Dec. 9

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INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

YASSMA KNITTING & DYEING.

Dec. 9

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CHAPTER-1

INTRODUCTION

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INTRODUCTION

Industrial training is one of the most essential parts of engineering & technical education. This

industrial training is included in our syllabus to acquaint us with the practical implementation of

the technology studied within the industrial environment. Though it is very helpful & lays the

milestone for starting the carrier for fresh Textile graduates.

Wet processing which occupies a vast field in modern Textile technology is undergoing many

stages of processing. Many problems are generally being encountered during each operation

stage starting from desizing to finishing section. Finally from mill training, I learn practical wet

processing under industrial environment. I think it will be helpful in my future carrier life.

Industrial training is an indispensable part to study of practical knowledge of an industrial unit

for student of textile Engineering. YASSMA KNITTING & DYEING Ltd. is the 100% export

oriented industry in Bangladesh. The factory is concerned about knitting, yarn dyeing and knit

garments. Due to the changing environment the textile sector faced with challenge, But the

YASSMA KNITTING & DYEING Ltd. will fully prepare to face the situation.

I have completed my 6 weeks long industrial training in dyeing and finishing section of

YASSMA KNITTING & DYEING Ltd. These training enable me to avoid the gap between

theoretical and practical knowledge. The incumbent is deputed to YASSMA KNITTING &

DYEING Ltd. for practical industrial training program.

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CHAPTER-2

COMPANY

PROFILE

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Company Profile:

Factory Name : YASSMA KNITTING & DYEING Ltd.

Type : 100% Export Oriented Yarn Dyeing Industry.

Year Of Establishment : 01 January 2009

Investors : Md.

Address:

Factory Address : Plot/23-25,Adamjee-EPZ,Siddirgonj, Narayangonj.

Head Office & Corporate Office : Baridhara –DOHS, Banani, Dhaka.

Sponsors : Islami Bank, HSBC Bank.

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Vision:

To establish as a one stop source for the Global knit Apparel market and to satisfy and meet

customers expectation by developing and providing products and services on time, which offer

value in terms of Quality, Price, Safety and Environmental impact.

Assuring complete compliance with the international quality standards and also providing the

employees internationally acceptable working condition and standards. To promote the

development and to use human talent and equal opportunity of employment.

Mission:

YASSMA KNITTING & DYEING Ltd. realizes the need to take out a competitive segment in

the changing global market of today through technological excellence and human expertise.

YASSMA KNITTING & DYEING Ltd. is committed to transpose its local success to the world

scene.

LOCATION:

The Project is located at Adamjee,EPZ,Siddirgonj,Narayangonj. It is about 40

kilometers away from Primeasia University,Banani,Dhaka.

Main Products:

Dyed cotton yarn

Viscose yarn

Acrylic-cotton blend.

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Major Buyers & Fashion Labels:

H & M ESPRIT

C & A DECATHLON

MQ

PUMA

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CHAPTER-3

MANPOWER

MANAGEMENT

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Management System:

The company has skilled administration, management and marketing team guided by proficient,

dexterous & experienced leaders of offer right solution for the consumers with the right

eminence & with the shortest lead-time for the export market in Bangladesh.

The best use of continuous development of human resources by providing them International

standard equal opportunity is the keys for achieving comprehensive competence in all level of

the organizational hierarchy.

Total Shift :

2 shifts per day.

Shift Duration

General 9.00 am- 6.00 pm

A 8.00 am- 8.00 pm

B 8.00 pm-8.00 am

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Organogram of Dyeing Section:

General Manager

Deputy General Manager

Manager

Deputy Production Manager

Asst. Production Manager

Sr. Production Officer

Production Officer

Supervisor

Asst. Supervisor

Sr. Operator

Operator

Asst. Operator

Helper

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Responsibilities of Production Manager :

1. To plan the production schedule with capacity & volume of order.

2. To observe dyeing finishing.

3. To supervise senior production officer & production officer.

4. To rectify any kinds of problems during dyeing.

Responsibilities of Production Officer :

1. To check recipe.

2. Batch preparation & pH check.

3. Control of supervisor, operator, astt. Operator & helper of dyeing floor.

4. To match shade as required.

5. To find out dyeing & yarn fault as early as possible.

6. To recover the finished yarn this is rejected from quality department.

7. To register each batch dyeing condition.

8. To check daily production report.

9. To check water level in dyeing stage.

10. To maintain connection with finishing & quality control department.

11. To maintain connection with maintenance department etc.

Remarks :

There are a sufficient number of Efficient Textile Engineers & Technical persons. This is why

they achieved a very good reputation in Knit Dyeing Sector.

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CHAPTER-4

MACHINE

DESCRIPTION

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MACHINE DESCRIPTION

For yarn dyeing process,YASSMA KNITTING & DYEING Ltd. uses state-of-the-art machinery

of SSM Brand from Switzerland, FADIS and DETTIN from Italy, and STRAYFIELD from

England.

Yarn Dyeing Capacity: 20 Tons/day

Machine List:

TYPE BRAND MC. QTY.

TOTAL 86 Nos.

Yarn Dyeing M/C Fongs, China 48 Nos.

Yarn Printing M/C Laip, Italy 01 Nos.

Soft Winding M/C Fadis, Italy 02 Nos.

Soft Winding M/C SSM, Switzerland 13 Nos.

Hard Winding M/C Fadis, Italy 02 Nos.

Hard Winding M/C SSM, Switzerland 10 Nos.

Hydro Dettin, Italy 04 Nos.

Dryer Stryfield, England 02 Nos.

Dryer Stalam, Italy 02 Nos.

Sewing Thread SSM (Hacoba), Switzerland 01 Nos.

Auto Dosing

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CHAPTER-5

RAW MATERIALS

AND CHEMICALS

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Type of Raw Materials : Grey Yarn:

Single Ply cotton yarn

Double Ply cotton yarn

Tree Ply cotton Yarn

AC blend yarn.etc

Commonly Used Dyes :

Name of Dyes

Synozol G,Yellow HF 2GR

Synozol Red HF 6BN

Synozol Black B

Synozol Orange SHF RR

Synozol Br,Blue R-SPCL

Synozol Turquise Blue HFG 266%

Synozol Yellow K-3RS

Synozol Red K-3BS

Synozol Navy Blue K-BF

Synozol Yellow 4GL

Synozol Yellow 4GR

Synozol Red SHF GD

Name of Dyes

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Synozol Blue K-BR

Synozol Ultra Black DR

Synozol B/Red BB

Synozol Yellow HB

Synozol Navy Blue HB

Synozol Deep Red HB

Synozol Red K-GD

Synozol Black HF GR

Sun White BVB

Syno White 4BK

Leucophor BBU

Rifazol Orange RN

Rifazol G,Yellow 4GR

Rifazol Turquise Blue G-165%

Rifazol Br,Blue R-SPCL

Rifazol Deep Black ED Conc

Drimaren Navy CLR

Drimaren Yellow HFR

Drimaren Blue HFRL

Remazol Yellow RR

Remazol Blue RR

Remazol Orange RR

Remazol Turquise Blue G

Commonly Used Chemicals & Auxiliaries:

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Agent of- Name of items

Chemicals of KBC Co.(Pvt). 2UD

Eco

Scouring & Bleaching agent

Imerol PCLF

TF-129B

Perlavin NDA

Sabilezer TF-122B

Causic Soda

Hydrozen peroxide

Acetic acid

Peroxide Killer Bactasol Sap

Lavelling agent Sarabid MIP

TF-210 B

Sequestering Agent

Sirrix 2UD

ladiquest-1097U

TF-510B

Periquest BSV

Antifoaming Agent Antimussol UFD

Periwet WDP

Salt Glober Salt

Refined salt

Soda Ash

Soaping Agent Ladipur RSK

Parlavin SR/SN

Fixing agent

Optifix EC

Perifixan RS

TF-234 B

Color Softner

Cepreton UCP

GTF-445C

Perifil 210 Liq

White Softner Nass-T ( Local )

GTF-442

Sodium hydrosulfite

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Source of Raw Materials:

Grey yarn is collected from buyers.

Dyes & Chemicals are imported from Germany , Switzerland , Singapore , Turkey , India , China

etc.

Remarks:

Price & Monthly consumption are unavailable.

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CHAPTER-6

PRODUCTION

PLANING, &

OPERATIONS

Operations

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Production Parameters:

PH:

For Scouring & Bleaching : 10-11

Before Enzyme : 4.2-4.5

Before Leveling : 5.5 (All Color)

6 for Black, Red, Deep Color.

After Leveling : 5.5 (All Color)

6 for Black, Red, Deep Color.

Before Dyes : 5.5 & 0.2

After Salt : 5.5 & 0.2

After Soda : 10.5-11.5

After Acid wash : 5.5-6.5

Before Softener : 5.5

Temperature:

For Scouring & Bleaching : 105°C

For Cold Wash : 40-550C

For Hot Wash : 80-950C

For Cotton Dyeing : 80-900C (For Hot Brand)

600C (For Cold Brand)

For Polyester Dyeing : 1300C

Time: For Scouring & Bleaching : 30-40 minute for Normal color

50 minute for Critical Color

For Reactive Dyeing : 60-90 minute.

Remarks:

Critical colors are Green , Turquoise Blue , Brown , Dark grey .

Material &Liquor ratio:

For Reactive Dyeing Material & Liquor Ratio is maintained in Between 1:8

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Production Flow Chart:

Grey yarn Collection from Grey store

▼

Winding on hard package

▼

Yarn loading to m/c

▼

Scouring & Bleaching

▼

Bio polish ( Enzyme Treament)

▼

Dyeing

▼

Soaping

▼

Fixing

▼

Softening

▼

Unloading from dyeing m/c

▼

Drying

▼

Inspection

▼

Winding on soft package

▼

Final inspection

▼

Packaging.

Grey yarn inspection section:

Object of inspection:

To check the actual count of yarn

To identify the yarn faults

To ensure about the yarn quantity

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Yarn fault:

1. Slub

2. Neps

3. Thick & thin place

4. Patta / Barre

5. Yarn contamination

6. Yarn hairiness

Batch Section Function or purpose of the batch:

Order sheet (Received from buyer)

To receive the grey yarn package from soft section or other source

To send the grey yarn to the dyeing floor by trolley with batch card

To prepare the batch of yarn on the carrier

Dyeing shade (Color or white, Light or Dark)

M/C capacity

Yarn structure.

Yarn type, etc

To keep records for every previous dyeing.

Keeping the no. of batch as less as possible for same shade, etc.

Minimizing the m/c washing time or preparation time.

Batch management:

Primary batch is done by the dyeing manager. Batch section in charge receives this primary

batch plan from dyeing manager. Then the works is adjusting, according to m/c condition.

Remarks:

Proper batch can minimize the batch to batch shade variation. It can near or same dyeing

condition for every batch of same shade. Thus it improves the dyeing quantity & minimizes a lot

of dyeing cost.

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Scouring-Bleaching Process:

Scouring-Bleaching is carried out in the same bath and at the same time simultaneously.

Scouring-Bleaching Chemicals Used in a batch:

Agent Brand Name g/l

Wetting agent TF-129 B 0.70

Sequestering agent TF 510 1.0

Stabilizer TF 122 0.5

Antifoaming agent Alkafoam AF-10 1.0

Alkali Caustic soda 1.8

Bleaching agent H2O2 2.5

Peroxide Killer Bactasol Sap o.85

Acid Acetic Acid 0.6

N.B : Amount of Chemical varies according to yarn consumption .

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Procedure of Scouring-Bleaching :

At first required amount of water is taken into the m/c.

Then the yarn is loaded

Then Wetting, Sequestering, Stabilizer is added by inject at 500C.

Then Temperature is raised to 600C.

Then Caustic soda is added by linear dosing for 6 minutes.

Then temp rised to 70°c .Then H2O2 is added by linear dosing for 8 minutes.

Then. Temp raised to 1050C. Runtime 60 minutes.

Then temp.is decreased to 900C.Rinse at 90

0

Then Hot wash at 900

Then Rinse at 900

-

Then Bayreduct PRN is added by transfer at 900C × 10΄

Then Rinse at 900

Then Drain out.

Fill water. Acid treatment for neutralization at 70°c °× 10´ & PH

is checked.

Then rinse at 55°c× 10΄

Then Primafast-100 is transferred at 55°c. Run time 20-50 minitues.

Then Hot wash at 800

Finally drain out

N.B :

1. In case of critical color after loading water & yarn first hot process is carried out with

sequestering agent & detergent to get better result. Rest of processes are same as usual.

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White dyeing process:

Batch No : 27942 Machine No : 02

Batch Date : 22.04.09 Water : 5600 Lit

Liquor ratio : 1:7 Yarn Weight : 1000.00 kg

Customer : United Count : 32/2

Color : White 10-100

Recipe :

Name of the Chemicals Amount (g/l)

Feloson NOF 0.40

Exstab BRH 0.40

Feloson NOF 0.50

Exstab BRH 0.40

Antisil CONZ 0.60

Caustic soda 2.50

Hydrogen per Oxide 6.00

Singo white-2BX 0.10 %

Singo white-BHV 0.33 %

Invatex-CS 0.10 %

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Procedure:

At first required amount of water is taken in the m/c.& the yarn is loaded simultaneously.

Then Wetting agent, Sequestering agent is added for first hot at 600C × 10´.

Then Temperature is raised to 800

C × 10´. After then Rinse for 10´ & decrease temp. to

40°c .

Drain out.

Filling new water & Wetting agent, Sequestering agent & Stabilizer is added by inject at

40°c × 5΄.

Then Caustic soda is added by linear dosing for 10΄ .

Then temp. is raised to 60°c & Then H2O2 is added by linear dosing for 10΄.

Then temp. raised to 70°c & Invatex-CS, Singo white-BHV, Singo white-2BX are added

by linear dosing for 20΄.

Then temp is raised to 100°c at 2°gradian for 35΄ (Check sample after each 20΄)

If white shade is matched then temp is decreased to 90°c at 3°gr with Ringe wash.

Then to 80°c at 2°gr & Rinse for 10΄ .After then to 70°c at 5°gr.

Bath drain.

Fill with new water & temp is set to 80°c × 10´

Then temp is decrease to 50°c with Rinse wash & continue for 5´-7´.

Acid is added for neutralization by inject & running for 10´

Again Rinse wash is performed for 10´ at 55°c.

Enzyme is added at 570C × 60´.

If OK then temp is raise to 70°c & Runtime 10´.

Down temp. to 500C. Rinse for 10

´.

Add Softener at 450C. Runtime 10

´

Then Unloading.

.

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Dyeing Procedure for all color without Turquoise, Brown, Khaki,

Chocolate Color:

At first required amount of water is taken in the m/c.& the yarn is loaded

simultaneously.

Then Felosan NOF and ExstabBRH are added by inject at 500C .

Then Temperature is rised to 800C and Runtime 10-15´.

Then Rinsing at 80°c×10΄

Then water is drained out and filling new water as required at 50°c

Then Felosan NOF, ExstabBRH and Antisil CONZ are added by inject at 500C . For s/j

anticreasing agent is added.

Then temp. is raised to 60°c and NaOH is added by linear dosing for 6´

Then temp rised to 70°c .Then H2O2 is added by linear dosing for 8 minutes.

Then. Temp rised to 1050C. Runtime 50 minutes.

Then temp.is decreased to 900C at rate of 2°gradian /min and Rinse at 90

0

Then Bayreduct PRN is added by inject at 900C and Runtime 10΄

Then Rinse at 900C* 10and decreasing Temp. to70°c at a time.

Then Drain out.

Filling new water. Acid treatment for neutralization at 70°c °× 10´ & PH

is checked.

Then rinse at 70°c× 10΄ and decreasing Temp. to55°c at a time.

Then Primafast-100 is transferred at 55°c For enzyme treatment. Run time 50΄

Then Hot wash 800

Finally drain out

Then filling new water as required and temp. is raised to 60°c.

Then Seragal CFTR is added by inject and for singal jersey Primasol JET is added.

Runtime 5-6´.

Then salt is added by inject and Runtime 10΄. In case of deep shade salt is added two

times.

Then PH

is checked & maintained within 5.5-6. and dye solution is added by linear

dosing for 20΄ and Runtime at 60°c×20΄

Then Soda is added by progressive dosing for 35΄ and Runtime at 60°c×60΄( After each

10΄ sample is cut and matched to swatch.)

Then temp. is cooled down to 50°c and Rinse at 50°c×15΄

After completed rinsing water is drained out and filling new water as required.

Then temp. is raised to 60°c and Avolan IS is added by inject

Then temp. is raised to 100°c and Runtime 10΄

Then temp. is felt down to 95°c with rinsing and Runtime 10΄

Then temp. is felt down to 80°c with rinsing and Runtime 20΄

Then sample is cut if ok then temp. is felt down to 50°c with rinsing .

After completed rinsing zelasal fix is added by inject at 50°c and Runtime 5´. Acetic acid

is used to maintain PH

Then Alcamine CWS is added by inject and Runtime 10΄

Then temp. is felt down to 45°c with rinsing and Runtime 6-7΄

Then unloading

Dec. 9

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Dyeing Procedure for Brown, Khaki, Chocolate Color, Grey Series:

At first required amount of water is taken in the m/c.& the yarn is loaded

simultaneously.

Then Felosan NOF, Exstab BRH are added by inject at 500C.

Then Temperature is raised to 800

C.and Runtime 6 minutes

Then Rinsing at 80°c×10΄

Then decreasing temp. to 50°c with rinsing and Drain out

Then filling new water as required at 50°c and Felosan NOF, Exstab BRH and Antisil

CONZ are added by inject at 500C. For s/j anticreasing agent is added.

Then temp raised to 60°c and NaOH is added by linear dosing for 6 minutes.

Then temp raised to 70°c and H2O2 is added by linear dosing for 8 minutes.

Then. Temp raised to 1050C. Runtime 60 minutes.

Then temp.is decreased to 900C. at the rate of 2° gradian/min and rinsing at 90

0

Then Bayreduct PRN is added by inject at 900C and Runtime 10΄

Then Rinse at 900

Then Drain out.

Filling new water. Acid treatment is carried out for neutralization at 70°c °× 10΄ & PH

is

checked.

Then temp.is decreased to55°c with rinsing

Then Primafast-100 is transferred at 55°c for enzyme treatment and Runtime 50-60

minitues.

Then Hot wash at 800C

Then temp.is decreased to 450C with rinsing and drain out.

Then filling new water as required.

Then Seragal CFTR is added by inject and for singal jersey Primasol JET is added.

Runtime at 45°c×10΄.

Then PH

is checked which must be 5.5-6 and color is added by linear dosing for 30´ and

Runtime at 45°c×20΄.

Then half salt is added by progressive dosing for 15´ and Runtime at 45°c×5΄.

Then rest of salt is added by progressive dosing for 15´ and Runtime at 45°c×5΄.

Then. Temp raised to 600C and Runtime at 60°c×25 minutes.

Then soda ash is added by progressive dosing for 55΄ and Runtime at 60°×60΄ ( After

each 10΄ sample is cut and matched to swatch.)

Then temp. is decreased to 50°c with rinsing and Runtime at 50°c×40΄

Then drain out and filling water as required.

Then. Temp raised to 550C and Acetic acid is added and run at 55°c× 10 minutes

After completed rinsing water is drained out and filling new water as required.

Then temp. is raised to 60°c and Avolan IS is added by inject

Then temp. is raised to 70°c and Runtime at 70°c×10΄

Then temp. is felt down to 50°c with rinsing and Runtime at 50°c×10΄

Then sample is cut if ok then zelasal fix is added by inject at 50°c for deep shade and

Runtime 5΄. Acetic acid is used to maintain PH

Then Alcamine CWS is added by inject and Runtime 10΄

Then temp. is felt down to 45°c with rinsing and Runtime 6-7΄

Then unloading.

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Stripping Process :

Recipe:

Full Stripping for Light Colour :

TF-129 B - 0.65 g/I

Soda - 1.0 g/I

Caustic soda - 1.0 g/I

Hydrose - 2.0 g/I

Full Stripping for Deep Colour :

TF-129 B - 0.75 g/I

Soda - 1.0 g/I

Caustic soda - 1.50 g/I

Hydrose - 3.0 g/I

Machine Wash :

Recipe :

Hydrose 4 kg

Caustic soda 4 kg

TF-129 B 2 kg

N.B : Amount of m/c wash chemical depends on m/c size.

Process :

Required amount of water is taken in the m/c. Then temp.is raised to 130

0C.

Then Relosan NOF, Caustic soda, Hydrose is added.

Runtime at 130°c×30 minutes.

Then temp. is decreased to 900C.

Decreasing temp. to 450C with rinsing and Runtime at 45°c×10 minutes.

Then Drain out.

Dec. 9

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Dyeing Fault:

Dyeing faults are given below -

1. Patchy dyeing effect: Reasons:

Faulty injection of alkali.

Faulty color.

Due to hardness of water.

Due to improper salt addition, etc.

2. Roll to Roll variation or meter to meter variation:

Reasons:

Yarn lot mix

Faulty heat setting.

Hardness of water.

Faulty m/c speed, etc

3. Dye –stain:

Reasons:

Un dissolved caustic soda particle in bath.

Un dissolved salt particle in bath.

4.Rub mark:

Reasons:

Due to reel cranking.

Due to sharp delivery.

Due to sharp delivery roller, etc

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CHAPTER-7

QUALITY

ASSUREANCE

SYSTEM

Dec. 9

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Quality Management System:

The Quality Assurance Department is assigned to maintain consistently uniform quality of the

material in process and various stages of its manufacturing.

Objects of quality control:

Research.

Selection of raw materials.

Process control.

Process development.

Product testing.

Specification test

Quality management system:

Off-Line Tests:

All the Off-Line tests for finished fabrics can be grouped as follows:

Physical tests

Chemical tests

Physical Tests:

Count of yarn.

Abrasion/pilling resistance

Rubbing test

Dec. 9

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Chemical Tests:

Fastness to washing.

Fastness to light

Fastness to heat

Fastness to Chlorinated water

Fastness to water spotting

Fastness to perspiration

Online Tests:

Dyed yarn

Shade check

Wash fastness

Water fastness

Crocking fastness

Quality standard:

Mainly this mill follows ISO standard for testing. But testing standard depends on buyer

requirements.

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CHAPTER-8

EFFLUENT

TREATEMENT

PLANT

Dec. 9

35

Effluent Treatment Plant (ETP)

Effluent Treatment Plant (ETP) is a plant by which waste water is treated in order to make the

waste water environmental friendly. Effluent Treatment makes sure that water releases meet

Bangladesh Environmental Association water quality standard. It is very important and essential

to keep the environment pollution free. Now a day ETP is the most important term to set a textile

industry. Government, Environmental Association and foreign buyers are creating pressure to set

ETP in every textile industry. So to ensure the proper growth of textile sector and pollution free

environment every textile industries have to set up an ETP.

Details on ETP :

There are three effluent treatment plants which are :

Physico-chemical treatment plant

Chemical-biological plant

Biological treatment plant.

Chemical treatment plant :

In this process effluent water are mainly converted into sludge of metal complex by chemical

reaction. Then it is separated from the water and dried and dipped into soil. But the sludge

remain activate which is harmful.

Biological treatment plant:

This process is mainly build up by using micor-organism. This is Bacteria. Amoeba, and

Protozoa. Bacteria are two types, one is Anerobic & Aerobic.. First one is hazardous for our

environment and second one is friendly for our environment. In here Bacteria break the bond of

harmful chemical by enzyme secretion. As a result harmful chemical converted into

environmental friendly. The sludge produces by this process is also used as different functions

such as fertilizer, fuel in the brick field.

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Micro organism is the main raw material for Biological plant :

Bacterial

Amoeba

Protozoa

Bacteria :

Bacilli

Cocci

Beggiatoa

Spirillum

Vitereoeilla

Protozoa :

Paramecium caudatum Euplotes

Coplidium

Amoeba :

Rotifiers

Collities

Novcotidia

Dec. 9

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Comparisons between Chemical-Physical and Biological ETP

TYPE OF INSTALLATION CHE-PHY BIOLOGICAL

General purifying yield > 90%

COD/BOD Reduction 50-60% 90-95%

Color Elimination Yes Yes > 90%

Ammonia Elimination No Yes >95%

Nitrogen Elimination Total 30% >95%

Phenol Elimination No >90%

Final Salinity With Respect Water To be

purified

Higher then input Same as Input

Sludge produced per m3 of Effluent Treatment 6 kg 0.1-0.2 kg

Sludge produced per Kg of COD 1.8 kg 0.2 kg

Sludge character Toxic Non-Toxic

Sludge disposal Very Difficult Very-Easy

Running cost per m3 of Effluent Treatment TK.25.0-30.0/- TK.3.5-4.0/-

Initial cost (Chemical-Physical Base 100) 100 200/220

Space Occupied For 1000 m3 /day 300-350m

3 At least 600 m

3

Reliability 30% 80%

Possibility Fish Life Directly In Purified H20 No Yes

Possibility Reuse of Purified Water for

Irrigation

No Yes

Compliance With European Laws (very strict) No Yes all

Produced of bad smell Yes No

Treatment Quality Improper, < Proper,European

Bangladesh

Standard

Standard

Dec. 9

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ETP PROCESS DIAGRAM

Under drain

Under hole

By pump

By over flow

By over flow

By under hole path By pump

Under drain pipe

By pump

Waste water from dyeing machine or incoming

Screening Unit

Storage & Homogenization Tank

Neutralization Unit

Distribution Unit

Biological Oxidation Tank

Sedimentation feeding tank

Sedimentation or clarifiers

Sludge recirculation pit

Sludge thickener tank

Sludge drying naturally at Sludge drying bed

Sludge out as fertilizer used in crops field or burning

at brick field after natural drying

H2O2 tank

H2SO4 by dosing

Manually feeding

Bacteria for proper

living on

Antifoam feeding by

dosing pump

Decolorant dosing for

coloring remove

Treated water used in

irrigation or river or

pond

Poly electrolyte

feeding by dosing

pump

Dec. 9

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Required Chemicals of Biological ETP :

98% H2S04.

Function : Neutralize the waster water by controlling ph.

It is auto dispensed in the neutralization tank.

Polyelectrolyte.

Function : Used for sedimentation/sludge coagulation and also killing bacteria.

[ Coagulation in water treatment, the use of chemicals to make suspended solids gather or

group together into small flocks.]

It is used auto/manually in sludge thickener tank.

Decolourant.

Function : Used for removing color.

It is used auto/manually in sludge thickener tank.

Anti foaming agent.

Function : Used for reducing/controlling foam.

It is used auto/manually in the distribution tank.

Sodium hypochlorite.

Function : It is used to killing harmful bacteria.

It is used in the Biological Oxidation tank.

Dec. 9

40

Standard value of effluent by :

USEAPA-United State Environmental Protection Agency

IWRA-International Water Resources Association

GOB-Government of Bangladesh .

Tank Parameter Unit Standard value

Clarifier

(treated effluent)

Phosphate, PO4 Ppm 5 to 14

Ph - 6 to 8

Colour APHA 220 to 250

BOD Ppm 29 to 60

COD Ppm 250 to 300

Ammonia, NH3 Ppm 5 to 10

Nitrate, No3 Ppm 10 to 15

Nitrate, No2 Ppm Less than 1

Sulphate, So4-2 Ppm 1000

Chlorine, C12 Ppm 1

Chloride, CI Ppm 500 to 600

Total suspended dissolve solides Ppm 60 to 80

Total dissolve solides Ppm 2100

Functions of different unit of Effluent Treatment Plant (ETP)

1. Screening unit :

Threads

Pieces of yarns

Small metal pieces etc.

In this unit a rotating brush is used for cleaning the pores of screen. A motor is used

here for rotating the brush. The brush rotates periodically.

2. Storage and Homogenization tank : Different waste water from various processes is

stored and makes a homogeneous mixture by mixing different concentric waste water.

Dec. 9

41

3. Neutralization tank : Neutralization of waste water is performed by dosing 98% H2S04 as

required to control the ph of waste water. P

H range : 6.5 to 7.5.

4. Distribution tank : It distributes the water to the biological oxidation tank. Continuous

aeration is supplied here. Antifoam is dosed here to control the foaming in the oxidation tank.

5. Biological oxidation tank : It is the heart of ETP. The entire harmful chemicals are

damaged here by breaking their bonds. This is done by bacteria. To ensure the proper functional

work & growth of bacteria few conditions must be maintain.

Temperature : 350 to 37

0C

PH : Maximum 7.5

Dissolved oxygen : 4 ppm

[Dissolved Oxygen-a measure of the oxygen dissolved in water expressed

in milligrams per liter.]

6. Sedimentation/Biological feeding tank : Treated water is overflowed here from

oxidation tank. Decolourent is used here to destroy the color of waste water.

7. Clarifiers : Settling tank, sedimentation basin. A tank or basin in which waste water is held

for a period of time, during which the heavier solids settle to the bottom and the lighter material

will float to the water surface. In this tank sludge is immersed and the harmless water is

discharged to drain on ponds, land, river, Lake Etc.

8. Sludge thickener tank : Sludge is taken here from clarifier. Polyelectrolyte is dosed to

coagulate the sludge. After one hour of polyelectrolyte dosing aeration is stopped and fresh water

discharge to drain when sludge is thicken. The thickened sludge is transferred to the sludge

thickener bed.

9. Sludge thickener tank : Here sludge is dried which is used as good fertilizer as well as

fuel of brick field. Sludge is dried under the sunlight.

Airation :

The process of adding air to water. In waste water treatment, air is added to freshen waste water

and to keep solids in suspension.

Remarks:

Utility service is sufficient to run this project. More projects can be run by the existing Utility

services.

Dec. 9

42

CHAPTER-9

STORE &

INVENTORY

CONTROL

Dec. 9

43

Frequently inventory control:

Monthly inventory control.

Annual inventory control.

The type of inventory carried in this mill is as follows :

Grey yarn: Imported/Own factory.

Dyes and Chemicals: Important.

Spare parts and Consumables: Local/Imported.

Packing materials: Local/Imported.

Finished yarns: Good/Reject.

The prime responsibility for the inventory management function in the company including the

estimation of consumption quantities of raw materials over the forecast period and initiation of a

purchase requisition keeping in view quantities is transit and an order and the adequacy as

otherwise of material coverage during lead time is as follows :

The Procurement Department is responsible primarily for the sourcing of raw material.

Inventory system of Raw materials :

Grey yarn is stored in the Grey store. The batch is prepared by taking Grey yarns from

Grey store.

There is a separate store for Dyes & Chemicals. Various types of Dyes &

Chemicals are stored here according to company's storing criteria. The operator takes

Dyes & Chemicals from this store according to Recipe Sheet.

Remarks:

Inventory management is good & satisfactory.

Dec. 9

44

CHAPTER-10

COST ANALYSIS

Dec. 9

45

Costing 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 fabric is collected

from local and foreign suppliers. Then it id calculated how much dyestuff and chemical is

required to the end of the processing of that specific fabric .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 prodsuct is done by the consideration of the

following factors:

Amount raw materials consumed.

Direct Labour

Indirect Labour

Factory Cost

Officer and administrative cost

Sales and distribution cost

Profit, etc.

Remark:

The costing of product is a secret matter of the industry. They are not interested to flash the cost

related data. So we could not collect the price of product and costing of the product.

Dec. 9

46

CHAPTER-11

MARKETING

ACTIVITIES

Dec. 9

47

Buyer of the Products :

H&M

Puma

C & A

G-Star

Wal-Mart

Decathlon

Esprit etc

Importing Countries :

Germany

Switzerland

Turkey

Singapore

China

India

Exporting Countries :

European Countries.

USA .

Canada .

Dec. 9

48

CHAPTER-12

UTILITY

Dec. 9

49

Utility Services of ATN:

Here the following utility services are available-

1. Water

2. Electricity

3. Compress air

4. Steam

5. Gas

6. other

1.WATER

Water for a textile plant may come from various sources. These include surface water from rivers

and lakes, and subterranean water from wells. In PPC they collect water from Under ground.

Natural and pretreated water may contain a variety of chemical species that can influence textile

wet processing in general, and dyeing in particular.

The various salts present in water depend on the geological formations through which the water

has flowed. These salts are mainly the carbonates (CO32-

), hydrogen carbonates or bi-carbonates

( HCO3- ), Sulphates ( SO4

2- ) and chlorides ( Cl

- ) of calcium ( Ca

2+), magnesium (Mg

2+) .

Although calcium and magnesium carbonates in limestone are relatively insoluble in water. So in

this reasons, water hardness can be divided into two ways-

1) Temporary hardness : Ca(HCO3)2 , Mg(HCO3)2 , Fe(HCO3)2 .

2) Permanent hardness : CaCl2 , CaSO4 , Ca (NO3)2 , MgCl2 , MgSO4 ,

Mg(NO3)2 .

Dec. 9

50

Standard water quality for dye house:

Parameter Permissible concentration

Color Color less

Smell No bad smell

Water Hardness <5 ppm

PH value 7-8 (Neutral)

Dissolve solid < 1 ppm

Inorganic salt < 500 ppm

Iron(Fe) < 0.1 ppm

Manganese(Mn) < 0.01 ppm

Copper (Cu) <0.005 ppm

Nitrate(NO3) < 50 ppm

Nitrate(NO2) < 5 ppm

2.Electricity:

Sl. No. Name of Machine Capacity Quantity Brand Origin

01 Gas Power 1125 KVA 02 sets Waukesha USA

02 Generator 490 KVA 01 set Caterpiller USA

03 Generator 490 KVA 01 set Cummins UK

04 Generator 150 KVA 01 set Volvo Sweden

05 Generator 250 KVA 01 set Weifeng China

06 Generator 650 KVA 02 sets Caterpiller USA

Dec. 9

51

3. Air Compressor:

Sl. No. Name of Machine Capacity Quantity Brand Origin

01 Air Compressor 4.25 m3/hr 03 sets Comp air UK

02 Air Compressor 9.61 m3/hr 03 sets Comp air UK

4. Steam:

Sl. No. Name of Machine Capacity Quantity Brand Origin

01 Boiler 5400 Kgs 01 set Cleaver

Brooks

UK

02 Boiler 9400 Kgs 01set Cleaver

Brooks

UK

5.Gas

DCKIL uses natural gas from Titas Gas Transmission Company. Gas is used as the fuel of

Boiler, Generator and also used for heating dryer, Stenter and compactor m/cs etc.

6.Other Machines:

Sl. No. Name of Machine Capacity Quantity Brand Origin

01 Air Dryer 4.25 m3/hr 03 sets Comp Air UK

02 Air Dryer 9.61 m3/hr 03 sets Comp Air UK

03 Multi grade wall

filter

120 m3/hr 01 sets IECID Ltd. India

04 Activated carbon 120 m3/hr 01 sets IECID Ltd. India

05 Softener 120 m3/hr 01 sets IECID Ltd. India

06 Deep Tube well

pump

0.75 Cusec 02 sets KSB India

07 Deep Tube Well

Pump

1.5 Cusec 02 sets KSB India

08 Cooling Tower 350 RT 01 set Linear Malaysia

09 Cooling Tower 350 RT 01 set Spaco Thailand

10 Cooling Tower 150 RT 01 set Linear Malaysia

Dec. 9

52

CHAPTER-13

MAINTENANCE

Dec. 9

53

MAINTENANCE:

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

to the behavior and utility of a particular element. In engineering, we use this terminology for

maintaining smooth and uninterrupted performance of machines, tools and metallurgical

characteristics in practical uses.

Objective of maintenance:

To keep the factory plants, equipments, machine tools in an optimum working condition.

To ensure specified accuracy to product and time schedule of delivery to customer.

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

production program.

To keep the production cycle within the stipulated range.

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

Three types of maintenance are performed in ATN:

1. Preventive Maintenance.

2. Routine/ Schedule Maintenance.

3. Breakdown Maintenance.

1. Preventive Maintenance: Actions performed periodically (or continuously) prior to

functional failure to achieve the desired level of safety and reliability for an item.

These actions are performed to prevent or reduce consequences of failures.

2. Schedule maintenance: It is time-based maintenance and pre-planned to perform on

machine and equipments. This plan usually made on monthly basis.

3. Breakdown maintenance: In this type of maintenance when the macine remains stop

that time the maintenance is done.

MANPOWER SET-UP FOR MAINTENANCE:

A Shift 8 AM 8 PM

B Shift 8 PM 8 AM

General Shift 9 AM 6 PM

Dec. 9

54

MAINTENANCE TOOLS & EQUIPMENTS:

1. Combination tools / spanner

Function : Tightening & looseng of nuts & bolts.

2. Socket ratchet set

Function : Tightening of nuts & bolts

3. Slide Range

Function : Tightening & loosening of nuts & bolts

4. Monkey pliers

Function : Tightening & loosening of nuts & bolts

5. Pipe threat cutting tools

Function : To cut the threat in pipe.

6. Bearing puller

Function : To assist the opening of bearing from shaft.

7. Pipe range

Function : Tightening & loosening of pipe joint

8. Pipe cutting tools

Function : for pipe cutting.

9. Hole punch

Function : Punching the hole.

10. Divider

Function : For circle making on metal & wood.

11. Easy opener

Function : To open the broken head bolt.

12. External threat die

Function : For external threat cutting.

Dec. 9

55

13. Heavy scissor

Function : Cutting of gasket & steel sheet

14. Pipe threat cutting tools

Function: To cut the threat in pipe.

15. Drill machine and drill bit.

Function : for drilling.

16. Grease gun

Function : For greasing of moving parts of M/C.

17. Grinding M/C

Function : For grinding & cutting of mild steel.

18. Welding M/C

Function : For welding & cutting.

19. Spirit leveler

Function : For perfect leveling.

20. File

Function : For smoothing the surface.

21. Harmmer

Function : For scaling & Right angling.

22. Circlip tools

Function : Circlip opening & closing.

REMARKS:

Maintenance of M/C’s are very essential to prolong the M/C life and good maintenance is

important consideration. It is necessary to check that all routine maintenance is being done

regularly and properly otherwise efficiency of each department will be reduced.

Dec. 9

56

CHAPTER-14

COMPLAINCE

Dec. 9

57

Compliance:

Compliance means comply something i.e. yield to the wishes another. The main aim of

compliance is to ensuring the all labor rights and facilities according to buyer code of conduct.

Different compliance issues which they are obeyed:

Admin & HR dept.:

Personnel policies:

Recruitment policy

Leave and holiday policy

Attendance and leave register card:

Their weekly working hour not more than 66 hours including overtime in a week.

They have the approved manpower list.

Health & hygiene:

First aid ensures.

Medicine registers.

Maternity and pregnancy register.

Pure drinking water

Towel for hand dry.

Safety:

Safety committee

Fire fighting committee

Rescue committee

Broken needle register

Needle detector

Fire alarm & switch

Evacuation plan

Rubber mats to every iron man.

Welfare:

Welfare committee

Day care centre

Canteen facility

Dec. 9

58

Salary and wages:

Fix wages in considering minimum wages which is declared by the government.

Salary and wages given before 7th

day of month.

Physical security:

They have separate cargo entrance area (receiving and unloading) from the front

side.

They do not keep any partially filled/ completed cartons on the floor at the end of

any working day. They keep it to finished goods store.

Education and training program:

They arrange security training program on regular basis for all employee of the factory.

Compliance item:

Some example of compliances item are given below:

First aid box

Water pot

Toilet

Wash basin

Complain box

Evacuation plan

Exhaust fan

Emergency exit/light/ light set

Smoke detector

Fire extinguisher

Hose cabinet

Manila rope

Gas musk.

Dec. 9

59

CHAPTER-15

Conclusion

Dec. 9

60

Conclusion

I have completed our Industrial Training successfully by the grace of Allah.

Industrial Attachment sends me to the expected destiny of practical life. YASSMA KNITTING

& DYEING Ltd. is a well known factory in the textile field of Bangladesh . The completion of

the two months industrial attachment at YASSMA KNITTING & DYEING Ltd. Textiles Ltd.

Gave me the inspiration that factory is one of the appropriate destiny to implement the

theoretical knowledge. From this industrial attachment we got the details idea about the factory

environment, production process, total management, store & inventory process, maintenance,

utility etc.

YASSMA KNITTING & DYEING Ltd. is well equipped and the working environment is

excellent. The relation between top management to bottom level is so nice.

We are lucky to get the opportunity of having training in this mill.

The factory runs by a number of efficient Textile Engineers, Skilled technical & Non-technical

persons.

All the Textile Engineers, technical & Non-technical persons are very sincere, co-operative and

helpful.

We wish good luck of them and also for this factory.