of +b 4 to

18%

Leaf grade-

Trash is expressed by leaf grade.

Application range of leaf grade- 1 to 7.

Working principle- for length : photo electric cell

For strength- Pneumatic

Length measurement:

UR= 50% span length/2.5% span length *100%

UI = ML/UHML*100%

Fibre length and uniformity is related to short fibre content.

SFI= 122.56-(12.55*UHML)-(1.22*UI)

7.9. USTER AFIS PRO :

Name of the Equipment :Uster Advanced Fibre Information System (AFIS)

objectives: To measure following fibre properties-

Nep (Cnt/gm)

Nep (um)

SCN (Cnt/gm)

SCN (um)

L(W) (mm)

L(W) (%cv)

SFC (W) (mm)

SFC (W)

(%<12.7)

UQL (W)

(mm)

L (n) (mm)


L (n) (%cv)

SFC (n) (%

<12.7)

IFC (%)

Maturity Ratio

Technical data :

Application range-

Number of fibres: maximum-1000 & default-3000

Sample weight-0.5 gm

Sample length : 30

Modules Testing:

Multidata testing module : UQL, SFC, Fineness, IFC, M.R Neps,

SCN, Dust, Trash, VFM.

Neps module- neps, SCN

Length &Dia module: UQL, SFC, IFC, M.R, Fineness

Trash module : Dust, Trash, VFM

Operating Procedure:

Switch on the power of the m/c

Select measurement from the main menu.

Select module

Select identifier

Select sample type

Input filename

Press start button.

Feed the prepared samples in the feed nozzie


The print out of the tested results could be obtained after the test.

Report Type:

AFIS quality report

results of each tested sample

Summary of the results with statistics

Graphical representation of each and every parameters e.g histogram etc.

Inspection : Visual inspection of the printed individual and summary test

results. Raw cotton selection is done from the measured neps, SFC,

Maturity Ratio etc. Test results help to select proper process parameter.

AFIS TEST SUMMARY

Table :7.3

Process Lay

down

After

Unifloc

After

Uniclea

n

After

Uniflex

Card

mat

Card

sliver

Sliver

(B/F)

Sliver

(F/F)

Ro

ving

Neps/

gm

242 231 256 281 309 74 71 67 50

NRE% 4.55% 10.82% 9.96% 9.96% 76.05% 4.05% 5.63% 25.37%

UQL 28.52 31.3 29.6 30.9 30.2 30.5 30.8 31.2 31

7.10. USTER TESTER-5:


Name of the Equipment : Uster tester-5 (UT-5)

Objectives : To test.

Thin -50% /km

Thick +50% /km

Neps +200% /km

U%

CVm

CVm 3m

CVm 10m

Hairiness

Number of Slots:

For Slivers: 1 Slot

For Roving:1 Slot

For Yarn : 2 Slot

Measuring Principle :

Electronic Capacitance Method.

Testing speed :

For Yarn: 400 m/min

For roving:50 m/min

For Sliver : 50 m/min

Quality parameters:

a) Unevenness- (Um%, CVm%) at different cut length

Cut length- For Sliver : 20 mm

For roving : 12mm

For yarn : 8mm

a) Imperfection index:

Thin place/km : at- 30%, 40%, 50% & 60% Sensitivity

Think place/km :at + 35%, +50%, +70% & +100% Sensitivity

Neps/km : at +140%, +200%, +280% & +400% Sensitivity

b) Hairiness (at different cut length and CV% of hairiness)

c) Periodic faults (mechanidal)


Operating System :

Switch on the power of the machine.

Select “Test Program” and then press recall button.

Write the changeable parameter through keyboard and start the test with

start button.

Feed the test sample manually through the proper guide. No interruption is

valid during test period.

The printer automatically prints a report along with diagrams just after a

test is being completed.

Electronic Capacitance Method.

7.11. Uster Classimate :

In the production of spun yarn, faults such as slubs, spun-in fly, hard piecings, long thin

Places result. These faults are to be avoided for two reasons: firstly, they cause breaks during

post spinning operations like winding, warping, weaving & knitting and secondly, they detract

(take away from) the aesthetic (relating to principle of beauty, taste & art) appeal of the fabrics.

Table: 7.4

Cross Section Length 0.1~1cm 1~2 cm 2~4cm Over 4 cmA B C D

+100% and above

A1 B1 C1 D1

+ 150% and above

A2 B2 C2 D2

+ 250% and above

A3 B3 C3 D3

+ 400% and above

A4 B4 C4 D4

7.12. Classification of Classimat Faults

The faults : A1, A2, A3, B1, B2, C1, C2, D1 & D2 are dependent on raw cotton and hence called

Raw material faults.


Determination of Classimat faults. It is recommended to test 300 km of yarn on the Classimat

system to determine the frequency of faults and express the results as number of faults per 100

km.

7.13. Quality Assurance Department

Table: 7.5

7.14. ELECTRONIC TWIST TESTER:

Name of the equipment : Twist Tester


ShortAbbreviationOf UsterStatistics

Standard as per Uster Statistics, 2001Meaning

Ne 30 KH Ne 30 CH5%USL 25%USL 5%USL 25%USL

CVm Co-efficient of variation of mass per 1m length

13.4 14.55 11.38 12.06

Thin/km Thin place(-50%) in one km of yarn

4 8 0.9 1.25

Thick/km Thick place (+50%) in one km of yarn

85 150 12 20

Nep/km Neps (+200%) in one km

140 200 29 42

IPI Imperfection Index. It is sum of. Thin, thick &neps

229 358 41.9 63.25

Hairiness (H) Total length of protruding fibres per unit length of yarn. So, the hairiness ‘H’ is the ratio of two length & therefore in simensionless.

4.8 5.35 4.3 4.6

CV-T Co-efficient of variation of count in he same bobbin.

1.45

CV-B Co-efficient of variation of count in different bobbins.

1.1 1.45 0.90 1.27

CSP Product of Count (Ne) &lea Strength in Ibs

2250 2250 2250 2250

Machine specification :

Sample clamp

load adjusting cursor

Scale

MAINTENANCE Level adjusting screw

Plum bob

Change leaver of untwisting direction ‘S’ and ‘Z’ twist.

Sample elongates and revolve chack

Handle for move the revolve chack.

Operating procedure :

Set the reference length (e.g. 10 cm) in the twist tester.

Adjust deflecting needle deflection ‘O’ degree as weight free.

Select proper weight from weight table.

Adjust deflecting needle again to the centre of the graduated scale

(i.e deflection ‘O’ degree)while attaching the sample yarn with real

end by fixed and rotating jaw.

Rotate the wheel against the twist in the yarn allowing the

deflection needle to move not or more than three graduations.

Rotate the wheel until deflection angle becomes ‘O’ degree again.

Report type : Calculation of twist per inch or cm from display

counter

Inspection: Check the twist variation and variation and take

necessary action.

7.15. Quality Reports:Category of Waste Cotton

Table: 7.6


Name of waste Cotton

Recovery On Consumption

Where To Found

Remarks

Hard Waste 1.00% Autoconer This waste Could not be recycled. It incurs production cost at per that of yarn production. So it tells upon productivity very adversely.

Pneumafil Waste

2.0% Ring Spinning machine

It incurs the same cast as Hard waste but it is recyclable. Usable for Open End Spinning.

Dropping # 1 3.0% Blow Room/Compactor # 2 & 4

Saleable. Good for Quilt making.

Dropping # 2 3.0% Taker-in dropping/Compact# 2 & 4

Saleable, Good for Quilt Making.

Flat Strip/Card Fly 2.0% Carding (Flat tops) Saleable. Good for Quilt making.

Sweeping Waste 0.80% All Sections. When Cotton is dropped on floor, becomes sweeping waste. In most of the case, they are good cotton but completely unusable owing to soiling. Salable

Filler Waste 0.50% A/C Fitters &Vouk drawing’s Filter box.

Salable

Roving 0.20% Simples Speed frame & Ring Frame

Usable For Open End spinning.

Comber Noil 16.0% Comber Filter Usable For Open End spinning.

Dust 0.50% In All Filter’s Completely Unusable.

Remarks: Customer buy justify product by the quality of the product. So quality of the product

should be maintained carefully. For this quality is checked in every step properly and advanced

quality assurance device should be attached in the processing machineries. . Quality assurance is


the link between production and customers, by which the desired quality can be produced which

meets the specification. Research and development can help for value addition through product

development, which can face competition in global market and satisfy the customers.


Maintenance

8.1. Maintenance :

Maintenance is a procedure by means of which we can maintain active functioning in operation

according to the behavior utility of a particular elements/substance. Machine, building and other

service facilities are subjected to deterioration due to their use and exposure to environmental

condition. Process if deterioration if unchecked culminates in rendering these facilities

unserviceable and bring them to a standstill. Industry therefore has no choice but to attend them

from time to times to repair and recondition them so as to elongate their life to the extent it is

economically and physically possible to do so. This is called maintenance that elongates machine

life and helps the machine to run smoothly. It is in this in the context that maintenance assumes

importance as an engineering function. It is made responsible for provision of a condition of

these machines, buildings and service that will permit uninterrupted implementation of plans

requiring their use.

8.2. Objectives of Maintenance:

There are many objectives of maintenance. These are -

To keep the factory plants, equipments, machine tool etc. in an optimum working

condition.

To ensure accuracy of products and time schedule to delivery to customers.

To keep the downtime of machines to the minimum thus to have control over the

production program.

To keep the production cycle to the stipulated range.

To modify the machine tools to meet the need for production.

To improve the productivity of existing machines and to avoid sinking of additional

capitals.

To reduce the maintenance costs as far as possible thereby leading to reduction in factory

overheads.

To prolong the useful life of the factory plant and machinery.


8.3. Types of Maintenance:

Preventive maintenance: Preventive maintenance is a predetermined routine activity to ensure

on time inspections or checking of facilities to uncover conditions that may lead to production

break downs or harmful depreciation.

Break down maintenance :In this case, repairs are made after the equipment is out of order and

it can not perform its normal functions.

Maintenance Procedure:

At the beginning of the maintenance operation, all the cover of the machines are opened and

machine is cleaned with a cloth internally. This is called general cleaning.Inside the machine all

machine parts, conveyor belt, spike lattice, different roller and gear are checked. At first find out

the problem and rectify problem.All the gears and chain of the machine are cleaned with oils or

lubricants as instructed by the manufacturer. Chain box is checked and jam is cleaned if

necessary.

Lubricant: GRXP 460(Used in PBL gear box)

Omella 320(Used in PIV gear box)

Maintenance carried out in the blow room:

Periodic maintenance: After 10 to 15 days.

8.4. Maintenance of carding machine:

Carding machine maintenance consists of following tasks-

Schedule maintenance

Find out the problem

Way of rectify

Setting adjustment

Existing setting check

Carding maintenance sequence after 18 days.


Schedule maintenance:

Schedule maintenance of carding machine consists of following tasks-

Cleaning the machine and machine parts by compressed air

Cleaning the cylinder by compressed air

Cleaning the flat by compressed air

Cleaning the doffer by compressed air

Cleaning the fixed carding segment

Find out the problem of different gear and belt

Grinding:

Grinding of carding machine is done according to the following-

1st grinding after 90 tons production

2nd grinding after 80 tons production

3rd grinding after 70 tons production

4th grinding after 60 tons production

Normally 4 times grinding possible

IGS grinding machine use doffer and cylinder

Emery fillet grinding machine use for flat

Grinding system: Table: 8.1

Flat Cylinder Doffer

Emery TSG TSG

stone Stone Stone

IGS IGS

Mounting:


Life time of wire approximately 300-350 ton production

Remove the faulty wire

Remove the rust by emery cloth

Wash by acetone

Wire mounting by mounting machine

Lakshmi mounting machine use for flat mounting

Graft mounting machine use for cylinder , doffer and T-in.

Wire company: Normally following company wire is used in carding machine-

1. Graf

2. Trutzschler

3. Beakerf

4. Toshin

5. ICC(Indian)

6. ECC(England)

Wire specification:

P-2040S×0.4-B8R

Here,

20 = height of wire

40 = angle of wire

0.4 = thickness of wire

8.5. Lubricating schedule of carding machine:


Lubricating points Lubricant Time interval

Flat tops driving gear box Omala 460/ Grxp-460/ Castrol Sp-460 3 years

Coiler driving gear box Omala 460/ Grxp-460/ Castrol Sp-460 3 years

Feed roller driving gear Omala 460/ Grxp-460/ Castrol Sp-460 3 years

Cylinder drive idler Ls-3 / KluberStaruragsNbu 12/300kp 3 years

Flat stripping motion gear Ls-3 / KluberStaruragsNbu 12/300kp 3 years

Coiler drive bevel gear box Ls-3 / KluberStaruragsNbu 12/300kp 3 years

Coiler head gear box Ls-3 / KluberStaruragsNbu 12/300kp 3 years

8.6. Maintenance of Lap former machine:

Lap former machine maintenance consists of following tasks-



Way of rectify

Setting adjustment


Lap former maintenance sequence comes after 30 days.

Schedule maintenance :

In schedule maintenance following works are done-



Cleaning the different gear and belt

Cleaning the top roller, feed roller, calender roller, conveyer belt

Cleaning the all cot rollers and all coil spring

Clean winding drum, lap plate, weighting plate, cut plate and table

Clean all cotton gears for cotton lapping

Clean fluted air pipe for air blowing in the winding zone

Clean top and bottom side of the conveyer belt

Clean all air piping

Clean all flexible suction line

Check tightness of gear fixing belt

Clean all suction duct line

Check the different gear and belt

Check the drafting zone

Check the all nuts ant bolts of the machine

Find out the problem of different parts

Rectify the problem

The whole machine is set sincerely

8.7. Lubrication schedule for lap former:

Lubricating Point Lubricants Frequency

Bearing PartAlvania Grease EP-2 15 Days

Open Gear Cardium compound D 15days

Roller Chain Tallus Oil –C-150 15 Days

Bearing Part Alvania Grease Ep-2 9 Months

Differ. GearOmala-150 6 Months


Differ.Gear Omala-150 6 Months

Reduction Gear Tellus-68 3 Months

8.8. Maintenance of Comber machine:

Comber machine maintenance consists of following tasks-



Way of rectify

Setting adjustment


Comber maintenance sequence comes after 15 days


The schedule maintenance tasks are-


Cleaning the different gear

Cleaning the top detaching roller

Cleaning the bottom roller

Cleaning the delivery plate

Cleaning the drafting zone

Cleaning the brush




Check the cylinder clothing

Inspection the top comb clothing

Inspection of different setting

Feed plate to detaching roller

Steel detaching to top comb


Depth of top comb


Rectify the problem


Change/Replacement:

Following parts are changed regularly-

Cylinder clothing(Normally one year)

Combing brush(After 6 month)

Top comb(Normally one year)

8.9. Lubricating schedule of Comber machine:

Lubricating points Lubricant Time interval

Can Bottom Chain

OMALA 150/ GRXP-150/

Castrol SP-150

1 Months

One way clutch Alvania grease ep2/

Castrol ap-2

5 months

Worm gear box for can Omala 150/ grxp-150/ castrol

sp-150

5 months

Gear end box Tellus-68/ castrol aws-68 5 months

Gear box for drawing Tellus-68/ castrol aws-68 5 months

8.10 Maintenance of draw frame machine:

Draw frame machine maintenance means-




Way of rectify

Setting adjustment


Draw Frame maintenance sequence comes after 15 days


Schedule maintenance means-



Cleaning the top roller(Petrol cleaning)







Rectify the problem


Special works:

Some special tasks are done in draw frame ,these are-

Top cot roller grinding(after 2 months)

Replacement of top cot roller(after 18 months)

8.11. Lubricating schedule of draw frame:

Lubricating points LubricantsFrequency

Gear end Box Tellus-68 180 days


Reducer Gear BoxOmela-320

120 Days

Spiral Gear Box Omela-320 120 Days

Ball BeringAlvania Grease-EP2 15 Days

Neddle Bering/End Bush Alvania Grease-R2 7 Days

8.12. Maintenance of Simplex machine:

Simplex machine maintenance means-



Way of rectify

Setting adjustment


Simplex maintenance sequence comes after 15 days


Schedule maintenance consists of following tasks-



Cleaning the top roller


Cleaning the cradle


Cleaning the guide




Check the different adjustment

Pressure arm cleaning




Apron resetting

Top roller resetting

Different gear oiling


Change/Resetting:

Following works are done after certain period of time-

Cot change (Normally one year)

Cot mounting by cot mounting machine (Short press)

Cot grinding by grinding machine

Berkolizing after grinding

8.13. Maintenance of Ring frame machine:

Ring frame maintenance means-



Way of rectify

Setting adjustment


Ring Frame maintenance sequence comes after 30 days





Cleaning the top roller



Cleaning the cradle


Cleaning the guide





Check apron, cradle damage

Pressure arm cleaning



Apron resetting

Top roller resetting

Different gear oiling

Rectify the problem


Change/Resetting:

Some changes are done after certain period of time in the ring frame machine, those are-

Cot change(Normally one year)

Cot mounting by cot mounting machine(Short press),

Cot roller grinding by grinding machine,

Berkolizing after grinding,

Ring gauging(After 2 month),Bottom roller gauge –6 month.

Spindle gauging(6 month),

Lappet gauging(monthly),

Traveler clearer setting(2 month),

Spindle oil change(After 4 year).

8.14. Maintenance of Rotor spinning machine:


Rotor spinning machine maintenance consists of following tasks-



Way of rectify

Setting adjustment

Rotor machine maintenance sequence comes after 30 days




Inside plate ,separator, naval clean by corium.

Central suction line open and clean.


Cleaning the guide






Different gear oiling-The whole machine is set sincerely

Special works:

Some extra work is done without above. those are-

Oil change after 1 Year.

Comber gauge and Separator gauge used when Rotor unit resetting.

8.15. Maintenance of Winding machine:

Winding machine maintenance means following tasks-




Way of rectify

Setting adjustment


Winding machine maintenance sequence occur after 15 days.

General cleaning every shift.


Schedule maintenance consists of following tasks-



Cleaning the bobbin chute

Cleaning the bobbin magazine




Rectify the problem

Setting adjustment: Following setting are adjusted-

Suction arm to cone holder (Normally 6-10mm,Empty cone).

Paper cone to drum: 2mm.

Bobbin to fixed belt cone: 8-10mm.

Bobbin peg central sensor to bobbin: 25-30mm.

Tension setting

Bobbin ejection setting

Bobbin angle setting (Normally 90o)


Length correction setting

Air pressure

Splicing setting

Blast time : (Normally 10-15 mile sec.)

Lubrication of Ring, Rotor and winding machine: Staburags NBU12,Polylub GA

352P,Kluberplex BE31222,Silicon oil 1000 are used for lubrication of Ring, Rotor and Winding

machine.

8.16. Maintenance tools and their functions:

Serial

no.

Tools name Function

1 Spanner To provide grip to apply torque o turn objects

2 LMT

3 Screw driver To drive screws or bolts with special slots through

mating drive system

4 Hammer To deliver an impact to an object

5 Torque Wrench To preciously apply a specific torque to a fastener

6 Adjustable wrench To be used with different size of fastener head

7 Combination Spanner To preciously apply a specific torque to a fastener

8 Open end Spanner To be used with different size of fastener head

9 Ring end spanner To be used with different size of fastener head

10 Cir-clip plier Used to hold object firmly for physical compression

11 Nise plier Used to hold object firmly for physical compression

12 Allen key (Star) Used to drive bolt and screw

13 Allen key (Special) Used to drive bolt and screw

14 Allen key (T-type) Used to drive bolt and screw


15 Allen key (Socket) Used to drive bolt and screw

16 Ratchet To move mechanical ports in one direction

17 Socket (Box) Used to fit different size of nuts & bolts

18 Puller Used to pull elements

19 Grease Gun To provide grease on required place

20 Flat file Used to cut something very slightly

21 Square file Used to cut something very slightly

22 Tumbler file Used to cut something very slightly

23 Round file Used to cut something very slightly

24 Flat level Used to level

25 Vernier calipers Used to measure little length

26 Filler gauge Used to adjust double seamer

27 Leaf gauge Used to adjust double seamer

28 Block gauge Used to adjust double seamer

29 Dial indicator To accurately measure small distance

30 Pressure gauge To measure pressure

31 Saddle gauge To maintenance saddle roller

32 Scanning roller gauge Used to scene roller shape and dia

33 Comber Special tools Used to comber maintenance

8.17. Cot grinding machinaries:

Cot grinding m/c is used for grinding of cot roller of different spinning m/c.For better

performance of cot roller after a certain period cot roller should be grinding.Machnaries used for

cot grinding is given below-

1)Berkol cot grinding m/c :By this m/c cot are grinding.


Specification of Berkol cot grinding m/c:

Origin: Switzerland

Per grinding reduce : 0.02 mm

Stone dia at frist: 200 mm

Stone dia when out: 150 mm

Stone auto cleaning: after 100 grinding

Stone is dressing: after 1000 cot grinding

Grinding rate: 3 cot/ minute

Fig. 8.1 cot grinding m/c

Grinding cycle:

Type of process Duration (months0

Lycra 2

Normal 3

2)Heat setting m/c:

Name of m/c:Berkol azing

Origin: Switzerland

Conditioning time: 3 minutes

Temperature: At starting- 37◦c Up to- 63-65◦c

3)Eccentricity and Taper tester:


Here two side of cot roller dia is measured and difference is measured.

Origin: India

Tolerable range: 0.5 mm

4) Sarbar cot grinding m/c:

Sarbar is cot grinding m/c by which draw frame, comber and unilap cot roller is grinding.

Here grinding is done by traversing of stone roller.

Table 8.2 Cot roller maximum and minimum dia

M/c name Maximum dia (mm) Minimum dia(mm)Ring (ERFANG RFA-

507 )29 27

Rotor (BT-903 ) 40 36Auto coro 28.5 24.5TFO ring (RY-2) 30 27.5Ring (lakshmi ) 30 27.5Compact (elit cot ) 29

4026.937.1

Simplex 28 26.5Drawing 38 36.5Comber drafting (E 60,

E60 H,E 62)45 42

Comber drafting (E 65 ) 39 36Comber detaching 24.5 23Unilap 39 36


Remarks: The maintenance department of SQUARE Textiles Ltd. is well equipped. It has

sufficient maintenance manpower including mechanical and electrical engineers. They do the

maintenance of the m/c even during the Eid vacation. Otherwise, they do the breakdown

maintenance. To increase the lifetime of the machineries and ensure the proper running of the

machinery.

Machine longevity depends on the proper maintenance. So maintenance of the machine should

be done timely and care.


Utility Services

9.1. Utilities:

Utility is an organization that maintains the infrastructure for a public services (often also providing a

service using that infrastructure). Utilities are subject to forms of public control and regulation ranging

from local community-based groups to state-wide government monopolies. (Common arguments in

favor of regulation include the desire to control market power, facilitate competition, promote

investment or system expansion, or stabilize markets. In general, regulation occurs when the

government believes that the operator, left to his own devices, would behave in a way that is contrary

to the community's best interests.)

The term utilities can also refer to the set of services provided by these organizations consumed

by the public: electricity, natural gas, water, and sewage .

9.2. Utility facilities :

Utility facilities are given below-

Table 9.1 Utility facilities

Utilities

Electricity (PDB and Generator)

15 M.W.

Steam (Boiler) 3000kg


9.3 Utility Department UTILITY

Electrical section Power house A/C, Chiller, Boiler

Utility (Elec+A/C, Chiller, Boiler, Generator) Maintenance

D.G.M

Sr. Manager (Electrical) Sr. Manager

Dy. Manager(P/H)

D.G.M.

Sr. Manager Dy.Manager

U-1 U-2 U-3 SyL Executive Executive

(electrical)

P/H-1 P/H-2 P/H-3 P/H-4 H.F.O

(At all unit there are Exe/ Sr. M.O / M.O)

A/C + Chiller + Boiler

(Sr. Executive)

Head of Mechanics, Helper(Unit wise)

Unit-1 Unit-2 Unit-3 SyL

1. Exe 1.Sr.Exe 1.Ass.Manager 1.Exe

2.Exe 2.Exe 2.Exe 2.Exe

3.Sr.M.O 3. M.O.3.Sr.M.O

4. M.O.4.M.O


Total manpower of utility:

1. Unit 1- 10 person

2. Unit-2 – 10 person

3.Unit 3 -13 person

4.Unit 4 (SyL)-10 person

9.4. Air compressor:

Compressed air:

Compressed air is required in the spinning section mainly for control purpose through valves

and cylinders. With the latest machinery and increased automation, use of compressed air has

increased substantially. In winding machine, the use of compressed air is for the purpose of

splicing of yarn.

Although, atmospheric air is free, its compression to the required higher pressure by air

compressors costs money as the compressors are operated by electric motors. With the rise in

power cost, it has become necessary to optimize compressed air consumption so that compressor

usage is curtailed thereby saving electrical power.

Type of Air Compressor Capacity Range

Table: 9.2

Reciprocating Compressor, Single Stage

Upto 50 cfm

Reciprocating, Two Stage 50-600 cfm

Screw Compressors 150-2500 cfmCentrifugal Compressors 2000-4000 cfm


Ring frame section:

SCD (Stationary cop doffing)

Tray moving

Cop gripping

Doffing bar in and out

9.5. Dryer:

It is to dry compressed air. Actually if wet air goes to

pneumatic system pneumatic valve, solenoid valve will be

defective frequently. Besides yarn quality may decrease.

Table: 9.3 Air Dryer

M/C name

Model Brand Year Qty Capacity – m3/min

Air Dryer

TE 121

KAESER

1998/2010 5 12

Air Dryer

TF 171

KAESER

1999 1 17

Air Dryer

TE 91 KAESER

1997 1 9

Air Dryer

DB 115

BOGE 2006 4 11

Air Dryer

DS 120

BOGE 2010 1 12

Air Dryer

DS 95 BOGE 2012 1 9

Winding section:

Cradle lifting

Suction mouth lifting

Retie pipe lifting

Tension device


9.6. Generator:

To provide the large amounts of steady power demanded by modern societies, large power plants

have been built. Most power plants make electricity with a machine called a generator.

Generators have two important parts: a) Engine/ Prime mover

b) alternator.

Generators use the principle of electro-magnetic induction, which exploits the relation between

magnetism and electricity. In large AC generators, an outer shell with powerful magnets rotates

around a stationary "armature" which is wound with heavy wire. As they move, the magnets

induce an electric current in the wire

9.7. Principle of generator:

Engine/Prime mover takes fuel (gas) then runs. Rotor of alternator is coupled with shaft of

engine. So when engine shaft rotates power is generated in alternator output terminal.


Fuel, GasEngine(Mechanical Energy)

Table: 9.4

In Square there is four power house in four unit and 1 HFO plant

Name of content Power house 1 Power house 2 Power house3 Power house 4

No of generator 4 3 3 3Model G3516 G3516Company Waukesha Caterpillar Waukesha Caterpillar Power generate 920 1025 1100 1950KVA 1281 1370 1288KW 1025 1100 1030Frequency 50 50 50Phase 3 3 3 3

No of wire 6 6 6

Excitation 33volts7.2amp

19volts5 AMPS

Generation 400 VA1849

400 volts1859 AMPS

No of frame 806 697

Rev/min 1000 1500 1000 1500

Max temp rise 105 ͦ C 105 ͦ C

Ambient temp 40 ͦ C

Insulation type Class f


Fig9.1: generator

9.8. HFO PLANT:

HFO means heavy fuel oil or Furness oil

Type : 4.1 MW Man Gegilski power plant

Company : MAGNUS Power PVT ltd

Capacity : 4.1 MW

Engine type : V type

No of cylinder: 16

There is 5 oil tank in HFO plant

1. Storage tank

2. Buffer tank

3. Day tank

4. Diesel tank

5. Sludge tank.


Fig9.2 : MW Man Gegilski power plant


Process how it run


ENGINEHTLT

Flow chart of power house:

9.9. Cooling tower:Main parts:

1. Housing2. Fan3. Motor

Main function:

Main function is to cool water. From Generator/ Chiller water driven to the

cooling tower by pump. After cooling water comes to engines. Thus it helps Generator / Chiller

in cooling system


CT1CT2

9.10. A/C plant:Air conditioning is the process of treating air also as to control simultaneously its temperature,

humidity, cleanliness and distribution to meet the requirements of "conditioned space". An air

conditioning system may use heating, cooling, humidifying, de-humidifying and filtering units of

combination of these depending upon the outside weather.

. Air conditioning plants are installed to maintain correct ambient condition for spinning process

to work smoothly. Norms of temperature and relative humidity for textile mills are established

through controlled experiments in laboratories and mills.

At SQUARE all A/C type is same

Brand: LUWA

Origin: Switzerland

At


Quantity :

Unit 1 Unit2 Unit 3 Syl7 set 6 set 4 set 4 set

Type: All induced forced type

Capacity: 350 TR; 700 TR

Water in: 28 m3/min

Water out : 33m3/min

Motor capacity: 7K.W.

Mfg. Company: Singapour

Colling water punp specification:

Motor capacity: 45 K.W.

1. UNIT 1 8 A/C2. UNIT2 4 A/C3. UNIT3 4A/C4. SYL 4A/C

Necessary information about A/C plant:

A/C number Supply Section

01 Carding m/c & Blow room

02 Blow room

03 Ring Frame

04 Ring Frame

05 Ring Frame

06

07

08

Ring Frame

Ring Frame

Winding/ Finishing


9.11. Chiller:A chiller is a device that removes heat from liquid using vapor-compression technology.

Chillers reduce the temperature of liquids (often water though other liquids can also be

cooled by chillers) for industrial applications. Chillers utilize four main components: a

compressor, an evaporator, a condenser and a metering device. Chillers operate with a

closed-loop system, which means that the coolant remains in the chiller and is recycled

across many uses. Closed-loop chillers contain a separate tank that filters and cleans the

coolant before returning it to the main storage area for re-use.

In Square textiles ltd Unit 1, 2 &3 the chiller use is given below

Unit1: There is 3 Chiller

Model: PHE0874444

Company: Macquee

Origin: U.S.A

Capacity: 400 ton of refrigerant(TR)

Type: centrifugal

Gas type: R134A

Bearing type: Sleepy type

Fan : induced force type

Consume: electric power

Nos: 3

No of cycle :1

Unit2: There is also three chiller

1. Vapor absorption Chiller

2. Steam fired Chiller

3. Hot water absorption chiller (Thermax)

Steam fired chiller:

Model: DW500


Company: Thermax

Origin: India

Capacity: 500 TR

Consume: Steam

Nos: 2

No of cycle :3

Dilute solution in absorber: Distilled water and lithium provide

Hot water chiller:

Model: LT525

Company: thermax

Origin: India

Capacity 320TR

Unit 3: there is one HOT Water Chiller and two Steam fired Chiller

Capacity: 260 TR

Company: Thermax

Origin: India

nos: 2

SYL unit: Absorption chiller consumes exhausted gas directly

9.12. Boiler:

A boiler is water containing vessel which transfers heat from a fuel source (oil, gas, coal) into

steam which is piped to a point where it can be used to run production equipment, to sterilize,

provide heat, to steam-clean, etc.

InSquare the boiler use is

Exhaust gas boiler

Capacity: 2.5 ton

Consume: Natural gas


Safety valve: 2

Wt of safety valve: 9.5 kg/ cm2

Cell & tube type : in cell there is water & in tube hot water

Exhaust temp: 450/500 ͦ C

Out temp: 200 ͦ C

9.13. Water softening system:

Water softening system makes hard water into soft water. It can be done by de mineralized process

Benefits of water softener:

Many industries require softened water for such uses as processing . Water softening systems are

installed in some municipal water systems for the dual purpose of protecting the plant equipment

and better serving industrial and residential users


Cooling tower Cold water

Raw water

Resin + softening

Hot water from M/C

Soft water tank

Soft water pump to M/C

There is 3 vessel among them

1st vessel is sand vessel

2nd vessel is resin vessel (softener)

3rd vessel standby vessel

Water Softening plant :

Treatment Capacity : 30 m3/hr

Pressure Filter Tank Size:

Height : 2133mm

Diameter : 914 mm

Resin Tank Size :

Height : 2133 mm

Diameter : 914 mm

Brine Tank Size:

Height : 1219 mm

Diameter : 609 mm

Regeneration Period: 2 hr 10 min

Regeneration Time :

Overflow : 30 minBackwash : 30 min

Type Of Resin: 540 g ,740 g

Salt consumption per resin : 100 kg


9.14. Other electrical equipment mostly use

Fig. 9.3 . Other electrical equipment

PLC( Programmable logic controller ):

It has some input output port. It sends an out signal to the SCU from specific input signal.

For example if door is open the respective limit switch or proximity switch give an input signal

to the PLC and PLC give an output signal to the SCU. Then SCU process the data and stop the

M/C showing the error. Safety circuit open or door open etc show on the display. In this case if

we by pass that limit switch or proximity, safety of that door only will not work.

Motor:

It converts electrical energy into mechanical. It is used to drive any rotating part like

cylinder ring shaft etc.

Frequency inverter:

It is used to vary the speed of the motor and also as motor saver , energy saver.


CKT Breaker:

To supply and cut the power and also to protect the over current. Normally it is operated

manually.

Magnetic contact:It makes contact between power sources (Breaker) to load (Motor, Coil etc). It is operated with

control CKT ( Push button switch, selector switch etc).

Overload: To protect over current.

Thermostat: To protect machineries from overheat. Normally used motor, dryer, refrigerator etc.

UPS( Uninterrupted power supply): It is power supply to provide power without interruption.

Power Unit:It’s function is to supply to control power of M/C to SCU and different switches.

Operating panel:

To perform M/C operation or to set up data initial start up everything is done by it. On/Off switch , jogging switch different key are mounted on it .

Limit switch: It is used to control the operation of M/C. It has two types of contact NO/NC. In case of any

movement of it’s limit bar . It’s NO contact becomes NC and NC becomes NO.It’s movement is

done by M/C’s door or any of the mechanical part.

Proximity switch:

It is used to control the operation of M/C . It has two types of contact NO and NC. IT sense the

presence of metallic item and when it sense some ones presence it’s NO contact becomes NC.

And NC becomes NO. It can be replacement of a limit switch.

Auto Leveling system:

The carding auto leveling system collects medium term variation by means of a micro

computer . At the in feed a measuring device detects cross sectional variation in the feed .Then


the microprocessor vary the speed of the feed roller, so that the variation of the feed is corrected.

A pair of stepped roller sense the cross section of the delivered sliver . Microprocessor compares

this measured value with selected nominal value and correct any deviation again by varying the

feed roll speed.

Spark detector:

IT is designed specially for detection of fast moving particles. The capacity of the detector

depends on distance, speed and size of the particles

minimum spark size: 3mm at .5 m

6mm at 1 m

Metal detector:

It is used to find any metal in pipeline and separate from cotton. The ejection of the product

takes place after the metal detector goes off

Pressure Switches: It is a switch which is controlled by pressure( suction or compresses air) . It’s

NO/NC contact becomes NC /NO after getting specific pressure.

Light barrier/Photocell:

It is used to control the operation of machine. It has two part receiver & transmitter and NO

/NC contact in it’s receiver part. Transmitter transmits ray beam to the receiver in normal

operation . When this ray beam is disturbed by something it’s NO contact becomes NC and NC

becomes NO.

LED:

(Light Emitting Diode): It is one kind of signal lamp to show the condition of machine.

Fuse:

When over current flows through the wire of M/C then the coil melts and it’s protect the M/C

from accident .

Remarks: SQUARE Textiles Ltd has good facilities for UTILITY department. It has well

established building, equipment, manpower to run the factory. Each and every section of utility

are well maintained and workers are well trained so the facilities can run smoothly.


Store And Inventory Control

10.1. Store and inventory control system:

A store is a place where things are stored, e.g. a ship's paint store.

An inventory control system is a set of hardware and software based tools that automate

the process of tracking inventory. The kinds of inventory tracked with an inventory control

system can include almost any type of quantifiable good, including food, clothing, books,

equipment, and any other item that consumers, retailers, or wholesalers may purchase. Modern

inventory control systems are almost exclusively based on barcode technology. Though barcodes

were initially developed to automate the process of grocery store checkout, their ability to

encode a wide variety of alphabetic and numeric symbols makes them ideal for encoding

merchandise for inventory applications. Inventory control systems work in real-time using

wireless technology to transmit information to a central computer system as transactions occur.

10.2. Classification of store:

Store

10.3. Raw materials store:

All the raw materials are stored in godown, near the blow room section. The raw materials are:

Cotton

Flax

Fleece

Polyester

Modal

Viscose

Tencel

Organic

Lycra


Raw material & wastage General (spare and packing material) Finished yarn

10.4. Spares:

In this mills required amount of spears of different machine are stored in mechanical store room.

All the shares are listed in a sheet which is controlled mechanical and maintenance personal.

Spares are arranged in store room according their size, quantity and requirements. There are

selves in store room to keep small spare parts. Different stationary used in the mill are given

below:

Sticker, formatting book, register, Raw cotton, wastage, yarn, chalan, quality certificate,

(MRR),gate pass, file, paper, pen, marker, calculator, paper connect.

10.5. Spare parts:

In Square Textiles differernt types of belt, bearing, bobbin holder, ring cup, knee break, apron,

top roller, gear, sensor, motor , diode, cable, bulb spark plug etc.

10.6. Finished goods:

Normally Spinning mill supplies its finished yarn to different fabric manufacturing industry. So

package yarns are stored for short time in the finishing section.

KH

CH

Inject

Siro

Neppy

Melange

Organic

Compact

White

100% polyester

Blended (viscose, modal )

Rotor

PC

Core spun

CVC

Viscose

Slub


10.7. Others:

Packing materials: Poly bag, Poly rope, Sticker, Sacks.

Remarks: SQUARE Textiles Ltd has individual stores for raw materials, finished goods etc.

There is enough space to store the finished goods. It has well security system and now it is

increasing the store area. The store for inventory control is satisfactory.


Cost Analysis:

11.1. Cost and cost analysis:

Costs are the values of all the resources (e.g., labor, buildings, equipment, and supplies),

tangible or intangible, used to produce a good or a service.

In everyday life we generally think of the financial or monetary cost of goods and services

we consume. The "price tag" is what we refer to at the store. It is a convenient measure of cost:

all the resources have readily available prices, and exchanges are based on monetary value.

Economists think of costs as consequences of choices. In the real world, resources are scarce.

Because resources are limited, all necessary interventions cannot be implemented. When

decision makers choose to implement a program, the resources expended will not be available

for other possible uses.

Cost analysis is an economic evaluation technique that involves the systematic collection,

categorization, and analysis of

program or intervention costs, and

cost of illness

11.2. Cost of the product:

Costing system mainly describes how the cost of the final product is fixed by the

company/beneficial. According to buyer/customers requirement at first the fibre is collected from

local and foreign suppliers. Then production cost of yarn is calculated. After that, the final cost is

fixed including some profit. Then the unit price is offered to the buyer for approves it.

Costing of the Products is done by the Consideration of the Following Factors:


• Amount of raw materials consumed

• Direct Labor

• Indirect Labor

• Factory Cost

• Officer and administrative cost

• Sales and distribution cost

• Profit, etc.

Table no.11.1

The table of cotton yarn price is given below:

Yarn count( Ne ) Carded

(US dollar /kg)

Combed

(US dollar /kg)

Slub

(US dollar /kg)

40/1 4.25 4.65 4.90

30/1 3.75 4.15 4.40

26/1 3.70 4.10 4.35

24/1 3.70 4.10 4.30

20/1 3.65 4.05 4.30

The table of blended yarn price is given below:

Table: 11.2

Yarn count( Ne ) PC (65/35)

(US dollar /kg)

CVC(60/40)

(US dollar /kg)

Melange(CM 90/10)

(US dollar /kg)

40/1 4.00 4.25 4.55

30/1 3.50 3.60 4.05

26/1 3.45 3.55 4.00

24/1 3.45 3.55 4.00

20/1 3.40 3.50 3.95

11.3. Raw material of cost:


Table: 11.3

Raw material Price in US dollar/kg

Cotton lint 0.379

polyester 1.341

BSF (viscose) 1.963

Viscose (long filament) 3.82

Table: 11.4

Corporate Operational Results of SQUARE Textiles LtdRESULTS

2011 2011 2010 2009 2008

Turnover (Net) 5,431,43 5,247,749 4,445,402 3,882,244 3,052,235

Gross Profit 980,853 1,070,758 886,759 533,374 463,216

Net Profit before tax 689,263 729,621 676,174 311,777 277,582

Net Profit after tax 581,038 620,178 564,769 260,634 236,530

Shareholders' Equity 4,486,731 4,061,542 3,571,239 3,119,404 2,964,646

Total Assets 6,153,122 7,225,737 6,605,934 5,508,282 5,807,897

Total Current Assets 4,389,591 4,804,457 4,301,132 3,224,730 3,437,050

Total Currecnt Liabilities 1,554,244 3,052,890 2,923,391 2,276,602 2,722,233Current ratio 2.82 1.57 1.4

1.42 1.26Ordinary Shares Outstanding 116,887,192 ,405,99 81,171,661

70,584,053 58,820,044 Face Value per Share 10 10 10 10

10Shareholders' Equity per Share 38.39 41.70 44.00 44.19 50.04Earning Per Share (EPS) 4.97 5.31 4.83 2.23 2.02EPS on Share Issued for Cash 23.06 24.62 22.64 10.45

9.39Quoted Price per Share (DSE) 102.80 111.20 209.80 111.5

117.3Quoted Price per Share (CSE) 101.70 111.5 207.80

111.37 118.00Price Earnings Ratio-DSE (Time) 20.68 17.46 30.14 30.22

24.90Price Earnings Ratio-CSE (Time) 20.46 17.50 29.86 30.265 25.05Cash Dividend Declared pe r Shar 1.80 1.60 1.60 1.60

1.8


Stock Dividend Declared 100:15 5:1 5:1 100:15 5:1

Total Dividend Declared (%) 33 36 36 31 38

Number of Shareholders 26,369 24,968 26,152 29,789 30,179

Human ResourcesExecutives 171 217 170 182

178Non-Executives 116 101 160 170

167Workers 1620 1590 1452 1532

1,520

Remarks: The costing of the product is most secret matter of the industry. They were not

interested to share the cost related data with us. So we could not collect detailed the price of the

product.

Marketing Activities

12.1. Marketing and marketing activities:

Marketing is an activity. Marketing activities and strategies result in making products

available that satisfy customers while making profits for the companies that offer those products.

Marketing activities are nothing but how one is going to handled the marketing mix (price,

product, place, promotion, positioning, people, physical evidence) in order to market his/her

product successfully. the various activities involved in handling the above mentioned comprises

the marketing activities.

Marketing activities are those things by you handle the marketing mix which are as follows:

Product

Price

Place

Promotion

Physical Evidence

People

Processes


12.2. Activities included in marketing:

Marketing activities are numerous and varied because they basically include everything needed

to get a product off the drawing board and into the hands of the customer. The broad field of

marketing includes activities such as:

Designing the product so it will be desirable to customers by using tools such as

marketing research and pricing.

Promoting the product so people will know about it by using tools such as public

relations, advertising, and marketing communications.

Setting a price and letting potential customers know about your product and making it

available to them.

12.3. Consumer of products:

SQUARE Textiles Ltd. is a 100% export oriented company. The main buyers of this factory are

given below:

SQUARE Knit Fashion Ltd

GMS Composited mills Ltd.

Evennce textiles Ltd.

Sinha textiles Ltd.

Hamid textiles mills Ltd.

Vyella textiles mills Ltd.

Envoy textiles mills Ltd.

Jamuna textiles mills Ltd.

12.4. Package level:

Package level contain following information

Yarn count.


Types of yarn

Code no.

Lot no.

Factory name.

Date of making yarn.

Weight in kg

12.5. Package Size:

Package size is given below:

Length of Packing bag =37”

Height of Packing bag =48” .

Bag weight = 51.3kg

A bag contains 24 cones.

Each cone contains 2.04 kg yarn.

Figure: 12. 3 :Yarn Package

12.6. Manpower:

Marketing plays a vital role in the field of displaying / showing the goods criteria of the products

to the buyer and to communicate with the buyer. There are about a lot of people in the marketing


section of the industry.Office marketing

12.7. Marketing strategy:

The marketing men at first analysis value of raw cotton present time and future time. If they see

that it will be better to buy cotton at present time, they will contract with foreign company by

L.C. immediately. Otherwise they will buy cotton in future time. The main task of marketing

strategy is -

Analysis the market.

Price strategy

How will act the market

100% export oriented

To take part on the economic condition of Bangladesh

To earn foreign currency

Marketing strategy is a very important factors to sale the products to the buyer. If the marketing

strategy is not so developed, it will be very hard to reach the goal. In Zarina Composite Textiles

Industries Ltd. mainly senior marketing officers, merchandiser and higher officials deal with the

buyer. There are some fixed buyers of the industry. The buyers give their orders continuously all

over the year. The marketing officers and the merchandisers communicate with the buying

houses to collect the orders.

12.8. Responsibilities and duties of sales man:

The main duty and responsibility of a sales man are-

Introductory call script


Standard call script

Create new customer by giving them concession

To introduce into new product.

To increase use procedure

To protect competition

To express the quality product for the customer

To analysis the test of customer

To bring stability of sales by following different techniques.

12.9. Responsibilities and duties of marketing officer:

Marketing officer is a very important person of a company .Dealing with the buyer and convince

the buyer is the main duty of marketing officer . A marketing officer also has some other duties.

The main duties and responsibilities of a marketing officer are given bellow-

Buying, Selling and Transportation.

Financing

Publicity and advertising.

Collection of marketing information.

Development of strategy for attacking and penetrating customer master list.

They analysis total consumption of yarn all over the year.

They produce a cost sheet of yarn

To take different steps by discussing with the high officials and merchandisers

To maintain a regular and good relationship between commercial officer and

merchandisers

To maintain a communication with the buyers and buying houses

Communicate with better criteria of the products

Actually the responsibilities and duties of marketing officer begins from getting order of buyer

and ends after receiving foods by the buyer. So, he should be always smart, energetic and


sincere.

Remarks: SQUARE Textiles Ltd. has a well learned marketing and merchandising team. They

always communicate with the buyers. So they can get order through the whole year.

CONCLUSION

The industrial training gives me the opportunity to work in mills. It is an experience of normal

academic learning,

This training gives me actual picture about man, machine, material, methods and market. I have

earned the direct knowledge about the raw materials, actual running condition of the m/c’s,

Works, technologist and administration.

This mill is a well-planned with enough expansion facilities . Working environment for the

labors is also good.

During my training I visited administration section, store, generator room, compressor section,

AC plant etc. Everywhere I got cordial behavior from all employees.

Above all this training for 60 days in the SQUARE Textiles Ltd.. has given me a new experience

for practical life.

Bangladesh University of Textiles has given me the field to perform the industrial attachment

with SQUARE Textiles Ltd. This attachment seems to me as a bridge to minimize the gap

between theoretical and practical knowledge. Undoubtedly, this attachment paved me the way to


learn more about Textile Technology, industrial practices, and industrial management and

production process.

Besides, this attachment gave me the first opportunity to work in an Industry and acquainted me

with the internal sight and sound of Textile Industries. I believe with all these, the experience of

the industrial attachment will help me future life as a Textile Technologist.
