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BEXTEX

Project
description
 Name : BEXIMCO KNITTING LIMITED (Dyeing section)

 Type : KNIT DYEING.

 Year of establishment: 1996


 Location : Beximco industrial park,
Chokroborty,
(5 km north from DEPZ).

Address :
Corporate Headquarter:
17, Dhanmondi, R/A,
Road no. 2,Dhaka-1205

Operational Headquarter & Factory :

Beximco Knitting Limited,


Beximco industrial park,
Sarabo, Kashimpur, Gazipur.

Sponsors : World Bank, Marubeni.


DEPZ

Dhaka Mymensing Road


Chakraborti

Bipile
Nobinagar
DEPZ

J. U. Beximco
Industria
l Park

Savar Ashulia

Tongi

Gabtoli
Mirpur Road

Mirpur Abdullahpur
Uttara

New Air port

Mohakhali

Prime
Minister’s
Old Air port
House

National Assembly
Asad gate College of
Textile
Technology

Farmgate

Sat Rasta
Fig: Location of BEXIMCO KNITTING LTD.

 Physical
Infrastructure : - Single storied building (only dye warehouse is double
storied )
- Concrete structure (about 30 ft high)

 Different dept : A) Production oriented department


- Production Planning and control
-Knitting
- Batch preparation
-Dyeing
-Finishing
- Lab& Quality assurance
- Dye warehouse
- Maintenance
- Utilty
- Finished warehouse
B) Supporting department
- personnel administration
- procurement
- marketing
- IT
- HRD
- finance & accounting.
 Remark:
- Available data on physical infrastructure was not available.
- Production per day ranges from 8-12 tons.
Manpower
management
ORGANOGRAM OF MANPOWER

Chief executive officer (CEO)

Head of manufacturing Chief operating officer

DGM (Production)

Maintenance Manager Knitting Manager Dyeing Manager Finishing Manager Q.C Manager

Asst. Manager Deputy Manager Shift officer Shift officer

Shift officer Shift officer

Electrical Incharge Mechanical Incharge


MACHINE
DESCRIPTION

Introduction:
BKL is an integrated computerized company. It has total 18 dyeing
machines among of them 10 machines are fully computerized. The machines are centrally
controlled by Beacon Controller.

Specification :
Dyeing machineries:

Machine No. : 1, 2, 3, 7, 8
Machine Name : Eco-soft
Company Name : Thies, Germany
No. of Nozzle : 4
Capacity : 500-600 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.
fig: Thies machine
Machine No. : 5
Machine Name : Mini-soft
Company Name : Thies, Germany
No. of Nozzle : 1
Capacity : 75 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.

Machine No. : 6
Machine Name : Eco-soft
Company Name : Thies, Germany
No. of Nozzle : 2
Capacity : 350 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.

Machine No. : 9
Machine Name : Luft-roto
Company Name : Thies, Germany
No. of Nozzle : 2
Capacity : 200-350 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.

Machine No. : 10
Machine Name : Luft-roto
Company Name : Thies, Germany
No. of Nozzle : 3
Capacity : 500-550 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.

Machine No. : 11
Machine Name : Local
Company Name : Beximco, Bangladesh
Capacity : 70 kg.
Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.

Machine No. : 12
Machine Name : Local
Company Name : Beximco, Bangladesh
Capacity : 10-20 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 200-250 m/min.

Machine No. : 13
Machine Name : Local
Company Name : Beximco, Bangladesh
Capacity : 5-10 kg.
Diff. Pressure : 500-600 m.bar.
Rope speed : 100-150m/min.

Machine No. : 14
Machine Name : Local
Company Name : Beximco, Bangladesh
Capacity : 120-150 kg.
No. of Nozzle : 1
Diff. Pressure : 500-600 m.bar.
Rope speed : 150-280 m/min.
Machine No. : 15
Company Name : Thies, Germany
Capacity : 150-200 kg.
No. of Nozzle : 2
Diff. Pressure : 500-600 m.bar.
Rope speed : 150-280 m/min.

Machine No. : 16, 17


Company Name : Thies, Germany
Capacity : 350-450 kg.
No. of Nozzle : 3

Machine No. : 18
Machine Name : Local
Company Name : Beximco, Bangla
Capacity : 8-15 kg.
Diff. Pressure : 500-600 m.bar.

DESCRIPTION OF FINISHING M/C:


HYDRO EXTRACTOR M/C:
Manufacturer : Nazar corporation (Pakistan)
Extraction % : 65% Maximum.
Speed : 1400 rpm.

.
DEWATERING M/C:
Manufacturer: CALATOR BORAS (SWEDEN)
Controlling Parameters:
Padder pressure : 4-7 bar
Pick up % : 85%
GSM : 20-35%
Speed at m/c : 8.5 m/min-60 m/min

DRYER
Controlling parameters:
GSM : 15-35%
Shrinkage : 12-15%

EQUIPMENT USED:
Following equipment are used for relax drying process:

a) Ruckh relax dryer (Germany):


* Gas burner heated.
* 4 chamber, 1 burner/ 2 chamber.

b) Santex Relax Dryer (USA):


* Steam heated.
* 2 Chamber.

MACHINE SETUP:
a) M/C set up for Ruckh relax dryer:
M/C parameter Set-up value
Temperature setting 1000c- 1200c for white shade
1200c-1300c for light shade
1300c-1400c for Dark shade
1500c-1700c for curing
Blower fan setting Auto
Exhaust fan setting Auto
M/C Speed 3-35 m/min. Depends on quality of fabric.
Over feed 0-40% depends on fabric construction.
Width of expreader setting 45-114 cm: Depends on the required width of
fabric.
Burner Gas pressure 10-15 m bar.
b) M/C set up for Santex Relax Dryer:
M/C parameter Set-up value
Temperature 1000c- 1100c for white shade
1100c-1200c for light shade
1200c-1300c for Dark shade
Blower fan setting Push button switch on
Exhaust fan setting Push button switch on
M/C Speed 1-12 m/min. Depends on quality of fabric.
Over feed 0-45% depends on fabric construction.

Checking parameters :
1. Shade Check
2. Width check
3. Weight check
4. Compaction check

SLITTER M/C:
Equipments used:
Airtex Slitter Machine (Sweden)
Speed : 20-25 m/min.

M/C parts :
a) Rotary blade b) Ring
c) Guide Roller d) Plaiting
e) Sensor

Checking parameters:
1) Cutting line check
2) Bow & slant check
3) Fault check :
STENTER M/C:
Equipment used:
Krantz Stenter Machine (Germany)
No of chamber : 7
No of Burner : 14
No of Padding through : 2
No of exhaust fan : 7 fig: stenter machine

Machine Setup:
M/C parameters Set up value
Padder pressure 2 to 8 bar
Temperature setting 90- 1800 c
Blower fan setting lower to high
Exhaust fan setting Manual
Width of m/c chain setting 110 cm up to 260 cm
Over feed 0-60%
Burner gas pressure 30-50 m/ bar
Machine speed 6 to 60 m/ min
Light wt (100-140 GSM) 20-30 m/min
Medium wt (150-180 GSM) 14-18 m/min
Heavy wt (190-250) 10-15 m/min
Checking parameters :
1. Shade Check
2. Width check
3. Weight check
4. Compaction check
5. Fault check : Operator checks -

TUBULAR COMPACTOR :
Equipment used:
Ruckh Tubular Compactor m/

M/C set up:


M/C parameters Set up value
Steam pressure 4-6 bars
Air pressure 5 bar
Temperature 90-1000c
Cooling fan Motor Auto
Width control 48 to 114 cm
Speed setting 5- 35 m/min

Checking parameters:
1. Shade Check
2. Width check
3. Weight check
4. Compaction check

Open compactor:
Manufacturer: Feraro (Italy)

Fig: Open Compactor m/c

M/C set up:


M/C parameters Set up value
Steam pressure 4-6 bars
Air pressure 5 bar
Temperature 700-1000c
Width 36”-100”
Speed 5-25 m/min.

Checking parameters:
1. Shade Check
2. Width check
3. Weight check
4. Compaction check
RAW
MATERIALS

INTRODUCTION:
Raw material is a unique substance in any production oriented textile
industry. It plays a vital role in case of continuous production & for high quality fabric.

 Types of raw material


The basic raw materials used are:
fabric
dyestuffs
chemicals & auxiliaries.
Names & source
• Fabric:
Different types of fabric treated in BKL dyeing section are namely
- Single Jersey
- Single jersey with lycra attachment
- Polo pique
- Back pique
- Rib Fabric
- Lycra fleece
- Jacquard
- Cross -rib

• Dyestuffs:

Dye Brand name Origin/source

Ciba Ciba , Switzerland

Kemafix Jaychem,India
Levafix Dystar , Germany
Procion Dystar, germany

Kemazol Jaychem,India
Remazol Dyestar , Germany
Solazol Solarfine , Taiwan
Solacion Solarfine , Taiwan
Terasil Ciba , Switzerland
Disperse dye Dianix Dystar, germany
Dispersol Dystar, germany
• Chemicals:

Brand name Type Source


Anti creasing agent Techna,Italy
Bluton BVB1 Violet tone brightener CHT,Germany
Cibacel DBC Sequestering agent Ciba,India.
Cibafix ECO Fixing agent Ciba ,Switz.
Cibafluid C Anticreasing agent Ciba ,Switz.
SandocleanPCLF Detergent Clarient,Germany
Permacol FA Stabilizer Techna,Italy
Novostone CR Enzyme Techna,Italy
Redder tone brightener CHT,Germany
Cyclanon E Fixing agent BASF,Germany
Cyclanon ECO Reduction cleaning agent BASF,Germany
Jinlev RLF349 Dispersing agent Geigy,Taiwan
Eulysin S pH buffer in PET dyeing BASF,Germany
Felosan NOF Detergent CHT,Germany
Uvitex EBF Whitening agent Ciba ,Switz.
Jinlev CL-225 Levelling agent for reactive dye Geigy,Taiwan
Oxalic caid Iron remover -
Palegal FA-8 Levelling agent for disperse dye BASF,Germany
Antifoaming agent BASF,Germany
Permacol SQ Sequestering agent Techna,Italy
Na thiosulphate Peroxide killer -
Uniperol O Washing agent for PET dyeing BASF,Germany
Uvitex EVF PET brightener Ciba, Switz.
Uvitex 2B Yellow tone brightener Ciba ,Switz.
Mollan129 Soapinging agent Rota,dystar
Acetic acid pH controller -
Reduction HCS Reduction cleaning agent Geigy,Taiwan
Mollan130 Sequestering agent Rota,dystar
Bluton 2B Whitening agent Ciba,India
SEQUENCE OF OPERATION:

Kniting

Grey inspection

Batch preparation

Pretreatment White Processing

Polyester dyeing Cotton dyeing


Hydro extracting

Dewatering

Drying

compacting

Final Inspection

Finished Store

Delivery to Garment industry

The BEXIMCO Knitting Limited is a self-sufficient modern company. Its knitting


section is divided into two sections –
1. Flat knitting section &
2. Circular knitting section.

1. Flat Knitting Section:


.
Equipments used:
1.1 Production Equipment
The following equipments are used for production:
Name Fabric Manu. Model Gauge Length No. of

type m/c.
STOLL semi- Germany -------- 14 84 inch 2

jacquard
MATSUYA Plain Japan M-100 14 100 cm 26
MATSUYA Plain Japan M-70 14 70 cm 22
KAUO Semi- Taiwan KH- 14 54 inch 17

HENG jacquard 313


MATSUYA Semi- Japan 14 64 inch 2

jacquard
Total machines = 69

2. Circular Knitting Section:


.

Equipments used:
2.1 Production Equipment

Gauge Model No. Origin No. of Cylinder Existing Set-up


18 1995 CAMBER, UK 05 0
20 1995 CAMBER, UK 10 08
24 1995 CAMBER, UK 14 14
28 1995 CAMBER, UK 26 06
16 (RIB) 1995 CAMBER, UK 01 01
18 (RIB) 1995 CAMBER, UK 01 01
20 (RIB) 1995 CAMBER, UK 01 0
Total 58
Note: There are 7 (Seven) machines with lycra facilities.

Knitting Faults:
❏ Barre or stripe ❏ Press off
❏ Miss stitch/ drop stitch ❏ Needle mark
❏ Sinker mark ❏ Oil stain
❏ Crease mark/Edge mark ❏ Holes
❏ Excessive slubs ❏ Spirility
❏ Broken needle ❏ Pin hole
❏ Tight course ❏ Missing Yarn,etc.

Greiege body and Rib Inspection


Equipment used:
a)Inspection m/c( Calator Sweden)
b) Inspection Table.
M/C Set up (Inspection m/c):

M/C set up Parameter range Set value


Roller speed 0-40 m/min 25-30 m/min
light Not applicable Artificial day light
Length measuring Not applicable Attached with m/c.
unit

Following faults are detected:


Faults:
H= Hole OS= Oil stain
DS= Drop stitch. WD=Wrong Design
NL = Needle line. S = Stripe
TT = Thick & Thin yarn. S = Slubs
SM = Sinker Mark. WP=Wrong Ply,etc.

Batch preparation

Process sequence of Batch preparation receive batch card from Grey In-charge

Make the priority as per dyeing plan

Take one specific Batch card.

Read the Batch Card for own understanding

Check the availability of fabric

Take required quantity of body fabric from ware-house.

Make required no. of Rope maintaining equal length.

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 up the production report form.

M/c for Batch preparation : Two types of m/cs

a) Turning m/c b) Plaiting m/c.

SINGEING :

Equipments used:
Machine: Sando Gas Singing m/c.
Manufactures: Sando Iron Works, Japan.

M/C Setup:

Setup parameters Range Set value


Speed(m/min) 0-120 55-60 for cotton.
70 for PC/CVC.
Potentiometer Setting (rpm) 0-150 80-90 for cotton fabric
60-70 for CVC/PC.
Burner in use 1 or 2 2
Burner operation mode. Auto/Manual Auto
Flame height (cm) 1-8 6 for white & light shade
fabric.
6.5 for medium & dark
shade fabric
Flame angle with the direction 450 to 90 0 450 for blends
of fabric. 900 for cotton
Flame intensity Low/normal/ Low – not used
high Medium – for white & light
shade
High – for medium & dark
shade fabric
Singeing Fault :

a)Singeing line :

b)Uneven singeing :

MERCERIZING PROCESS
Merc

erizing:

Equipment used: Dornier Mercerizing m/c (Germany).

Required parameters :

Parameters Value
Squeeze pressure 1.5-2 bar (by compressed air)
Temperature of washing 800-90 0c
PH after mercerizing 7-7.5
Caustic solution temperature In mixing tank : 80-90 0c
In caustic stroage tank : 70-80 0c
In chiller : 140c
In Mercerizing bath : 16 0-20 0c
1st sigar diameter Set with fabric dia +3 ″
2nd sigar diameter Set with fabric dia +5″
Caustic strength 280 Be′

PRE-TREATMENT

SCOURING
:
Single Stage Scouring-Bleaching:
Process steps :
❏ Take water in bath at required level.
❏ Load fabric.
❏ Circulate fabric & raise temp. at 60oc
❏ Add Anti-creasing agent, Detergent, sequestering agent, stabilizer.
❏ Add Caustic soda
❏ Circulate fabric.
❏ Add H2O2.
❏ Continue circulation fabric 25 min. at 100oc
❏ Decrease temp. at 800c
❏ Rinse & Drain.
❏ Add Detergent & H2O2 killer and raise temp 80oc
❏ Continue circulation for 10’ at 60oc
❏ Rinse & Drain.

Hot wash for T/C TTC:


❏ To remove waxes, fats.
❏ Increase absorbency for T/C & TTC for dark shades.
Curve:

900c
15′

2
600c

Recipe :
1. Anti-creasing Agent : 1 g/L
2. Detergent : 1.5 g/L
Steps :
❏ Take water in bath at required level.
❏ Load fabric.
❏ Circulate fabric & raise temp. at 60oc
❏ Add Anti-creasing agent, Detergent.
❏ Circulate fabric and raise temp.

Enzyme Treatment:
If dead fibre or hairiness present in fabric then enzyme treatment is
done.
Function: It attacks surface cellulose fibre and removes it from surface.
Precaution :
Excess enzyme is harmful for cellulose fabric.
Application of enzyme is done by two ways :
a) Pretreatment → Enzyme treatment → Dyeing
b) Pretreatment → Dyeing → Enzyme treatment

Enzyme treatment carve :


750c
2+3
10′
550c 30′

1
Drain 3 Drain

REACTIVE DYEING

1.REACTIVE DYEING FOR SENSITIVE SHADE AT 60oC


.
Dyeing curve:
90˚c
60˚c 60˚c

1300c

Rinse
0
REACTIVE DYEING60FOR
c DARK SHADE AT 60oC:
17. Unload fabric.
Rinse
Dyeing curve: 600c
60˚c 60˚c 80˚c 70˚c
Rinse
600c Rinse

Rinse
600c

Rinse
600c DYEING :
HOT BRAND REACTIVE
DYEING AT 92oC :
Rinse
600c
Dyeing curve : Rinse
9200c 60′ Shade
60 c
20′ check
Rinse5
600c Rinse 600c
0
0
2 5′ 10′ 0
80 c 10′ Rinse Rin 60 c
60 c Rinse se 10′
600c
1 3 4
Rinse
0
Rinse
600c

Rinse
600c

Rinse
600c
POLYESTER DYEING
Rinse
Disperse dye: 600c
Disperse dye is one kind of organic colouring substances which is free of ionizing
Rinse
group, less soluble in water &0used on hydrophobic Textile material .
60 c
.Dyeing curve:
Rinse
600c
30′ Shade check 800c
Rinse
4
500 600c
Rinse 10′
c 780c
1 2 3
Rinse
0 5+6 800c Rinse
60 c
600c 7 Rinse
400c
Rinse
600c 400c
Recipe :
Rinse 1350c
1. Acid Buffer
600(Eulusin
c FAS) : 1.8 g/L
2. Dispersing agent (Jinlev
Rinse RLF349): 1.8 g/L
3. Antcreasing agent60
Rinse (Ciba
0
c fluid C): 0.5 g/L
0
4. Dianix Red60: c0.106 %
Rinse
Dianix Yellow : 0.07%
Rinse0.7860%0c
Dianix Black:
600c
5. Reduction clearing (Reduction HCS): 1-3 g/L
Rinse
6. Acetic Acid:
Rinse 1g/l.600c
6. Detergent 60
(Albatex
0
c S): 0.5 g/L
Rinse
Rinse 60part:
Process steps for Polyester
0
c
0
60 c
Rinse
STRIPPING: Rinse 600c
600c
Rinse
Rinse 600c
600c
Rinse
600c
Rinse
Rinse 600c
600c
Rinse
Stripping is carried
Rinse 60remove
out to 0
c uneven of shade or to reduce dark
shade. In BKL Stripping 60is
0 done for 100% cotton, T/C, CVC & TTC.
c
Rinse
I. FULL STRIPPING RinseFOR 600100%
c COTTON:
600c
. Rinse
Curve: Rinse 100Cx60min
600 0c
600c 100 c
Rinse
80C Rinse Rinse60 0
c CR 60CX15
0
50C 60 c 80C 80CX10

3 Rinse
Rinse
60 0
c
0
1 2 60 c
Rinse
Rinse
60 0
c
0
60 c
PolyesterRinse
striping
Rinse
60 0
c
0
60 c
Process curve : Rinse Cold rinse
Rinse
60 0
c
6030′
0
c Check shade 900c
Rinse
3c/min Rinse
60 0
c 10′
30′
0
60 c 700c
2 4 5′ Rinse
500c Rinse 600c 5′
Rinse
60 0
c
0
60 c 10′ 600c
1 3 Rinse
Rinse
60 0
c 6
Whitening: 0
60 c
Whitening Is A Chemical treatment, fabric white at a desried level by
Rinse
bleaching & OBA treatment.Rinse
60 0
c
0
60 c
Factors Influencing Whitening:Rinse
Rinse
60 0
c
1. PH 0
60 c
2. Temp.
Rinse
Rinse
60 0
c
0
60 c
Rinse
Rinse
60 0
c
0
60 c
Rinse
60 0
c
0
60 c
Rinse
Rinse
60 0
c
0
60 c
3. Time
Rinse
Rinse
60 0
0 c
110
Whitening Process for 100% 0c
cotton:
60 c
Rinse
Rinse
Process curve: Rinse
60 0
0 c
60 0c
60 c 900c
30′
Rinse
Rinse
Rinse
60 0
0 c 0 Rinse
60 0c
60 c 70 c 0
60 10′
c
800c
Rinsec Rinse
Rinse
6 Rinse
60 0
0 c 0 Rinse
4 5′ 60 0c 60 c Rinse 10′
60 c 600c
600c 600c
Rinse Rinse
Rinse
Rinse
60 0
0 c 0 Rinse 10′
1 2 3 5 7 60 0c
60 c 60 c 0 8
60 c
Rinse Rinse
Rinse
Rinse
60 0
0 c
Rinse
60 0c
60 c 600c 0
Process steps: 60 c
❏ Rinselevel.
Take water at required
Rinse Rinse
Rinse 0 Rinse
❏ Load fabric. 60 0
0c 60 c 0
60
0 c 60fabric.
c
❏ Raise temp. at 60 c & circulate
❏ Add Detergent, Rinse
Anti-creasing
Rinse agent stabilizer.
Rinse 0 Rinse
❏ Add caustic & circulate
60 0
0c fabric.
60 c 0
60 c 60 c
❏ Continue circulation & add Hydrogenperoxide
❏ Add Uvitex 2b & circulate
Rinse fabric.
Rinse
Rinse 0 Rinse
❏ Add Glauber salt60 &0ccontinue
0
60 c5 min.
❏ 60 0 c
Raise temp. at 100 c & continue 600c60 min.
❏ at 800c. Rinse
Decrease temp. Rinse
❏ Rinse for 10 min.Rinse
&00cDrain. 0 Rinse

❏ 60 c at 800c cand
60
Hot fill & raise temp
60
600ccontinue 10 min. & Drain.
❏ Drain. Rinse Rinse
❏ Mixed water fill,Rinse
add
60 0c 60 c
Rinse 0
0 acetic 0acid & raise temp at 60 c & continue

10 min. 60 c 0
60 c
❏ Rinse & Drain. Rinse Rinse
Rinse 0 Rinse
60
60 c
0
0c 60 c 0
60 c
T/C whitening process: Rinse
Rinse
Rinse Rinse
Process curve : 60 0
600cc 600c 0
60 c
Rinse
Rinse Rinse
Rinse
60 0
600cc 600c 0
60 c
Rinse
Rinse Rinse
Rinse
60 c 60 c
Rinse
Rinse Rinse
Rinse
60 0
600cc 600c 0
60 c
Rinse
Rinse Rinse
Rinse
60
60
0
0c 600c 0
30′c 60 c
Rinse
Rinse Rinse
Rinse
600c 600c 0
60 c
4 5 7 9
Rinse RinseRinse 800c
0
60 c Rinse 600c
600c 600c 0 10′ 10′
60 c
1 2 3 6 8 10
Rinse Rinse
Rinse
600c 600c 0
60 c
Rinse Rinse
Rinse
FINISHING
600c 600c 0
60 c
Rinse Rinse
Rinse
INTRODUCTION 600c 600c 0
60 c
After dyeing, knit fabric is required to finish. During dyeing all knit fabric are dyed in
tubular form. According to buyer’s Rinse Rinse knit fabric are finished in Open form or
requirement
tubular form. Rinse
0
60 c 600c 0
60 c
For Tubular form followingRinse
m/c areRinse
required:
Rinse
600c 600c 0
Hydro-extractor60 c

Rinse Rinse
De-watering0 Rinse
600c 60 c 0
↓60 c
RinseDryer
Rinse
Rinse
0
60 c 60↓0c 0
Tubular 60 c
Compactor
Rinse
Rinse Rinse
600c 600c 0
60 c
Rinse RinseRinse
For open form following m/c
600care required
600c 0 :
60 c
Hydro-extractor
Rinse Rinse Rinse
600c 60↓0c 0
De-watering 60 c
Rinse Rinse ↓
Rinse
600c 600c 0
60 c
Rinse Rinse
Rinse
600c 600c 0
60 c
Rinse Rinse
Rinse
600c 600c 0
60 c
Rinse Rinse
Rinse
600c 0
60 c
Dryer
Rinse
↓ Rinse
0
Slitter c
60

Rinse
Stenter

Open compactor

For collar & cuff finishing following m/c are required :

Hydro-extractor

Softening Machine

Dryer

Chemicals used:

TC collars & cuffs:

1. Softener (cationic & nonionic)


2. Additive
3. Stiffener
4. Acetic Acid to adjust pH
100% cotton fabric (soft):
1. Softener
2. Additive
3. Acetic acid to adjust PH
100% cotton collar & cuffs (cross-linking):
1. Softener (cationic /nonionic)
2. Additive
3. Resin
4. Catalyst.
5. Acetic acid to maintain PH
CVC collar & cuffs:
1. Softener (cationic & nonionic)
2. Additive
3. Stiffener
4. Acetice acid to maintain PH

CVC collar cuffs (soft):


1. Softener
2. Additive
3. Acetic acid to maintain PH
Water Repellent collar & cuffs:
1. Hydrophobic agent.
2. Softener
3. Additive
4. Acetic acid to adjust the PH

M/C set up:


M/C parameters Set up value
Padder pressure 2-7 bar
M/C speed As standard speed set by
manufacturer.

FINAL INSPECTION

\
Equipments used: a) Nazer Inspection m/c, Pakistan.

b)Verivide Day Light box.

Following faults are detected & identified in final inspection for body :
a) Penalty points legend:
H= Hole
OS = Oil stain
CS= Chemical stain.
W= Water spots.
Fy= Fly yarn.
YC = Yarn contamination.
WX= White speaks.
IS = Insect spots.
R= Rub mark.
DS= Dye stain.
D= Dirt stain.
Rs= Rust stain.
Collar & cuff inspection.

Following faults also detect and identify:

Faults Decision
1. Rub mark Reject
2. Cutting Reject
3. Hole Reject
4. Crumple Reprocess
5. Tipping bleed Reprocess
6. Uneven shade Reprocess
7. Neps Enzyme wash
8. Oil spot Reject
9. Role to role variation Reprocess
10. Yarn contamination Reject
11. Barre mark Reject
QUALITY ASSURANCE
SYSTEM

LAB
Equipment used in Lab:
a) Rota Dyer:
Manufacturer : Qayyum Textile Ltd., Pakistan.
Capacity : 12 beaker per m/c
Purpose : Sample dyeing ,Measure wash fastness.
b) Ahiba Nuance dyeing m/c:
Manufacturer : Data color International
Capacity : 12 beaker per m/c
Purpose : Sample dyeing.

c) Ahiba Spectra dye:


Manufacturer : Data color International
Capacity : 24 beaker per m/c.
Purpose : Sample dyeing.

d) Incubator:
Purpose :
❏ Pre-drying., Water fastness.

e) Taba Gs:
Purpose : ❏ To boil water.,Washing fastness.

f) Electrolux Washcator:
Manufacture : James H. Heal & Co. Ltd. Halifax.
Country : England.
Purpose : Washing & Hydro-extraction.

g) Tumble dryer :
Country : UK (Electra).
Purpose : Drying.

h) Pilling Tester:
Manufacturer : James H. Heal & Co. Ltd. Halifax.
Speed: 30-60rpm.
i) Electronic Balance:
Manufacturer : ohaus corp. USA
Readability:0.001gm
Maxm Capacity:210gm
Some Fabrics used in BKL Lab:
1. Single jersey.
2. Polo Pique.
3. Back Pique.
4. Normal Rib.
5. Interlock.

Chemicals & Auxiliaries Used:


For reactive Dyeing:
For Cibacron Dyes:
L: R = 1: 8
600C Dyeing:

For Levafix Dyes:


L: R = 1: 8
600c Dyeing:

For Remazol Dyes:


L: R = 1: 8
600C Dyeing:
For Procion Dyes:
L: R = 1: 8
820C Dyeing:
L: R = 1: 8
920C Dyeing:

For Disperse Dyeing :


i) Temp. : 130 0c
ii) Dispersing agent : 0.8-1 g/L
iii) Acetic acid : 0.5-1 cc/L
iv) PH : 4.5-5

Program Number in Ahiba Dyeing Machine:

Program no. Temperature Time


1 100 0c 68′
2 800c 90′
3 400c 20′
4 600c 50′
5 500c 37′
6 620c 60′
7 900c 96′
8 600c 40′
9 800c 40′
10 600c 45′
11 600c 70′
12 700c 30′
13 950c 30′
14 950c 10′
15 950c 60′
16 130 0c 76′
17 110 0c 30′
18 100 0c 40′

On line quality control


WORKING AREA OF ON LINE QUALITY CONTROL:
a) On line circular knit:
.
b) On line flat knit:
c) Greige inspection:
.d) On line finishing:
Response to faults:
Following response are to be taken:
Faults Response
Greige inspection Inform yarn supplier & knitting
department.
Knitting fault Inform knitting Department
Finishing fault Inform Finishing Department

Off line quality control


Typical Quality control in BKL:
a) Shade Check.
b) Gram per square meter (GSM) test
c) Width on dia check.
d) Shrinkage test
e) Spirality test
f) Crocking/Rubbing Fastness test.
g) Pilling resistance test.
h) Wash fastness test.
i) Water fastness.
j) Color fastness to perspiration.
a) Shade check:
Shade check after finishing of fabric is done according to customer's
recommended light source.
Equipment used: Verivide Light box.
Manufacturer: James H. Heal & Company, Halifax, England.
Light sources:
❏ Artificial day light D65
❏ TL 84
❏ F (Filament)
❏ UV (Ultra violet) light etc.
b) Gram per square Meter:
After finishing of fabric gram per square meter is check by GSM
cutter.
Equipment used: GSM cutter.
Manufacturer: James H. Heal & Company, Halifax, England.

c) Width or Dia Check :

After finishing of fabric width on dia of the fabric is check by


measuring tape.

d) Shrinkage test:
After finishing of fabric shrinkage is tested.
Equipment used: Electrolux wascator
Manufacturer: James H. Heal & Co. Ltd. Halifax, England.

Test Method
BS 26330 3A 60 +/- 3 0c Prog – 13
BS 26330 4A 50 +/- 3 0c Prog – 14
BS 26330 5A 40 +/- 3 0c Prog – 15
\
Standard Shrinkage %:
Length (max): 5% after domestic washing
Width (max): 5% after domestic washing.
e) Spirality test:
After finishing of fabric spirilily is tested.
Equipment used: Electrolux wascator.
Manufacturer: James H Heal & Co. Ltd. Halifax, England.
Procedure:
1
Test Method
BS 26330 3A 60+/-3 0c Prog – 13
BS 26330 4A 50+ /-3 0c Prog – 14
BS 26330 5A 40+/-3 0c Prog – 15

Where,
L= Length of Sample.
L L
D1, D2 = Distance of seam movement.
←D1→
Calculation: ←D2→

1st Side  D + D2  2nd Side


Spirility % =  1 ÷ L × 100
 2 

Standard spirility % :
Maximum : 5% after domestic washing.
f) Rubbing / Crocking fastness:
After finishing of fabric rubbing fastness is measured.
Equipment used: Crock meter.
Manufacturer: James H. Heal & company, Hali fax, England.
Method: AATCC 8

g) Pilling resistance test:


After finishing of fabric pilling resistance test is carried out.
Equipment used: ICI pilling box
Manufacturer: James H. Heal & Company, Halifax, England.
Method: BS 5811 or according to customer requirement.
Revolutions for BS 5811 method:

a) 7000 cycle for low pilling


b) 9000 cycle for Medium pilling
c) 11000 cycle for High Pilling.

h) Wash fastness test:


After finish of fabric wash fastness is checked:
Equipment used :
a) AG machine.
Manufacturer : Quyyum textile Engineering, Pakistan
b) Ahiba Nuance.
Manufacturer : Data Color International, U.K.
Method : ISO 105-C06

Standard result:

Light shade Dark shade


Staining scale 4 3/4
i) Water fastness:
After finishing of fabric water fastness is checked.
Equipment used:
a) Perspirometer
b) Carbolite (Thermostat Oven)
Manufacturer:
James H. Heal & Company, Halifax, England.
Standard result:
Light shade Dark shade
Staining 4 ¾

j) Color fastness to perspiraion:


After finishing of fabric color fastness to perspiration is checked
Equipment used:
a) Perspirometer
b) Carbolite
Manufacturer:
James H. Heal & Company, Halifax, England.

Method: AATCC 15.


Maintenance

Maintenance:
Maintenance
Types of maintenance:

Preventive Maintenance Corrective Maintenance

Mechanical Electrical Mechanical Electrical


Maintenance Maintenance Maintenance Maintenance
PM Tasks list
Maintenance : Mechanical
Machine : Thies Dyeing Machine
Sl. Item need to be checked & Serviced
No.
1. Crease the winch bearing (Grease Staburag NBU-12)
2. Complete cleaning of machine
3. Cleaning of drain valves, replace seals if required
4. Check air supply filters, regulators, and auto drain seals
5. Clean filters element and blow out
6. Greasing of Unloading Roller Bearings by BP Energrease LS-2
7. Checking of Oil level and bolts of Unloading Roller Gearbox.
8. Checking of unloading roller coupling and packing
9. Checking and cleaning (if required) of Main Vessel Level Indicator
10. Check the oil level of pump bearing and refill if required by BP Energol
THB-100
11. Check the function of heat and cool modulating valves
12. Check all belts and belt tension
13. Check all door seals
Maintenance : Electrical
Machine : Thies Dyeing m/c
Sl. No. Items need to be checked & Serviced
1. Check & clean fluff and dirt at all motor fan covers
2. Check all motor's terminals
3. Check main panels (by using compressed air)
4. Check panel cooling fan & clean it filter
5. Clean main pump inverter and its cooling fan
6. Check all on/off switches
7. Check current setting of all circuit breaker & motor over loads.
8. Visual checking of all power & control cables
9. Check all emergency Switches
10. Check DC drive of neel motors
11. Check all pressure switches
12. Check calibration of main vessel & all additional tank
13. Check all pneumatic solenoids
14. Check calibration of heating/cooling. Modulating value.
15. Check all indicating lamps
 Maintenance tools & equipments :

1. Pliers
2. Inside Calipers
3. Outside Calipers
4. Digital Multi Meter
5. Heating Shoulder
6. Hammer
7. Philes
8. etc.
Chapter 8
Utility services
Available facilities of utility:
Electricity
Gas
Water
Compressed air
Steam.

 Electricity:
The main utility electricity is supplied from PDB and also by Generator.

Specification:
Equipment used: Gas generator.
No. of generator: 8 (1 self start able & other 7 are air+CH4
start able).
Manufacturer : Wartsila-Frank.
-Gas engine used.
-16 cylinders per engine.
-Overall efficiency : 80%.
-Heat recovery possible from 4 engines.
-Pressure of gas : 60-62 milibar.
-Air pressure : 7 bar.
-Electricity take up from PDB : 1.5MW/sec.
Total power is then distributed as per requirements of different section of Beximco industrial
park.

 Gas:
Gas is mainly used for steam production.
The gas is used from TITAS.
Generally 36 m3 gas is required to produce 1 ton steam.

 Water:
Continuous supply of water for BTL,BDL&BKL must be ensured by pump.
Mainly two pumps are used for water pick up.

PUMP CAPACITY SETUP


Submersible pump-I 260 m3/hr Discharge value:100% open
Submersible pump-II 204 m3/hr Discharge value:100% open
Depth of pump: 140ft.
Also pumps for chemical dosing & Centrifugal pump for yarn dyeing.

 Steam:
Pure steam with required temperature must be produced to meet the
continuous demand of steam in different sections.
-Fire tube type boiler is used.

-No. of boiler: (4+1) twine boiler.


1 boiler is operated by using burn gas.
4 boiler is operated by Titas gas.
-3 pass heating system.
-Measuring meter for water supply.
-4" depth greasol insulation so no heat at outside of drum.
-Boiler capacity; 10ton.
-Steam pressure; 8.2bar.
-Steam flow = 7 ton(approximately)
-Manufacturer: Thermax;India.
-Model: TD-100-10-54/6AS/E.
-Fuel: Natural gas.
-Water pressure: 10.3bar.
-Evaporation= 1000*3 kg/hr.

COMPREESOR

Parameters Set value

Unloading pressure 7.5 bar


Pressure difference 0.6 bar
Oil pressure 1.2 bar
Motor running time 15 sec

-Total no. of compressor = 3+3 =6


-Capacity: 774 lt air/compressor/sec.
-Manu: Atlas capco.
-Country: Belgium.
Oil free air is prepared by Electronikon.

Chiller:
Manufacturer: Thermax.
Country: India.
-To start a chiller electricity & steam is required.
-Capacity :[(21083)+(500*1)] ton = 1130 ton water cooling.
-Absorption type Chiller is used.

 Source of Utility:
Electrically : PDB & Generator.
Steam : Boiler.
Water : Pump.
Compressed air : Compressor.
Temperature control : Chiller.
Gas : TITAS.

 The effluent treatment plant:

Characteristics of raw effluents:


Volume : 3600 cubic meter/day
Peak flow : 225 cub met/hr
pH : 10-12.5
BOD : 500-800 PPM
COD : 1300-2000 PPM
TDS : 2000-5000 PPM
SS : 100-400 PPM
Colour : Black/ Blue

Chemicals used & their colours:

Chemicals used Appearance


Ferrous sulphate Granular solid, greenish colour
Lime White bulk form
Polyacrylate White granular solid
Sulphuric acid Clear liquid
Alum White bulk form
Na-hypochlorite Clear liquid
Hydrochloric acid Clear liquid
Flow chart of effluent treatment:

Raw effluent

Skin chamber

Collection Sump

Pump station

Dissolved Air Floatation Tank

Clarifier fig: Aeration tank

Aeration tank

Setting tank

Clear water, pH check

Sand filter

Carbon filter

Drain

Sludge separation:
Sludge of DAF

Sludge thickening plant

Sludge drying be

Typical output of the plant:

Raw effluent treated 15000 LPH


Raw effluent colour Black
Raw effluent pH 11
Treated effluent colour Light greenish
Treated effluent pH 8.5
Treated effluent temp. 38 C
To0tal suspended solids 35 PPM
STORE & INVENTORY
CONTROL
☻Frequency of inventory control:
- Monthly inventory control
- Annual inventory control

 Scope of inventory control


- Raw materials
• Dyes store
• Others chemicals store
• Grey fabrics
- Finished fabric
- Spare parts
- General store
Capital equipment
Accessories
Stationary
Maintenance parts.

 Store capacity
- Dyes 6-7tons
- Chemicals 33-35tons
- Grey fabric 20-25 tons
- Yarn storage 50 tons
- RFD 50 tons
- Set range of dyes 80-100kg/day
- Set range of Chemicals 2-2.5ton/day
COST ANALYSIS
Costing of the product:
Costing of the product is done by the consideration of the following factors:
1.Amount of raw materials consumed.
2.Direrct labour.
3.Indirect labour.
4.Factory cost.
5.Office and administrative cost.
6.Sales and distribution cost.
7.Profit,etc.

Remarks:
The costing of product is a secret matter of the industry. They are not interested to
flash up the cost related data.So, we could not collect the price of the product and costing of
the product.
MARKETING
ACTIVITIES
Consumer of the products:
Beximco knitting LTD. is a100% export oriented industry. . Name of the
main buyers of the products of the industry are given below:
1.Ash city.
2.B&C.
3.Wall mart.
4.Haddad.
5.Pimkie.
6.Zara.
7.Charter House.
8.H&M.

Package size and label:

Local Market:
Beximco knitting LTD. is a100% export oriented industry. All the goods
produced in this industry are exported into various foreign
countries. So,goods are not supplied into local markets.
Importing countries:
The countries which are importing goods from Beximco knitting Ltd are given below:
1.USA.
2.Canada.
3.Germany.
4.Europian countries.
CONCLUSION

LIMITATION OF THE REPORT:

►Because of the secrecy act, the data on costing and marketing activities has not
been supplied and hence this report excludes these chapters.

►we had a very limited time. In spite of our willing to study more details it was
not possible to do so.

►Some of the points in different chapters are not described as these were not
available.

►These whole process is not possible to bind in such a small frame as this report,
hence our effort spent on summarizing them.
LASTLY:
The special in this report is that the information, data and description is very much
subjective and practical. So, one can easily have an idea about the whole dyeing unit of BKL
at a single look on it.

The new comer can use this report for further details study or can know Beximco
knitting Ltd. without much work. But what should be remembered the chemicals, some
process steps may be modified within the period this paper goes to the reader.