INDUSTRIAL ATTACHMENT OF BISWAS GROUP LTD

Process control of knitting: Yarn in cone form Creels Pipe Knot catcher Tension disk Inlet stop motion Yarn guide PF Wheel Out let stop motion Guide Needle Fabric Fabric take up roller I

Trang 1

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

BISWAS GROUP LTD.

Trang 2

TABLE OF CONTENTS Serial No Topic Page No 01 Introduction 05

02 Company Profile 06

03 Knitting Section 12

04 Quality Control 30

05 Batch Section 33

06 Dyeing Lab 35

07 Dyeing 39

08 Finishing Section 68

09 Fabric Inspection 75

10 Quality Assurance system 77

11 Maintenance 79

12 Utility 85

13 Effluent Treatment Plant 89

14 Conclusion 91

Trang 3

INTRODUCTION

By means of practical knowledge its not possible to apply the theoretical knowledge

in thepractical field For any technical education, practical experience is almost equal importance in association with the theoretical knowledge

The industrial attachment is the process, which builds understanding skills and attitude of the performer, which improves his knowledge in boosting productivity and services University education provide us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to

be familiar with technical support of modern machinery, skillness about various processing stages

It is also provide us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance

of machinery and their operation techniques etc

Textile education cannot be completed without industrial training Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment We got an opportunity to

complete our industrial training at BISWAS SYNTHETIC LTD It has well planned &

equipped fabric dyeing-finishing and printing unit in addition to facilitate knitting and knitwear manufacturing

Trang 4

COMPANY PROFILE

GENERAL INFORMATION ABOUT THE COMPANY:

 Biswas Group was established in 1985

 Biswas Group deals in Apparels, Textile and Accessories

 Biswas Group have 9 fully automated garments factories in Dhaka

 7 associate factories in Dhaka

Product Range- Men's Women's Boys, Girls, Kids and Toddlers, T-Shirts, Polo

Shirts, Woven Women's Blouses, Men's Shirts, Pants/Shorts Casual/Denim Men's, Women's and kids, Jogging Suits, Swimwear, Nighwear, Winter Wear and All kinds

of Accessories

Monthly Capacities : 43000 pcs woven bottoms, 300000 pcs woven tops, 380000

pcs pants, 600000 pcs knit tops, 30000 pcs knit bottoms

 Work force - 9000 employees

Trang 5

Web: www.biswasgroup.com

Project location:

Trang 8

General Manpower Organogram:

Chairman

Director

Executive Director

Production QualityAdminAccounts MarketingMaintenance Utility store security

Production QualityAdmin Accounts Marketing Maintenance Utility store security

ManagerManagerManagerManagerManagerManager Mngr Mngr.officer

Assistant Senior AdminAccountsMarketingMaintenanceUtilitystore Assist

Manager Officer OfficerOfficerOfficer Engineer Engineer Officer Officer

Senior Assistant Cashier Fore man Assistant Helper security Production Officer Admin Engineer Guard Officer Officer Fitter man Worker

Production Lab Helper Worker officer Assistant

Assistant Lab Worker

Trang 9

Shifting:

In Biswas Synthetic Ltd the whole day production time is divided into 2shift Per shift 12 hours

Shift Duration

Shift A 8:00 am- 8:00 pm Shift B 8:00pm – 8:00 am

Responsibility of Production officers:

1 To give dyeing program slip

2 To match production sample with target shade

3 To collect production sample lot sample matching next production,

4 To observe dyed fabric during finishing running & also after finishing

5 To identity disputed fabrics & report to P.M/G.M for necessary actions

6 To discuss with P.M about overall production if necessary

7 To sign the store requisition & delivery challan in the absence of P.M

8 Also to execute overall floor works

9 To maintain loading'/unloading khata

10 Any other assignment given by higher authority

Title :Production Office

Report To : Sr Production Officer

Job Summary:

To plan, execute & follows up the production activities & control the quality … production

with related activities

Duties & Responsibilities:

 Overall supervision of dyeing, finishing production

 Batch preparation & pH

I chock

Trang 10

 Dyeing m/c

 And also any other over work as & when required by the management

Title : Sr Production Office

Report To :Manager

Job Summary:

To plan.execute& follows up the production activities & control the quality production with related activities

Duties & Responsibilities:

 Overall supervision of dyeing, finishing production

 Checks the sensitive parameters of different machine for smooth dyeing

 Checks the different log books of different areas & report to management

 Checks out the plan to control the best output from supervisors & workers

 To trained up& motive the subordinates how to improve the quality production

 Control the supervisor, operator, Asstt Operator & helper of dyeing

Trang 11

KNITTING SECTION

Trang 12

Knitting section layout:

Office

Store

QC Wash

room

Trang 13

Process flow diagram of knitting:

PRODUCTION

QUALITY INSPECTION

Trang 14

Process control of knitting:

Yarn in cone form Creels Pipe Knot catcher Tension disk Inlet stop motion Yarn guide

PF Wheel Out let stop motion

Guide Needle Fabric Fabric take up roller Inspection

Numbering

Trang 15

Knitting:

Knitting is the method of creating fabric by transforming continuous strands of yarn into a series

of interlocking loops, each raw of such loops hanging from the one immediately preceding it The fundamental structure unit of a knitted fabric is the loop Any circular knitted fabric is composed of row after row of intermeshed loops Different types of fabric are made of different method of intermeshing the loop The gross dimension of knitted fabric is simply a relation of average shape and size of individual loop There are several key variables in the production which affect the average shape and size of the loop After knitting the grease fabric is dyed to required shade and finished to required weight and width

 Classification of knitting:

Warp knitting:

A method of making a fabric by normal knitting means is which the loop made from each warp thread is formed substantially along the length of the fabric Characterized by the fact that each warp thread is feed more or less in the line with the direction in which the fabric is produced

Weft knitting:

A method of making a fabric by normal knitting means is which the loop made from each

Knitting

Weft knitting Warp knitting

Flat knitting Circular knitting

Double jersey Single jersey

Trang 16

Primary knitting elements:

Types of knit cam:

1.Knit cam 2.Tuck cam

3.Miss cam

Trang 17

Sinker:

Sinker is a thin metal plate with action at right angles to and fro between adjoining needles

Functions of Sinker:

1) Loop formation: The main objects of a sinker are to assist the needles in loop formation by

sinking or knitting the newly laid yarns into a loop

2) Holding down: It also holds down the loops at a lower level of the needles stems and

prevents the old loops from being lifted as the needles raise to clear them for their hooks

3) Knocking over: The function is knocking over at which the needle passes through the old

loop by drawing a new loop

End Products of Single Jersey Circular Knitting Machine:

1.S/J Plain 2.Single Lacoste

3.Double Lacoste 4.Single pique

5.Double pique 6.Terry

Trang 19

Machine profile of knitting section:

Knitting Machine (Single Jersey)

SL M/C Dia/Gauge M/C Quantity Capacity (Per Day) Origin Brand

1 17x24 GG 1 Set 200 Taiwan Min Hua

5 23x24 GG 1 Set 220 Taiwann Min Hua

Knitting Machine (rib Interlock)

1 30x18 GG/24 GG 1 Set 300 Taiwan Min Hua

Knitting Machine (Micro-Polar)

1 26x18 GG 7 Set 1750 Taiwan SandaDask

3 28x19 GG/24 GG 19 Set 5320 Taiwan SandaDask

Trang 20

Knitting Machine

CVC Fleece (Cross/Straight Terry)

Flat Rib

1 60x20 GG 6 Set 2400 Pcs Chaina Sen Huang

Total= 6 Set 2400 pcs

Trang 21

 Required time (M/C running time);

 Take down tension

 Yarn quality

 Machine gauge

 Machine Diameter

 Machine rpm

 No of feeds or feeders in use

 Machine running efficiency

Machine pitch (t) : Is defined as the distance between the centers of two adjacent

Needle of the same needle row indicated in mm

25.4

Pitch = m.m

Gauge(E)

Machine gauge (E) : Machine gauge denotes the number of needles per inch , arranged

On the needle carrier and based on the nominal machine diameter 25.4

Gauge (E) = mm

Pitch

Loops : It is a basic unit consisting of a loop of yarn meshed at its base with

previously Basic unit

Stitch : The smallest dimensionally stable unit of all knitted fabrics is the stitch It

consists of a yarn loop which is held together by being intermeshed with another stitch or

other loops

Stitch length:Stitch length is a length of yarn which includes the needle loop & half the sinker

loop on either side of it Generally the larger the stitch length, the more extensible & lighter the

Trang 22

Raw materials for knitting:

Key accessories used in Circular knitting:

 Yarn feeder guide

 Sinker cam cap

 Sinker trick ring

Lycra yarn 20D,40D

PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S

CVC 24S, 26S, 28S, 30S

Trang 23

Production calculation:

A Production/shift in kg

B Efficiency:

Trang 24

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 Grey GSM should be less than finish GSM

Yarn Twist and Yarn Count:

The amount of twist is an important factor in finished consumers’ goods It determines the appearance as well as the durability

and serviceability of a fabric Fine yarns require more twist than coarse yarns If the yarn twist increase, the yarn strength increase up to certain level after that yarn strength decrease

The twist factor for combed cotton yarns for knitted fabrics should not exceed 3.7, whereas in case of carded yams, a twist factor up to 3.9 is tolerated of yarns for knitted fabrics

In case of knitting yams a part of the yarn strength has to be sacrificed for a better and softer handle

Yarns with low twist are used for knitted fabrics, yarns with high twist are used for crepe yarns Yarnswith average twist are used for regular woven fabrics

Trang 25

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

Knitting defect & remedies :

Fault name Causes Remedies image

# Badly knot or splicing

# Yarn feeder badly set

# If yarn tension too high

#Yarn strength must

be sufficient to withstand the stretch

# If needle does not catch yarn

# Needle should be straight as well as from broken latch

# Maintain same Yarn tension during production

# Use good conditioned needles

Trang 26

# Take-down mechanism too loose

# Insufficient yarn tension

# Badly set yarn feeder

#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

5.Bariness

# Use of irregular yarn having higher long term irregularities

# Using different count thread

# Remove irregular yarn

# Use proper yarn count

#We can use it for white fabric

# Set proper yarn tension

Trang 27

7.Lycra out

Cause by If lycra is missed or Lycra attach with the yarn

Check the feeder and attatchlaycra

9.Oil mark

# Excessive oil flow in the needle

# Leakage of oil line

# Ensure that oil does not pass on the fabrics

# Well maintenance

as well as proper oiling

Trang 28

10.Fly

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

# 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

11.Yarn

contamination # If yarn contains foreign

fiber then it remains in the fabric even after finishing,

# If lot, count mixing occurs

# By avoiding lot, count mixing

# Fault less spinning

12.Sinker

Mark

# When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes

# If sinker head bend then sinker mark comes

Sinker should be changed

Trang 29

Quality Control

Quality assurance system of knitting division:

The quality assurance department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing After collecting fabric rolls from different machines, these fabrics need to inspect thoroughly by the quality inspectors to assure required quality before dying Quality assurance of knitted grey fabric is described here

Quality control

On-lineOff-line

Quality control equipment:

Following equipment are used to ensure proper quality of the produced fabric

 Yarn tension meter

 Stitch length meter

Trang 30

Collar & cuff inspection:

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

Quality Control Standard Value:

Fabric inspected by 4-point system

Shortly describe about 4-point system

This is the universal system for the inspection of grey and finished fabric In this system, we count penalty point for different kind of defect as well as according to the defect size Different types of defect may come from yarn fault, manufacturing fault, transportation fault

Parameter of penalty point:

All holes, regardless of size will be penalized 4 point

Four point grading system

Trang 31

Calculate points per 100 square yards fabric:

widthActual

36length

Roll

Actual

countedpoints

Defects For Rejection:

Trang 32

Batch section

Batching:

Primarily batching is done by batching section which is supervised by dyeing manager The main function of batching section is to prepare the batch for dyeing according to machine capacity, order and emergency This section receive the grey fabric from knitting section and make batch according to order for particular shade Then this batch delivers to dyeing section for dyeing

Function or purpose of Batch section:

 To receive the grey fabric roll form knitting or other source

 Turn the gray fabric if require

 Prepare the batch for dyeing according to the following criteria:

 Order sheet (Received from buyer)

 Dyeing shade ( light or dark, color or white)

 Machine capacity

 Type of fabric ( 100% Cotton, CVC, Stripe fabric)

 Emergency order

 Fabric construction (single jersey, Rib, Lycra Rib, Lacost, Pique etc.)

 To send the grey fabric to the dyeing floor with batch card

 To keep record

Proper Batching Criteria:

 To use maximum capacity of existing dyeing machine

 To minimize preparation time & machine stoppage time

 To use a particular machine for dyeing same shade

Batching Ratio Calculation;

Batching Ratio = (Fabric Dia × Batch quantity) / Total quantity

Trang 33

Process flow chart of Batch preparation:

Receive the order sheet from in-charge

Make the batch card on the priority of shipment

date Take the Batch card which order have to deliver

first

Check the availability of the fabric

Turn off the fabric (if necessary)

Distribute the collar/cuff or Rib in each rope

equally ensuring equal length

Take collar/cuff as per size and keep the total

weight

Take require quantity of body fabric from the

store

Stitch the fabric

Write down weight against roll no in the back

side of the Batch card

Write the total weight in the batch card

Trang 34

Dyeing Lab

In every dye house, a laboratory equipped with machines & equipment is essential It assists in production prediction, minimization of time consumption and wastage reduction It is also producing the product of desired quality

Prior to the bulk production, laboratory plays a vital role in shade matching & detecting the characteristics of the dyes and chemicals to be used in the large scale of production

In Biswas Synthetic Ltd dyeing Lab is divided into two section

Key accessories for Lab:

 Data color computer

 Lab, receive file

Trang 35

Lab Dip Procedure to Dyeing Floor Or Bulk Production:

Receive swatch Spectrophotometer inspection Ref recipe

Stock solution preparation

Sample measuring

Dyeing

Unload and wash in cold water

Hot wash with detergent

Wash in cold water

Squeeze and Dry

Preparing Lab dip

If not ok send to buyer if ok

Send recipe for sample dyeing

 NaOH – 10% stock solution

 Salt – 25% stock solution

Trang 36

Range of Salt and Soda according to the shade %:

 Dye solution=(sample weight x recipe amount% )/stock solution% cc

 Salt required=(total liquor x recipe %)/ (1000 x stock solution%) cc

 Soda Solution =(total liquor x recipe %)/ (1000 x stock solution%) cc

SAMPLE CALCULATION FOR 1% SHADE:

 Sample wt = 5 mg

 Material liquor ratio = 1: 8

 Total liquor (5  8) = 40 cc

Trang 37

SL Machine Name M/C Quantity Origin Brand

1 MSI 1 Set Taiwan Mingscape International

2 Multi Light Color Compersion

Cabinet 1 Set Taiwan Model: CT-100

3 Spector Photo Meter(Data color) 1 Set U.S.A Spectra flash SF-300

4 Rapid 4 Set Taiwan Labortex co ltd

5 Dexter 2 Set Taiwan Yuan Shein

6 Labtec 1 Set Taiwan Newave lab equipment

7 Dryer 1 Set Taiwan Labortex co ltd

Trang 38

DYEING

Trang 39

Layout of Dyeing section:Dyeing m/c Symbol

Batch section

Chemical Store

office Office

Squeezer

Fabric store

Fabric

store

Office

Squeezer Squeezer

Squeezer

Trang 40

Machine specification:

Knit Dyeing Machine

SL Machine Name Capacity

(Per Day)

M/C Quantity Origin Brand

1 Dyeing M/C 300 1 Set Taiwan Toonggeng

4 Dyeing M/C 150 1 Set Taiwan Hsiang Fu

5 Dyeing M/C 150 1 Set Taiwan Hsiang Fu

6 Dyeing M/C 150 1 Set Taiwan HuanJenn

7 Dyeing M/C 90 1 Set Taiwan HuanJenn

8 Dyeing M/C 1800 1 Set Taiwan Tong wutaiwan

14 Dyeing M/C 3000 1 Set Taiwan Ak

19 Dyeing M/C 1800 1 Set Taiwan Tong geng

22 Dyeing M/C 4500 6 Set Taiwan Taiwan

Total= 29040 yds 27 Set

Định dạng
Số trang	95
Dung lượng	2,25 MB