University of South Asia

Dept of Textile Engineering

Industrial Attachment
At
AJI Textiles Industry Limited

Supervised By
Professor Dr. Md. Zulhash Uddin
Guest Faculty
Department of Textile Engineering
University of South Asia

Submitted By
Md. Abdul Alim
ID No. : 133-0092-002

Date of Submission: 1st November, 2017

1
 Acknowledgement

A number of people have made significant contributions to the preparation of this

report. Their insights, advice and suggestions helped us a lot.

Firstly, we are very much thankful to our head of the department Professor M.A
Muhit Pro. VC of University of South Asia.

I would also like to express our heartfelt thanks to our supervising teacher Professor
Md. Zulhash Uddin, , Guest faculty, University of South Asia of all necessary
information for preparation this report. He has enriched us with necessary ideas and
concepts for incessant improvement of the report. Without his help and direction it
was not possible for us to complete our Industrial attachment.

I would like to thank the Chairman, Managing Director, General Manager, Deputy
General Manager, Manager, Assistant Manager, Senior Production Officer,
Production Officer, Assistant Technical Officer, Technical Officer who gave us scope
& helped for doing industrial attachment in the factory as well as for giving scope to
work in their respective section.

I have also very much grateful to AJI Textiles Industry Limited authority for giving us
opportunity to do our internship work in their factory.

Finally I want to give thanks for all the workers, supervisors who have assisted,
helped & inspired us to complete this report at various stages.

2
3
CHAPTER: 01

4
1.0 Location of AJI Textiles Industry Limited

1.1. About company

Name of the company : AJI Textiles Industry Limited

Status : Private Limited Company

Type : 100% export oriented composite Textile

Industry

Year of Establishment : 1999

Location : 226, Singair Road,

Hemayetpur, Saver, Dhaka, Bangladesh.

BANGLADESH

Contact : Phone No. : +880.2.7741539,

Fax: +880.2.7748898

E-mail Address: [email protected]

Website: www.aji-group.com

Corporate Office: : Factory and Office: 226, Singair

Road,
Hemayetpur, Saver,
Dhaka, Bangladesh.

5
1.2. Name of the unit
1) AJI Apparels Industry Limited.
2) FRM Fashion House Limited
3) Polo Composite Knit Industry Limited.
(a) Polo Knitting Unit
(b) Polo Dyeing Unit (Open Width and Tubular)
(c) Polo Washing Unit
(d) Polo Screen Print Unit
(e) Polo Embroidery Unit
(f) Polo Flat Bed Print Unit
(g) Marketing section
(g) Effluent Treatment Plant (ETP)

1.3. Production capacity:

Knitting Capacity: 12 tons/day

Total Dyeing & Finishing Capacity: 30 tons/day

Cutting capacity: 80,000 pcs/day

Sewing (Packing) capacity: 100000 pcs/day

Printing: 50000 pcs/day

Embroidery capacity: 10000 pcs/day

6
Table 1: Buyers & Exporting Country

Buyers & Exporting Country:

1. FOX – UK. 2. TEDDY SPA – ITALY. 3. U.S. POLO ASSOCIATION

– TURKEY

4. BERSHKA, ZARA – 5. TESSIVAL- ITALY 6. S. NAUTICA – ITALY

SPAIN.

7. CORTIFIEL – SPAIN. 8. UNITESSILE, SPA – 9. TERANOVA-

ITALY.

10. OVIESSE, COIN – 11. KAPPA – ITALY, 12. PIMKIE - FRANCE

ITALY. GERMANY.

13. DICKIES, ANIMAL – UK. 14.. WOMEN SECRET 15. GOOD MAN-

16. DHL, POST DESIGN – 17. COLIN’S – TURKEY 18. BENETTON-ITALY

GERMANY.

19. INSTYLE, SPA- ITALY. 20. PIZZA ITALIA. – 21. ALL STYLE-USA
ITALY

22. KIABI –FRANCE. 23. SPRING FIELD-SPAIN. 24. COLLIN’S LOFT –

TURKEY.

7
 25. W.W GROUP-UK. 26. TAXI CLOTHING- 27. TESSIVAL LTD. –
AUSTRALIA. ITALY.

28. IF ANY – HONGKONG 29. COOP-ITALY. 30. GIO GOI – UK.

31. 2 EIN SPA – ITALY. 32. CLAM –ITALY. 33. KIK – GERMANY ETC.

34. KOKSE – ITALY. 35. CENTER LINE- 36. GUELDENPFENNING-

GERMANY.

37. El-CORTE INGLES 38. ANCHORBLUE – USA 39. CAMAIEU –FRANCE

Table 2: Annual turn over

Annual turn over (In million)

1995 USD: $3.20
1996 USD: $ 3.50
1997 USD: $ 4.00
1999 USD: $ 4.25
2000 USD: $ 4.40
2001 USD: $ 4.50
2002 USD: $ 13.06
2003 USD: $ 27.04
2004 USD: $ 36.07
2005 USD: $ 41.66
2006 USD: $ 51.15
2007 USD: $ 58.39
2008 USD: $ 73.12
2009 USD: $ 84.93
2010 USD: $ 117.50
Table 3: Bank & insurance:

#) Mutual Trust Bank

Panthapath Branch
Chandrashila Suvastu Tower
69/1, Panthpath

8
Dhaka, Bangladesh
Phone : +88-02-862-4687
Swift Code # MTBLBDDHAPPB
1.4. Different Section of knit-dyeing Composite Unit:

a) Knitting section.
►Knitting
►Inspection

b) Dyeing section

►Batch section

►Dye house

►Dyeing lab

►Quality control

►Finishing

c) Garments section

Different Sections ►Merchandising

►Sample section

►Cutting section

►Sewing section

►Finishing section

d) Maintenance section
e) Store section
f) Administration section
g) Security section
h) Marketing section
i) IT section
j) Industrial Engineering Dept.
k) Production planning and control
l) Human Resource &Development
Section

9
 CHAPTER: 02

2.1. Layout plan of Knitting Section

10
 24 31 38

11 17 23 30 37

5 10 16 22 29 36
Office

4 9 15 21 28 35
Toile

3 8 14 20 27 34

2 7 13 19 26 33
t

1 6 12 18 25 32

2
2 3
Fabric Inspection machine

4 1

Collar section

W E
ENTRY

Office room
S

11
2.2. Process definition:

Knitting is a process by which thread or yarn may be turn into cloth or other fine
crafts. Knitting process consists of consecutive loops, called stitches. As each raw
process, a new loop is pulled through an existing loop. The active stitches are hold on
a needle until another loop can be passed through them. This process eventually
results in a final product, often a garment.

Knitting may be done by hand or by machine. There exit numerous styles and
methods of hand knitting.

2.3. Process flowchart for knitting

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and
tension device

Knitting withdraw the rolled fabric and weighting

Inspection

Numbering

12
2.4. Raw material for knitting

• Yarn

• Lycra

Type of Yarn Count

cotton 24s, 26s, 30s, 32s, 34s, 40s
Polyester 75D, 72D, 100D
Spandex yarn 20D, 40D, 70D
Grey Melance(C-90% & V-10%) 24s, 26s
PC ( 65% polyester & 35% Cotton) 24s, 26, 28, 30
CVC 24s, 26s, 28s, 30s
Table 4: Types of yarn used & their count

Table 5: Specification of circular knitting machine

Machine No.: 01 Machine No.: 02

Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 30 Machine dia: 38
Gauge: 24 Gauge: 24
No. of needle: 2260 No. of needle: 2864
No. of feeder: 120 No. of feeder: 114
Machine No.: 03 Machine No.: 04
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 38 Machine dia: 36
Gauge: 24 Gauge: 24
No. of needle: 2864 No. of needle: 2714
No. of feeder: 114 No. of feeder: 108
Machine No.: 05 Machine No.: 06
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Lisky
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 36 Machine dia: 17
Gauge: 24 Gauge: 24

13
No. of needle: 2714 No. of needle: 1282
No. of feeder: 108 No. of feeder: 51
Machine No.: 07 Machine No.: 08
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Lisky Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 18 Machine dia: 19
Gauge: 24 Gauge: 24
No. of needle: 1357 No. of needle: 1432
No. of feeder: 54 No. of feeder: 57
Machine No.: 09 Machine No.: 10
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 20 Machine dia: 21
Gauge: 24 Gauge: 24
No. of needle: 1508 No. of needle: 1582
No. of feeder: 60 No. of feeder: 63
Machine No.: 11 Machine No.: 12
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Lisky
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 21 Machine dia: 22
Gauge: 24 Gauge: 24
No. of needle: 1582 No. of needle: 1660
No. of feeder: 63 No. of feeder: 66
Machine No.: 13 Machine No.: 14
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 22 Machine dia: 24
Gauge: 24 Gauge: 24
No. of needle: 1660 No. of needle: 1810
No. of feeder: 66 No. of feeder: 72
Machine No.: 15 Machine No.: 16
Machine type: Single Jersey Machine type: Single Jersey
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 24 Machine dia: 26
Gauge: 24 Gauge: 24
No. of needle: 1810 No. of needle: 1960
No. of feeder: 72 No. of feeder: 78
Machine No.:29 Machine No.:30
Machine type: Rib Machine type: Rib

14
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 38 Machine dia: 34
Gauge: 24 Gauge: 22
No. of needle: 2866 No. of needle: 2350
No. of feeder: 76 No. of feeder: 68
Machine No.:31 Machine No.:32
Machine type: Rib Machine type: Fleece
Brand name: TaYu Machine Co.Ltd Brand name: Lisky
Country of Origin: China Country of Origin: Taiwan
Machine dia: 30 Machine dia: 32
Gauge: 22 Gauge: 20
No. of needle: 2072 No. of needle: 2010
No. of feeder: 60 No. of feeder: 96
Machine No.:33 Machine No.:34
Machine type: Fleece Machine type: Rib
Brand name: Lisky Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 32 Machine dia: 42
Gauge: 20 Gauge: 18
No. of needle: 2010 No. of needle: 2356
No. of feeder: 96 No. of feeder: 84
Machine No.:35 Machine No.:36
Machine type: Rib Machine type: Rib
Brand name: Jiunn Long Brand name: Lisky
Country of Origin: Taiwan Country of Origin:
Machine dia: 20 Machine dia: 38
Gauge: 18 Gauge: 18
No. of needle: 1130 No. of needle: 2388
No. of feeder: 40 No. of feeder: 76
Machine No.:37 Machine No.:38
Machine type: Rib Machine type: Rib
Brand name: Jiunn Long Brand name: Jiunn Long
Country of Origin: Taiwan Country of Origin: Taiwan
Machine dia: 36 Machine dia: 30
Gauge: 16 Gauge: 22
No. of needle: 1810 No. of needle: 2072
No. of feeder: 72 No. of feeder: 60

Collar section
Machine no.: 01 Machine no.: 02
Brand name: Shima Seiki Brand name: Shima Seiki
Country: Japan Country: Japan
Type: SFF 152-T Type: SFF 152-T

15
MFG no.: 3824 MFG no.: 3826
Gauge: 14 G Gauge: 14 G
Machine no.: 03 Machine no.: 04
Brand name: Shima Seiki Brand name: Shima Seiki
Country: Japan Country: Japan
Type: SFF 152-T Type: SFF 152-T
MFG no.: 3827 MFG no.: 3825
Gauge: 14 G Gauge: 14 G

Fig. 1: Knitting floor

16
 Fig. 2: Single jersey circular knitting machine

Fig. 3: Flat bed knitting machine

2.5. Knitting calculation

WPI x CPI x S . Lx 1.09 x 453.6

GSM =
( 0.0254 )2 x 1000 x 840 x Ne

Length X Width X GSM=Fabric Weight (gm)

Length x Width x GSM/1000 = Fabric Weight (Kg)

2.6. Production calculation:

17
Parameter:

Machine dia

Machine gauge

Machine RPM

Yarn count

No of feeder=diax3 (for single jersey 3feeder)

=dia x 2 (for rib)

No of needle=π x dia x gauge

No of needle x no of feeder x S . L x 1.09 x rpm x 60 x 24

Production /day=
1000 x 840 x count ( Ne ) x 2.204

2.7. Stitch length measurement:

Single jersey: 100 wales count then measure

Rib: 50 wales count then measure

2.8. Fabric dia setting:

machine dia x 2
(2∗1) Rib=
3

Machine dia x 2
(2∗2)rib=
4

machine dia x 2
(2∗1) Lycra rib=
3

machine dia x 2
(2∗2) Lycra rib=
4

1*1 Rib=machine dia ±2

[for higher count =dia -2]

18
[Lower count=dia +2]

Table 6: Cam and Needle Arrangement:

Cam arrangement needle arrangement

1 2 3 4 1, 2
   
   

Single Jersey
1 2 3 4
   
1,2
   
   
   

(1*1) Rib
1 2 3 4
 =  =
=  = 
 =  =
=  =  1,2

19
 C

Interlock

1 2 3 4
   1,2
∏
   ∏
Single lacost

1 2 3 4 5 6 1,2
 ∏ ∏   
    ∏ ∏

Double lacost

1 2 3 4 5 6
∏ ∏   ∏ ∏ 1,2
  ∏ ∏  

Pique

1 2 3 4 5 6 7 8 1,2,3,2,1,2,3
 ∏  =  ∏  =
 =  =  =  =
 =  ∏  =  ∏
F/terry

--------------knit

∏-------------tuck

=--------------Miss

20
2.9. Fabric inspection:

Inspection machine:

Brand name: Uzu

Company: AATPR Industry Co. Ltd.

Country: Thailand

No. Of m/c: 02

2.10. Penalty point Legends:

H= Hole

OS= Oil Strain

CS= Chem Stain

RS= Rust Stain

GS= Grease Stain

MS= Missing Yarn

DS= Drop Stitch

DS= Dust Stain

NL= Needle Line

UT= Uneven Tension

Lyc= Out

Lyc=Drop

TT= Thick & Thin

Oil= Spot

21
 S= Stipe

OL= Oil Line

ND= Needle Mark

AJ=Mark

Fl= Fly contamination

MY = Mixed Yarn

YC= Yarn Contamination

PH= Pin Hole

BE= Birds Eye

WD= Wrong Design

BR= Berre Mark

2.11. Four point System:

3 inch or less = 1 Point

>3inch <6 inch = 2 Points

>6 inch < 9 inch = 3 Points

> 9 inch =4 Points

2.12. Acceptance calculation:

Formula, B/A-100=Points -36

A= Roll Length Yards

B= Total point

22
2.13. Classification:

<40 points=A

41-60 points=B

61-90 points= C

90 Above = Reject

2.14. Faults, causes & their remedies in knitting:

2.14.1. Hole

Causes:

o Holes are the results of yarn breakage or yarn cracks.

o During loop formation the yarn breaks in the rejection of the needle hook.
o If the yarn count is not correct on regarding structure, gauge, course and
density
o Badly knot or splicing
o Yarn feeder badly set.

Remedies:

o Yarn strength must sufficient to withstand the stretch as well as uniform.

o Use proper count of yarn.
o Knot should be given properly.

2.14.2. Needle mark:

Causes:

o When a needle breaks down then needle mark comes along the fabrics.

23
 o If a needle or needle hook is slightly bends then needle marks comes on
the fabrics.

Remedies:

o Needle should be straight as well as from broken latch.

2.14.3. Sinker mark:

Causes:

o When sinker corrode due to abrasion then sometimes can not hold a new
loop as a result sinker mark comes.
o If sinker head bend then sinker mark comes.

Remedies:

o Sinker should be changed

2.14.4. Star

Causes:

o Yarn tension variation during production.

o Buckling of the needle latch
o Low GSM fabric production

Remedies:

o Maintain same yarn tension during production

o Use good conditioned needles.
2.14.5. Drop Stitches

Causes:

o Defective needle
o If yarn is not properly fed during loop formation i.e. Not properly
laid on to the needle hook.
o Take down mechanism too loose.
o Insufficient yarn tension.
o Badly set yarn feeder.

24
Remedies:

o Needle should be straight and well.

o Proper feeding of yarn during loop formation
o Correct take up of the fabric and correct fabric tension.
o Yarn tension should be properly.
2.14.6. Oil stain

Causes:

o When oil lick through the needle trick then it pass on the fabrics
and make a line.

Remedies:

o Ensure that oil does not pass on the fabrics.

o Well maintenance as well as proper oiling.
2.14.7. Rust stain

Causes:

o If any rust on the machine parts

Remedies:

o If any rust on the machine parts then clean it.

o Proper maintenance as well as proper oiling
2.14.8. Pin hole

Causes:

o Due to break down or bend of the latch, pin hole may come in
the fabric.

Remedies:

o Change the needle

2.14.9. Grease stain

Cause:

25
 o Improper greasing
o Excess greasing

Remedies:

o Proper greasing as well as proper maintenance

2.14.10. Cloth fall-out:

Causes:

o Cloth fall-out can occur after a drop of stitch especially when

an empty needle with an closed latch runs into the yarn feeder
and remove the yarn out of the following needles.

Remedies:

o Male sure all the latches of needle are closed with feeding yarn
after a drop stitch.

2.14.11. Barre

A fault in weft knitted fabric appearing as light or dark course wise stripe.

Causes:

o This fault comes from yarn fault

o If different micro near value of fiber content in yarn
o Different lusture, dye affinity of fibre content in yarn
o During spinning different similar classes of fiber is mixed
specially in carded yarn & these fibers have similar
characteristics.
o In draw frame different similar classes sliver is mixed and
make one sliver.

Remedies:

o We can use these fabric in white color.

2.14.12. Fly dust
26
 Causes:

o In knitting section too much lint is flying to and fro that are
created from yarn due to low twist as well as yarn friction. This
lint may adhere or attaches to the fabric surface tightly during
knit fabric production.

Remedies:

o Blowing air for cleaning and different parts after a certain

period of time
o By cleaning the floor continuously
o By using ducting system for cleaning too much lint in the floor
o Over all ensure that lint does not attach to the fabric.

2.14.13. Yarn contamination:

Causes:

o If yarn contains foreign fiber then it remains in the fabric even

after finishing.
o If lot, count mixing occurs

Remedies:

o By avoiding lot, count mixing.

o Fault less spinning.
2.14.14. Yarn fault
Neps
Slubs
Yarn count variation
Thick/thin place of yarn
Hairiness

2.15. Different parts of knitting machine

Creel: Creel is used to place the cone

Feeder: feeder is used to feed the yarn

27
Tension device: Tension device is used to give proper tension to the
yarn
VDQ pulley: VDQ pulley is used to control the GSM by controlling
the stitch length,
Guide: guide is used to guide the yarn
Sensor: sensor is used to seen & the machine stop when any problem
occurs.
Spreader: Spreader is used to spread the knitting fabric before take up
roller.
Take up roller: Take up roller is use d to take up the fabric.
Fixation feeder: these types of feeder are used in electrical auto striper
knitting machine to feed the yarn at specific finger.

Fig. 4: Different parts of knitting machine

28
2.16. defect
&
remedies :

Fault name Causes Remedies Sample

# yarn breakage or yarn #Yarn strength must
cracks. be sufficient to
withstand the stretch
# If the yarn count is not as well as uniform.
correct on regarding
structure, gauge, course #Use proper count of
yarn.
1. Hole Mark and density.
# Badly knot or splicing. #Correctly set of yarn
feeder.
# Yarn feeder badly set.
#Knot should be
given properly

# When a needle breaks # Needle should be

down. straight as well as
from broken latch.
# If a needle or needle
hook is slightly bends .
2. Needle

# Yarn tension variation # Maintain same

during production. Yarn tension during
production.
3.Star Mark # Buckling of the needle
latch. # Use good
conditioned needles.
# Low G.S.M fabric
production

29
 # Defective needle. #Needle should be
straight & well.
# If yarn is not properly
fed during loop formation # Proper feeding of
i.e. not properly laid on to yarn during loop
the needle hook. formation.

# Take-down mechanism # Correct take up of

too loose. the fabric & correct
fabric tension.
# Insufficient yarn

# Use of irregular yarn # Remove irregular

having higher long term yarn
irregularities.
# Use proper yarn
# Using different count count
thread.
#We can use it for
5.Bariness white fabric

# If needle latch is hard # Clean or change

or curve. the needle.

# if yarn tension is loose # Set proper yarn

tension
.
6.Loop

30
 Check the feeder and
Cause by If lycra is attatchlaycra.
missed or Lycra attach
7.Lycra out with the yarn

8.Seat up # if needle latch is not

(cloth work properly/jaum Make sure all the
fallout) latches of needle are
# Causes by thick yarn
closed with feeding
# Improper/large knot yarn after a drop
stitch.

# Ensure that oil does

# Excessive oil flow in not pass on the
the needle fabrics.
9.Oil mark
# Leakage of oil line # Well maintenance
as well as proper
oiling.

31
 # Blowing air for
In knitting section too cleaning and different
much lint is flying to and parts after a certain
fro that are created from period of time.
yarn due to low twist as
well as yarn friction. This # By cleaning the
lint may adhere or floor continuously.
attaches to the fabric
# By using ducting
surface tightly during knit system for cleaning
fabric production. too much lint in the
10.Fly
floor.

11.Yarn # If yarn contains foreign # By avoiding lot,

contaminatio fiber then it remains in count mixing.
n the fabric even after
finishing, # Fault less spinning.

# If lot, count mixing

occurs

# When sinker corrode

due to abrasion then
Sinker should be
some times can not hold a changed
new loop as a result
12.Sinker
sinker mark comes.
Mark
# If sinker head bend then
sinker mark comes

32
CHAPTER: 03

33
3.1. Definition:

Batching is a process where p[roper planning is done for dyeing the fabric by
considering the capacity of the dyeing machine according to the sample for a
particular lot of a particular order.

3.2. Function or purpose of batching:

 To receive the grey fabric roll from knitting section or other source.
 Turn the grey fabric if require.

3.3. Object of Batching

 To store the Grey fabric coming from Knitting And arrange them properly.
 Preparing the batch of different fabric for Dyeing according to order sheet.
 Turning the grey fabric if required.
 Sending the Grey fabric to the Dyeing floor with the Batch card
 Keeping the record of previous dyeing
 Preparing the batch for dyeing according to the following criteria-
 Order Sheet (Received from Buyer)
 Shade (Light or Dark, Color or White)
 Machine availability
 Machine capacity
 Emergency
 Type of fabrics (100% Cotton, PC, CVC, Viscose)

3.4. To prepare the batch of fabric for dyeing according to the

following criteria-

 Order sheet (received from buyer)

 Dyeing shade(color or white , light or dark)
 M/C capacity
 M/C availability
 Type of fabric (100% Cotton, PE, PC, CVC)
 To send the grey fabric to the dyeing floor with batch card.

34
  To keep the records for every previous dyeing

3.5. Proper batch Criteria

 To use maximum capacity of existing dyeing machine

 To minimize the washing time or preparation time & machine stoppage
time
 To keep the no of batch as less as possible for same shade
 To use particular machine for dyeing same shade

3.6. Batch management

 Primarily batching is done by fdyeing manager talking the above criteria under
consideration. Batch section in charge receives this primary batch plan from
dyeing manager. Some time planning is adjusted according to machine
condition or emergency.
 Care should be taken about this process otherwise lot can be mix-up which
may cause dyeing problem.

3.7. Formula for batch selection

 Maximum time for loop revolution=3 mins

 For one KG loop length, L1= (Dia *2* 2.54)/100
 Loop length= (1000* Grey weight)/ (L1*Grey GSM)

3.8. Machine used in Batch section

 Company name: Dong Num

 Machine name: Air turning machine
 Model:DNAT-400
 Origin: Korea

35
Table 8: Process loss considered for different products:

Products Process Loss

Body parts 12%

Collar 5%

Cuff 5%

36
 Fig. 5: Batch section

Fig. 6: Machine in batch section

37
CHAPTER: 04

38
4.1. Definition

A lab dip is a swatch of fabric test dyed to hit a color standard. Several lab dips may
be submitted for feedback until the standard is achieved and the lab dip is approved.
Lab dips are reviewed in a light box.

4.2. Objective of lab dip:

The main objective in knit lab is as follows:

To calculate the recipe for sample dyeing

To compare dyed sample with swatch by light box or spectroflash.

To calculate revise recipe for sample dyeing & approved by lab dip.

4.3. Sequences of operation in dyeing lab

Receive swatch

Closer finding

Spectrophotometer inspection

Recipe formation (Changing various shade%)

Reprose Sample dyeing

Match sample with standard

Send to buyer for approval

Not OK OK

Send recipe to dyeing floor for sample production

Sample dyeing

39
 Not OK OK

Send to dyeing lab for re-lab

Lab ok

Send lab dip recipe for bulk production

Bulk production

4.4. Preparation and storage of stock dyes and chemicals

Available stock solution:

Red-0.1%, 0.5%, 1%, 2%

Yellow-0.1%, 0.5%,1.0%, 2.0%,

Blue- 0.1%, 0.5%, 1.0%,02.0%

4.5. Preparation:

To prepare 0.1% stock solution, it necessary to mix 0.1 gm dye with 100cc water.

To prepare 0.5% stock solution, it necessary to mix 0.5 gm dye with 100cc water.

To prepare 1.0% & 2.0% stock solution similar procedure is followed.

To prepare 10% stock solution of soda ash, it necessary to mix 10 gm soda with 100cc
water.

4.6. Recipe calculation

Fabric weight x Shade %

Amount of dye solution=
Stock solution%

Liquor ratio=1:10
40
 Sample weight= 5 gm

4.7. Example-

Recipe:

Rem Torq G= 0.52%

Rem Blue RR= 0.032%

Rem Yellow RR= 0.0052%

Gluber Sault=40 gm/L

Soda ash= 8 gm/L

Leveling agent= 1%

4.8. Calculation:

0.52 X 5
Rem Torq G=
0.1
=26 cc

0.032 x 5
Rem Blue RR= =1.6 cc
0.1

0.0052 X 5
Rem Yellow RR= =0.26
0.1

5 X 10 X 40 X 100
Sault= =10cc (S.S=20%)
1000 X 20

5 X 10 X 8 X 100
Soda= = 2 cc (S.S=20%)
1000 X 20

1X5
Leveling agent= =5 cc
1

Amount of water=50-(26+1.6+0.26+10+2+5) =5.14 cc

4.9. Testing lab

Two types of material are tested in testing lab.

41
 1. Fabric
2. Raw material

4.10. Fabric testing:

 Fabric inspection by 4-point system

 G.S.M test
 Width of the fabric measure
 Rubbing test
 Pilling test
 Shrinkage test
 Chemical test
 Colorfastness to water
 Color fastness to wash
 Colorfastness to rubbing
 Color fastness to perspiration
 Oxidative test damage

4.11. Raw material testing

Water : pH & hardness test

Gluber salt : Purity test

Acetic acid : Strength test

Caustic soda : strength test

Soda ash : Strength test

Hydrogen per oxide : Strength test

4.12. Machine used in testing lab

 Rubbing tester
 Pilling tester
 Yarn twist tester
 Yarn count measurement tester
 Color fastness to perspiration

42
 Color fastness to washing
 G.S.M. cutter
 Measurement tape
 Scale
 Scissor

43
CHAPTER: 05

44
 5.1. Lay out plan of dyeing sector:
1 2
Calator S-9 S-10 S-11 S-12
GATE

Washing machine

STAIR
Stair
S W-7

Store E W
W-6
Office

Toilet male
EXIT

N
W-5

Fabric inspection Table W-4

Toilet Female
2
Compacting

W-3
Machine
Ferraro

S-8

S-7
W-2
S-6
Dryer
Soft setting

S-5
Machine

S-2
S-4

S-3 S-1
W=Winch Dyeing machine
S= Sample Dyeing Machine
W-1

W-8

45
Table 7: Some fabric sample &their specification:

Recipe :
SL. No. Recipe Sample
1
RHU-TN-3GLS-1.2
DIS-B-M2R-0.52
DIS-Y-4G-0.012
209/5
2. Black (M/F)
Helo-Y-Brown-0.48
RCH-RKRBN-074
Helo-Black Hew-2.8
98/2
3.
DK (Grey)
Helo-Y-Brown-0.356
RUH-R-K FBN-0.196
RUH-N-B-Eco-0.43
201/4
4.
Pink
TAI-R-VY-2.25
TAI-R-XFY-0.46
197/2
5.
Procyarn-C
DIS-B-BGF-1.5
DIS-B-M2R-0.18
DIS-Y-YG-0.013
86/15

6.
D/Blue
DIS-Y-Brown-0.56
DIS-R-RB-0.22

46
 DIS-NB-ECO-1.24
128/10

7.
RED
Helo-Y-EBD-0.42
Helo-R-EBD-0.38
Col-R-3BSN-0.7
35/6

8.
Anthra
TAI-Y-Brown-0.384
DIS-R-FB-0.052
DIS-N.B-0.274
59/8

9. K.Pink
DIS-Pink-f BG-1.0
RCH-R-FBY-0.16
13/1

47
5.2. Raw material for dyeing

Raw materials used in dyeing section are:

Grey fabric

Dyes

Chemicals

5.3. Grey fabric:

Following types of grey fabric are dyed:

Single jersey

Single jersey with lycra

Polo pique

Single lacoste

Double lacoste

Fleece

Terry

Interlock

Rib with lycra

1*1, 2*1,2*2, rib

Different types of collar and cuff.

5.4. Source of grey fabric:

All types of grey fabric come from knitting section. The required grey fabric are
produce in this industry.

48
 Pic: Dyeing

Table 9: Dye used in dyeing section of AJI Textiles Industry

Limited.

Red Yellow Blue

Red RR Yellow 3GL Blue CA
Red cl SB Yellow RR Blue HFRL
Red 3BS Yellow 3RS Blue HF2B
Red 6BS Yellow 4GL Blue RR
Red KHW Yellow CA Nevy Blue GG
Red CA Yellow cl 2R Nevy Blue 2GL
Red 3GX Black B
Red HF6BL Tarq Blue G
Blue cl R
Table 10: Following chemical used in dyeing section:

Felosan RGN Sirrix 2 UD MFL

STAB H2O2 Hydrose Power
Caustic soda Acetic acid Uvetex 2B
Synowhite 4BK Common salt Gluber salt
NSR Soda ash Dyapol XFL
DSP 1250 VO Ladiquest 1097-U
Cotoblenc. NSR Sandofix EC Cappa tex R-98
Rezyme-1000 Welzyme-1200L Avospers AD
Finocon KRCP Primafast-100 Jintex TPA
49
Cetasaft-CS E2R Avozyme CL plus
PW Silicon
 Pic: Dyeing machine

5.5. Machines in dyeing section in AJI Textiles Industry Limited.

Machine type: Winch machine

Brand name: Tong Geng

Country: Taiwan

Brand name: Man Dol

Country: Korea

Brand name: Dilminlar

Country: Turky

Brand name: Dong Num

Country: Korea

5.6. Flow chart of cotton fabric dyeing process:

Fabric loading

Scouring & bleaching

50
 Hot wash

Neutral wash

Enzyme wash

Color dosing

Salt dosing

Alkali dosing

Color drop

Hot wash

Neutral wash

Fixing

Softener

Unload

5.7. Dyeing Process for 100% Cotton Fabric

51
 Fabric Type Double Lacost
Shade Tanne
Batch Weight 473 Kg
M:L 1:8
Total Liquor 3800 Lit

Process with Respective Chemicals

Machine Wash:

Hydrose(2 g/l)+Caustic(2 g/l)+Antifoaming Agent(0.5 g/l)

(80®Cx20’)

Machine Washed

A.Acid

(50®Cx10’)

Machine Neutralize

Demineralization:

Wetting Agent (0.3 g/l)

Sequestering agent (0.3 g/l)

Scouring & Bleaching (80®Cx10’)

Wetting Agent (1.0 g/l)

Anti creasing Agent (1.0 g/l)

Sequestering Agent (1.0 g/l)

Peroxide Stabilizer (0.4 g/l)

H2O2 (2.5 g/l)

Caustic (0.5 g/l)

Jet (0.1 g/l)

Neutralization (Scouring & Bleaching): (100®Cx40’)

A.Acid (1.0 g/l) (50®Cx15’)

Peroxide Killer (0.4 g/l) (50®Cx10’)

52
 Enzyme Wash:

Biopolish CNL 500 (0.7 g/l)

(55®Cx45’)

Dyeing: PH check (5.8 – 6.5)

Leveling Agent (1.0 g/l)

Anti creasing Agent (0.5 g/l)

Sequestering Agent (0.5g/l)

Antifoaming Agent (0.1 g/l)

Dyes (According to Shade%)

Salt (According to Shade%)

Soda (According to Shade%)

Neutralization (Dyeing): (60®Cx60’)

A.Acid (1.0 g/l)

Soaping: (50®Cx15’)

Soaping Agent (0.5 g/l)

Sequestering Agent (0.3 g/l)

Ant creasing Agent (0.5 g/l)

Finishing: (80®Cx15’)

Fixing Agent (1.0 g/l) (40®Cx20’)

Bath Drain

5.8. Dyeing Curve of 100% Cotton fabric:

40’

100®C 15’ 10’

50®C 50®C

Scouring & Bleaching Neutralization H 2O2

Killer

53
 50®C Drain Drain
Drain

40®C Wetting Agent

Anti creasing Agent

Sequestering Agent
Peroxide Stabilizer
H2O2
Caustic
10’

80®C

60®C 60’ Soaping

55®C 50®C 15’ Drain

20®C

Dyeing A. Acid 40®C

Fixing

Drain Drain
Drain

Dyes

40®C Salt Soda

Auxiliaries

5.9. Dyeing Process for 100% Polyester Fabric

Fabric Type 100% Polyester S/J
Shade Menta
Batch Weight 500 Kg
M:L 1:8
Total Liquor 4200 Lit
Process with Respective Chemicals:

54
 Machine Wash:

Hydrose(2 g/l)+Caustic(2 g/l)+Antifoaming Agent(0.5 g/l)

(80®Cx20’)

Machine Washed

A.Acid

(50®Cx10’)

Machine Neutralize

Demineralization:

Wetting Agent (0.3 g/l)

Oxalic Acid (1 g/l)

(80®Cx10’)

Dyeing: PH check (4 – 4.5)

Disperse Leveling Agent (1.0 g/l)

Disperse Buffering Agent (0.5 g/l)

Dyes (According to Shade%)

Shade OK

Bath Drain

5.10. Dyeing Curve of 100% Polyester fabric:

30’

135®C

55
 6 0®C Drain

40®C Disperse Leveling Agent

Disperse Buffering Agent

Dyes

5.11. Dyeing Process for PC/CVC Fabric

Fabric Type Double Lacost
Shade Tanne
Batch Weight 473 Kg
M:L 1:8
Total Liquor 3800 Lit

Process with Respective Chemicals

Machine Wash:

Hydrose(2 g/l)+Caustic(2 g/l)+Antifoaming Agent(0.5 g/l)

(80®Cx20’)

Machine Washed

A.Acid

(50®Cx10’)

Machine Neutralize

Scouring & Bleaching:

Wetting Agent (1.0 g/l)

Anti creasing Agent (1.0 g/l)

56
 Sequestering Agent (1.0 g/l)

Peroxide Stabilizer (0.4 g/l)

H2O2 (2.5 g/l)

Caustic (0.5 g/l)

Jet (0.1 g/l)

Neutralization (Scouring & Bleaching): (100®Cx40’)

A.Acid (1.0 g/l) (50®Cx15’)

Peroxide Killer (0.4 g/l) (50®Cx10’)

Dyeing: Polyester Part, PH check (4 – 4.5)

Disperse Leveling Agent (1.0 g/l)

Disperse Buffering Agent (0.5 g/l)

Dyes (According to Shade%)

Reduction Cleaning: (135®Cx30’)

Caustic (3.0 g/l)

Hydrose (3.0 g/l)

(80®Cx20’)

A.Acid (1.0 g/l) (50®Cx15’)

Biopolish CNL 500 (0.7 g/l)

(55®Cx45’)

Dyeing: Cotton Part, PH check (6 – 6.5)

Leveling Agent (1.0 g/l)

Anti creasing Agent (0.5 g/l)

Sequestering Agent (0.5g/l)

Antifoaming Agent (0.1 g/l)

Dyes (According to Shade%)

Salt (According to Shade%)

57
 Soda (According to Shade%)

Neutralization (Dyeing): (60®Cx60’)

A.Acid (1.0 g/l)

Soaping: (50®Cx15’)

Soaping Agent (0.5 g/l)

Sequestering Agent (0.3 g/l)

Ant creasing Agent (0.5 g/l)

Finishing: (80®Cx15’)

Fixing Agent (1.0 g/l) (40®Cx20’)

Bath Drain

5.12. Common fault and their Remedies in knit dyeing

5.12.1. Uneven dyeing:

Causes:

 Uneven pretreatment (Uneven scouring & Bleaching)

 Improper color dosing
 Using dyeing with high fixing property
 Uneven heat setting in case of synthetic fiber
 Lack of control on dyeing machine

58
Remedies:

 By ensuring even pretreatment

 By ensuring even heat setting
 Proper dosing of dyes and chemicals
 Batch to Batch shade variation:

5.12.2. Shade variation

Causes:

 Improper dosing time of dyes and chemicals

 Batch to batch weight variation of dyes and chemicals
 Dyes lot variation
 Improper reel speed, pump speed, liquor ratio

Remedies:

 Use standard dyes and chemicals

 Maintain the same liquor ratio
 Maintain the same dyeing cycle.
 The pH, Hardness and sodium carbonate of supply water should check daily.

5.12.3. Crease mark:

Causes:

 Poor opening of the fabric rope

 Shock cooling of synthetic material
 If pump pressure and reel speed is not equal
 Due to high speed m/c running

Remedies:

 Maintain proper reel speed and pump speed.

 Lower rate rising and cooling the temperature
 Reduce the m/c load
 Higher liquor ratio.

59
5.12.4. Dye spot:

Causes:

 Improper dissolving of dye particle in bath

 Improper dissolving of caustic soda particle in bath

Remedies:

 By proper dissolving of dyes and chemicals

 By passing the dissolved dyestuff through a fine stainless steel mesh strainer,
so that the large un-dissolved particles are removed.

5.12.5. Wrinkle mark:

Causes:

 Poor opening of the fabric

 Shock cooling of synthetic material
 High temperature entanglement of the fabric

Remedies:

 Maintain proper reel speed & pump speed

 Lower rate rising and cooling the temperature
 High liquor ratio

5.12.6. Softener mark:

Causes:

 Improper mixing of the softener

 Improper running time of the fabric during application of softener

Remedies:

 Maintain proper reel speed & pump speed

 Proper mixing of softener before addition
 Prevent the entanglement of the fabric during application of softener

60
CHAPTER: 06

61
6.1. Sequence of operation in finishing section:

Dyed fabric from dyeing section

Tube fabric open fabric

Dewatering Slitting & Dewatering

Dryer padding & drying

Compacting stentering

Final inspection Compacting

Final Inspection

6.2. Machine used in finishing:

6.2.1. Dryer (Gas & Steam):

 Brand name: Dong Num

 Origin: Korea

6.2.2. Squeezer:

 Brand name: Marsan

 Origin: Turkey

62
  Brand name: Calator
 Origin: Sewden
 Brand name: Je Young
 Origin: Korea
 Brand name: Suntex
 Origin: Korea
 Brand name: Dong Num
 Origin: Korea
 Brand name: Bangla
 Origin: Bangladesh

6.2.3. Stenter m/c:

 Brand name: Shangai montex

 Country: China
 Brand name:ACC
 Country: Turkey

Pic: schwager machine

63
6.2.4. Functions of Stenter:
 Heat Setting
 Increase dimensional Stability of the Fabric
 Width control
 Spirality control
 Increase soft feel property of the fabric
 Fabric GSM control
 Softener Application
 Drying
 Moisture control
 Loop control

Pic: Stenter Machine

6.2.5. Compactor m/c:

 Brand name: Feraro

 Country : Italy
 Brand name: Lafer
 Country: Italy

64
  Brand name: Dilmenler
 Country: Turkey
 Brand name: Tube Tex
 Country: USA

6.2.6. Function:

 Shrinkage Control
 Width control
 GSM control

6.3.7. Hydro extractor:

 Brand name: Dong Num

 Country: Korea

6.2.8. Function:
 Extracting Excess water

6.2.9. Soft setting:

 Brand name: Dong Num

 Country: Korea
 Steam Setting:
 Brand name: Dong Num
 Country: Korea

6.2.10. Heat setting:

 Brand name: Dong Num

 Country: Korea

6.2.11. Rising m/c:

 Brand name: Ikuang

 Country: Italy

6.2.12. Emarise/ Peach/ Carbonise:

 Brand name: Mario Costa

 Country: Italy

6.2.13. Tumble dryer:

 Brand name: Guohang

 Country: China

65
Fig. 7: Slitting machine Fig. 8: Stenter machine

Fig. 9: Tumble dryer Fig. 10: Hydro extractor

CHAPTER: 07

66
7.1. Definition:

Printing is the art of design by mechanical and chemical operation. It entails the
localized application of dyes or pigments as a result the design being created by
different colors and motives.

So, by the term “Textile Printing” we mean the localized application of dyes or
pigments and chemicals by any method which can produce practical effect of color on
the fabric according to design.

7.2. Types of printing:

1. Pigment printing
2. Rubber printing

67
 3. Crack printing
4. Discharge printing
5. High density printing
6. Flock printing
7. Foil printing
8. Glitter printing
9. Emboss/Puff printing

7.3. Chemical used in printing:

 Acid Oils
 Starch
 CMC
 Cellulose
 Oil and fats
 Alkaline Sodium Silicate
 Aluminium Sulphate
 Aluminium Powder
 Ammonium Acetate
 Barium Sulphate
 Benzoic acid
 Bio Chemical
 Copper Sulphate
 Cupros chloride
 Detergent chemicals
 Dioctyl phthalate
 Disodium Phsphate
 Iron Oxide
 Hydrochloric Acid
 Industrial salt

7.4. Printing process sequence

7.4.1. Pigment printing:

Recipe:

68
 Thickener---------------2%

Binder------------------8%

Fixer-------------------2%

Water-----------------90%

Sequence:

Table preparation

Fabric plaited on the table

Pigment printing paste apply with the help of screen

Curing at 160c

Delivery

7.4.2. Rubber printing:

Recipe:

Rubber -------------60%

Clear----------------38%

Fix-----------------2%

Sequence:

Table preparation

69
 Rubber printing paste apply with the help of screen

Hanging the fabric for 30 min

Curing at 150C (belt speed 5 m/min)

Delivery

7.4.3. Crack printing:

Recipe:

Rubber ------------98%

Fixer---------------2%

And Crack paste/clear

Sequence:

Table preparation

Fabric plaited on the table

Crack paste/ clear apply with the help of screen

Dry in air temp or hand dryer m/c(slight)

70
 Curing at 190 C (belt speed 2m/min)

Delivery

7.4.4. Flock printing

Recipe:

Flock paste ----------90%

Fixer (Nylon) -------10%

And flock power (Synthetic or cotton)

Sequence:

Table preparation

Fabric plaited on the table

Apply flock paste with the help of screen

Flock power apply with the help of flock gum

Manually dry by hanging for 3 min

Curing at 180 C(belt speed 3m/min)

Brushing

71
 Delivery

7.4.5. Foil printing

Foil paper solid color which is made by Buyer requirement

Recipe:

Foil paste ------------90%

Fixer-----------------10%

Sequence:

Table preparation

Fabric plaited on the table

Foil gum/foil paste apply by screen

Dry slightly in air temp /hand dryer

Apply foil paper on the fabric

Heat apply by heat press m/c (150 C for 5 sec)

Cooling for 4 sec

Foil paper removed by hand

72
 Delivery

7.4.6. Emboss/puff printing

Recipe:

Rubber paste ---------49%

Pub/emposs-------49%

Fixer----------------2%

Sequence:

Table preparation

Fabric plaited on the table

Apply printing paste by screen (3 times)

Hanging for 15 min

Curing at 170 C (belt speed 3 m/min)

Delivery

7.4.7. Discharge printing

Recipe:

Discharge rubber paste--------------90%

Discharge /RNS power -------------49%

Sequence:

73
 Table preparation

Fabric plaited on the table

Apply printing paste with the help of screen

Curing at 190 C(belt speed 3 m/min)

Delivery

7.4.8. High density printing:

Recipe:

High density paste -----------100%

Sequence:

Table preparation

Fabric plaited on the table

High density paste apply by screen

Curing at 160 C (belt speed 3 m/min)

Delivery

7.4.9. Glitter printing

74
 Rubber paste ------------70%

Fixer---------------------2%

Glitter-------------------28%

Sequence:

Table preparation

Fabric plaited on the table

Glitter paste apply by screen

Hanging for 15 min for dry

Curing at 160C (belt speed 3 m/min)

Delivery

Table 11: Printing sample:

Type of print Sample

Pigment print

Rubber print

Puff print

75
 Foil print

Creck print

Gliter print

High density print

CHAPTER: 08

76
8.1 MARKETING SECTION

Marketing:

Merchandising department is the star of the department among all the working
departments in the Export concern, because Merchandising is the only department
having maximum control over the departments and total responsible for Profit and
loss of the company. FGS Landry Ltd. have strong merchandising department the
merchandising team who are always concern about the main objectives of their job
description that is 4R.

Right Quantity: To dispatch right quantity of product what buyer ordered.

Right Quality: It should be with right quality as accepted both parties.

77
Right Cost: Everybody wants more from what they are paid.

Right Time: No one wants to wait idle even in a Restaurant. Keeping

delivery schedule is mandatory.

CHAPTER: 9

78
9.1. Definition:

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

9.2. Quality assurance procedure:

The decision plan and action that is necessary to provide adequate confidence that a
product or service will satisfy given requirement for a particular quality.

9.2.1. Body & rib inspection:

79
All roles are kept in front of the inspection m/c time to time as require. The fabric are
spread all over the milky white acrylic inspection board ensures high transparency and
even reflection of light. Then by the inspection machine fabric are inspected visually
at a standard speed against light. For any major and minor faults like thick-thin, barre
mark, fall out, contamination, fly holes, oil lines, needle line, slub etc are recorded in
inspection report to classify the fabric based on the four point system.

9.2.2. Collar & Cuff inspection:

Collar & cuff are inspected visually under the light box. For any major or minor faults
in collar/cuff like wrong ply, hole, needle line, slubs, wrong design, first round
problem etc are properly counted and recorded.

Quality inspector shall check 100% of receive fabric for quality. We will identify any
defect, hole or stain in the fabric and make calculation given below-

9.3. Point calculation system :

Defect area point

1” to 3” 1

3” to 6” 2

6” to 9” 3

Above 9 4

For hole in fabric 4

9.4. Calculation of points is done by-

Actual point X 100

Inapected total Yard
=Actual grade point

80
If point grade is 40 or below then fabric is ok. If the result is more than 40 points, then
inform it to GM or respective merchandiser.

The fabric is also checked for shading defect in side by side and length. Any non-
conformities/shade will be notified to asst. masnager using inspected reports. Roll
wise color uniformity card is maintained for identification of shade variations.

During the fabric inspection if theyardagre of any roll is reperted more or less by the
fabric inspection m/c then the one specified in the roll,the roll will be measured
manually using measuring tapes. Only calibrated measuring tape will be used

The result of fabric inspection will be recorded in fabric inspection repert

9.5 Quality standard:

The quality standard: ISO 9001-2001

CHAPTER: 10

81
10.1. Definition

Quality control is concerned with the evaluation of test data and its application to
control of the textile process, raw materials, intermediate products and final products.

It is concerned with the presentation of tangible values to measure quality and change
in quality. In order to control quality one must know about the consumers’
expectations.

10.2. Objects of quality control:

 Research/analysis
 Selection of raw materials
 Process control and development

82
  Product testing
 Specification test
 Should be given economic requirements
 Quality assurance and so on

10.3. List of equipment for quality control:

 Yarn grade tester

 KERN Electronic balance
 Spray rating tester
 Incubator
 Iron
 Button tester
 Lab dip dyeing machine
 Thermoplastic water bath
 Rota wash
 Orbiter pilling & snagging tester
 Crock meter
 Spectra photometer
 Thermo hydrograph
 PH meter

10.4. Quality control flow chart

Yarn receiving

Sample knitting

Batching

83
 Dyeing (Check shade & Faults of dyeing)

Dewatering & untwisting

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

Compacting

Final inspection

If sample ok go to the bulk production

CHAPTER: 11

84
11.1. Definition

Maintenance is a process by which equipment is looked after in such a way the

equipment can give the best services of it. Machine, building and other facilities are
subjected to deterioration due to their use and exposure to environmental condition.
Process of deterioration, if uncheckd, culminates in rendering these service facilities
unserviceable and brings them to a standstill. In industry, there fore has no choice but
to the extent it is economically and physically possible to do so. Maintenance
increases the life time of the machine. Now-a-days maintenance has become the
essential for the modern time industrialization.

11.2. Objective of maintenance:

85
  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
consumer.
 To keep the downtime of machines to the minimum thus 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

11.3. Flow chart of maintenance:

Problem

Inform to the maintenance department

Detect problem

Problem can be repare or replace

Repair can be solve immediately, replacing requires time (parts needed to

buy & then solve the problem)

11.4. Maintenance tools, equipments & their function

Name of tools Functions

Hammer To give Shape

Slide Wrench tightening &opening bolt

Spanner tightening &opening bolt

Pillar cutting, Holding, Joining wire

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Hacksaw Cutting

Pipe Wrench Tightening, Opening, Gripping pipe

Chisel Shaping, Cutting

File Shaping

Clamp Gripping

Name of equipments functions

Grinding m/c Grinding

Cutting m/c Cutting

Drill m/c Drilling

Shaping m/c Shaping

Lathe m/c To make something

Bending m/c Bending

CHAPTER: 12

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 Water treatment plant

12.1. Natural water quality:

Water is supplied in different sections continuously by using submersible and

centrifugal pump.

Water for a textile plant may come from various sources. These include surface water
from rivers and lakes, and subterranean water from wells. This water may be obtain
directly from the source or from the local municipality. Natural and pretreated water
may contain a varity of chemical species that can influence textile wet processing in
general, and dyeing in particular.

The various salt present in water depend on the geological formations through which
the water flowed. These salts are mainly the carbonate (CO 32-), Hydrogen carbonates
or bi-carbonates(HCO3-), Sulphates (SO4-) and Chlorides (Cl-)of Calcium (Ca2+),

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Magnesium (Mg+). Although calcium and magnesium carbonates in lime stone are
divided into two ways-

1. Temporary hardness: Ca(HCO3)2, Mg(HCO3)2, Fe(HCC3)2

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

This water hardness cause some serious consequences in textile dyeing and finishing
industries and these are-

12.2. Precipitation of soap

Redeposit ion of dirt and insoluable soaps on the fabric being washed, this can cause
yellowing and lead to uneven dyeing and poor handle

Precipitation of some dyes as calcium and magnesium salts

Scale formation on equipment and in boilers and pipelines

Reduction of the activity of the enzymes used in washing

Incompatibility with chemicals in finishing recipes and so on

12.3. Removal of water hardness

Necessary equipments and chemicals:

Buffer solution

Indicator

Liquid EDTA solution

Beaker

Procedure:

Take 50 ml water in a biker which treated by WTP plant

Take 4/5 drops buffer solution in a beaker

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Take 1 drop indictor in a beaker and from the violet color

Now EDTA solution is dropped until the pink color is not from a crystal color

Here , 1 drop EDTA solution = 3 ppm

12.4. Result

Industrial soft water std. range is 5 ppm but it is very difficult to control. So in this
industry water hardness scale maintains 7 to8 ppm of CaCO3.

Table 12: Standard water quality for dye house:

Parameter Acceptable Limit

Color Color less
Smell No bad smell
Water hardness <25 ppm
pH value 6.5-7 ( Natural)
Total Dissolved Solid <65-135 ppm
Inorganic salt <500 ppm
Iron (Fe) <.0.1 ppm
Manganese (Mn) <0.01 ppm
Copper(Cu) <0.005 ppm
Nitrate (NO3) <50 ppm

Effluent Treatment Plant (ETP)

12.5. Major sources of Liquid Discharge are:

The effluent generated from different sections of a textile industry must be treated
before they are discharged to the environment. Various chemical and physical means
are introduced for this purpose.

Capacity: 80 m3

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Type: Biological plant

Use urea and phosphate as the food of bacteria.

Following parameter must be control in a range:

PH : 6 to 9

Dissolve O2 : 4.5 to 8.5

BOD : 50

COD : 200

TDS : 2100

CHAPTER: 13

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13.1. Definition

Compliance means conformity of certain standard. PPC maintain a moderate working

condition for their employees. Through it is well established project, there is some
lacking of proper compliance issue.

13.2. List of compliance issue:

Here is the list of compliance in which some points are maintained fuly and some are
partially.

 Compensation for holiday

 Leave with wages
 Health resister
 Time care
 Accident resister

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  Equal remuneration
 National holiday
 Overtime resister
 Labor welfare
 Sexual harassment policy
 Child labor abolition policy
 Anti disctrmination policy
 Zero abasement policy
 Working hour policy
 Hire/ recruitment policy
 Environment policy
 Security policy
 Buyer code conduct
 Health and safety committee
 Canteen

13.3. Health

 Drinking water at least 4.5 L/day/ employee

 Cup availability
 Drinking water supply
 Water cooler, heater available in canteen
 Drinking water sign in bangle and English min.20 feet away from work place
 Drinking water vassal clean at once a week
 Water center in charge person with cleanliness
 Suggestion box resister

13.4. Toilet

 Separate toilet for men and women

 A seat with proper policy and lock facility
 Urinal accommodation

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  Effective water wage system
 Soap toilet & water tap
 Dust bins
 Toilet white washed one in every four month
 Daily clean log & non smoking sign
 Ladies and gents toilet signs both bangle and English
 Deposal of wastes and effluent

13.5. Safety guard

 Metal globes in good condition

 Rubber mats & ironers
 First aid box
 Ironers wear sleepers
 First trained employee
 Motor /needle guard
 Eye guard
 Nurse
 Doctor
 Medicine
 Medical issuing resister
 Welfare officer
 Fire sufficient fire extinguisher and active
 Access area without hindrance
 Fire sign in both language
 Emergency exit

13.6. Other

 Room temperature
 Lighting facility

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CHAPTER: 14

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14.1 Conclusion:

I have completed my industrial attachment successfully by the grace of almighty

“Allah”. Industrial attachment sends me to the expected destiny of practical life. The
completion of two months industrial training at “AJI Textiles Industry Limited. ” I
have got the impression that ,this factory is one of the most modern export oriented
knit composite mill in Bangladesh. The factory has good reputation for its best
performance over many other export oriented textile mills.

This training gives us the natural picture about the men, machines, material, methods
and market. I have earned the direct knowledge about the raw materials actual
summery condition of the machine, works technology and administration. Above all
the training in AJI Textiles Industry Limited has given me a new experience in
practical life.

University of South Asia has gave me the field to perform the industrial training with
AJI Textiles Industry Limited. this attachment seems to me as a bridge to minimize
the gap between theoretical and practical knowledge undoubtedly. This attachment
shows me the way to learn more about textile technology, industrial practices,
industrial management and production process.

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Besides, this attachment gives me the first opportunity to work in an industry and
acquainted me with the internal sight and sound of textile industries.

I hope this industrial training with AJI Textiles Industry Limited will help me very
much in my future career

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