Report on Industrial Attachment At
METRO KNITTING & DYEING MILLS LTD. (From 01 July to 31 August, 2012) Supervising Teacher RASHEDA BEGUM DINA
(Lecturer) Dept. of Wet Processing Engineering Bangladesh University of Textiles Submitted by SERIAL NO.
NAME
IDENTIFICATION NO.
01
UDAY RAY
2008-1-046
02
ELIAS KHALIL
2008-1-048
03
QMD. IMRAN HASSAN
2008-1-073
04
MD. SAMSUL ALAM
2008-1-104
sister Concerns • Metro Knitting & Dyeing Mills Ltd (Factory-2) • Bea-Con Knitwear Ltd • Mercer Design Tex Ltd • KB Traders ltd • AAA Textile Mills Ltd • Panam Agrovet Ltd
Export Growth Turnover
Man power Management(Dyeing Section) GENERAL MANAGER SENIOR PRODUCTION MANAGER PRODUCTION MANAGER
LAB (QAD)
LAB (COLOR MATCH
DYEING
FINISHING
IN-CHARGE
ASST. MANAGER
PRODUCTIO N OFFICER
PRODUCTIO N OFFICER
ASST. IN CHARGE
SENIOR OFFICER
FLOOR INCHARGE
FLOOR INCHARGE
SR. SUPER VISOR
OFFICER
SHIFT INCHARGE
SHIFT INCHARGE
SUPER VISOR
ASST. OFFICER
SUPERVISO R
SUPERVISO R
ASST. SUPER VISOR
TECHNICIA N
ASST. SUPERVISO R OPERATOR
ASST. SUPERVISO R OPERATOR
HELPER
HELPER
Machine Description THIES Machine
Dyeing
Origin: Germany Maxm Temperature: 130-135oC Loading per nozzle: 250kg Capacity: 250-750kg
SCLAVOS DYEING MACHINE ORIGIN : GREECE QUANTITY: 10 MAXIMUM CAPACITY: 1500 KG MAX TEMPARATURE:142oC MAX NOZZLE: 6
WORKING PRESSURE: 2.8 BAR
FONG DYEING MACHINE
CIRCULAR KNITTING MACHINE
ORIGIN:CHINA MAXTEMPERATURE: 140oC NO OF NOZZLE: 1~8
BRAND: MAYER& CIE PAILUNG, JUINN LUNG, LISKY QUANTITY: 106
STENTER MACHINE BRAND: BRUCKNER ORIGIN: GERMANY SPEED: 4-100 M/MIN PADDER PRESSURE: 0.7-10 BAR MAX. PRODUCTION: UPTO 10 TON / MACHINE
GARMENTS MECHINERIES
COMPACTING MACHINE BRAND: TUBETEX ORIGIN: USA SPEED: 5-35M/MIN MACHINE PRESSURE: 20-35 BAR TEMPERATURE:90-120oC
BRAND:JUKI, PEGASUS, YAMATOBROTHER, UZU, OSHIMA, TOYO LOCK, HASHIMA LEEWAI, NISSIN
TOTAL :1229
Raw Materials Types of raw material used: 1. Yarn 2. Fabric 3. Dye stuff 4. Chemical and auxiliaries
Sources of yarn: 1. Cotton (Both Carded & Combed) - Loyal, Malek, N.ZJabber, KeyaS.Q Gill, Mix, Israq, Negreeka, Multizim 2. Polyester - India 3. Mélange -Shamim spinning mill -Prime spinning mills -Thermex spinning mill 4. Lycra -Korea, Vietnam, china
FABRICS USED COMMONLY •Single Jersey •Lycra Single Jersey •1x1 Rib •2x1 Rib •2x2 Rib •Fleece •Terry
COMMONLY USED DYES •Begacron (China) •Novacron (China) •Remazol (Germany) •Levafix (Germany)
•Supra (India)
MOSTLY USED CHEMICALS • Caustic Soda • Soda Ash • Hydrogen Peroxide • Glauber Salt • Hydrose
•Sumifix(China) •Dianix (Germany) •Terasil (China)
Production per day: • Maximum
Loading capacity 100% (11.36 tons) • Possible maximum loading 80% (9.088 tons) • Total production per days (3 shifts) = 9.088 x 2.5 (considering 2.5 batch in 3 shifts) = 22.72 tons .
Dyeing Parameter PH • • • • • • • •
Scouring PH – 10.5-11 During H2O2 bleaching PH 10.5-11 Enzyme PH – 4.5 Before dyeing (Leveling) PH – 6.5 Salt PH – 7-8 During reactive dyeing PH 10.5-11.5 During disperse dyeing PH 4.5-6.0 Softener PH – 6.5
3) Time: -For white shade 4-5hrs -For 100% cotton 8-10hrs -For 100% polyester 5hrs -CVC 2 parts 13-14 hrs.
4) M: L ratio: -For reactive dyeing M: L ratio maintained within 1:6
2) Temperature For cotton fabric scouring: 105ºC During NaOH addition 65oC During H2O2addition 70oC Peroxide killing at 80oC Sequestering at 90oC Bio-polishing at 55oC For cotton dyeing: Low brand – 45oC Medium brand - 600C Hot brand – 80oC o Migration for turquoise color at – 90oC o Optical brightening agent (OBA) atb 80oC o Polyester dying: 1000-1300C o Softener at – 45oC
Cycle Time 2-3 mins
Reel Speed 250-300 m/min
Dyeing Faults 3%
1% 2% 1% 1%
1 Uneven dyeing 2 Running shade 32%
3 Dye spots
30%
4 Batch to batch shade variation 5 Crease mark
30%
6 Roll to Roll 7 Soda spot 8 Others
Uneven Dyeing
Soda spot
Dye Spot
Hole
Resist spot
Finishing Types of Finishing: 1. Mechanical Finishing (Used to control dimension to improve appearance & handle) 2. Chemical Finishing (Used to make glossy protection. To improve performance or serviceability)
Knit fabrics are finished in 2 forms 1.Tubular form 2.Open form
Effects of Finishing -Easy care. -Crease recovery. -Dimensional stability. -Good abrasion resistance. -Improved tear strength. -Good sew ability. - Soft or stiff handle. -Shine or luster.
Machine used in finishing section: •Dewatering machine •Slitting machine •Dryer •Compactor (Open/Tube) •Stenter •Raising machine •Sueding machine •Padder
Flow diagram of open & tube fabric finishing
Quality Control system mainly two types: 1. Online QC Raw material Control Process Control Laboratory test
2. Offline QC
A. Physical tests GSM test Shrinkage test Spirality test Tensile strength Abrasion resistance Pilling resistance Button Strength Testing Crease resistance Dimensional stability Bursting strength test
B. Chemical Test Color Fastness to washing. Color Fastness to light. Color Fastness to Chlorinated water. Color Fastness to water spotting. Color Fastness to perspiration. Color Fastness to Sea-water. Fiber analysis. PH test. Spray test (water repellency
Fabric Inspection Grey Fabric Inspection Grey Fabric Inspection is performed according to 4-point system.
Finished Fabric Inspection Uneven Shade Crease Mark Oil Spot Spirality
Maintenance Maintenance of Machinary Routine/Schedule
Preventive
Breakdown
Maintenance Tools and their Functions Name of the Tools
Functions
L-Key
Loosen and tighten the screw
Air suctioner
Clean machines by suctioning
Screw driver
Loosen and tighten the screw
Spanner
Loosen and tighten nut & bolts
Star driver
Screw unlocking
Pliers
Cutting, Holding, Joining of wire, Gripping
Pulley Key
To loosen pulleys
Utilities Utilities services available in Metro Industries Ltd Electricity Water Gas Steam
Source of utilities: Electricity Steam Water Gas
: PDB & Generator : Boiler : Pump : Titas gas Ltd
Types of Generator: A.Gas Generator (Running) 1.Brand: Perkins, England Capacity: 400 KW 2.Brand: Waukesh, USA Capacity: 900 KW B. Diesel Generator (Backup) Brand: Perkins, England Capacity: 200 KW Fig:Gas generator 1
Diesel generator
Gas generator 2
Boiler
Brand: COCHRAN , Scotland Maximum Temperature: 188 Maximum Steam Output: 10 ton/hr Steam pressure: 7.5 bar Boiler
Store & Inventory Control Objectives Financial activities
Property protection
Operating
Scope of Inventory Control Grey Fabric Store
Dyes & Chemical Stores
Spare Parts
Finished Goods
Others
Effluent Treatment Plant Types of ETP PhysioChemical
ChemicalBiological
Biological
Metro has Combined Bio-chemical ETP in the factory premises. The output of the ETP is about -200CBM/Hr) Consumption of the chemical used
Chemical Name
Chemical Used
H2SO4 & HCl
25 Kg/Day
Lime
250Kg/shift
Alum
250Kg/Day
Polyelectrolyte
1 Kg/day
H3PO4
1 Kg/shift
Urea
1 Kg/shift
Discharge water quality of Metro Industries: pH = 6-9 BOD = 50 mg/ L COD = 220 mg / L Suspended solid = 145 mg/L Color = color less.
Functions of different chemicals used in ETP: H2SO4 & HCl: Neutralize the water from alkaline state. Ferrous Sulphate & Lime: To remove the color of the effluent. Alum & Polyelectrolyte: To agglomerate the smaller particles. For sedimentation of the smaller particle. H3PO4/Urea: For increasing the production of the bacteria.
Finishing Cost Dyeing Cost Along with Dyes and Chemical Sl. No.
Types Of Shade
Type Of Finishing
Price/Kg
1 2 3 4 5 6 7
Light Color Light Color Medium Color Medium Color Dark Color Dark Color Black Color Or Extra Dark
Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish Tube Finish
65 Tk 75 Tk 75 Tk 85 Tk 85 Tk 95 Tk 110 Tk
8
Black Color Or Extra Dark
Open Finish
125 Tk
9
Deep Black Or Deep Royal
Tube Finish
115 Tk
10
Deep Black Or Deep Royal
Open Finish
125 Tk
11 12 13 14
Only Wash Only Wash White White
Tube Finish Open Finish Tube Finish Open Finish
25 Tk 35 Tk 40 Tk 50 Tk
Serial No.
Price quotation of finishing
Price
1 2 3 4 5 6 7
ONLY STENTER ONLY OPEN COMPACTING STENTER + OPEN COMPACTING ONLY TUBE DRY TUBE COMPACTING ONLY SUEDING SUEDING+ STENTER+ OPEN COMPACTING ONLY BRUSH
20 TK/KG 15 TK/KG 30 TK/ KG 8 TK/KG 8 TK/KG 25 TK/KG 55 TK/KG
8
15-20 TK/KG
Knitting Cost Serial No. 1.
Fabrication
Knitting Price(Tk./Kg)
Single Jersey
8-10
2.
Lacoste/PK
14
3.
Terry
14
4.
Fleece
18-20
5.
1x1 Rib
14
6.
Interlock
18
7.
Single Jersey E. Stripe
100
8.
Lacoste/PK E. Stripe
120
Marketing Activities
Exporting countries: Germany Netherland Japan UK Singapore Canada USA
Conclusion So, that was the very brief of our Industrial attachment program. It excludes so many subjects and facts. In this short presentation its very hard to include everything we did and learned in that program. Thanks for giving us the opportunity to do this presentation.
