INDUSTRIAL ATTACHMENT OF YASSMA KNITTING & DYEING.

I have completed my 6 weeks long industrial training in dyeing and finishing section of YASSMA KNITTING & DYEING Ltd..  Then the yarn is loaded  Then Wetting, Sequestering, Stabilizer

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

YASSMA KNITTING & DYEING.

CHAPTER-1

INTRODUCTION

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

CHAPTER-2

COMPANY PROFILE

Company Profile:

Factory Name : YASSMA KNITTING & DYEING Ltd

Type : 100% Export Oriented Yarn Dyeing Industry

Year Of Establishment : 01 January 2009

Investors : Md

Address:

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

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

Major Buyers & Fashion Labels:

CHAPTER-3

MANPOWER MANAGEMENT

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

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

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

CHAPTER-4

MACHINE DESCRIPTION

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:

Auto Dosing

CHAPTER-5

RAW MATERIALS AND CHEMICALS

Type of Raw Materials :

Grey Yarn:

 Single Ply cotton yarn

 Double Ply cotton yarn

 Tree Ply cotton Yarn

Synozol Blue K-BR

Synozol Ultra Black DR

Synozol B/Red BB

Synozol Yellow HB

Synozol Navy Blue HB

Synozol Deep Red HB

Remazol Turquise Blue G

Commonly Used Chemicals & Auxiliaries:

Agent of- Name of items

Chemicals of KBC Co.(Pvt) 2UD

Eco Scouring & Bleaching agent

Imerol PCLF TF-129B Perlavin NDA Sabilezer TF-122B

Hydrozen peroxide

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

Cepreton UCP GTF-445C Perifil 210 Liq White Softner Nass-T ( Local )

GTF-442

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

CHAPTER-6

PRODUCTION PLANING, &

OPERATIONS Operations

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

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

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

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

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

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:

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 900

 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´ & P H 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

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

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 800C × 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

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 900

 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´ & P H 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 P H 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 P H

 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

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 800C.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 900

 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΄ & P H 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 P H 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 P H

 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

 Required amount of water is taken in the m/c

 Then temp.is raised to 1300

C with rinsing and Runtime at 45°c×10 minutes

 Then Drain out

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

 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