Industrial attachment of APS group ltd

Considerable points to produce knitted fabrics: When a buyer orders for fabric then they mention some points related to production and quality.. - Yarn count - Types of yarn combed or

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

APS GROUP LTD.

Introduction

Industrial Attachment is the first step to professional life of a student Especially of technical side it’s an indispensable part of study a practically running processing technology of an industrial unit for a student In our University, processing machines are not in continuous running condition So

it would only provide demonstration of mechanical features & processing technology of the material in accomplishment of the theory there of but not of the situational variables to achieve practical knowledge Six weeks industrial attachment program in a dying mill was arranged for us this type of attachment program enabled us to avoid the gap between theory & its applicability the

mill practice the incumbent was deeded to APS Group (Dyeing Unit)

In the field of ever changing moderns fashion work APS Group (Dyeing Unit) considers its prime mission to every new test Which & demand of customers from around the World & all strains human culture DGL acts on the basis premise that fashion is an exploration in to the images people seek to convey about themselves & the way they live

We have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for our future carrier

Table of Content

Chapter-1 Over View of the Factory 5-17

Chapter-7 Water Treatment Plant “WTP” 77-79

Chapter-10 Description of ETP 106-108

Chapter-13 Store & Inventory control 119-121

Chapter-14 Social & Environmental information 122-127

CHAPTER: 1

Address: Pubail, Gazipur, Sadar, Gazipur

AT A GLANCE

APS Group (Dyeing Unit)

100% Export Oriented Composite Knitwear Factory

Address: Pubail, Gazipur, Sadar, Gazipur

Tel: +88-02-9815028, www.aps-group.org

Head Office - Pubail, Gazipur, Sadar, Gazipur

Tel: +88-02-9815028

Factory - Pubail, Gazipur, Sadar, Gazipur

Nature of project - 100% Export Oriented Composite Knitwear Factory

Bank - Bangladesh Shilpa Bank, Head Office, Dhaka

Management - 1 Md Alfaz Managing Director/Chairman

Contact Person - 1 Engr Md Rashedul Islam (Babu), General Manager (Fac.)

Mobile: 01713454160

 -2 Md Rezaul Karim (Babu) Manager (Dyeing & Finishing) Mobile: 01718218497

 3 Md Bellal Uddin Manager (Knitting)

 4 Md Musa Kalim (Manager Finishing)

Composition of Factory

The Enterprise have been organized in the following manner:

APS Group (Dyeing Unit) Unit : Fabrics Knitting

APS Group (Dyeing Unit) Unit : Fabrics Dyeing

Year of Establishment : January, 2000

Location:

Our Head office is located at a posh area called Uttara while the factory is located in an industrial area

at Pubail, Gazipur which is only 2.2 Km

Production Capacity and Facilities :

a)

Machine Circular Knitting Machineries

Sl.No Dia Gauge

Qty of feeder Brand/Origin Fabrics

No of Machine

1 21"

20+24

63

Jiunn long/Taiwan

Single Jersey 2

Single Jersey/Pique

1 52"

2

temperature & high

Machine : Fabrics Inspection Machineries

b) Type of Machine : Finishing Machineries

2

Tensionless Dryer

c) Type of Machine : Laboratory Machineries

The Factory is equipped with a most modern set up of brand new & latest Model Laboratory

FABRICS BRUSHING UNIT

01 Fabrics brushing Machines:

Per Machine 24 Roller; Made

in Taiwan Ar Tex For S/J Light

Brush, Fleece One side Brush

& polar fleece-bith sides

brushed

2 Sets

1 We Have 2 set brushing Machines We are able to raise/brushing for one side

or both side brush

Capacity: 6000 Kg per day with standard quality

Factory Information

Industry

Dyeing : 15.5 ton/day (Average)

Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear& all kinds of knit garments & Knit fabrics

BASIC LAY-OUT OF THE FACTORY

6 Fabric dyeing & finishing section

7 Yarn dyeing section

8 Garments section

9 Garments section

10.Maintenance Building

11.Water Treatment Plant (WPT)

12.Human Resources Department (HRD)

13.Generator House

Man Power Management in APS Group (Dyeing Unit) Textile Ltd

Fitter man Operator

GM DGM

PM

Incharge

Finishing Incharge

Lab Incharge

Sewing man Squeeze Operator Dryer Operator Compactor Operator

Helper

Lab Technician

Q.C

Technician

Chapter- 2

“Raw Materials”

Tara Textile Mills ltd 20S/1 Comd 3.00 175 1500.00

 1 x 1 rib & others

 Collar & cuff

Sources:

The required grey fabric is produce in the industry

3 Chemicals:

Chemicals Rate per kg

04 Reactofix Orange ME2RL 294

CHAPTER: 3

“KNITTING SECTION”

Machine Description of Knitting Section:

M/C Model

No Of Feeder

No Of Needle

M/C Spec

96 2400 S/J PAI LUNG TAIWAN

End products of Circular Knitting Machine:

Single Jersey M/C:

S/J Plain Single Lacoste Double Lacoste Single pique Double pique Mini jacquard Terry

Interlock M/C:

Interlock pique Eyelet fabric Mash fabric Honeycomb fabric Face/Back rib

Considerable points to produce knitted fabrics:

When a buyer orders for fabric then they mention some points related to production and quality Before production of knitted fabric, these factors are needed to consider Those are as follows-

- Type of Fabric or design of Fabric

- Finished G.S.M

- Yarn count

- Types of yarn (combed or carded)

- Diameter of the fabric

- Stitch length

- Color depth

Name & Picture of Knitting Machine in APS knitwear Textile Ltd

Machine Name Number of machine Production per

shift(kg)

S/J Machine (Mayer &

Cie)

Rib Machine (Mayer &

Fig: PAI LUNG Knitting Machine

Fig: FUKAHARA Knitting Machine

Fig: Mayer & Cie knitting machine

Knitting Production and Raw Materials:

Methods of increasing production:

By the following methods the production of knitted fabric can be increased –

By increasing m/c speed:

Higher the m/c speed faster the movement of needle and ultimately production will

be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed

By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time

By using machine of higher gauge:

The more the machine gauge, the more the production is So by using machine of higher gauge production can be increased

By imposing other developments:

 Using creel-feeding system

 Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage

 Using yarn feed control device

 Using auto lint removal

Production calculation:

A Production/shift in kg at 100% efficiency:

count Yarn

mm SL Needle of

No Feeder of

No RPM

) (

.

B Production/shift in meter:

100 /

12 60

/

min /

Efficiency Feeder

of No RPM

cm Course Course

C Fabric width in meter:

100 /

.

100 /

knitting in

used Needles of

no Total

cm Wales

wales of no Total

Process flow chart of 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

Raw materials for knitting:

Some points are needed to maintain for high quality fabric:

Brought good quality yarn

Machines are oiled and greased accordingly

G.S.M, Stitch length, Tensions are controlled accurately

Machines are cleaned every shift and servicing is done after a month

Grey Fabrics are checked by 4 point grading system

Changing of GSM:

Major control by QAP pulley Minor control by stitch length adjustment Altering the position of the tension pulley changes the G.S.M of the fabric

If pulley moves towards the positive direction then the G.S.M is decrease

And in the reverse direction G.S.M will increase

Other m/c in Knitting Section:

Gray Inspection M/c, Brand : Uzu fabric inspection machine Electric Balance for Fabric Weight

Electric Balance for GSM check

Compressor 2 pieces

Production Parameter:

Machine Diameter;

Machine rpm (revolution per minute);

No of feeds or feeders in use;

Machine Gauge;

Count of yarn;

Relationship between knitting parameter:

1 Stitch length increase with decrease of GSM

2 If stitch length increase then fabric width increase and Wales per inch decrease

3 If machine gauge increase then fabric width decrease

4 If yarn count increase (courser) then fabric width increase

5 If shrinkage increases then fabric width decrease but GSM and Wales per inch increase

6 For finer gauge, finer count yarn should use

7 Gray GSM should be less than finish GSM

Considerable points to produce knitted fabrics:

When a buyer orders for fabric then they mention some points related to production and

quality Before production of knitted fabric, these factors are needed to consider

Those are as follows-

Type of Fabric or design of Fabric

Finished G.S.M

Yarn count

Types of yarn (combed or carded)

Diameter of the fabric

Stitch length

Color depth

Effect of stitch length on color depth:

If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact In dark shade dye take up% is high so GSM is adjusted then Similarly in case of light shade loop length should be relatively smaller

Factors that should be change in case of fabric design on quality change:

a) Cam setting

b) Set of needle

c) Size of loop shape

Faults & Remedies of knitting fabric:

Hole Mark:

Causes:

 Holes are the results of yarn breakage or yarn cracks

 During loop formation the yarn breaks in the rejoin of the needle hook

 If the yarn count is not correct on regarding structure, gauge, course and density

 Badly knot or splicing

 Yarn feeder badly set

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

2.Use proper count of yarn

3.Correctly set of yarn feeder

4.Knot should be given properly

Needle Mark:

 When a needle breaks down then needle mark comes along the fabrics

 If a needle or needle hook is slightly bends then needle mark comes on the fabrics

Remedies:

 Needle should be straight as well as from broken latch

 Yarn tension variation during production

 Buckling of the needle latch

 Low G.S.M fabric production

Remedies:

 Maintain same Yarn tension during production

 Use good conditioned needles

 Take-down mechanism too loose

 Insufficient yarn tension

 Badly set yarn feeder

Remedies:

 Needle should be straight & well

 Proper feeding of yarn during loop formation

 Correct take up of the fabric & correct fabric tension

 Yarn tension should be properly

Oil stain

Causes:

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

Remedies:

 Ensure that oil does not pass on the fabrics

 Well maintenance as well as proper oiling

Rust stain:

Causes:

 If any rust on the machine parts

Remedies:

 If any rust on the machine parts then clean it

 Proper maintenance as well as proper oiling

Remedies:

 Proper greasing as well as proper maintenance

Cloth fall- out:

 Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles

 This fault comes from yarn fault

 If different micro near value of fiber content in yarn

 Different lusture, dye affinity of fiber content in yarn

 During spinning different similar classes of fiber is mixed specially in carded yarn &

these fibers have similar characteristics

 In draw fame different similar classes sliver is mixed and make one sliver

Fly:

Causes:

 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

Remedies:

 Blowing air for cleaning and different parts after a certain period of time

 By cleaning the floor continuously

 By using ducting system for cleaning too much lint in the floor

 Over all ensure that lint does not attach to the fabric

Yarn contamination:

Causes:

 If yarn contains foreign fiber then it remains in the fabric even after finishing,

 If lot, count mixing occurs

Remedies:

 By avoiding lot, count mixing

 Fault less spinning

CHAPTER:4

“LABORATORY SECTION”

Machine Description of Dyeing Lab:

Brand : Robolab 240 Mfg : Sclavos International Origin : England

Brand : Datacolor (AHIBA IR) Origin : India

Brand : Datacolor (AHIBA Nunance) Origin : India

Brand : Datacolor (AHIBA Nunance) Origin : India

5 Name : Sample Dyeing m/c (High Temp.)

Brand : Dexter Mfg : Yuan Shen Enterprise Co., Ltd

Origin : Taiwan

6 Name : Washfast Test m/c

Brand : Washfast uni Mfg : Mag Engineers Ltd Origin : India

Name and source:

Cosmos-S-MAX Navy-SLF Orange-S-MAX Red-S-2B Red-S-2B-150%

Red-SGT Red-SLF Red-S-MAX Rubine-S-MAX Scarlet-S-2GF Yellow-S-3R-150%

Yellow-SLF Yellow-S-MAX Yellow-V-5GL

Dianix

Black-CC-R

Dychufix

Blue-CC Blue-S-BB Blue-SE-2R Dianix blue-ER-150 Navy-CC

Red-EFB Rubine-CC Turquise-CC Yellow-E-3GE Yellow-S-EG

Chemicals:

Generic Name

Ablu Ablusoft-AC-720

Ablutex-AP-750HC Ablutex-BBV Boiler Nalco-450

CHT Felosan-NOF

Meropan-CIT Meropan-Red Polyavin-3000 Saravid-VP-174

Clariant

Antioxidant-M Destofil-LC Diresul-Antioxidant-M-Liq Ladiquest-1097

Sandozin-EH

Cognis

Adalin-11 Adasil-SME Cottoclarin-114 Dyapol Dyapol-ECO

Effluent

Ferrous-Sulphate-(Feso4-7H2o) Hydrochloric-Acid(HCL)

Lime Polymer Sodium-Hypo-Chloride(NaOCl) Urea-Fertilizer

Chapter- 5

“Batch section”

Solid Batch Ratio Batch

 Solid Batch: It is a process to get ready the same dia fabrics that should be dyed

 Ratio Batch: It is a process to get ready the different dia fabrics that shoud be dyed

Batch process follow-up:

Grey Fabric Inspection

Batch m/c (From back side to face side)

Batch

Fabric Turning

Stitch the fabric

Storing for dyeing

Grey fabric inspection:

Grey Fabric Check to Inspection Table Tow person are checking continuously Do have any problem find out any Fabric Then mark as defect zone To inform the upper position and also to take this problem solves Proper inspection report is not available To attach numbering in defect fabric

Fabric faults identification & their causes and remedies:

1 Hole Mark:

Causes:

1 Bad needle

2 Take down mechanism too tight

3 High tension on yarn

4 Badly tied knots

Remedies:

1 Yarn strength must be sufficient to withstand the stretch as well as uniform

2 Correctly set of yarn feeder

3 Knot should be given properly

2 Take-down mechanism too loose

3 Insufficient yarn tension

4 Badly set yarn feeder

Remedies: