Industrial Training Research Paper on Esquire

AHSANULLAH UNIVERSITY OF SCIENCE & TECH no.OGY Dept. of Textile Technology Course no. Tex-600 Course Title industrial Training Session Fall 2010 REPORT ON INDUSTRIAL TRAINING From 1st June 2011 to 30th July 2011 ESQUIRE KNIT COMPOSITE LTD 22/58, Kachpur, Sonargaon, Narayangonj Supervising Teacher Nahida Akter proofreader Dept. of Textile Technology, AUST Report Submitted By- come across ID Md. Imtiaz Ahmed 07. 01. 06. 0 Md. Iftekhar Hossain 07. 01. 06. 067 Md. Husne Mubarak 07. 01. 05. ACK noneLEDGEMENT At first our gratefulness goes to Almighty Allah to give us strength & ability to complete the industrial training.Industrial Training is an academic course of the Textile Technology Department of AUST. We want to give thanks Professor Dr. Mustafizur Rahman, Head, Department of Textile Technology, Ahsanullah University of Science and Technology, gave us an opportunity to acquire preferable mill for Industrial Training. We chose Esquire Knit Composite Limited gracefully with the s upervision of our teacher Mrs. Nahida Akter , Lecturer. We would like to thank her for her logical guide auras, constant inspirations necessary book of instructions and proper supervision.During the training in Esquire Knit Composite Limited we worked in all the departments related with the Wet Processing Section. We also worked sincerely in the knitting Section, Maintenance and Effluent Treatment Plant. Moreover we learned ab come out timber hear Section, undefiled Fabric Inspection Section, coating & specially dis an nonate. We would like to thank the management of Esquire Knit Composite Limited for giving us the opportunity to do industrial training successfully and also for their valuable suggestions. Our heartiest appreciation goes to Mr. Ehsanul Karim Kaiser, ED of operation EKCL and Mr.Hafizur Rahaman Nixon DGM (Fabric dye) for their permission to conduct our industrial training without which it would be incomplete. We would also like to thank Mr. Md. Zaman Manager (F abric gloss) and Mr. Md Helal Sr. Manager (Fabric finish) for their insightful suggestions, guidelines and sharing their values with us. At last we want to thanks all the executives, senior executives and officials of EKCL for helping us to conduct industrial training successfully. Chapter 1 full general INFORMATION ABOUT FACTORY 1. NAME OF FACTORY Esquire Knit Composite Ltd. 2. STATUS Private Ltd. Comp or so(preno arcminuteal) 3.NATURE OF BUSINESS 100% Export point building complex knit Dyeing 4. OWNER OF THE MILL Md. Mofazzal Hossain. 5. LOCATION OF MILL 22/58, Kanchpur, Sonargaon, Narayangonj. 6. HEAD OFFICE Ideal Trade Centre (9th & 10th Floor) 102, Shaheed Tajuddin Ahmed Sarani, Tejgaon I/A, Dhaka. Tel 9113161, 9129396 Fax. 880-02-812 email emailprotected net 7. YEAR OF ESTABLISHMENT Fabric colour project July-1993 Yarn dyeing project September-1993 8. Project Cost Taka four hundred, 00,000 9. Project Area 200000 sq. feet 10. Total hands a. Yarn Dyeing 350 b.Embroidery 120 c. Fabric Dyeing cd d. Maintenance 150 e. Knitting 400 f. Garments 4310 g. Printing 150 h. Administration 120 11. INSTALLED electrical condenser 1. 54 Million kg 12. TOTAL TUR nary(prenominal)ER Average 13. harvestION a. Total450 Metric ton per month b. Knitting 12 tons/ twenty-four hour period c. Yarn dyeing 8 tons/day d. Fabric dyeing 15 tons/day e. Garments 50000 pcs/day Site location of the mill westbound SOUTH no(prenominal)TH Jatrabari Chowrasta EAST Dhaka-Chittagong Highway Esquire Knit Composite Limited Kachpur Bridge Sinha Textile Dhaka-Shylet Highway Dhaka-Chittagong Highway Different DepartmentsThe mill has several constituents to triumph smoothly, they atomic number 18 condition bellow * KNITTING SECTION 1. Knitting 2. Inspection * KNIT DYEING SECTION 1. plenitude section 2. Store set up for dyes & chemicals 3. Dyeing section 4. Lab & QC 5. Finishing * YARN DYEING SECTION 1. Batch section 2. Store house for dyes &chemicals 3.Dyeing section 4. Lab & QC 5. F inishing * GARMENTS SECTION 1. merchandising 2. Sample 3. Production * MAINTENANCE 1. Electrical 2. Mechanical 3. Utility * ACCOUNTS & COMMERCIAL SECTION * PLANNING DEPARTMENT * HUMAN RESOURCE SECTION * ADMIN SECTION PRODUCT MIX a) Knitted grey models Single jersey Plain Fabric, 11 Rib, 21 Rib, 22 Rib , Lycra single jersey, Lycra Rib, Interlock, Polo Pique, Lacoste(Single/Double), engineering science Stripe, Feeder Stripe, Drop needle, 2/3 Thread fleece(Brushed/Un-brushed), Collar & Cuff etc. ) Knit Garments T-shirt, Polo shirt, Sweat shirt, Golf shirt, menuigan, Jogging suit, Short/Trouser, Legging, Fashion queue up & Children wears etc. COMPANY PROFILE About Esquire Esquire group is one of the leading among manufacturers & suppliers of a comprehensive range of quality knitted stuffs, washy fabrics , Dyed yarns 7 Garments products for assorted customer requirements . Our range of products include dyed yarn , Dyed of knitted fabrics, hoar fabrics Single jersey, Double jerse y, CVC Fleece, Terry fabrics, Plain interlock, PC, 100% Polyester fabrics, Grey Melange and final products is Garments & printing.An ISO 90012000 certified comp all Esquire Group continues to play a leading spot in the manufacturing of Quality Garments in Bangladesh with the intent to further settle its position for its quality products. With our decades of experience and extensive industry knowledge, we have been able to face the challenges of the global market place and deliver quality products in adhesion with market standards and parameters. Whatever your specification or quantity desired, our expertise and quality of service constantly remain the same .Modern mathematical product and techniques and flexible procersses and procedures allow us to offer efficient service for small batch as well as large nightclubs . Esquire knit Composite is a 100% export oriented company and work with the objective of achieving maximum customer satifaction. The Company has adopt innovative procedures and practice to meet customer expectations everytime they deal with us. We always welcome any feedback or suggestions from clients in localise to serve them better . Vision We will work together to define and down the stairsstand every deal per figure outed by the rganization and continuosly progress to to improve the quality at defferet stage of production and supply. Our aim is to g class by providing standard and superior dyeing products and Garments and support services that ar always astep ahead,Eco-frriendly , and loved by our customers . We will give our customers every reason to rely on us and will touch our vision by developing win-win confederacy with our clients and open communications with our all stake holders including associates , customers and suppliers . MisionOur mission is to lead the industry to the front with complete commitment and dedication on standards , Quality, productivity and customer gratification . Esquire Team Another major asset to our sophisticated production facilities and technical expertise is our team of experienced and qualified people who atomic number 18 committed to achieve maximum customer satisfaction by delivering superior value products . The team whole shebang under the able guidance of our chairman Mr. Mofazzol Hossain , under whose leadership, The company has reached so far in this business. Our senior management include * Mr. Mofazzol Hossain-(Chairman) Esquire group Mr. Ehsanul Habib- Managing Director (M. D) * Mr. Ehsanul Karim Kaiser- oecumenic Manager(G. M) * Dr. Md. Ali Haider-G. M(R&D) * Mr. A. S. M. Hafizur Rahman-DGM (Fabric dyeing) * Mr. Nazrul Islam Khan-AGM (Garments) * Mr. Faroqure rahman-AGM (Yarn dyeing) REMARKS Esquire knit composite Ltd. is a member of Esquire group of companies , a leading house of industries and commerce in Bangladesh . It contains Esquire Electronics , Esquire knit composite , Esquire Knit Wears, Esquire Dyeing Industry , Esquire sourcing , MMH textiles , Fashion Paradise Ltd. CHAPTER 02 cutting Material RAW MATERIALRaw textile is a unique substance in any production oriented textile industry. It plays a vital role in case of continuous production & for high quality fabric. The EKCL always try to use high quality raw material to export high quality and world class product. Raw material for knitting Yarn Count Cotton20/1s ,24/1s, 26/1s,30/1s,40/1s) Polyester50/D,75/D, 100/D Lycra120/D PC30/1s CVC30/1s Gray Millenge28/1 s Raw material for yarn dyeing Yarn Cotton(20/1s,24/1s,26/1s,30/1s,40/1s), Polyester (50/D, 75/D100/D), Lycra (120/D), PC(30/1s), CVC(30/1s) Thread Dyes Remazol, Ciba, Bezaktive SLF, Drimarene, Kimsoline.Auxiliaries Raw material for Fabric dyeing Fabric Single Jersey, Lycra Single jersey, 1? 1 Rib, 2? 1 Rib, 2? 2 Rib, Lycra Rib, Interlock, Single lacoste, Double lacoste, Terry fleece, Polo pique, Lycra fleece, Gray Millenge. Dyes Dyes list is given in the next page Auxiliaries Auxiliaries list is given later dyes li st chemicals & Auxiliaries use in EKCL Sr. none Type Chemical call forth provider 01. Acid donor 01. DYAPOL-AB DYAPOL 02. MEROPAN-CIT CHT 03. OPTAVON-4UD ZSCHIMER & SCH WARZ 04. SANDASID PB CLARIANT 05. SENTAVIN RCO H & M LTD. 2. Anti-creasing Agent 01. ALBAFLUID CD HUNTSMAN 02. BIAVIN 109 (10% Sol. ) CHT 03. BIAVIN SFT (10% Sol. ) CHT 04. Cibafluid C N/A 05. JINSOFTER-ACN JINTEX 06. JINSOFTER CBA JINTEX 07. JINSOFTER BSK JINTEX 03. Antifoaming factor 01. ALBATEX FFC (10% Sol. ) CIBA CHEMICALS 02. CIBAFLOW Jet CIBA CHEMICALS 03. CONTIPON S (10% Sol. ) ZSCHIMER & SCH WARZ 04. JINDAFOAM spout JINTEX 05. CROSCOLOR CDA EURO DYE CTC 06. CROSCOLOR NJA N/A 07. CROSCOLOR PTM H & M LTD. 08. TISSOCYL RC9 H & M LTD. 09. Zetafoam Zero (5% Sol. ) ZSCHIMER & SCH WARZ 04. Anti-pilling Enzyme 01. Al-Chemi (Conj) N/A 02. BEIZYM TEC HUNTSMAN 03. Bio-polish Tex Resources 04. Biotex PIL(30% Sol. ) N/A 05. DELTA-BP H. P. CHEMICALS 06. Ecotouch Quality Colour & Chem. LTD. 07. Fibrilase HD 350 N/A 08. FORYLASE-DLS 170 N/A 09. HDL-160 Ablu 10. JINTEXME OEM JINTEX 11. Liquid Enzyme N/A 12. MEGA-EH3 Ablu 13. Retrocell PL7X H & M LTD. 14. Retrocell ELX H & M LTD. 15. Retrocell PLEX N/A 16. Retrocell-PLX-TRA FINTEX TRADING CORP. 17. ROCKSOFT TM BIO-ACE dyadic International 18. SILTEX PE40 CRECOON PVT LTD (PAK) 05. Creasing performer 01. INVATEX SA HUNTSMAN 06. Detergent 01. INVATEX DA HUNTSMAN 07. Dispersing means 01. Domapol-B-conc. N/A 02. DYAPOL XLF ZSCHIMER & SCH 03. INVATEX AC HUNTSMAN 04. OPTAVON SV H & M LTD. 05. SETAMOL BL BASF 06. SETAMOL WS N/A 08. Emulsifier 01. MA-Humi-W(terge AP) Elitte Textile 09. Enzymatic Killer 01. SILTEX ASILON OL CRECOON PVT LTD. (PAK) 10. Fixing Agent 01. ALBAFIX ECO HUNTSMAN 02. ALCOFIX R N/A 03. JINFIXER JINTEX 04. ZETAFIX-R-(WER) ZSCHIMER & SCH WARZ 05. ZETAFIX WER ZSCHIMER & SCH WAR Z 06. Zetasal-WER JINTEX 07. TAIGAL N-600 N/A 11. General Chemicals 01. ACETIC ACID CENTARY FAITH IND. LTD 02. BLEACHING POWDER CENTARY FAITH IND. LTD 03. Biorol-JK N/A 04. CAUSTIC SODA (Pearls) ARABIAN ALRAIS. COM LTD 05. Chelam-NEX N/A 06. Common Salt (Sikder) N/A 07. DISODIUM inorganic phosphate N/A 08. GLAUBER SALT GRASSIM IND. LTD 09. Green-Acid (Jintex-CPS) JINTEX 10. GREEN ACID (Jintex-CPS) N/A 11. GSS. FINTEX TRADING 12. H2O2 (35%) H. P. CHEMICALS 13. H2O2 (50%) CENTARY FAITH IND. LTD 14. JINTEX RH JINTEX 15. Lazim PE N/A 16. Lubisol-AM N/A 17. SCOURNER BF-70 N/A 18. SETAVIN AS N/A 19. Soda Ash ZSCHIMER & SCH WARZ 20. Sodium Hydros NIMIR SPECIALLY CHEMICAL LTD. 21. Soda PS SHUNG SHUNG CHEM. COM. LTD. 22. TRI SODIUM PHOSPHATE N/A 23. Visco discolorise ARABIAN ALRAIS. COM. (SA) 24. Visco tinge ARABIAN ALRAIS. COM. (SA) 12. Levelling agent(For Reactive dyes) 01. Ablutex-STR Ablu 02. ALBATEX LD HUNTSMAN 03. Alcoperse AD N/A 04. BITGEN DL/P N/A 05. CROSCOLOR ADM H & M LTD. 06. CROSCOLOR HPJS H & M LTD. 07. JINLEV CL-225 JINTEX 08. JINTEX RLA JINTEX 09. Levajol-RL N/A 10. MA SCOUR AIN (Perp-IN) Ellite Textile 11. Sera-Gal-C-FTR Scarlet Services 12. TAIGAL NL-4DH N/A 13. TAIGAL SET N/A Levelling agent(For Dispersedyes) 01. CROSPREP PBS H & M LTD. 02. Doregal-SFD N/A 03. DYAPOL-XLF DYAPOL 04. JINLEV RLF JINTEX 05. LYOGEN PES LIQUID-200 JINTEX 3. Peroxide Killer 01. Catalase BF CHT 02. LORINOL ULTRA-125 N/A 03. R-THN/Catalase BF ZSCHIMER & SCH WARZ 04. Setavan-PK(THN) 50% ZSCHIMER & SCH WARZ 05. Reduzol PK (50% Sol. ) N/A 14. Reducing agent 01. IRGASOL DAM CIBA CHEMICALS 02. MCL-TH CLARIANT 03. Meropan / Redulite Red CHT 04. Redulite RED CHT 05. REDUPAL SU CLARIANT 06. Zetasol OR ZSCHIMER & SCH WARZ 15. Sequestering agent 01. ANTISIL CONZ N/A 02. HEPTOL KEB CHT 03. JINTEXALATE SQ -117 JINTEX 04. LADIQUEST 1097 CLARIANT 05. MEROPAN DPE CHT 06. SECURON-C COGNIS 07. Trilon TB BASF 08. TRILON TB (10% Sol. ) CLARIANT 16. Silicone 01. MICROCIL AM SILVIA 17. Soaping agent 01. ASUTOL-PA Ablu 02. CEREFAST CRD N/A 03. COTOBLANCE NSR CHT 04. ERIOPON R HUNTSMAN 05. JINTEXALATE QSE JINTEX 06. REACTIVE W Texotech 18. Softener 01. Astrost SA (10% Sol. ) N/A 02. Bevasoft CF (10% Sol. ) N/A 03. CROSOFT NBC (10% Sol. ) EURO-DYE CTC 04. Decosoft Jcc (10% Sol. ) Tex Color Int. 05. INSOFT CL (10% Sol. ) NIMIR SPECIALLY CHEMICAL LTD. 06. JINSOFT AW-509 JINTEX 07. JINSOFTER FS/CS JINTEX 08. Jinsofter ME N/A 09. Jinsofter NF (10% Sol. ) JINTEX 10. JINSOFTER WCS-(FLAKES) JINTEX 11. Ma-Smooth AL EURO-DYE CTC 12. MEGASOFT FMG HUNTSMAN 13. TUBINGAL CHT 19. Washing agent 01. Ablutex BBV Ablu 02. FELOSAN NOF CHT 03. Flock-BM/Hydrostat-BM N/A 04. Hydrostat BM N/A 05. MA Disp-ARE (SOAP REA) Ellite Text ile 06. SCOURNER S-300 N/A 07. SINCAL MED ZSCHIMER & SCH WARZ 08. SQ-117 JINTEX 09. smirch REMOVER N/A 10. ZETASOL SPECIAL ZSCHIMER & SCH WARZ 20. Wetting agent 01. Ablutex AP-500 Ablu 02. Ablutex -AP-750 (42% Sol. ) Ablu 03. AMIDOPAL PB ZSCHIMER & SCH WARZ 04. APRETAN EM ZSCHIMER & SCH WARZ 05. ASILON OIL MM TRADING 06. Chtex BS-401 Centary Faith Industrial Ltd. 07. Crosquent DS H & M LTD. 08. DEPICOL RC-9 ZSCHIMER & SCH WARZ 09. DIAMUL SHC YORKSITE 10. DYAPOL HWF H & M LTD. 11. FELOSAN RGN CHT 12. FORYI 146 (CONC. ) COGNIS 13. JINTERGE SCF Cond N/A 14. JKY T.CORPORATION 15. Lorinal R. K N/A 16. MA-Lizen XLC Ellite Textile 17. Optavon-AC-BL-100(ABC) ZSCHIMER & SCH WARZ 18. Optavon 4UD H & M LTD. 19. PERLAVIN NDA N/A 20. RADUZIN ABC Ablu 21. RADUZIN ABC ZSCHIMER & SCH WARZ 22. RADUZIN AC-BL-100 ZSCHIMER & SCH WARZ 23. Zetasal WER (10% Sol. ) N/A PRODUCTION PLANNING & SEQUENCE OF OPERATION Introd uction and Basic Procedure of prep and Control A planned work brings success. Without think cipher is completed within the required time. So planning has its own importance which is intolerable. Planning gives a scheduled task and nurse completes it successfully. But production planning and defy is not an easy task. So EKCL has a self-sufficient and high-performance department called Production Planning & Control. Its Basic works procedure is as follows 1. fetching orders from trade division. 2. Analyzing the orders. 3. Planning for knitting the fabric. 4. Planning for dyeing the fabric. 5. Planning for finishing the fabric. It is only a basic procedure. It may change according to the fibre of order. Sometimes, order is places only for finishing the material or only for dyeing the white goods.Then some steps are omitted for planning procedure. 1. Taking orders from marketing division EKCL marketing division supplies Fabric Orders to the Planning and control division by a s pecial format. 2. Analyzing the orders This section analyze the orders according to emptors, Order Quantity, type of orders (i. e. type of fabric, color to be dyed etc. ), tar date etc. Then it selects which M/C. to use, no of M/C. to use, time required for production etc. This section plans for required quantity of fabric to be knitted (Order quantity + 6% of Order Quantity), knitting balance, fabric need to be dyed.Dyeing balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery balance. 3. Planning for knitting This section plans for knitting production. It selects machine for knit the fabric for specific type of fabric, type of yarn used, required GSM, width etc. It also gives delivery data for knitted fabric. It also places orders for buying of yarn from spinning mills by a specific schedule. 4. Planning for dyeing the fabric Production planning for dyeing is called Batch Plan. According to the batch no. And color, width, style and social system the batc h plan is made. For easy understand this section gives some T. cards. T cards are serialized according to the priority of delivery. The batches and T cards also serialized as to dye flatboat shade at first and lastly the dark shades, since faulty shades evoke be converted to dark color later. 5. Planning for finishing the fabric Finishing schedule is same us the dyeing. After dyeing the material goes to the finishing section with the batch plan. Finished data is written to the batch card and is informed to the planning section. However, this section always enforces to all the departments to finish all the works within the delivery time given by the buyers.This section delivers materials by truck, micro, air etc to the customer within the meantime. Thus it plays a very important role in the success of the company. Production planning Marketing Lab dip Lab dip approval Sample production Sample approval and order for bulk production Knitting Sample production according to buyer recom mendation lot knitting production Batching Pre- treatment Dyeing Finishing wadding Ready for delivery (RFD) Garments section SEQUENCE OF OPERATION Knitting Grey inspection Batch preparation White Processing Pretreatment Cotton dyeing Polyester dyeing Hydro-extracting Dewatering Drying CompactingFinal Inspection inspection Finished store Delivery to Garment industry Lab Section Lay out for Lab Chemicals Dexter HT Dyeing m/c Lab table Wash fast UN-1 Mathis Labomat Digi Oven Ahiba Naunce Rapid dyeing m/c Ahiba Naunce Rapid dyeing m/c Ahiba sample dyeing-1Robolab-1 Robolab-2 Trumble dryer Washactor-2 Spectophotometer-1 Lab Office Washactor-1 Spectophotometer-2 Lab Quality Control machines apparatus Specification SL. none Specification SL. No. Specification 01. ROBOLABModel No. XPNManufacturer Sclavous International do in Greece survive 1. Making ocellus tooth root accurately. 2. Auto dispersing of given recipe. MACHINE TYPE Robolab XPNMANUFACTURED BY TALOS-66100DRAMA G R MANUFACTURE IN YEAR 2009SERIAL No. 0963TOTAL WEIGHT 800 KGPOWER 4 KWELECTRICAL FEATURES 220v 50HzPHASES 1 MAX. CURRENT 20 A 02. ROBOLABModel No. XPNManufacturer Sclavous InternationalMade in GreeceFunction 1. Making stock solution accurately. 2. Auto dispersing of given recipe. MACHINE TYPE Robolab XPNMANUFACTURED BY TALOS-66100DRAMA GR MANUFACTURE IN YEAR 2009SERIAL No. 0963TOTAL WEIGHT 800 KGPOWER 4 KWELECTRICAL FEATURES 220v 50HzPHASES 1 MAX. CURRENT 20 A 03. Ahiba IRSample Dyeing machineModel No. USTCManufacturer USAFunction 1. Sample dyeing for cotton substrate. No. f pots in the dye cleanse 20Brand datacolor SPECTRUM family of solutions 04. Ahiba NuanceSample Dyeing machineModel No. ECOManufacturer Datacolor Function 1. Sample dyeing for cotton substrate. No. of pots in the dye privying tub 20Brand datacolor SPECTRUM 05. Ahiba NuanceSample Dyeing machineModel No. ECOMade in USAManufacturer Datacolor Function 1. Sample dyeing for cotton substra te. No. of pots in the dye bath 20Brand datacolor SPECTRUM 06. MATHIS LabomatSample Dyeing machineModel No. AGCH-8156Manufacturer Warner MathisFunction 1.Sample dyeing for cotton substrate. No. of pots in the dye bath 24 07. Dexter High Temperature Dyeing machineModel No. 73Manufacturer Yuan Shen Enterprise Ltd. Made in TaiwanFunction 1. Sample dyeing in high temperatureTemperature maintained by Glycerine bath. No. of pots in the dye bath 24 DexterPH 3 ,VOLT 220 Hz , INPUT 9 KWMODEL No. 73 assignment 93 07YUAN SHEN ENTERPRISE CO. LTD. 08. Wash Fast UNIModel No. 60351Serl. No. 145338 Manufacturer cartridge clip EngineersMade in IndiaMethod used (ISO-105C06,C01 AATC-61/135)Function 1. For checking color swiftness after washing.No. of pots in the bath 08 09. DIGIOVENModel No. C1301Manufacturer Mag EngineersMade in IndiaMethod used (ISO-105E 01, E 04/AATCC-107/15-2002)Function 1. Sample drying for perspiration water fastness test. 10. PERSPIRPMETERMod el No. C2301Manufacturer Mag EngineersMade in IndiaMethod used (ISO-105 E 01,E 04/AATCC-107/15-2002)Function 1. For checking color fastness to perspiration. 11. RAPID DYEING MACHINEFunction 1. Sample dyeing . 2. Wash-off the dyed sample. 3. Different pretreatment for dyeing. Required time cant set in this machine . No. of pots in the dye bath 24 12. RAPID DYEING MACHINEFunction 1. Sample dyeing . 2. Wash-off the dyed sample. 3. Different pretreatment for dyeing. Can pre set the dyeing time. No. of pots in the dye bath 24 13. TUMBLE DRYERModel No. T4130Manufacturer ElectroluxMethod used (ISO-6330/AATCC-135)Made in SwedenType Front LoadingFunction 1. For drying fabrics/Garments after wash . 14. WASCATORModel No. F0M71CLSManufacturer ElectroluxMade in SwedenMethod used (ISO 6330-2000 ISO 3759-1999 ISO 5077-1984) (DIN EN 25077/26330-1994)Type Front loading , Rotating attire .Function 1. For checking appearance after wash . 2. For checking dimensional stability . 15. WASCATORModel No. F0M71CLSManufacturer ElectroluxMade in SwedenMethod used (ISO 6330-2000 ISO 3759-1999 ISO 5077-1984) (DIN EN 25077/26330-1994)Type Front loading , Rotating drum . Function 1. For checking appearance after wash . 2. For checking dimensional stability . 16. SPECTROPHOTOMETERModel No. SF600X(Spectraflash)Manufacturer ElectroluxMade in USASoftware Used 1. DCI match. 2. Color toolsFunction 1. Color matching . 2. quantity color difference . 3. Measuring the reflectance % of a dyed sample. 4. Measuring the strength of dyestuff. 17. SPECTROPHOTOMETERModel No. CM-3600dManufacturer MinoltaMade in IndiaSoftware Used 1. JaypakFunction 1. Color matching . 2. Measuring color difference . 3. Measuring the reflectance % of a dyed sample. 4. Measuring the strength of dyestuff. 18. precision OVENSample dryerModel No. DO-452Manufacturer JF Instrument Co. LtdMade in TaiwanFunction 1. Sample drying after washing drying . 19. CROCKMETERJames H. Heal Co. Ltd . Halifax , HX 36EP , England. 20. CROCKMETER Model No. 125302Manufacturer RoachesMade in EnglandMethod used (ISO105X12 / AATCC-8)Function 1. For checking color fastness to rubbing of yarn . 21. Wrap Reel Balance(Yarn count tester)Model No. Roaches International Ltd. Made in EnglandFunction 1. To determine Yarn count . 22. Yarn Appearance Tester(Auto winder RB)Model No. Y0831Manufacturer Mag EngineersMade in India Function 1. Checking eveness of yarn grading accordingly . 23. Unistretch M/CModel No. C0501Manufacturer Mag EngineersMade in India Method used 1. Button / kidnap pull test IHTM020/ASTM 4846. 2. Seam slippage UNI 9743/BS 33203.Lea strength ISO 6939/ASTM D 15784. Single yarn strength test ASTM D2256 24. Mag Sun FastModel No. C 0605Manufacturer Mag EngineersMade in India Method used ISO-105B02/AATCC-3Function 1. For checking color fastness to light . 25. Auto Burst 28(Bursting Strength Tester)Model No. C 0601Manufacturer Mag EngineersMade in India Method used ISO-13928-2/12945-1ASTM D 3787 , 3786Function 1. To government note bursting strength to fabric . 26. Auto pill(Pilling Tester)Model No. C 1401Manufacturer Mag EngineersMade in India Method used ISO-12945-1,2Function 1. To check pilling of fabric. 27. pH MeterModel No. 6173Function 1. To banknote pH value . 28. Friction TesterModel No. TextechnoManufacturer ReibwertwaageMade in GermanyFunction 1. To measure co-efficient of friction . 29. Grey photographic plate ISO 105-A03 1993 BSEN 20105-A03 1995 BS 1006-A03 1990 SDC Standard Methods 5th Edition A03 Grey Scale (Two scale) For Assessing staining . Assessing color change . 30. Matching BoothLIGHT BOX 9 (Supervision 2C)(Visual color matching chamber)Model No. G0201Manufacturer Mag EngineersMade in India Function 1. Checking color difference under different light source. Like D65 ,TL84 , UV , CWF etc. 31. Matching BoothLIGHT BOX (Century Faith)(Visual color matching chamber)Model No. 7008 0Function 1. Checking color difference under different light source. Like D65 ,TL84 , UV , CWF etc. 32. Q SUNXenon Test ChamberLight Fastness TesterModel No. B02 Recipe formulation Buyer can give fabric sample or colour code. So at first the colour is to identify if the buyer gives colour code or pantone number. It is easier to formulate recipe by spectrophotometer from colour code or pantone number because they are very specific. But if it is fabric sample accordingly with the help of spectrophotometer several numbers of recipes are to formulate.Process spring chart of lab Swatch from buyer Checking the quality parameter Recipe Formulation Record Matching Visually Recipe Correction Exact matching with swatch Two or to a greater extent than options of Lab-dip get by to buyer Approved Not Approved Go for production Matching Re-Lab-dip Chemicals used in lab For Cotton Scouring and Bleaching YARN ring fall Function Cottoclarin-KD 1. 25 g/l Soaping agent Stabilol-ZM 0. 4 g/l P eroxide killer Securon-C 0. 75 g/l Sequestering agent cutting 2 g/l Scouring agent H2O2 4. 0 g/l Bleaching agentacetic biting 1 g/l neutralisation reaction make up Amount Function Reduzin-ABC 2 g/l Wetting agent Jinsofter-BSK 0. 75-1. 5 g/l Anticreasing agent Jintexalate-SQ117 1 g/l Sequestering agent Contavan-GAL 0. 75 g/l Stabilizer Caustic 2. 5 g/l Scouring agent H2O2 4. 5 g/l Bleaching agent Fabric For Cotton dyeing squall Amount Function Ladiquest-1097 1 g/l Sequestering agent Jinsofter-BSK 1 g/l Anticreasing agent Jinlev CL-225 1. 5 g/l Levelling agent Formic Acid 0. 1 g/l Controlling pH Glauber salt For Fixation Soda For fixation contolling pH For Washing Name Amount FunctionJintexalate-QSE 1. 5 cc Soaping agent Cotoblance-NSR 1. 5 cc Soaping agent Acetic Acid Neutralization For Polyester Dyeing Name Amount Function Dyapol-AB 1 g/l Acid donar Setamol-WS 0. 75 g/l Dispersing agent Jinlev-RLF 0. 5 g/l Levelling agent Acetic acid 0. 6 g/l Controlling pH Deragal-SFD 1 g/l Buffering + Dispersing agent Domapol B. Conc. 2 g/l Buffering + Dispersing agent For reduction Clearing Name Amount Function Hydrose 2 g/l Reducing agent Caustic 2 g/l Reducing agent Salt-Soda Chart Amcazol spectre % Up to 0. 05 0. 05-0. 075 0. 075-0. 10 0. 1-0. 2 0. 2-0. 3 0. 3-0. 0. 4-0. 5 0. 5-0. 6 Salt(g/l) 2 3 5 7 9 12 16 20 Soda(g/l) 2 3 4 5 7 8 9 10 civilization % 0. 6-0. 7 0. 7-0. 8 0. 8-0. 9 0. 9-1. 0 1. 0-1. 20 1. 2-1. 4 1. 4-1. 6 1. 6-1. 8 Salt(g/l) 22 24 26 28 32 34 38 42 Soda(g/l) 11 12 12 13 13 14 15 16 Shade % 1. 8-2. 0 2. 0-3. 0 3. 0+ Salt(g/l) 46 50 60 Soda(g/l) 18 20 20 Bezctive Shade % 0. 1 0. 1-0. 5 0. 5-1. 0 1. 0-2. 0 2. 0-3. 0 3. 0-4. 0 4. 0-5. 0 Salt(g/l) 10 20 30 40 50 60 70 Soda(g/l) 5 10 15 20 20 25 25 Shade % 5-6 6 Salt(g/l) 80 90 Soda(g/l) 25 25 Remazol Shade % 0. 1 0. Up to 1. 0 Up to 2. 0% 2-3% 3-5% Salt(g/l) 20 30 40 50 60 80 Soda(g/l) 3 3 10 13 15 20 Imcozine Shade % 0. 5 0. 5-1. 0 1. 0-2. 0 2. 0-3. 0 3. 0 Salt(g/l) 30 45 60 70 90 Soda(g/l) 8 12 18 20 25 Cibacron Shade % 0. 01 0. 01-0. 05 0. 05-0. 1 0. 1-0. 5 0. 5-1. 0 1. 0-2. 0 2. 0-3. 0 Salt(g/l) 20 20 20 25 30 50 60 Soda(g/l) 6 6 6 8 10 12. 5 15 Shade % 3. 0-4. 0 4. 0+ Salt(g/l) 60 80 Soda(g/l) 17. 5 20 Kimsoline Shade % Up to 0. 05 0. 05-1. 0 1. 0-1. 5 1. 5-3. 0 3. 0-4. 0 4-6 6-8 Above 8 Salt(g/l) 20 30 40 50 55 60 80 100Soda(g/l) 10 13 15 18 20 20 20 20 Synozol Shade % Below 0. 1 0. 1-0. 5 0. 5-1. 0 1. 0-2. 0 2. 0-3. 0 3. 0+ Salt(g/l) 10 20 30 40 50 60 Soda(g/l) 8 10 13 16 18 20 Levafix CA Shade % 0. 1 0. 1-0. 5 0. 5-1. 0 1. 0-2. 0 2. 0-3. 0 3. 0-5. 0 5. 0 Salt(g/l) 15 20 35 50 60 80 80 Soda(g/l) 5 7 10 13 15 20 20 Drimarine CL Shade % 0. 5 0. 5-1. 0 1-1. 5 1. 5-2 2. 0-3 3 Salt(g/l) 20-50 60 65 70 80 80 Soda(g/l) 5 10 15 18 20 20 Drimarine EX-XN Shade % 1. 0 1. 0-3. 0 3. 0 above Salt(g/l) 20-40 40-60 60-80 Soda(g/l) 5. -10 10-15 15-20 Revatol S 1. 0-2. 0 1. 0-2. 0 1. 0-2. 0 Sumifix Shade % 0. 1 0. 1-0. 3 0. 3-0. 6 0. 6-1. 0 1. 0-1. 5 1. 5-3. 0 3. 0+ Salt(g/l) 3 7 10 15 20 40 50 Soda(g/l) 10 10 15 15 20 20 20 Dychufix Shade % 0. 05-0. 1 0. 1-0. 5 0. 5-1. 0 1. 0-2. 0 2. 0-3. 0 3. 0-4. 0 4 Salt(g/l) 20 30 40 50 60 70 80 Soda(g/l) 10 15 20 20 20 20 20 Shade % 3. 0-4 4. 0+ Salt(g/l) 60 80 Soda(g/l) 17. 5 20 season of dyeing 100% cotton fabric in lab Select bleach fabric (5 gm) Recipe making Select dyes Dyeing warm wash Neutralization Soaping Cold washDrying Match with standard sample yes Bulk production Sequence of dyeing Polyester/Cotton fabric in lab Select bleach fabric ( 5 gm ) Carbonizing of cotton part Fabric weight measure with carbonized part Recipe making Select dyes Dyeing of polyester part Matching dyed PES part with standard yes Dyeing of cotton part Hot wash Neutralization Soaping Cold wash Drying Total sample match with standard sample yes Bulk production Calculation Usually following calculations are followed Recipe % ? Sample Weight ** Dye Solution = (cc). Stock solution % g/L ? Total Liquor ** Salt (cc) Stock solution ? jet g/L ?Total Liquor ** Soda Solution = (cc). Stock solution ? 1000 g/L ? Total Liquor ** Chemicals = (cc). Stock solution ? 1000 Problems for lab-dip -Shade variation ( major problem ) . -Soda or alkali spot come. -Metamerism problem . Problems overcome by -Dye adjust between std. and lab-dip. -Accurate dyes and chemical measure. -By shading (additional way). -By stripping. Samples engineer to buyer Now for every separate sample dyeing with separate recipe are send to buyer for approval. The buyer approves one sample and the recipe of that approved sample is now send to dyeing section. Batching Section Batch Section BatchingBatching preparation is the process where visually inspected grey fabrics are divided into different batches with reasonable quantity in order to make them suitable for the further operation. During batching the following factors are considered 1 1. Order priority 2 2. Yarn type 3 3. Yarn dyed/Color (Light-medium/Deep) 4 4. Fabric quantity 5 5. expertness of a vailable machines 6 Proper batching criteria To use maximum capacitance of existing dyeing m/c To ensure every dyeing m/c running in full production. To minimize the m/c washing time or preparation time. To keep the no of batch as less as possible for same shade, etc.Batch Preparation Process eon of Batch preparation receive batch card from Grey In-charge Make the priority as per dyeing plan Take one specific Batch card. Check the availability of fabric Take required quantity of body fabric from store Make required no. of Rope maintaining equal space Take collar/cuff as per size, keep the total weight. Distribute the collar /cuff or Rib in each rope equally unsure equal length Stitch the fabric Write down the weight against roll no. in the back side of the Batch Card Write the total weight in Batch Card Put signature date Fill the production report formSewingSewing means fasten. The necessity of sewing -To adjust the rolls by sewing which is adjusted with hand by knotting in t urning before sewing? -They fulfill the sewing row in process Route Card and fulfill the particular sewing chart then it goes for dyeing. Turning Normally turning is through for those fabrics which are not same in both face back to protect the face side of fabric from any dust, spot, other color, machine corrosion or any visual or physical disturbance. The machine by which counting of rolls face/back side of fabric is opened is called turner machine. Fabric Dyeing SectionLayout and crystallineation plan of fabric dyeing section Fabric Dyeing car Specification No. of Sample Dyeing railcar 10 No. of Bulk Dyeing railcar 17 List of Sample Dyeing mechanism Sl No Machine type Specification 01. Fongs-20 M/C NO. ALLFIT-25SER. NO. 24009628CERT. NO. HKG-930003/2YEAR construct 1999DESIGN CODE BS 55001997 CAT2DESIGN draw 400 KPaDESIGN TEMPERATURE 140CHYDRAULIC TEST obligate 650 KPaTEST period 1999SAFETY VALVE SET 400 KPaTESTED BY LLYODS COMPANY, Fongs Manufacturer Fongs them e Engineering (Shenzen) Co.Limited. Manufacturing Country Taiwan mental object 20 Kg 03. Fongs-30/2 M/C NO. ALLFIT-30SER. NO. 27013515CERT. NO. HKG-0230011/4YEAR BUILT 2002DESIGN CODE BS 55001997 CAT2DESIGN wring 400 KPaDESIGN TEMPERATURE 140CHYDRAULIC TEST PRESSURE 650 KPaTEST appointee 2002SAFETY VALVE SET 400 KPaTESTED BY LLYODS COMPANY , Fongs Manufacturer Fongs National Engineering (Shenzen) Co. Limited. Manufacturing Country Taiwan subject matter 30 Kg 04. Fongs-120 M/C NO. ALLFIT-120SER. NO. 25010850CERT. NO. HKG-030008/37YEAR BUILT 2000DESIGN CODE BS 55001997 CAT2DESIGN PRESSURE 400 KPaDESIGN TEMPERATURE 140CHYDRAULIC TEST PRESSURE 650 KPaTEST DATE 2000SAFETY VALVE SET 400 KPaTESTED BY LLYODS COMPANY , Fongs Fongs National Engineering (Shenzen) Co. Limited. Manufacturing Country TaiwanCapacity 120 Kg 06. HAF-30 CAPACITY30 KGSTOTAL POWER9 KW working(a) MEDIUM WATER 240Lit. DATE 2005. 4MFG. NO. 2005-HAF-30-1MODEL TGRU-HAF-1-30BODY maximal WORKING PRESS URE 4 KG/cm? TOTAL WORKING TEMP. 140CHEATER MAXIMUM WORKING PRESSURE S/T-5/4KG/cm?MAXIMUM WORKING TEMP. S/T 158C/140CNDT carve up RT 20%Manufacturer TONG GENG ENTERPRISE CO. LTD Manufacturing Country chinaware 07. ATHENA-50/1 Brand Name Athena by SCLAVOSCountry of contrast GreeceSerial No. 03-1B-2931Year Built 2009Design decree ASME vii DivSpecial Features AQUACHORN equal Soft lessen SystemMaximum work contract (MPa) . 28Testing air pressure (MPa)0. 40Maximum working(a) Temperature (C) 142 visible No. 5. 621. 937Capacity 50 KgElectronic Information Machine potential drop (V) 3? 380 ACControl electric potential (V) 24 DCTotal Horse agent (HP) 9 KW 08. ATHENA-50/2 Brand Name Athena by SCLAVOSCountry of Origin GreeceSerial No. 03-1B-2932Year Built 2009Design Code ASME vii Div-1Special Features AQUACHORN Twin Soft extend SystemMaximum work pressure (MPa) . 28Testing pressure (MPa)0. 40Maximum working Temperature (C) 142 tangible No. 5. 621. 937Ca pacity 50 KgElectronic Information Machine potency (V) 3? 380 ACControl Voltage (V) 24 DCTotal Horse Power (HP) 9 KW 09. KRSNA(10 kg)/1 COUNTRY OF antecedent AHMEDABAD , INDIATEL +91-79-22818537 TELE FAX +91-79-22823093/27680745EMAIL emailprotected com/infokrsnadyeingmachine. om Website http//www. krsnadyeingmachine. com Serial No. 12/38 Year10/09-10 Model ATM 10. KRSNA(10 kg)/2 COUNTRY OF ORIGIN AHMEDABAD , INDIATEL +91-79-22818537 TELE FAX +91-79-22823093/27680745EMAIL emailprotected com/infokrsnadyeingmachine. com Website http//www. krsnadyeingmachine. com Serial No. 13/38Year 10/09-10Model ATM Bulk production dyeing Machine Sr. No. Machine type Specification 01. ATH-1/1 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 250 KgNo. of snout 1Serial No. 04-1A-2/11Design Code ASME eight-spot DIV. Maximum work pressure (bar) 2. 8Testing pressure (bar)4. 0Maximum working Temperature (C) 142 unmixed No. 5-621-937Year of construction 2005Spe cial Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 33Control Voltage (V) 24 DCTotal Horse Power (HP) 19KW 02. ATH-1/2 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 250 KgNo. of snob 1Serial No. 04-1A-250Design Code ASME VIII DIV. 1Maximum work pressure (bar) 2. 8Testing pressure (bar)4. 0Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2004Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 42Control Voltage (V) 24 DCTotal Horse Power (HP) 24 03. ATH-1/3 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 250 KgNo. of neb 1Serial No. 04-1A-2874Design Code ASME VIII DIV. 1Maximum work pressure (MPa) 0. 28Testing pressure (MPa) 0. 40Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2007Special Features AQUACHORN Twin Soft Flow S ystemElectronic Information Machine Voltage (V) 3? 80 ACMax. Current (A) 42Control Voltage (V) 24 DCTotal Horse Power (HP) 24 04. ATH-1/4 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 250 KgNo. of Nozzle 1Serial No. 04-1A-2868Design Code ASME VIII DIV. 1Maximum work pressure (MPa) 0. 28Testing pressure (MPa)0. 40Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2007Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 73 AControl Voltage (V) 24 DCTotal Horse Power (HP) 24 05. ATH-2/1 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 500 KgNo. of Nozzle 2Serial No. 04-2A-2870Design Code ASME VIII DIV. 1Maximum work pressure (MPa) 2. 80Testing pressure (MPa)0. 40Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2007Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 59 Control Voltage (V) 24 DCTotal Horse Power (HP) 35 06. ATH-2/2 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 500 KgNo. f Nozzle 2Serial No. 04-2A-2869Design Code ASME VIII DIV. 1Maximum work pressure (MPa) 0. 28Testing pressure (MPa)0. 40Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2007Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 59 Control Voltage (V) 24 DCTotal Horse Power (HP) 35 07. ATH-3/1 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 750 KgNo. of Nozzle 3Serial No. 04-3A-2607Design Code ASME VIII DIV. 1Maximum work pressure (bar) 2. Testing pressure (bar)4. 0Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2004Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 68Control Voltage (V) 24 DCTotal Horse Power (HP) 48 08. ATH-3/2 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 750 KgNo. of Nozzle 3Serial No. 04-3A-2880Design Code ASME VIII DIV. 1Maximum work pressure (MPa) 0. 28Testing pressure (bar)4. 0Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2007Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 73Control Voltage (V) 24 DCTotal Horse Power (HP) 47 09. ATH-6 Brand Name Athena2 by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 1500 KgNo. of Nozzle 6Serial No. 04-6A-2907Design Code ASME VIII DIV. 1Maximum work pressure (MPa) 0. 28Testing pressure (bar)0. 40Maximum working Temperature (C) 142 Patent No. 5-621-937Year of construction 2009Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 80 ACMax. Current (A) 134Control Voltage (V) 24 DCTotal Hors e Power (HP) 88 10. AA-3/1 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 750 KgNo. of Nozzle 3Serial No. 06-3A-2963Type DSL 750 FMaximum working Temperature (C) 98Pmax. 3. 55 KWVmax. 3? 440 volt 50/60 HzPatent No. 5-621-937Year of construction 2009Electronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 75Control Voltage (V) 24 DCTotal Horse Power (HP) 48 11. AA-3/2 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 750 KgNo. f Nozzle 3Serial No. 06-3A-2964Type DSL 750 FMaximum working Temperature (C) 98Pmax. 3. 55 KWVmax. 3? 440 volt 50/60 HzPatent No. 5-621-937Year of construction 2009Electronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 75Control Voltage (V) 24 DCTotal Horse Power (HP) 48 12. S. HT-2 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 360 KgNo. of Nozzle 2Serial No. 03-2A-2193Design Code ASME VIII DIV. 1Maximum work pressure (bar) 3. 5Testing pressure (bar)5. 3Maximum working Temperature (C) 140 Patent No. 5-621-937Year of construction 1993Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 44Control Voltage (V) 24 DCTotal Horse Power (HP) 25/185 13. S. HT-3/1 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 540 KgNo. of Nozzle 3Serial No. 03-3A-22/1Design Code ASME VIII DIV. 1Maximum work pressure (bar) 3. 5Testing pressure (bar)5. 3Maximum working Temperature (C) 140 Patent No. 5-621-937Year of construction 1993Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 80 ACMax. Current (A) 50Control Voltage (V) 24 DCTotal Horse Power (HP) 36/26. 25 KW 14. S. HT-3/2 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 540 KgNo. of Nozzle 3Serial No. 03-3A-22/2Design Code ASME VIII DIV. 1Maximum work pressure (bar) 3. 5Testing pressure (bar )5. 3Maximum working Temperature (C) 140 Patent No. 5-621-937Year of construction 1993Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 380 ACMax. Current (A) 50Control Voltage (V) 24 DCTotal Horse Power (HP) 36/26. 25 KW 15. S.HT-4/1 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 720 KgNo. of Nozzle 4Serial No. 03-4A-2305Design Code ASME VIII DIV. 1Maximum work pressure (bar) 3. 5Testing pressure (bar)4. 0Maximum working Temperature (C) 140Patent No. 5-440-771Year of construction 2000Special Features AQUACHORN Twin Soft Flow SystemElectronic Information Machine Voltage (V) 3? 400 ACMax. Current (A) 64Control Voltage (V) 24 DCTotal Horse Power (HP) 39 16. S. HT-4/2720 Brand Name Athena by SCLAVOSCountry of Origin ATHENS-GREECEM/C Capacity 720 KgNo. of Nozzle 4Maximum work pressure (bar) 3. Testing pressure (bar)4. 0Maximum working Temperature (C) 140Special Features AQUACHORN Twin Soft Flow SystemTotal Horse Power (HP) 40 SPECIAL FEATURES OF SCLAVOS MACHINE Twin soft flow system The main pump liqour flow in sclavos is distributed into two nozzles achieving minimum pressure. The technical solution results in a perfact fabric transpose liqour penetration at a very low nozzle pressure. The patented plaiting system ensures good storage of the fabric with the uniqe liqour bypass system diverting the biggest amont of liqour out side the chamber. This avoids abrasion of fabric surface.Advantages * less(prenominal) compacting system * Extended fabric liqour exchange * Reorientation of the rope at every turn * Vertical plaiting Aquacron radical continuous wash system, diverting contaminated liquor at the exit of TSF outside the j box to a drain pipe. A continuous flow of either preheated (via Sclavos Heat Recovery) or cold water turns Sclavos into a virtually nonstop operation dyeing machine. Drainage of contaminated liquor via the liquor bypass avoids liquor droppin g on to the stored fabric. High liquor renewal speed caused by very low liquor level during washing. Advantages 1. Efficient washing effect. . Less water consumption. 3. Less temperature shocks when weft with cold water. 4. Precise calculation of water consumption. FULLY AUTOMATIC FUNCTION * Automatic salt soda dosing system. * Automatic chemical injection system. * Automatic heat exchanging process. Ciba new process Bleach+Enzyme Machine filling with water at shape Temperature Fabric loaded at normal temperature (36-400C) Chemicals Contipon S (10%solution), Jintex Stab, Antisil Conz Jinsofter BSK , Ablutex-AP-750 (42% Soln) Dozing at 60 0C Run for 4 min H2O2 (35% Soln) is added at 600C within 3-4 minute NaOH is added for 7 min at 700CRun time 20 min at1100C Cooling at 95-80 0C then aquachron is done for 12 min Absorbency test is done. Water is leveled Acetic Acid is added at 550C runtime 6 min Per oxide Killer (Raduzin-THN (50% Soln)) is added at 55C for 10 min, Per oxide is ch ecked (if H2O2 = O) PH is Checked (PH=4. 8) Enzyme ( Retrocell PLX-TRA) at 550C run for 45 min Aquachron is done at 550C for 5 min Hot wash at 80 C for 20 min Aquachron is done at 550C for 5 min Water is leveled Dyeing (ciba new process) Dyeing auxiliaries(Jinlev-CL225, Antisil conz) and acitic acid /RL)is added at 600C for 30 min PH is Checked (PH= 6-6. 5 ) Runtime 20 minDyes is dosing at 600C 20min added at run for 10 min. Glauber salt dosing at 600C for 30 min and run for 20 min Soda dosing at 600C for 20 min 1st part Soda dosing at 600C for 20 min2nd part After 5 min shade is checked If shade is not OK then its checked after every 5 min until matching If shade is OK Liquor is drained Water filling and aquacron is done for 25 min Soaping Acid wash is done at 600C and run for 6 min for neutralization PH is checked (acidic condition) Soaping agent (Jintexalate QSE) is added at 950C run for 12 min Aquachron is done at 70 C for 5 min Hot wash at 900C run for 9 minAquachron is done for 10 min Drain out Nova Ciba Fixing Fixing agent (WER)is added for 10 min at 400C and run for 10 min Acidic acid +Dosssing Bevsoft-CF +Jinsofter WCS is added for 10 min at 400C run for 20 min Unload Finishing Section Lay-out of the Finishing section DEWATERING SLITTING M/C Production Officers live FINISHED Goods STENTER MACHINE 02 STENTER MACHINE 03 STENTER MACHINE -01 OFFLINE QUALITY CONTROL ROOM COMPACTORM/C- 03 LAFER COMPACTOR M/C-01 DEWATERING-2 DEWATERING-1 DRYER MACHINE FINISHED Goods FINISHED Goods COMPACTOR M/C C- 02 CALANDER M/C RAISING M/C SLITTING M/CSUEDING M/C Online QC Officers Table Finishing After dyeing knit fabric is required to finish. During dyeing all knit fabric are dyed in tubular form. According to buyers requirement knit fabric are finished in open form or tubular form. Dyed Fabric from Dyeing Department Shade check Flow chart of finishing process Dewatering Open width Tubular form Dewatering Drying Slitting Calendering compactor Stentering/ thirsty Final Inspection Open compactor Packing Final Inspection Delivery Packing Delivery Machines of Finishing section M/C No. M/C Name M/C specification 01. Hydro-1Dewatering M/C -1 SANTEX AG CH-9555 TobelControl panel Inspected by Santex agType SANTASTRETCH 140Com. Nr. 3887Electr. diagr. Nr. 95-3887Electr. Voltage 3? 380V+N+E 230V 50 HzConnected Load 8KWYear of Construction 1995Made in Switzerland 02. Hydro-1Dewatering M/C -1 SANTEX AG CH-9555 TobelControl panel Inspected by Santex agType Santastretch PlusCom. Nr. 5872Electr. diagr. Nr. 03-5872Electr. Voltage 3? 400+PEN 230V 50 HzConnected Load 20 KWYear of Construction 2003 Made in Switzerland 03. Slitting bianco S. P. AMACCHINE TESSILIVial Industria, 4 -12051ALBA CN ITALIATel. 173/440402-(5 line r. a. )Fax0173/34872-0173/297000-Telex-212357 BIANCOMACHINE Linea TaglierinaSERIAL NO. 960112CONSTRUCTION YEAR 1996VELOCITAMAX(m/min. ) 04. Dewatering+Slitting bianco S. P. AMACCHINE TESSILIVial Industria, 4 -12051ALBA CN ITALIATel . 0173314111Fax 01734872 Email bianco-spa. comMACHINE Linea TaglierinaSERIAL NO. M04639-022215CONSTRUCTION YEAR 2006VELOCITAMAX(m/min. ) 900 05. Dryer LK LH CO. , LTD. TAIWAN TAIFEI 06. Calendering Compacting SANTEX AG CH-9555 TobelControl panel Inspected by Santex agType SANTASPREAD 140Com. Nr. 3889Electr. diagr. Nr. 95-3889Electr. Voltage 3? 380V+N+E 230V 50 HzConnected Load 8KWYear of Construction 1995 Made in Switzerland 07. Stentering m/c1 LK LH CO. , LTD. 08. Stentering m/c-2 ICOMATEXTERRASS(SPAIN)TIPO DE MAQUINA FL-3No. DE FABRICATION 481ANO DE FABRICATION 2005 09. Stentering m/c-3 ICOMATEXTERRASS(SPAIN) 10. Compacting m/c-1 FERRAROCONSTRUZIONI MECCANVia Busto Arsuzu,12021015 Lonate FozzoloITALYCOMPTEX7RA-2600 3957Year of Construction 1998 11. Compacting m/c-2 TUBETEXC 2500 compactor 12. Compacting m/c-3 LaferSPA MACCHINE TESSILISEDE LEGALE,UFFICI E STABILIMENTO Via Laga di Garda no. 8 Z. I 36015-SCHIO (VI) ITALYMACCHINA KSA 500ALTEZZA TAVOLA 2600MATRICOL A 10KS02767ANNO 2009 13. Sueding m/c LaferULTRASOFT-YTexen s. r. l. factory automationVia lago di vico , 4B 36015 schio (VI) Italytel +39. 0445. 694101 fax. 39. 0045. 694120www. laferspa. com/emailprotected comSERIAL NO. /DRAWING NO. N 10GSY2355PHASES NO. N 3VOLTAGE v 400FREQUENCY Hz 50NOMINAL CURRENT A 100INTERRUPTION CAPABILITY KA 25 14. Raising m/c Mario CostaM/C Type MC-20/24Serial No. 8969Power Supply 3? 400 V 50/60HzYear 2007 Month 11Max. Power 69 KWTensione asiliari 24/5 VDCAux.Power Supply 230/24 KWMade in Italy Factor Consideration shoplifting control -Shrinkage is controlled by proper over feeding. -To apply less or more over feed speed fabrics reduce along to length and increase along to width. Maximum 70 75% shrinkage is controlled by using it. GSM Control -GSM is also controlled by applying proper over feeding speed. -If over feed is more than GSM is also more. -If Over feed speed is less then GSM is also is less. -If Dia is more than GSM of the fa bric will less. -If Dia is less than the GSM of the fabric will more. N. B If GSM of the fabric is OK then shrinkage is also OK.Dia Control -Dia is controlled by dia peremptory meter scale. -If any fault, GSM of the fabric is reduced then to increase the GSM of the fabric dia will have to be reduced (2 3) inch. -If Over feed speed is more than Dia of the fabric will be more. -If Over feed speed is less then Dia of the fabric will be less. -If length is more than width of the fabric is reduced. -If length is less then width of the fabric is more. N. B Fabric speed is controlled on the fabric dia. Here, Dia less or More fully depends on yarn count and buyer order. Dia is done less or more by using expander rod.Finishing section is divided into two section, they are -Open line -Tube line Production parameters 1 1. Squeeze pressure 2 2. Fabric speed 3 3. Fabric tension 4 4. Temperature 5 5. Fabric diameter 6 6. Fabric GSM 7 7. Fabric shrinkage 8 8. Air pressure 9 9. Steam pressure 10 10. Softener Types of finishing 1) Chemical finishing * Chemical reaction of auxiliaries with fibers. * Application of the handle modifying products / additives. 2) Mechanical finishing * Mechanical treatment with machines. The machines that are used in open line that are given bellow 1. Slitting m/c 2. De-watering m/c 3. Stenter 5. CompactorThe machines that are used in tube line that are given bellow 1. De-watering m/c 2. Dryer 3. Calendering Stentering Other machines 2. Sueding m/c 3. Raising m/c Dewatering m/c 01 After finishing the dyeing process from the dyeing machine then the fabrics are ready for de-watering. This is the process to remove the water from the fabric completely by squeezing. This is the main function of the de-watering machine. But here also control the some important factor of the fabric quality Function 1. Reduce water content. 2. Apply chemicals specially to make the fabric soft. 3. Open the fabric from the rope form. . Shrinkage is controlled by overfeed mechanism Slitting m/c 01 M/c name bianco S. P. A Serial Nr. 960112 Construction year 1996 Highest Speed 100M/min cartroad speed 60-70 M/min Normal speed 40-50 M/min N. B. * Photocell detects Needle Mark according to the needle mark tube fabric is cut by the plate. * Fabric Diameter is set by Basket. * Fabric is spreaded by the basket. Purpose of the m/c * To open the fabric from tubular form to open width form * Fabric is cut according to the needle mark. Dryer m/c Drying Drying is defined as a process where the liquid portion is evaporated from the fabric.Curing Curing can be defined as a process following addition of a finish to textile fabrics in which materials are heated for a short time in elevated temperature to effect a chemical reaction Functions 1. To dry the fabric with the help of steam 2. To control the shrinkage 3. To prepare the fabric for next subsequent process 4. To dry fabric without tension Figure Dryer Main parts of the machine 1. heat energy chamber 2. Bl ower 3. Synthetic blanket as a conveyor 4. Folder 5. Exhaust fan Heating system * Gas fired Checking parameters * Shade Check * Width check * Weight check * Compaction check Fault check Operator checks * Knitting faults * Spinning faults * Dyeing faults * Other faults * leaping check Yarn Dyeing Section Yarn dyeing machines and their specification SL No. Machine Type ear No. Bobbin no. M/C Specification 01. Lab m/c (AL-6A) spike heel No. 016 Bobbin / SpindleTotal Bobbin=(1*6) =6 HEAT EXCHANGERSER NO. 2901587-1CER. NO. HKG. 043003/92DESIGN CODE PD55002003CAT2YEAR BUILT 2004CAPACITY 6 KG JACKET SHELLDESIGN PRESSURE 400 KPa 520 KPaDESIGN TEMP. 50C 140CHAYDRAULIC PR . 600 KPa 800 KPa TEST DATE 2004 2004SAFETY VALVE SET 400KPa 520kpaHEATING/COOLING MEDIUM WATERTESTED BY LLYOYDS REGISTERFONGS theme ENG. (SHENZEN) CO. LTD 02. Lab m/c (AL-6B) Spindle No. 016 Bobbin / SpindleTotal Bobbin=(1*6) =6 HEAT EXCHANGERSER NO. 2901587-1CER. NO. HKG. 043003/92DESIGN CODE PD55002003CAT2 YEAR BUILT 2004CAPACITY 6 KG JACKET SHELLDESIGN PRESSURE 400 KPa 520KPaDESIGN TEMP. 50C 140CHAYDRAULIC PR . 600 KPa 800 KPa TEST DATE 2004 2004SAFETY VALVE SET 400KPa 520kpaHEATING/COOLING MEDIUM WATERTESTED BY LLYOYDS REGISTERFONGS NATIONAL ENG. (SHENZEN) CO. LTD 03. CH-10/1 Spindle No. 033 Bobbin / SpindleTotal Bobbin=(3*3) =9 CAPACITY 10 KGTOTAL POWER 6 KWWORKING MEDIUM (WATER) 80 Lit. DATE 2006. 11MFG. NO. 2006-CH-10-3MODEL TGCH-10BODY OPER. PRESSURE 4 KG/cm? MAXIMUM WORKING TEMP. 140CHEATER OPER. PRESSURE S/T4/10KG/cm? MAXIMUM WORKING TEMP. S/T140C/183CNDT CLASS RT 20%TONG WU PRECISION MACHINERY CO.LTDTAIWAN 04. CH-10/2 Spindle No. 033 Bobbin / SpindleTotal Bobbin=(3*3) =9 CAPACITY10 KGTOTAL POWER 6 KWWORKING MEDIUM (WATER) 80 Lit. DATE 2006. 11MFG. NO. 2006-CH-10-3MODEL TGCH-10BODY OPER. PRESSURE 4 KG/cm? MAXIMUM WORKING TEMP. 140CHEATER OPER. PRESSURE S/T4/10KG/cm? MAXIMUM WORKING TEMP. S/T140C/183CNDT CLASS RT 20%TONG WU PRECISION MACHINERY CO. LTD TAIWAN 05 . CH-15/1 Spindle No. 044 Bobbin / SpindleTotal Bobbin=(4*4) =16 CAPACITY15 KGM/C NO. CAS-50L-4SER. NO. 24009627CERT. NO. YKG 930003/4YEAR BUILT 1999DESIGN CODE BS55001997CAT2DESIGN PRESSURE 660 KPaDESIGN TEMPERATURE 140CHYDRAULIC TEST PRESSURE 1020 KPaTEST DATE 1999SAFETY VALVE SET 660 KPaTESTED BY LLYOYDS REGISTER Fongs 06. CH-15/2 Spindle No. 035 Bobbin / SpindleTotal Bobbin=(5*3) =15 CAPACITY15 KGSTOTAL POWER7 KWWORKING MEDIUM (WATER)120Lit. DATE 2005. 4MFG. NO. 2005-CH-15-2MODEL TGCH-15BODY OPER. PRESSURE 4 KG/cm? MAXIMUM WORKING TEMP. 140CHEATER OPER. PRESSURE S/T4/10KG/cm? MAXIMUM WORKING TEMP. S/T140C/183CNDT CLASS RT 20%TONG WU PRECISION MACHINERY CO.LTD TAIWAN 08. CH-30/1 Spindle No. 057 Bobbin / SpindleTotal Bobbin=(5*7) =35 CAPACITY30 KGSTOTAL POWER9 KWWORKING MEDIUM (WATER)240Lit. DATE 1995-4MFG. NO. 951-CH-30-1MODEL TGCH-30BODY OPER. PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECISION MAC HINERY CO. LTD TAIWAN 09. CH-30/2 Spindle No. 057 Bobbin / SpindleTotal Bobbin=(5*7) =35 CAPACITY 30 KGSTOTAL POWER 9 KWWORKING MEDIUM (WATER)240Lit.DATE 1995-4MFG. NO. 951-CH-30-1MODEL TGCH-30BODY OPER. PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5KG/cm? TEST PRESSURE 8KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECISION MACHINERY CO. LTD TAIWAN 10. CH-50/1 Spindle No. 087 Bobbin / SpindleTotal Bobbin=(8*7) =56 CAPACITY 50 KGSTOTAL POWER 12 KWWORKING MEDIUM (WATER)400Lit. DATE 1995-4MFG. NO. 951-CH-50-2MODEL TGCH-50BODY OPER. PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8KG/cm?MAXIMUM WORKINGTEMP. 140C TONG WU PRECISION MACHINERY CO. LTD TAIWAN 11. CH-50/2 Spindle No. 087 Bobbin / SpindleTotal Bobbin=(8*7) =56 CAPACITY 50 KGSTOTAL POWER 12 KWWORKING MEDIUM (WATER)400Lit. DATE 1995-4MFG. NO. 951-CH-50-2MODEL TGCH-50BODY OPER. PRESSURE 4KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8 KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECISION MACHINERY CO. LTD TAIWAN 12. CH-100/1 Spindle No. 167 Bobbin / SpindleTotal Bobbin=(16*7) =112 CAPACITY 100 KGSTOTAL POWER 21 KWWORKING MEDIUM (WATER)800Lit. DATE 1995-6MFG. NO. 951-CH-100MODEL TGCH-100BODY OPER. PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8 KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECISION MACHINERY CO. LTD TAIWAN 13. CH-100/2 Spindle No. 167 Bobbin / SpindleTotal Bobbin=(16*7) =112 CAPACITY100 KGSTOTAL POWER21 KWWORKING MEDIUM (WATER)800Lit. DATE 1995-6MFG. NO. 951-CH-100MODEL TGCH-100BODY OPER.PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8 KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECISION MACHINERY CO. LTD TAIWAN 14. CH-200/1 Spindle No. 327 Bobbin / SpindleTotal Bobbin=(32*7) =224 CAPACITY 200 KGSTOTAL POWER 32 KWWORKING MEDIUM (WATER)2000Lit. DATE 1993. 3MFG. NO. 921-CH-200-10MODEL TGCH-200KGBODY OPER. PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8 KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECISION MACHINERY CO.LTD TAIWAN 15. CH-200/2 Spindle No. 327 Bobbin / SpindleTotal Bobbin=(32*7) =224 CAPACITY 200 KGSTOTAL POWER 32 KWWORKING MEDIUM (WATER)2000Lit. DATE 1993. 3MFG. NO. 921-CH-200-10MODEL TGCH-200KGBODY OPER. PRESSURE 4 KG/cm? HEATER OPER. PRESSURE 5 KG/cm? TEST PRESSURE 8 KG/cm? MAXIMUM WORKING TEMP. 140C TONG WU PRECIS