Industrial Attachment On Aboni Textiles Ltd.

Department of Textile Engineering Faculty of Engineering Course Title: Industrial Attachment Course Code: TE 410

A report on Aboni Textiles Ltd. (A Concern of Babylon Group)

Submitted by: Name

ID

Md. Tariqur Rahman Moshfiqur Rahman

131-23-3333 131-23-3437

Supervised by: Dr. Engr. Md. Saifur Rahman Professor Department Of Textile Engineering (A report submitted in partial fulfillment of the requirements for the degree of Bachelor

of Science in Textile Engineering)

Semester- Fall Year- 2016 ‘©Daffodil International University’

Letter of Approval The internship report on Aboni Textiles Ltd. is prepared by Md. Tariqur Rahman of bearing ID: 131-23-3333 and Mushfiqur Rahman of bearing ID: 131-23-3437. This report is submitted in partial fulfillment of the requirements for the degree of BACHELOR OF SCIENCE IN TEXTILE ENGINEERING. The whole report is prepared under my supervision and guidelines. During the internship the student was found sincere, punctual and hard working. I wish him every success in life.

Dr. Engr. Md.Saifur Rahman Professor Department of Textile Engineering Faculty of Engineering Daffodil International University

Page i ‘©Daffodil International University’

Declaration We hereby declare that, this internship has been done by us under the supervision of Professor Dr. Engr. Md. Saifur Rahman, Professor, Department of Textile Engineering, Faculty of Engineering, Daffodil international University. We also declare that, neither this report nor any part of this has been submitted elsewhere for award of any degree or diploma.

Md. Tariqur Rahman ID: 131 -23-3333 Department of TE Daffodil International University

Mushfiqur Rahman ID: 131 -23-3437 Department of TE Daffodil International University

Page | ii ‘©Daffodil International University’

Dedication At first we have to thank almighty ‘ALLAH’ to make us enable to finish our study and also give us the opportunity to reach a healthy destination of our life. We pray to ’ALLAH’, gives us forgiveness and helps us to fight through the complexity of our lives with right path. We dedicate this report to our honorable and respectable ‘PARENTS’.

Page | iii ‘©Daffodil International University’

Acknowledgement All pleasure goes to the Almighty Allah to give us strength and ability to complete our two months long industrial attachment at Aboni Textiles Ltd. It was a great opportunity for us to complete the industrial attachment with the assistance of persons employed in Industry name. We feel grateful to our academic supervisor Dr. Engr. Md. Saifur Rahman, Professor, Department of Textile Engineering, Faculty of Engineering, Daffodil international University as well as to Name of your industry supervisor, our factory supervisor for their continuously guiding us about the development and preparation of this training report. They have enriched us with sharing necessary theoretical and practical ideas and supervised us to complete this report on time. We would like to express our thanks to Prof. Dr. Md. Mahbubul Haque, Head, Department of Textile Engineering, Faculty of Engineering, and Daffodil international University for his kind help to finish our training report. We would like to express our thanks to Prof. Dr. Md. Zulhash Uddin, Dean, BUTex for providing us necessary information to complete the report. We are also grateful to the supervisors, technicians, operators and all other staffs of Aboni Textiles Ltd. , who were most cordial and helpful to us during the tenure of internship. Finally, we would like to express a sense of gratitude to our beloved parents and friends for their mental support, strength and assistance throughout writing the training report.

Page | iv ‘©Daffodil International University’

Executive Summary This report is about ‘Aboni Textiles Ltd.’. By achieving practical knowledge from the industrial attachment is possible to apply the theoretical knowledge in the technical field. For any technical education practical experience is almost equally necessary in association with the theoretical knowledge. The industrial attachment is the most effective process of achieving the practical experiences. It provides us sufficient practical knowledge about production management, productivity, and evaluation, industrial management, planning and controlling utilities and maintenance of machineries and their operation techniques. Aboni Textiles Ltd. is a modern textile industry based on knit garments production. Our approach was to know and work with all parameters of each section and practice with technical persons. As our academic advance study was in Textile Wet Processing. Our emphasis was in understanding and learning oif Fabric, Fiber and Dyeing. Industrial Attachment is an essential part of 4 years B. Sc in Textile Engineering course of Daffodil International University. We had the opportunity to perform the Industrial Attachment with Aboni Textiles Ltd. during 2 months long. We studied about Man, Machine, Material and Planning, Grey Fabric Inspection, Finished Fabric Inspection. According to our studies in the whole chain of factory we have prepared the following report and like to present our internship report B. Sc in Textile Engineering is combination of the theoretical knowledge and practical experiences. The main objective of this training is to comprehend our theoretical knowledge with the practical knowledge. It is enable us to orient ourselves with the practical environment which is our place of future work.

Page | v ‘©Daffodil International University’

Table of Contents Chapters

Contents Letter of approval Declaration Dedication Acknowledgement Executive Summery Table of contents

Chapter-1

Information about Factory

Chapter-2

Details of Attachment

Page No. i ii iii iv v vi 1-06

Knitting section

7-18

Dyeing laboratory section

19-27

Batching section

28-30

Dyeing section

31-40

Finishing section

41-46

Q.C. Section

45-49

Utilities

48-51

Effluent Treatment Plant

52-57

Maintenance

58-61

Chapter-3

Impact of Internship

62

Chapter-4

Conclusion

63

Page | vi ‘©Daffodil International University’

Chapter-1 Information about Factory Babylon Group started its journey in 1986 with Babylon Garments Limited with a humble setup. Relentless efforts and a constant persuasion of quality resulted in the group’s expansion to 18 different concerns. All the units function independently but operate under the direct supervision of the group head quarter. Babylon has strong footing in both knit and woven products. Several units of the group are dedicated to produce finest quality products for buyers around the globe. The group is self reliant and is involved in woven wear manufacturing, knit wear manufacturing, washing plant, printing house, knitting unit, dyeing and finishing of knitted fabrics, embroidery, trims manufacturing, paper converting and packaging, apparel trading etc. It also has fashion wear retailing

outlets

to

satisfy

the

growing

local

demand.

The company currently employs over 11,500 skilled employees and had a turnover of about $127.00 million in the year 2011. In all the different production with the workers have to go through a process of continuous and rigorous training to maintain a high standard of production set by the management. The group also caters this driving force by ensuring facilities that exceed the minimum set by international regulators. It maintains medical and day care services, scholarship programs and other benevolent initiatives for the employees and their family members. As part of their commitment towards the society, the group has established a medical service station open for all. Babylon distributes relief materials including cash to the victims in any part of the country during natural adversities. Buyers have been the soul partners of Babylon. Many of the brands that rule the global fashion industry have relied on Babylon to manufacture their products. Some of the prominent names include KOHL’s, J C Penney, Tesco, Mothers Work, JONES, CHARMING SHOPPES Inc., Walmart, Sears, Inditex, HAGGAR, K-MART, PVH, Arcadia Group PLC, Dimensions, New Look, CELIO, JULES, MONOPRIX, H & M (Hennes & Mauritz), ZARA and many more. With the growing number of renowned names to work with Babylon looks forward to explore new frontiers with the promise of quality and excellence. The Aboni Textiles Ltd. was established on April 2001. Page 1 ‘©Daffodil International University’

Address of Factory Plot# 169-171 TETULJHORA UNION, HEMAYETPUR, SAVAR, DHAKA Address of Head office 2/B-1, DARUSSALAM ROAD, MIRPUR-1, DHAKA, 1216

Page | 2 ‘©Daffodil International University’

Organ gram General Manager

Assistant General Manager

Knitting

Dyeing

Knitting Manager

Assistant Manager

Dyeing Lab

Finishing

Jnr. Manager

Jnr. Manager

Q.C. Deputy Manager

Jnr. Manager

Senior Officer

Junior Officer

Senior Supervisor

Supervisor

Operator

Helper


Site Location of Aboni Textiles Ltd.

Member of Certificates 1. ISO 2. BGMEA 3. WTO

Different Sections of the Company 1. 2. 3. 4. 5. 6. 7.

Babylon Garments Ltd. Aboni Textiles Ltd. Babylon Washing Ltd. Aboni Knitwear Ltd. Junipeer Embroideries Ltd. Babylon Printing Ltd. Babylon Trims and Accessories Ltd.


Different Buyers of the Company 1. 2. 3. 4. 5. 6. 7. 8.

TESCO DAVID HOWARD CELIO H∞M BELLA OEKO TEX TRENDZ MANGO

Name of The Products Exported 1. 2. 3. 4. 5. 6. 7. 8. 9.

Shirt Pant T-Shirt Polo Shirt Ladies Pant Tank-top Casual Shirt Denim Shirt Denim Pant


Pictorial View of the Factory


Chapter-2 Details of Attachment KNITTING SECTION Introduction ABONI TEXTILE LTD. Knitting section is self sufficient to produce the fabric for fulfill the requirements of garments. Overall 73 machine stands in the section including 50 knitting m/c, 13 Flat knitting m/c and 3 inspection m/c. Three shifts working hour here and occupancy here about 220. The capacity to produce fabric in this knitting section is about 3 tons per shift. This knitting section has enough space both in height and width for a hygienic environment. Knitting is the interlocking series of loops by one or more yarn with the help of sinker, needle and cam. The lengthwise loops are called Course and widthwise loops are called Wales. The VDQ mechanism determines the stitch length or loop length and GSM. GAUGE corresponds to the number of needle per inch in knitting machine.

Section Layout


M/C Specification Types And Number Of m/c Single Jersey m/c (20) Rib m/c (30) Interlock m/c (2) Flat Knitting m/c (18) Fabric Inspection m/c (3)

Name PAI LUNG M/C JIUNN LONG M/C MAYER α CIE M/C PAI LUNG M/C FUKAHAMA M/C JIUNN LONG M/C

Origin

Cylinder Diameter

TAIWAN

23”, 28”, 38”.

TAIWAN

26”, 30”, 34”, 36”, 40”, 42”

FUKAHAMA M/C

TAIWAN

32”

18

KEVO HENG

TAIWAN

×

14

EUZU CLOTH INSPECTION M/C

THAILAND

24”, 32”,

GAUGE

26”, 34”, 18, 22, 24, 26. 32”, 38”,

18, 22.

×

Types Of Yarn Used Used In Knittin

a. b. c. d. e. f. g. h. i.

100% Cotton Combed Yarn (32 Ne, 32/1, 30/1) 100% Cotton Carded Yarn (30/1, 26/s) 100% Organic Cotton (28/1, 34/s) 10% Grey Mélange Yarn (34/s, 26/1) 100% Cotton Slab Yarn (28 Ne) CVC Carded Yarn (Ne 28) Polyester 20% Cotton 80% (32/1) Lycra (40,30 denier) 100% Organic GOTS.


Description Of Knitting Yarn package set up in creel

Production wise needle, cam and sinker setting by maintenance

VDQ pulley setting for required stitch length and GSM

The yarn pass trough guide to tension bar to feeder through needle

Machine is now to start

Production of fabric is ready now

The fabric is collect by the take up roller Fabric Inspection Store

Different Brands Of Lycra Only ‘Chinese’ brand of Lycra used here. Count varies from 25-40 deniers.

Sources Of Yarn Used a. B.S.B. b. OMAX Page | 9 ‘©Daffodil International University’

c. d. e. f. g. h. i. j. k. l. m. n. o.

RSWM Y/P V-MAN SQUARE ON ISRAQ MATAM AMAN M.S.A. HASSAIN DYEING ACATI PTHM BADSHAH

p.

NAHAR

End Product

a. b. c. d. e. f. g. h. i.

Single Jersey Rib Pique Stripe Loop Back Single Locoest Double Locoest Flat Knit Fleece


Production Calculation Machine No.-29 1×1 Rib (Color Stripe) Given, Count= 30 We Know, Ne × Tex =590.5 So, Tex =

590.5 32

=18.453

CPI= 34 Gauge= 18 RPM= 16 Feeder= 84 M/C diameter= 42” Efficiency= 95% Loop Length (mm)= 2.4 Now, Production In Length/shift =

=

RPM×No.of Feeder×60×8×efficiency

16×84×60×8×95 34×36×100

CPI×36

yards/shift

yards/shift

=500.71 yards/shift

Production in weight per shift = RPM×No.of feeder×3.1426×Cylinder dia(inch)×Gauge×Loop length(mm)×tex×60×8×efficiency 1000×1000×1000

=

16×84×42×18×2.4×18.45×60×8×.95 1000000000

kg/shift

= 20.519 kg/shift

For Rib fabric= Weight×2 = 41.04 kg/shift Page | 11 ‘©Daffodil International University’

Production Parameters a. b. c. d. e. f. g. h. i. j. k.

Cylinder RPM M/C Gauge No. of feeder Stitch length Yarn Count M/C efficiency CPI Types of fabric production Quality of Yarn Worker skill VDQ mechanism

Knitting Faults

a. b. c. d. e. f. g. h. i. j. k. l. m. n.

Hole Needle line Missing yarn Stain Lycra missing Crease mark Softener spots Bowing Slab Dirt stain Drop stitch Pin hole Wrong Design Grease spot


Quality Assurance System In Knitting 4-Points System

Size Of Defect

Penalty

3 inches or less

1 point

Over 3 but not over 6

2 points 3 points

Over 6 but not over 9 Over 9 inches

𝐹𝑜𝑟𝑚𝑢𝑙𝑙𝑎 =

4 points

Total point found × 36 × 100 Actual roll length(yds) × Actualwidth(inch) =Points/100 sq Yards

Knitting Cost Of Different Fabric Style= Single Jersey GSM= 200 Grey fabric costing for 1 Kg = (cost of yarn+ knitting charge + carrying charge) per kg Given, 1 Kg Cotton Combed Yarn= 265.2 Taka Knitting charge= 12 Tk./Kg Carrying cost= 5 Tk./Kg So, Total cost of grey fabric per Kg = (265.2+12+5) Tk. =282.2 Tk.


Pictorial View Of Knitting Section




Textile Dyeing Lab Introduction The dyeing lab can test and measure all the result of Fabric, Dyeing, Finishing, Washing and Garments requirement. The lab is usually combined with dyeing and washing procedure with workforce. The lab is separated in two parts; one is official and other part is working area. The sample dyeing procedure works here not actual but the shade matching or initial dye conc. measurement did here and the appropriate shade of color for the cotton or polyester creating here. This lab includes different types of dyes, auxiliaries and chemicals which are essential for complete the task. Different types of m/c are here like; Sample Dyeing m/c, Washing m/c, Woven, pH shaker, Rubbing m/c, Data Color, Light box etc. Generally Data Color gives the recipe by scanning with Spectrophotometer through Computer. Then sample dyeing procedure done with required programmed. Then shade match with the Light box visually or in Spectrophotometer; if mach then ok for sample dyeing in dyeing floor or if not ok then manual arrange the color concentration or again sent to Data Color. The lab works maintain Lab Head In charge.

Section Layout


M/C Specification a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r.

Manual twist Tester – India Yarn Appearance Tester – India Yarn Count Tester – India Rubbing m/c –1 Pilling Tester –1 Incubator – 1 Tumble Dryer –1 Dryer – Bangladesh -1 Washing m/c –3 Lab dyeing m/c (ECO DYER) –2 Rapid Lab dyeing m/c (ASIAN STAR) –2 Balancing m/c –1 Oven – England –1 pH meter -2 pH shaker -1 Modern Pipette -2 Data Color Verified Light Box

Different Light Source In Light Box a. b. c. d. e.

D65 Tungsten Light P15 TL83 UV


Description Of Dyeing Lab Pantone Code or Swatch received Place Swatch on Spectrophotometer and collect the dye concentration by Data Color Cut the required scoured fabric in piece of 5 gm. Mix the water and dye concentration and auxiliaries if need then immersed the fabric into the little bath and close the top of the bath Then programmed set for Polyester, Cotton or types of fabric or types of color like Turquoise, Dark/Black or General Shade For adding Salt, Soda Or Acid when required in which step of the programmed Time and temperature fixed in programmed; after done the procedure sample out from the m/c Then hot wash, soap wash and rise done Dry the sample Then shade match visually with Light Box or by Spectrophotometer

If OK then approved

If NOT OK then Topping or re-procedure


Collection Of Lab Dip Samples


Different Tests Of Fabric

a. b. c. d. e. f. g. h. i. j. k. l.

Twist Rubbing (Dry and Wet) Color Fastness To Water Perspiration (Acid Or Alkaline) Phenol Yellowing Test Dimensional Stability Test ( Length And Width) Average pH Color Fastness To Wash Fabric Weight Yarn Count Test Yarn Twist Test

Yarn Appearance Test m. Resistance to light

Pictorial View Of Dyeing Lab




Batching Section

Introduction This section stands just beside the dyeing floor and consist of two air tuning m/c. In here no fabric inspection is needed because of knitting section is also own of the company. So the fabric received from the knitting section and lot wise and m/c capacity, order and color wise separate the required fabric.

Batching Criteria

To prepare the batch of fabric for dyeing – a. b. c. d. e. f. g. h.

Order Sheet (Received from Buyer) Color Shade (white, light or Dark) M/C Capacity M/C available Types of fabric (100% Cotton, CVC, PC etc.) Emergency Send the grey fabric with batch card Keep records every previous dyeing

Batch Distribution and Management Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in-charge receives the plan from dyeing manager. Sometimes planning is adjusted according to m/c condition or emergency.


Pictorial View Of Batching Section


Dyeing Introduction In Dyeing section of this company is fully planned and well equipped of m/c for environment friendly and suitable situation for workforce. The dyeing m/c is vertically integrated in two columns and intersection with a way. The height of the dyeing floor is about two and half floor with covered by insulator shed for reducing the temperature of the floor. Dyeing m/c’s are also covered by insulator, window of this floor is huge and m/c wise floor space is also huge for being maintain the quality of the job environment. Some heat releasing system of fan or pipe line also stands here. Three dyeing managers control the floor. This section includes dyeing, finishing and quality control department. All the waste water of dyeing and washing are treated in ETP of their own to save our environment and society.

Section Layout


M/C Specification M/C Name

Origin

Capacity

No. of m/c

SCALVOS

Greece

180 Kg, 360 Kg, 540Kg, 50 Kg, 1 ton

5

LONGCLOSE

Korea\

400 Kg

1

DILMENLER

Turkey

600 Kg, 1000 Kg, 450 Kg, 15 Kg

6

BENERS

Turkey

25 Kg, 150 Kg, 750 Kg

5

Bangla m/c

Bangladesh

15 Kg, 30 Kg

2

Dyeing Cost Of Different Color a. b. c. d. e. f. g. h. i. j. k. l. m. n.

Chocolate - 111.91 Taka/kg Olive 17-210 – 62.11 Taka/kg Blue light – 70.91 Taka/kg Russet Brown – 68.76 Taka/kg Antelope – 51.70 Taka/kg Ecru (11-0602 TPX) – 17.81 Taka/kg LT Pink – 39.45 Taka/kg Khaki Green – 42.88 Taka/kg Heather Gretna – 63.37 Taka/kg Black – 58.97 Taka/kg White – 10.70 Taka/kg Turquoise – 23.54 Taka/kg Fig – 70 Taka/kg Fluorescent White – 110.55 Taka/kg


Flowchart Of Different Dyeing Process Fabric: Polyester Cotton Blend (S/J) Color: Blue Light

Demineralization (Temp.-80C, Time-20 min)

Leveling Agent (Desired pH=4.25) Disperse Dye add to the Solution (Temp.-135C, Time-) Scouring with Bleaching Agent (Temp.-80C, Time-20 min) Wash Acetic Acid (55C, 5 min)

Peroxide Killer (55C, 10 min)

Enzyme Wash (55C, 45 min)

Leveling Agent (30 min)

Glabrous Salt (30 min) Reactive Color Dosing (30 Min) Soda Ash Dosing (45 min) Acetic Acid (55 C, 10 min) Detergent Wash Softener


Fabric: Cotton (S/J) Color: Black Demineralization (60 C, 10 min) Scouring (60 C, 30 min) Hot Wash (90 C, 5 min) Acetic Acid (55 C, 20 min) Enzyme Wash (55 C, 45 min) Cross color ADM (80 C, 5 min) Glaubers Salt (Dosing 30 min) Color Dosing (30 min)

Soda Dosing (20 min)

Caustic Soda Flax (30 min)

Acetic Acid

Hot Wash 2 times (60 C, 10 min)

Fixer Softener Page | 29 ‘©Daffodil International University’

Fabric: S/J Color: White Demineralization (105 C, 45 min)

\Scouring and Bleaching

Wash

Acetic Acid Wash

Softener

Total Production For the Month of October 2016 Production Date- 18/10/2016 Total production required = 1, 40,019 Ton Average Production per day =8,574 ton Today = 11,994 ton


Recipe Sheet Of different dyeing process





Production Parameters a. b. c. d. e. f. g. h.

Reel speed Types of Fabric Types of dying process M/C fitness Fabric load capacity Types of dyes and chemical used Operator efficiency Lab fastness

Dyeing Faults a. b. c. d. e. f. g. h. i. j. k.

Machine fitness problem Maintenance Operating Tangle Shade variation Uneven dyeing Soda spot Color spot Yellow spot Red contamination Slabs


Pictorial view of dyeing Section



Finishing Section

Introduction In Finishing section of this company is fully planned and well equipped of m/c for environment friendly and suitable situation for workforce. The Finishing m/c are vertically integrated in two columns and intersection with a way. The height of the dyeing floor is about two and half floor with covered by insulator shed for reducing the temperature of the floor. D Finishing m/c are also covered by insulator, window of this floor is huge and m/c wise floor space is also huge for being maintain the quality of the job environment. Some heat releasing system of fan or pipe line also stands here. Three Finishing managers control the floor. This section includes dyeing, finishing and quality control department. All the waste water of dyeing and washing are treated in ETP of their own to save our environment and society.

Machine Specification a. b. c. d. e. f. g.

CORINO Slitting m/c -2 SANTEX Dewatering Machine SANTEX Dryer (Two chamber) SANTEX Dyer (Three chamber) SANTEX Tube Compactor STENTER SANTEX Open Compactor

Machine Arrangement In Finishing Section

For Tube Fabric— Dewatering m/c

Dryer

Tube Compactor Page | 38 ‘©Daffodil International University’

For Open Fabric— Slitting m/c

Stenter m/c

Open Compactor m/c

Description Of Finishing All the process of finishing open or tube fabrics are maintaining the quality of the fabric. Some very important properties of fabric controlled in this section are

a. b. c. d. e.

Diameter control Shrink control Shade control GSM control Spirality/ Twist control

Without White colored fabric others all color of fabric softener added in dewatering m/c for tube fabric and in Stenter m/c for open fabric in this section and all the machining process control the above system of the fabric.

Pictorial View of Finishing Section Page | 39 ‘©Daffodil International University’




Quality Control Introduction In Q.C. section of this company is fully planned and well equipped of m/c for environment friendly and suitable situation for workforce. The Q.C. m/c are well integrated. The height of the dyeing floor is about two and half floor with covered by insulator shed for reducing the temperature of the floor. Window of this floor is huge and m/c wise floor space is also huge for being maintain the quality of the job environment. Q.C. manager control the floor. This section includes quality control department and finished goods.

M/C Specification 1. Fabric Inspection m/c – 5 2. Washing m/c -3 3. Light box -1

Different Test Required In This Section a. b. c. d. e. f. g. h. i. j. k.

Washing fastness Rubbing fastness Dimensional stability Perspiration test pH test Pilling test GSM Twist measurement Diameter Shrinkage test Shade check

Final Inspection a. b. c. d. e.

Yellow spot Grease spot Stripe Contamination Crease mark Page | 43 ‘©Daffodil International University’

f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u. v.

Thick and Thin Yarn Knitting Hole Back sewing hole Red Contamination Yellow contamination Oil spot Print problem Needle line Needle drop Slab Uneven Dyeing Compactor problem More twist More shrink Less or more dia GSM failure Shade failure

Quality Assurance System 4-Points System

Size Of Defect

Penalty

3 inches or less

1 point

Over 3 but not over 6

2 points 3 points

Over 6 but not over 9 Over 9 inches

𝐹𝑜𝑟𝑚𝑢𝑙𝑙𝑎 =

4 points

Total point found × 36 × 100 Actual roll length(yds) × Actualwidth(inch) =Points/100 sq Yards


If the produced fabric follows the 4 point method and passed the testing result to fulfill the buyer requirement then the fabric is approved for finished goods.

Pictorial View Of Q.C.



Utilities Section This section is included or divided into three parts, which are-

1. 2. 3. 4.

Water Treatment Plant Generator Air Compressor Boiler

Water Treatment Plant Water Plant Normal Filter Tank Resin Filter Tank Supply Resin = Remove iron and heavy particles from water. Salt = Clean the resin (using 980 Kg salt per 12 hours) Total Water Production per Shift or 12 hours = 552 m3 + 708 m3 = 1260 m3 = 1260×1000 L =1260000 L No. of Water Plant = 3 No. of Pump = 6



Generator No. Of Gas Engine Generator = 2 Model a. G3516 b. G3517 Capacity = 1 MW/engine Total = 2 MW No. OF Diesel Engine Generator =1 Model = MDEC1250 Capacity = 1 MW No. Of small Engine Generator = 2 Capacity = 150 MW/engine Total = 300 MW



Boiler No. of Boiler = 2 Brand Name = COCHRAN Origin = Scotland Capacity = 1. 5 ton/hour 2. \7.5 ton/hour Total Production of steam = (5+7.5) ton/hour = 12.5 ton/hour


Air Compressor

No. of air compressor = 5 No. of air dryer = 5 Origin = Belgium


Effluent Treatment Plant Introduction In this factory ETP treated the waste water of dyeing and washing plant. The ETP section is situated at side by side of knitting section and also attached with the garments section. Its height is almost three stored building. This section includes ETP lab, electrical and mechanical works and also does the task of maintenance task. This section is able to purify the waste water from dyeing and washing. A major source of liquid discharge is a River little far from factory.

Process Sequence Collection Tank (Dyeing and Washing water) Equalization tank (Adding HCL to maintain pH) Biological tank (Feeding Bacteria) Secondary Clarifier (Store dirt and dust) Electro Coagulation tank Electro Skip (440 Volt and Heat, Broke water particle to collect dust 94%) Flash mixer (Polyelectrolyte – anionic) HRSCC tank

Sludge thickener (Excess dust with water)

Sand Filter (For water)

Press filter (For dust) Page | 53 ‘©Daffodil International University’

Characteristics of waste water 1. 2. 3. 4. 5. 6. 7. 8. 9.

Colorful water Odor of water pH range is high or low Water includes Salt Water includes Soda Water includes Acid Water includes Softener Water includes Fibrous dust Water includes hazardous chemical

Chemicals Used In ETP And Their Function 1. HCL: To control pH 2. 3. 4. 5. 6. 7.

Blower: Mixing all color in one color and reduce the temperature. Bacteria: Destroy color 30-40%, DO increase, Chemical concentration reduce. Electro Skip: Individualize the water and dust particle. Polyelectrolyte: Combine dust particle each other. Dust tank: Collect only dust in a filter box. Sand filter: Purify the treated water finally for environment.

Final Treated Quality of Water a. b. c. d. e. f. g.

Colorless Odorless Maintained pH about 6.5 to 7.5 Removing or neutral the water from chemical No hazard create in nature Environment friendly. 100% purified water

Total Capacity of purifying water = 20, 00, 000 Liter/Day





MAINTANANCE Introduction Machine, Building and other facilities are subjected to deterioration due to their use and exposure to environmental condition process of deterioration, if unchecked culminates in rendering these service facilities unserviceable and bring them to standstill. In Industry has no choice out to attend them from time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so.

Types Of Maintenance

Maintenance

Preventive Maintenance

Electrical

Mechanical

Breakdown Maintenance

Electrical

Mechanical


Maintenance Tools And Their Function 1. Combination tools / spanner 2. Function: Tightening and loosing of nuts and bolts. 3. Socket ratchet set Function: Tightening of nuts and bolts. 4. Slide range Function: Tightening and loosing of nuts and bolts. 5. Monkey pliers Function: Tightening and loosing of nuts and bolts. 6. Pipe threat cutting tools Function: To cut the threat in pipe. 7. Bearing puller Function: To assist the bearing from shaft. 8. Pipe range Function: Tightening and loosing the pipe joints. 9. Pipe cutting tools Function: For pipe cutting 10. Hole punch Function: punching the hole 11. Divider Function: For circle making for wood and pipe. 12. Easy opener Function: To open the broken head bolt 13. External threat die Function: For External threat cutting 14. Heavy scissors Function: Cutting of gasket and steel sheet. 15. Pipe threat cutting tools Function: To cut the threat in pipe. 16. Drill machine and drill bit Function: For drilling 17. Grease gun Function: For greasing of moving parts of the machine. 18. Grinding machine Function: For grinding and cutting of machine 19. Welding machine Function: For welding and cutting 20. Spirit leveler Function: For perfect Leveling. 21. File Function: For smoothing the surface. 22. Hammer Function: For scaling and right angling 23. Circle tools Page | 59 ‘©Daffodil International University’

Function: Circle opening and closing 24. Hacksaw blade Function: For metal cutting 25. Handsaw Function: For wood cutting 26. Grinding stone Function: For smooth finishing 27. Grinding paste Function: For easy cutting of metal.

Pictorial View Of Maintenance Tools



Chapter-3 Impact Of Internship Knitting Section We know about yarn, Machine set up for individual fabric production. We know about Knit fabric manufacturing and their fault. Batching Section We know about batching criteria and management. Dyeing Lab We know about recipe formulation. We know about shade matching. We know about different kind of test procedure. We have known about Lab Dip. Dyeing Section We have known about sample dyeing procedure. We have known about bulk dyeing method for different fabric and different color. We have known about overall procedure for dyeing method. Finishing Section We have known about different machine mechanism. We have known about the problem of fabric can be control. We have known about how finish a good quality of fabric which fulfill the buyers requirement. Q.C. Section We have known about the final inspection of the finished fabric. We have known about the fabric quality. We have known about the store the finished fabric ETP We know why ETP use in industry. We know procedure of ETP. How we benefit from ETP. Functions of ETP. Compliance To know about their compliance system We know about medical facilities Page | 62 ‘©Daffodil International University’

Chapter-4 Conclusion After all we want to say that Aboni Textile was really a very nice and helpful textile industry. We have learned many things about knitting, dyeing, finishing and quality control. The operators were very friendly and helpful. We have learned how to operate the machine and total working procedure from them. We were very responsible about factory’s rules and regulation. We always obeyed their instruction during the attachment period. We entered into the factory within just time and came out in just time. We learned details theoretically about textile in classroom but practically we applied our knowledge during attachment period. We think this knowledge will help us in our future period to meet with different people and lead the operator.


Industrial Attachment On Aboni Textiles Ltd.

Recommend Documents