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INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
The Delta Composite Knitting Ind. Ltd.
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PROJECT DESCRIPTION
CHAPTER - 1
Page no: 3
CHAPTER – I
1. Name of the company: The Delta Composite Knitting Ind. Ltd.
2. Status : Private Ltd. company
3. Type : 100% Export oriented composite knit
dyeing industry
4. Year of establishment : 1998
5. Location : South Zurun, Kashimpur, Gazipur
6. Address :
Factory : South Zurun, Kashimpur, Gazipur
Head Office : Plot No. 389 Lane No:6
DOHS, Baridhara, Dhaka
7. Sponsor : Engineer A.K.M. Faruqe Ahammed.
8. Product mix : 100% cotton, 100% polyester, Chief value
cotton, P/C
9. Annual production capacity 2800 tons
10. Project cost 20 crs (Initial), 60 crs (Present)
11. History of the project development
1998 – Establishment of the industry
Sample dyeing m/c 2 pcs
Production dyeing m/c 5 pcs
2003 – 2 pcs production dyeing m/c
2004 – 10 pcs dyeing m/c
12. DIFFERENT DEPARTMENTS :
To run the factory smoothly, there are some department in the factory . They are
given bellow:-
KNITTING SECTION:
 Knitting
 Inspection
DYEING SECTION
 Batch section
 Dye house
 Dyeing lab.
Page no: 4
 Quality control
 Finishing
MAINTENANCE
 Electrical
 Mechanical
ACCOUNTS & COMMERCIAL SECTION
ADMIN SECTION
 Time section
 Cleaning
 Security
 Store
13. Total area of the industry : 129500 sq. ft.
14. Area of the plant :
1
st
dyeing floor 10800 sq. ft.
2
nd
dyeing floor 27000 sq. ft.
REMARKS:
The Delta Composite Knitting Ind. Ltd. is a well established Knit Composite Industry. The area is
sufficient for the industry. But its drainage system is not very good. There is no system for effluent
treatment.
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MANPOWER MANAGEMENT
CHAPTER - 2
Page no: 6
THE DELTA COMPOSITE KNITTING INDUSTRIES LTD.
SOUTH JARUN, KASHIMPUR, GAZIPUR
ORGANOGRAM
Sl.
No.
Marketing Commercial A/C &
store
Production
Dyeing
Production
Knit
Quality Utility Administrati
on
01
General Manager
02
DGM DGM DGM DGM
03
AGM AGM AGM AGM (Factory)
04
Manager Manager Manager Manager
(Dyeing)
Manager
(Knit)
Manager Manager Manager
(Admin)
05
Assist
manager
Assist
manager
Cost
Accountant
Assistant
Manager
Assistant
Manager
Assistant
Manager
Electrical
Engineer
Administrati
on Officer
06
Sr.
Executive
Sr.
Executive
Sr.
Executive
Sr. Prod.
Engineer
Sr. Prod.
Officer
QC officer Mechanical
Engineer
Sr.
Executive
Admin
07
Executive Executive Executive Production
Engineer
Asst.
Production
Engineer
Assistant
QC Officer
Sub.
Assistant
Engineer
Executive
Admin
08
Jr.
Executive
Jr.
Executive
Jr.
Executive
Asst. Prod.
Officer
Shift In-
charge
QC In-
charge
Forman Asst. Officer
Admin
09
Assistant Assistant Accounts
Assistant
Lab. Chemist Production
Clark
Sr. QC
Supervisor
Supervisor Security
Officer
10
Cashier Sr. Lab.
Assistant
Sr.
Supervisor
QC
Supervisor
Assistant
Supervisor
Computer
Operator
11
Purchase
officer
Lab. Assistant Supervisor Assistant
QC
Supervisor
Sr. Fitter Office
Assistant/Ti
me Keeper
12
Sr. Store
officer
Report Clerk Assistant
Supervisor
QC Fitter Assistant
Time
Keeper
13
Store
officer
Batch
Incharge
Tr.
Supervisor
Assistant
QC
Assistant
Fitter
Typist
14
Asst. Store
Officer
Finish
Incharge
Fitter Tr. QC Electrician Telephone
Operator
15
St. Store
Keeper
Froman Assistant
Fitter
Tr. Assistant
QC
Assistant
Electrician
Delivery
Supervisor
16
Store
Keeper
Sr. Supervisor Operator QC Man Boiler
Operator
Peon
17
Asst Store
Keeper
Supervisor Assistant
Operator
Boiler
Assistant
Driver
18
Store
Assistant
Assistant
Supervisor
Tr. Operator Generator
Operator
Gardener
19
Helper
Store
Tr. Supervisor Tr. Assistant
Operator
Compressor
Operator
Loader
20
Tr. Asst.
Supervisor
Helper Asst.
Operator
Cleaner
21
Sr. Operator W.T.P.
Attendant
Painter
22
Operator Tr. Operator Sweeper
23
Asst. Operator Helper
24
Tr. Operator
25
Assistant Tr.
Operator
26
Helper
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MANAGEMENT SYSTEM:
 Intercom telephone
 Fax
 Written letters &
 Oral
SHIFT CHANGE: There are two shifts in this industry. So the shifts are changed at every 12hours
RESPONSIBILITIES OF PRODUCTION OFFICER:
I. To give dyeing program slip.
2. To match production sample with target shade.
3. To collect production sample lot sample matching next production,
4. To observe dyed fabric during finishing running & also after finishing.
5. To identity disputed fabrics & report to P.M/G.M. for necessary actions.
6. To discuss with P.M about overall production if necessary.
7. To sign the store requisition & delivery challan in the absence of P.M.
8. Also to execute overall floor works.
9. To maintain loading'/unloading khata.
10. Any other assignment given by higher authority.
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JOB DESCRIPTION OF PRODUCTION OFFICER:
REPORT TO : Sr. Production Officer
JOB SUMMARY: To plan, execute & follows up the production activities &. control the
quality production with related activities.
DUTIES & RESPONSIBILITIES:
 Overall supervision of dyeing, finishing production.
 Batch preparation & p
H
I chock.
 Dyes & chemical requisition issue & check.
 Write Fabrics loading & unloading time from m/c
 Programmaking, sample checking, colour measurement
 Control the supervisors, operator, ass. operator and helper of
dyeing m/c.
 And also any other over work as & when required by the management.
JOB DESCRIPTION OF Sr.PRODUCTION OFFICER:
REPORT TO : A.G.M. (production)
JOB SUMMARY: To plan. execute & follows up the production activities & control the
quality production with related activities.
DUTIES & RESPONSIBILITIES:
 Overall supervision of dyeing, finishing production.
 Checks the sensitive parameters of different machine for smooth
dyeing
 Checks the different log books of different areas & report to
management
 Checks out the plan to control the best output from supervisors &
workers.
 To trained up& motive the subordinates how to improve the quality
production.
 Control the supervisor, operator, Asstt. Operator & helper of
dyeing.
 Maintenance of machine & equipment Any other works & when
required by the management
REMARKS:
The man power management system of The Delta Composite Knitting Ind. Ltd. is well arranged.
Every officers & stuffs are responsible for their duty. But there are only two textile engineers in the
industry (2 for dyeing). It is not sufficient fluent production. It requires more technical people.
Page no: 9
MACHINE DESCRIPTION
CHAPTER - 3
Page no: 10
MACHINE DESCRIPTION
DYEING FLOOR
DYEING MACHINES:
The Delta composite Knitting Ind. Ltd.. There are 19 dyeing machines. Among them 10 machines are
in the first floor and 9 machines are in the second floor. Among first floor, 2 Fongs sample dyeing
machines, 5 Thies ,2 Dilmenler and 1 AYTC production dyeing machine. We worked on the first
floor. The description and specifications of the machine are given below-
Machine Type 01
Name of the machine : Sample Dyeing Machine
Brand Name : Fong
Manufacturer : Fong’s National Engineering (SHENZHENE) Co. LTD.
Capacity : 25 Kg
Year of manufacturing: 1997
Specification :
No of nozzle: 1
Design Pressure: 400
Hydrolic Test Pressure: 650
Motor :
Winch motor – 1
Pump motor – 1
Stirring motor – None
Machine Type 02
Name of the machine : Winch Dyeing Machine
Brand Name : Thies ( No. of machines :5)
Manufacturer : Germany.
Capacity : 150,200,400,400,600Kg
Year of manufacturing: 1995-97
Specification :
Maximum operating temp – 140
0
C
Maximum operating pressure – 3.5 bar
Machine Type 03
Name of the machine : H.T. Dyeing Machine
No. of machine : 02
Brand Name : DILMENLER
Manufacturer : Turkey
Capacity : 700 Kg
Specification :
Maximum operating temp – 145
0
C
Maximum operating pressure – 3 bar
No of nozzle – 4
Motor
Winch motor – 4
Pump motor – 1
Stirring motor – 1
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Machine Type 04
Name of the machine : ATYC Dyeing Machine
No. of machine : 01
Brand Name : ATYC
Manufacturer : TERRASSA
Capacity : 900 Kg
Year of manufacturing: 2002
Specification :
Maximum operating temp – 135
0
C
Maximum operating pressure – 3.5 bar (6 bar max.)
Operation process:
a. Preparation:
1. Turn on power on main panel
2. Open valve for cooling water of main pump
3. Check stream, water & air
+ Steam pressure : 5 – 6 kg/cm2 G
+ Water pressure : 1.2 – 2 kg/cm2 G
+ Air pressure : 5 – 7 kg/cm2 G
4. Adjustment of feeding valve as per production item & capacity
b. Putting fabric into the machine:
1. Select water supply level
2. Supply water automatically by pushing ‘turn on’ button and stop by ‘turn off’ button.
3. Take up edge of fabric to fabric gate through guide of the reel
4. Put edge of fabric to nozzle
5. Start main pump and put whole fabric with adjusting feeding by valve upto remaining 2 -3
meters fabric end
6. Stop main pump and pull up 2 -3 meters of fabric edge by stick
7. Joint both ends of fabric
8. Start main pump & reel to circulate whole fabric and adjust torque of speed
9. Make sure if fabric circulation is normal, then close the door of the gate, (Check again reel
speed)
c. Operation:
1. Close the door
2. In-put the pattern on programme controller
3. Mix dyeing stuff & chemical in dyeing-mixing tank and pour it with using pouring pump by
adjusting feeding valve, after poring, feeding valve shall be closed
4. Switch ‘run’ on programme setting device
5. Automatic operation
1) Select the switch of water supply to ‘automatic’ on main panel
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2) Push the button of automatic operation, then automatically operation will go through
heating, holding, cooling, washing as per programming. Put ‘stop’ button when
finishing buzzer will ring
3) Open the door and take out fabric
Caution:
1. Before operation:
(1) Check the power (Voltage/hz) wrong Voltage / Hz will cause to brake motor, meter etc
(2) Check air pressure
(3) Clean inside of tube before dyeing
(4) Set the meter correctly as per dyeing method
(5) Check every valves
2. Starting operation:
(1) Check closing the door perfectly
(2) Set pressure below 1 kg / cm
3
by watching pressure meter
(3) When temperature will be over more than 80
0
C, do not forget item (1) & (2)
(4) Do not start pump when tube is empty
(5) Put definitely cooling water before starting operation because pump & reel is made for
cool water
3. During operation
(1) Check if meter is working correctly during operation
(2) Check if any strange vibration
(3) Check if any strange sound of pumping
(4) Check if pressure in the tube is too high
(5) Check if temperature in the tube meet programming
(6) Start pump when feeding steam & cooling water
(7) Check if reel is working correct under high temperature & high pressure
4. Nozzle installation
Set nozzle base into nozzle-casing and install nozzle by turning it clock wise.
After install nozzle, turn it one round by anti-clock wise to make 2 mm gap. The gap on nozzle
shall be adjusted by kind of fabric
5. After operation:
(1) Before opening the door, check if air pressure of inside the tube is 0 kg/cm2 and
temperature of inside the tube is between 80
0
-90
0
C if the pressure is still remained or
temperature is more than 80
0
C, it is very dangerous to open the door
(2) Temperature inside the tube shall be under 80
0
C for manual draining
(3) Turn off the power after operation and close the valve
6. Maintenance:
(1) Keep cleaning seal packing of the door and surface to touch the packing to be prevented
from dust and hurting
(2) Keep electric portion, pump and control panel not to be wet by water
(3) Keep tight valve shaft seal ground packing of each valve by tightening sometime
(4) Check valve seat part of air valve & drain valve sometime
(5) Keep tight each volt
(6) Make often oiling rotating part
(7) Inspect mechanical seal according to manual of pump
(8) Keep adding grease & oil in pump bearing part according to manual of pump
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(9) Inspect sometime if safety valve is working correctly
(10) Inspect sometime if steam trap is working correctly
(11) Inspect meters of pressure and temperature
Machineries of the Dyeing Lab:
The dyeing lap of The Delta Composite Knitting Ind. Ltd. is not so developed. The description of the
machineries of the dyeing lab are given bellow-
Laboratory facilities & equipments:
 Light box
 Electric balance
 Iron
 Sample dyeing m/c
 Lab dip m/c
 GSM tester
 Washing m/c
 P
H
tester
 Dryer
Light box:
 Visual assessment of color by reflectance & transmission
 Mainly used for shade matching
 Four types of light source are used
 Sometime it may be more such as TL84, CWD etc
 Metamerism of the fabric is checked
Brand Name Model Manufacturing country
VITIVIDE CAC-60 U.K.
Types of light source which is used in the m/c is given below-
Symbol Full meaning Functions
UV Ultra violet Used for white color
matching
F Fluorescent light Check the metamerism of
the fabric
TL84 Tube light Do
L D65 Artificial day light Used for color matching
Crock meter:
Feature:
 Mainly used for rubbing fastness
 Rub may be wet and dry
Brand name Mgf. Country Serial no.
James H.Heal& Company England S-9011
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Electric balance:
Features:
 Weight of the fabric and dyes and chemical is measured digitally which give good result in
weighting
 Used for accurate measurement
 Maximum weight that can be perfectly measured is 121 gm and minimum weight which
can be measured perfectly is 1.001 gm
 Accuracy 0.001 gm
Brand Name Company Model Country
Sartorius James H. Heal &
Co. Ltd
BL310 UK
Iron:
Feature:
 Used for drying the sample
 Wet sample is placed between the two white fabric and temperature and pressure is given
 A dial is provided indication the different temperature marked on tits upper surface and
gives accurate temperature for cootn, silk, wool etc. which is adjusted manually.
Sample dyeing Machine:
There are three sample dyeing m/c in the laboratory, which features are described below in brief
Solvent – Glycerin
Model – HR
No: 3800
M/c type Brand name Company Country
H. T. m/c ROACHES ROACHES England
Lab. Dip m/c Mathis labomat Werner Mathis. AG Switzerland
Sample dyeing m/c:
Feature:
 Sample can be dyed above 100
0
C, 130
0
C or more
 Glycerin bath is used
 18 holders are providing in this machine
Main parts of the machine:
 Program set panel
 Glycerin bath
 Holder
 Holder carrier
Controlling point:
 Time
 Temperature
 Rotation speed
 Auto stop
Type of fabric processed: COTTON AND POLYESTER
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GSM Tester:
Feature:
 Used to measure GSM for gray, dyed and finished fabric
 One GSM tester is in finishing section and another GSM tester is in Knitting Section
 100 Cm
2
cut sample is weighted by electric balance 3 and given value of in gm.
Multiplied by 100 is the GSM of fabric, Say, 100 cm
2
sample weight in 1.9 gm that
means its GSM is 180
Washing machine:
 All the washing condition and parameter can be controlled
 Model – RS-12MS
 Temp 120
0
C
 Solvent – water + glycerin
m/c no Brand name Company Country
1. INDESIT INDESIT Italy
Wash fastness machine:
It also used as a dyeing machine. Specification is unknown
Hot air rapid drying oven:
Country – Taiwan
Component – Timer, Temperature indication meter
Machinaries of the finishing section:
Dewatering machine:
Feature:
 Used to remove excess water after pretreatment and dyeing
 Delivered fabric is crease free state
 Before squeezing ballon is formed with the help of compressed air passing by a nozzle
 It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism
 To impart soft finish to the fabric
Brand name Origin Prod.Capacity
AB-CALATOR Sweeden 7 ton/day
FAB-CON American 8 ton/day
Main parts of the machine:
- Sqeeze roller (to remove water)
- Stretcher (to control width)
- Over feeding wheels (to control GSM)
- De-twisting device (To delivery the fabric roll in untwisted form)
- Folding device (to delivery the fabric in folded form)
Utilities:
1. Electricity
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2. Processed air (to form the tube fabric into ballon with a view to remove crease)
Control system:
1. Overfeed control
2. Pressure
3. Speed control
4. Width control
Dryer:
M/C no Origin
RUCKH Germany
SAN-TEX Switzerland
Functions:
1. To dry the fabric with help of steam
2. To control the shrinkage
3. To prepare for next subsequent process
4. To dry tubular and open width fabric without tension
Main parts of the machine:
1. Heating chamber (2)
2. Blower (8)
3. Synthetic blanket as a conveyor
4. Folder
5. Exhaust fan
Heating system:
1. Gas fired
Utility:
1. Gas (to make fire)
2. Electricity (to rum the machine)
3. Compressed air (to spread the fire)
Setting according to fabric construction:
Fabric type Speed m/min Temperature Over feed speed (%)
Single jersey 15 140 20
Interlock 20 – 22 140 25 – 30
Rib 10 140 15 – 20
T/C P/C Viscose 20 – 23 130 40 – 45
Lacoste 30 140 40 – 45
Collar 20 140 40 – 45
Lycra 17 130
Compector m/c:
Brand Name Manufacturing Country Production / day
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FERRARO Italy 3 - 6 tons/day
FAB-CON America 3 – 6 tons / day
Control Point :
- Water pressure 2.5 lb
- Air pressure 4 lb
- Steam pressure 6 lb
Function:
1. To compact the fabric
2. To control the shrinkage
3. To maintain proper width and G.S.M
Main parts of the machine:
1. Heating chamber
2. Blower (8)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
Heating system: Steam
Raising m/c:
In which process a layer of fibers lifting from the body of the fabric to achieve soft and lofty effect on
the surface is called raising.
Brand name Country Production / day
XETMA Germany 2-3 tons
Main parts:
1. Pin roller
2. Counter pole roller
3. Blower
4. Clean roller
Utility Section:
1. Generator
2. Boiler
3. Air Compressor
1. Generator:
An electrical generator is a machine that converts mechanical energy of power into electrical
energy or power.
Brand Name Manufacturer Capacity
WAUKESHA 1125 KVA
CATER PILLAR 390 KVA
Specification:
P.F. 0.8
Power produced 250 KVA
Page no: 18
Inlet jacket water temp 53
0
C
Outlet jacket water temp. Oil temperature 72
0
C
Air temp. in filter 33
0
C
Oil pressure 4.6 bar
Raw water pressure 0.5 bar
Gas pressure Inlet air pressure 0.5 bar
Boiler:
Brand Name Manufacturer Production
Cleaver brooks U.S.A 100,00 kg/hr
Specification:
Feed water temp 60
0
C
Feed water hardness 2
Steam pressure 500 PSI
Types of steam Wet system
Steam temp. 150
0
C
Fuel used Natural Gas
Air compressor:
An air compressor is a m/c to compress the air and to raise its pressure. The air compressor sucks air
from the atmosphere, compresses it and delivers the same under in high pressure to a storage vessel.
From a storage vessel, it may be conveyed by the pipeline to a place where the supply of compressed
air required.
Utility:
1. Air
2. Mobil
3. Electricity
Component:
- Motor
- Piston
- Compressed a
- Oil drain plug
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LIST OF THE MACHINERY:
Dyeing machines:
M/C
NO
M/C TYPE BRAND NAME
ORIGIN OF
MACHINE
MANUFACT-
URING YEAR
CAPACITY
01 WINCH THIES GERMANY 2000 150
02 WINCH THIES GERMANY 2000 200
03 WINCH THIES GERMANY 2000 400
04 WINCH THIES GERMANY 2000 400
05 WINCH THIES GERMANY 2000 600
06 H.T. H.P DILMENLER TURKY 2003 700
07 H.T. H.P DILMENLER TURKY 2003 700
08 H.T. H.P ATYC TERRASSA 2002 900
09 SAMPLE FONG SHENZHEN 1997 25
10 SAMPLE FONG SHENZHEN 1997 25
Page no: 20
DYEING LAP
Sl. No. Name of the m/c Brand Name Manufacturing
Country
01 Light box VITIVIDE U.K.
02 Crock meter James H.Heal&
Company
U.K.
03 Electric balance Sartorius U.K.
04 Sample dyeing
m/c
1. H. T. m/c
2. Lab. Dip m/c
ROACHES
Mathis labomat
England
Switzerland
05 GSM Texter INDESIT Italy
Finishing Floor:
Sl. No. Name of the m/c Brand Name Manufacturing
Country
Production
Capacity
01 Dewatering m/c AB-CALATOR Sweeden 7 ton/day
02 Dewatering m/c FAB-CON American 8 ton/day
03 Dryer RUCKH Germany 4.5 tons/day
04 Dryer SAN-TEX Switzerland 6 tons / day
05 Compactor m/c FERRARO Italy 3-6 tons/day
06 Compactor m/c FAB-CON American 3-6 tons/day
Utility Section:
Sl. No. Name of the m/c Brand Name Manufacturing
Country
Production
Capacity
01 Generator WAUKESHA 1125 KVA
02 Boiler Cleaver brooks U.S.A 390 KVA
03 Air Compressor VESPA Taiwan 150 PSI
REMARKS:
The average machineries in this factory are more or less same compared to the other knit
dyeing factories but the dyeing machineries are very much different from the other factories.
Page no: 21
RAW MATERIALS
CHAPTER - 4
Page no: 22
Raw Materials:
In The Delta Composite Knitting €
Ind. Ltd., the raw materials used for production are –
1. Grey Fabric
2. Dyes
3. Chemicals
1. Grey fabrics:
Following types of grey fabrics are dyed-
a. Single jersey
b. Single jersey with lycra
c. Interlock
d. Lacoste
e. Rib
f. Lycra rib
g. 1 x 1 rib & others
h. Collar & cuff
i. Polyester fabrics
Sources:
The required grey fabric is produce in the industry
Chemicals Rate per kg
01. Soda ash light 13
02. Caustic Soda 30
03. Common salt 7
04. Glauber Salt 9
05. H
2
O
2
28
06. Acetic Acid 12
07. Oxalic Acid 44
08. Bleaching Powder 22
09. Hydrose 48
10. Leuphore BMB 520
11. Uvtex BHT 309
12. Uvtex BHV 289
13. Uvtex BAM 310
14. Syno White 4BK 340
15. Uvtex BFE 919
16. Albatex FFC 344
17. CHTE nt. K50 249
18. Invadine Lun 136
19. Feloson NOF 174
20. Invadine DA 180
21. Invatex CS 74
22. Cibacel DBC 107
23. Sarbid LDR 150
24. Mcropan DPE 126
Page no: 23
25. Cibapon R 150
26. Ctobalance NSR 189
27. Rucozen RES 118
28. Tinofix FRd 150
29. Lily XXL powder 40
30. Rewan Acp 145
31. Cibatex ECO 150
32. Invatex CRA 200
33. Heptole EMG 114
34. Cibafluide C 89
35. Biovin 109 181
36. Tinozym 44L 569
37. Beizym ULBD 347
38. Invatex PC 97
39. Invatex AC 117
40. Catalar BF 324
Dyes Rate per kg
01. Solazol Black sp GRI 300
02. Reactofix Red ME4BL 262
03. Cottofix Red ME4BL 262
04. Reactofix Orange ME2RL 294
05. Reactofix N.ME2GL 354
06. Reactive Yellow H4GL 500
07. Reactive Deep Black N 200
08. Cottofix Black B 141
09. Reactive Blue R(SP) 950
10. Remazol Red RR 1080
11. Remazol Yellow RR 746
12. Remazol Blue RR 908
13. Remazol Blue BB NEW 2280
14. Remazol T. Blue G 344
15. Remazol B Yellow 3GL 1167
16. Remazol Red RGD 725
17. Cibacron Red FN2BL 1488
18. Cibacron Red FB 918
19. Cibacron Red FN3G 1018
20. Cibacron Red WB 542
21. Cibacron Blue FNR 1488
22. Cibacron Blue FGFN 1540
23. Cibacron Navy WB 323
24. Drimarin Yellow CL2RL 510
25. Drimarin Red CL5B 494
26. Drimarin Violet K2RL 1600
27. Drimarin Navy CLB 743
Page no: 24
28. Drimarin Blue CT2R 1647
29. Bezaktrive Yellow S3R 516
30. Bezaktrive Yellow SLF 975
31. Bezaktrive Yellow V GL 1321
32. Diss Yellow F5GL 400
33. Diss Red BF 600
34. Diss Blue FRL 1100
35. Diss Navy 2GL 300
36. Diss Black EXNSF 300
37. Terasil Black WNS 300
38. Terasil Red FB 600
39. Terasil Red WFS 600
40. Terasil Red W4BS 600
Page no: 25
THE DELTA COMPOSITE KNITTING IND. LTD. IMPORTED YARN PRICING THROUGH L/C:
PARTY NAME YARN
CATEGORY
RATE $
(KG)
RATE (Tk. /
KG)
QUANTITY
(KGS)
Shameem Spinning 20s/1 CVC 2.70 158 400.00
Shameem Spinning 30s/1 CVC 2.80 163 500.00
Padma Textile Mills 30s/1 CVC 3.00 175 3628.80
Square Textile Mills 24s/1 Comd 2.95 172 850.00
Square Textile Mills 12s/1 Kard 2.05 120 500.00
Square Textile Mills 10s/1 Kard 1.65 96 1850.00
Prime Composite Mills 32s/1 Comd 2.95 172 2550.00
Arief Knitspin Ltd 20s/1 Kard 2.58 151 2000.00
Arief Knitspin Ltd 26s/1 Kard 2.62 153 2000.00
Arief Knitspin Ltd 30s/1 Kard 2.62 153 3250.00
Prime Composite Mills 32S/1 Comd 2.95 172 22500.00
Arief Knitspin Ltd 24S/1 Comd 3.02 176 10000.00
Arief Knitspin Ltd 34S/1 Comd 3.25 190 20000.00
Shamsuddin Spinning 24S/1 Comd 3.00 175 6700.00
Shamsuddin Spinning 26S/1 Comd 3.00 175 4350.00
Arief Knitspin Ltd 20S/1 Comd 3.00 175 1500.00
Saiham Textile Mills
ltd.
30s/1 Kard 2.55 149 661.84
Shamsuddin Spinning 30s/1 Comd 3.05 178 1150.00
Shamsuddin Spinning 26s/1 Comd 3.00 175 1800.00
Prime Composite mills 20s/1 Kard 2.40 140 1400.00
Prime Composite mills 24s/1 Comd 2.85 166 1900.00
Prime Composite mills 26s/1 Kard 2.82 165 650.00
Prime Composite mills 30s/1 Kard 2.82 165 350.00
Hanif Spinning Mills 28s/1 Comd 3.05 178 3800.00
Square Textile Mills 26s/1 Comd 2.95 172 500.00
Square Textile Mills 24s/1 Kard 2.50 146 500.00
Square Textile Mills 10s/1 Kard 1.65 96 600.00
Shameem Spinning 30s/1 CVC 2.80 163 1600.00
Square Textile Mills 30s/1 Comd 3.00 175 1000.00
REMARKS:
The Delta Composite Knitting Ind. Ltd uses best quality raw materials. It produces fabrics
from best quality yarn. They uses the best quality dyes like REMAZOL, REACTRON, REACTIVE ,
TERACIL etc. During the time of using dyestuff they give importance upon the quality of dyes than
the price of the dyes and chemicals.
Page no: 26
PRODUCTION PLANNING,
SEQUENCES AND OPERATIONS
CHAPTER - 5
Page no: 27
Production parameters:
a. pH:
- During H
2
O
2
bleaching pH 9 – 11
- During reactive dyeing pH 10.5 – 12
- During disperse dyeing pH 4.5 – 5.5
b. Temperature:
- For cotton scouring 90
0
-95
0
C
- For cotton cold wash 30
0
– 40
0
C
- For cotton hot wash 70
0
-80
0
C
- For cotton acid wash 60
0
-70
0
C
- For cotton dyeing 80
0
-90
0
C (For hot brand)
40-60
0
C (For cold brand)
- Polyester dyeing: 100
0
-130
0
C
c. Time:
- For scouring 60-90 mins
- For reactive dyeing 60-90 mins
- For disperse dyeing 60-90 mins
d. M:L ratio:
- For reactive dyeing M:L ration maintained beween 1 : 8 to 1 : 10
Description of production process:
Washing for colored fabrics:
- The colored fabrics to be washed is loaded in the machine
- Required amount of water is taken
- PCLF (detergents) added & washing continued at 80
0
C for 20 mins
- Cold washing
Scouring-bleaching:
- Fabric to be scoured is loaded in the machine
- Required amount of water is loaded
- Washing agent/ detergent is added
- Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when the temperature
reaches at 50
0
C
- When the temperature reaches at 60
0
C then stabilizer is added
- Then H
2
O
2
is added
Page no: 28
- Temperature is then raised to 90
0
C and the process is then carried out for 60-90 mins
depending on the requirements
- The liquors are then drained
- Then cold wash at 30
0
-40
0
C, hot wash at 70
0
-80
0
C and acid wash at 60
0
-70
0
C is done
Dyeing:
- After acid wash all liquors are drained out
- Required amount of water is taken
- Then leveling agents, anti-creasing agents, de-foaming agents are added according to the
requirement
- Steam pipes are on & after 10-15 mins dyes are added
- Salts are added after another 30 mins
- Then soda ash after another 30 mins
- Then the temperature is raised slowly up to the mark
- The process is carried on and samples are taken after every 30-40 mins to match with the target
shade. It continues until shade matching.
- If the sample is matched, then the liquors drained out
- Then cold wash at 30
0
-40
0
C, hot wash at 70
0
-80
0
C, acid wash at 60
0
-70
0
C is done
- Then softener is added at 40
0
C for 20-30 mins
- Fixer is applied for deep shade only before adding softener
Re-dyeing:
When shade is not matched then fabric is treated again in dyeing machine for shade matching is
known as re-dyeing.
Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur when the fabrics
absorb one or two colors more or less. One re-dyeing process is described below.
- Drain the let off solution
- Hot wash at 70
0
-80
0
C
- Acid wash at 60
0
-70
0
C(60
0
for light shade & 70
0
for deep shade).
- Soda ash washes at 90
0
-100
0
C for 60mins to reduce the depth of shade.
- Acid wash at 60
0
C.
- Addition to required dyestuffs.
- Salt addition.
- Soda ash addition.
- Other operations are same as previous described dyeing operations.
DYEING CURVE:
Auxiliaries
Dye
Soda
Time
60 min
60
0
C
Temperature
30
0
C
Page no: 29
Production flow chart:
Production flow chart for 100% cotton

Grey fabric loading

Scouring & Bleaching at 95
o
C for 1 hour


H
2
O
2
killer [invotex PC or gazyme PC]

A.Acid

Enzyme [pH 4 – 4.5, temp 60
o
C for 40’-60’]

Hot wash

Levelling [Ladiquest 1097]

Dyeing
Salt
Color
Soda

A. Acid

Hot wash [Decol SN, RSK, RFL]

Fixing [VNF, ECO]

Softener [LCF, Non ionic]

Unload
Page no: 30
CVC dyeing sequence:
Perergent + Artioreasomg agent at 80
0
C for 20'

cad wash

A.Acid [pH 4-4.5]

Levelling agent + Antioreasomg agent

Buffering agent [jinlab RFL]

Color at 130
o
50'

↓ ↓
If OK If not oK
↓ ↓
Bath Drain temp 130
0
↓ ↓
½ scouring If OK
↓ ↓
Cotton dyeing sequence Bath drain

½ scouring

Cotton dyeing sequence
Page no: 31
Dyeing sequence for white:
Scouring + bleaching, 95
0

Blutton´50'

15' Sample test

Water drain

Hot (without chem.: at 80
0
C for 20')

A.cAcid

↓ ↓
If OK If not oK
↓ ↓
Sequester Softener
↓ ↓
Softner Unload

Unload
Page no: 32
STANDARD RECIPE OF SCOURING
& BLEACHING
SCOURING & BLEACHING:
DEEP SHADE LIGHT SHADE
01. ALBATEX FFC : 0.15 G/L : 0.15 G/L
02. LADIQUEST 1097 : 0.25 G/L : 0.25 G/L
03. CIBAFUUIDE C : 0.50 G/L : 0.50 G/L
04. HOSTAPOL JU : 2.00 G/L : 2.00 G/L
05. CAUSTIC SODA : 2.50 G/L : 2.00 G/L
06. SODA ASH : 2.50 G/L : 2.00 G/L
07. STABILIZER SF. : 0.35 G/L : 0.30 G/L
08. H
2
O
2
(50%) : 3.50 G/L : 3.00 G/L
09. ACETIC ACID : 1.00 G/L : 1.00 G/L
10. INVATEX PC : 0.30 G/L : 0.25 G/L
LEVELLING:
01. CIVAFLUDIE c : 0.50 G/L : 0.50 G/L
02. LADIQUEST 1097 : 0.80 G/L : 0.60 G/L
(FOR LYCRA S/J CIBAFLUIDE C : 0.70 G/L)
LEVELLING: FOR TURQUISE BLUE, R-BLACK, ROYEL COLOUR
01. CIBAFLUIDE C : 0.70 G/L
02. LADIQUEST 1097 : 1.00 G/L
03. E2R : 0.50 G/L
[ FOR WHITE SHADE ]
H2O2 ( 50% ) : ( 4.00 G/L - 7.00 G/L)
Page no: 33
White Dyeing Recipe For (100% Cotton)
Buyer Name : Tom Tailor M : L = 1 : 8
Order No : Cross line Mtl wt. = 100 kg
Batch No : 19100 Water = 800 Liter
Fabric Type : (1 * 1) Rib Fab dia. = 42 inch
G. S. M. : 200 – 210 Colour = White
Serial No Name Dosing (g/l) Quantity Remarks
01 Hostapol JU 0.20 160 gm
02 Cibafluide-C 0.20 160 gm
03 Albatex – FFC 0.20 160 gm
04 Cibafluide – C 0.73 584 gm
05 Hostapol JU 1.20 960 gm
06 Sequester – K 1.00 800 gm
07 Caustec Soada 2.25 1.80 Kg
08 Soda Ash 1.00 800 gm
09 Stabilizer SF .30 240 gm
10 H
2
O
2
4.00 3.20 Kg
12 Acetic Acid 0.60 480 gm
13 Sequester – K 0.40 320 gm
14 Softener (Non - Ionic) 1.50 1.20 Kg
Prepared by : ………………… Checked by : …………………………..
Dyeing Incharge : ……………. Production Manager : …………………..
Page no: 34
Flow Diagram of White Dyeing Process of 100% Cotton
95
0
C
H
2
O
2
A
Scouring Chem
dosing time 30 min
10 min
6 min
10 min
50 min 25 min
10 min
20 min
Cold wash
80
0
C 20 min
Levelling Agent
+ Anticreasing agent
30 25 20 25
Acetic
acid
Acid
Wash
Softener
Unload
Page no: 35
Colour Dyeing Recipe (100% Cotton)
With Reactive Dye
Buyer Name : H & M M : L = 1 : 8
Order No : Cross line Mtl wt. = 100 kg
Batch No : 19100 Water = 800 Liter
Fabric Type : S / J Fab dia. = 42 inch
G. S. M. : 160 – 170 Colour = Navy
Serial No Name Dosing (g/l) Quantity Remarks
01 Hostapol JU 2.00 1.60 kg
02 Ladiquest 1097 0.40 320 gm
03 Albatex – FFC 0.15 120 gm
04 Cibafluide – C 0.50 400 gm
05 Stabilizer SF 0.50 400 gm
06 Soda Ash 2.50 3.60 kg
07 Caustec Soada 3.00 2.40 Kg
08 H
2
O
2
4.00 3.20 Kg
09 Acetic Acid 1.00 800 gm
10 Invatex PC 0.15 120 gm
11 Cibafluider – C 0.50 400 gm
12 Ladiquest 1097 0.80 640 gm
13 Reactive S Yellow F3R 0.33 % 330 gm
14 Reactive S Red F3B 0.79 % 790 gm
15 Reactive Black – 5 4.20 % 4.20 kg
16 Salt 62.00 49.60 kg
17 Soda Ash 20.00 16 kg
18 RFL 0.80 640 gm
19 A. Acid 1.00 800 gm
20 Softner (Non Ionic) 1.00 800 gm
Remarks:
The Delta Composite Knitting Ind. Ltd. strictly follow the production parameters like the time, temperature, M:L
ratio pH etc. As they do some difficult shade, it takes more time for the production of the batch. Because of the trolley
shortage and generator failure, the production process is sometime hampered. Considering these limitations, the production
officer and the Sr. Production Officer try their best to reduce the production time.
Page no: 36
QUALITY ASSURANCE
CHAPTER - 6
Page no: 37
CHAPTER-VI
Q. C. Department
Quality Policy:
It is the policy ofThe Delta composite Knitting Ind Ltd to produce quality dyed knit fabrics
that meet or exceed customers expectations & needs. To implement this policy the top management of
UKDL is committed to provide adequate resources in terms of good raw materials and trained
personnel & continually improve / upgrade its processes and systems.
Quality Objectives:
 Overall material/product loss (Level of rejection) for the company during the production
process (in a year) shall not exceed 1.5 %
 Defects during dyeing & knitting operations to reduced by 10% by the Jan ‘03
 Process capability shall be maximized by maximizing the m/c breakdown time. M/c
breakdown time should be reduced to 20 % form its current status/position by the mid 2003.
 A quality procedure manual in line with the requirement of ISO9001 shall be developed and
implemented by August 2002.
 To ensure better work environment for the personnel working in the organization.
Machines:
 Wash Fastness Tester
 Light fastness tester
 Rubbing fastness tester
 Electronic balance
 G.S.M. cutter
 Fabric inspection table
 Light box
 Shrinkage (%) meter
Inspection area:
 Shade match of fabric
 G.S.M.
 Fabric diameter
 Shrinkage (%)
 Length wise
 Width wise
 Fiber type
 Wash fastness
 Light fastness
 Rubbing fastness
 Faults
 Dyeing faults
 Knitting faults
Page no: 38
FAULTS ARE FOUND IN QC DEPERTMENT:
Knitting faults:
 Hole
 Slub
 Thick place
 Thin place
 Neps
 Stripe
 Missing yarn
 Contamination
 Light
 Medium
 Deep
Dyeing faults:
 Uneven shade
 Running shade
 In fastness property
Finishing faults:
 GSM variation
 Spirality
 Shrinkage control
 Length wise
Page no: 39
QUALITY ASSURANCE SYSTEM
Quality assurance procedure:
The Delta Composite Knitting Industries Ltd. assures the quality of their products in the following
three steps:
 In laboratory
 In Dyeing section &
 In finishing section
Procedures are described below:
In laboratory:
 Swatch card from buyer according to their requirement
 Recipe prediction for sample dyeing
 Sample dyeing until matching with swatch card
 If matching is OK, then it is sent to the buyer for approval.
 If buyer approves the sample then bulk production.
In dyeing section:
 After approval form the buyer, sample dyeing is done in dyeing m/c in dyeing shed &
again matched with the approved sample
 If result is OK. then balk production,
 During dyeing, samples are taken until accurate shade matching. The interval may be 30-
40 minutes
 After dyeing sample is collected after softening matching is done
 Last of all, sample is collected after fixation & matched
 Then allowed the fabrics to be finished
In finishing section:
 Correctly dyed, after treated & matched fabrics are allowed for finishing
 By using a series of finishing machines correct width, softness & appearance are maintained
according to requirements
 Then sampling is done for several times to test GSM, Shrinkage & fastness properties.
 Finally fabric is inspected & prepared for delivery
List of Equipments:
Machineries & equipment used :
 Spectrophotometer with software (Datacolor)
 Colour light box
 Sample dyeing machine (2)
 Lab. Dip
 Iron
Page no: 40
 Electric Balance
 Crock meter
 Washing m/c
 GSM Tester
 P
H
meter
Quality standard:
The Delta Composite Knitting Industries Ltd. follows the quality standard: ISO-9001
.
2000
REMARKS:
The Delta Composite Knitting Ind. Ltd. always aware about the quality of the product. The quality of
the product is always approved by the buyer. They follows the quality standard: ISO 9001: 2000, The
Delta Composite Knitting Ind. Ltd. is well equipped for checking the quality of the product.. They
sent the quality report to the buyer time to time/ batch to batch.
Page no: 41
MAINTENANCE
CHAPTER - 7
Page no: 42
CHAPTER-VII
MAINTENANCE
Mai ntenance of Machinery:
Maintenance of machinery is very essential mechanical effort for achieving smooth running of
different machines. Maintenance is a process by which equipment is looked after in such a way
that trouble free. Services and increased machine life can be ensured and specific product quality
required by the customers is sustained. On time maintenance increase m/c lifetime & ensures
trouble free services.
The Delta composite Knitting Ind. Ltd . 2 types of maintenance are done:
1. Break down maintenance
2. Routine maintenance
1. Break down Maintenance: Break down maintenance is done instantly when problem
arises in machine. In this case, repairs are made after the equipment is out of order and it cannot
perform its normal functions.
2. Routine Maintenance: After a particular little the machines are cleaned &
reordered, that is routine or schedule maintenance. PPC does it once in a month.
Schedule maintenance varies, time in time & also depends on situation according to
types of machines, because maintenance is directly related to production.
Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also done. Workers
inform about the problem areas of the machines. Depending on their information. maintenance
is done, Maintainers analyses the machine records & take steps according to requirements.
Maintenance
Routine Maintenance Break Down Maintenance
Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance
Page no: 43
Maintenance procedure:
Duringmaintenance procedure following points should be checked.
Checklist of different parts:
Maintenance: Mechanical
Machine: Dyeing Machines
Sl. No. Item need to be checked & Serviced
1 Crease the winch bearing.
2 Complete cleaning of machine
3 Cleaning of drain valves, replace seals if required
4 Check air supply filter, regulators, and auto drain seals
5 Clean filters element and blow out
6 Greasing of Unloading Roller Bearings.
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 Min Vessel Level Indicator
10 Check the oil level of pump bearing and refill if required.
11 Check the function of heat and cool modulating valves
12 Check all belts and belt tension
13 Check all door seals
Maintenance: Mechanical
Machine: Lab dyeing m/c.
Sl. No. Item need to be checked & Serviced
1 Check rotating main shaft bearing.
2 Check cooling water inlet and outlet nose and nose clips.
3 Check cooling fans
4 Check driving bells and pulleys.
Page no: 44
Maintenance: Mechanical
Machine: Lab 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 motors terminals
3 Check min 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 circuit breaker, magnetic contractors and relays
7 Check current setting of all circuit breaker & motor over loads.
8 Visual checking of all power & control cables
9 Check DC drive of reel motors
10 Check all pressure switches
11 Check calibration of main vessel & all additional tank
12 Check all pneumatic solenoids
13 Check calibration of heating/cooling. Modulating value
14 Check setting of tangle sensor.
15 Check setting & operation of lid safety switches
16 Check all emergency Switches
17 Check all indicating lamps
18 Check all on/off switches
19 Check all signal isolators
20 Check key pad & display of controller
21 Check proximity switches
The following tasks are generally done during maintenance:
 Inspections & check ups
 Lubrications
 Planning & scheduling
 Record analysis
 Training of the maintenance crew
 Collection or purchase of spares
Page no: 45
MAINTENANCE WORK TO THE DIFFERENT MACHINES:
BOILER MAINTENANCE SCHEDULE:
Daily:
 Check gas pressure
 Maintain log sheet
 Chemical dosing
Weekly:
 Check all steam line
 Fire quality of boiler
Monthly:
 Check all steam line
 Fire quality of boiler
 Gas consumption report
 Burner clean
Quarterly:
 Burner clean
 Economizer clean
 Feed tank clean
 Chemical tank clean
 Sight glass clean
Half yearly:
 Burner clean
 Feed tank clean
 Chemical tank clean
 Economizer clean
 Replace gasket
 Replace valve
 Check gas line & filter & pressure
Yearly:
 Overhauling of boiler
 Chemical cleaning of boiler
 Safety valve test
 Economizer clean
 Feed tank clean
 Chemical tank clean
 Burner clean
 Check safety valve setting
 Replace valve & gasket
 Boiler inspection by authority
Page no: 46
Dyeing m/c maintenance Schedule
Daily:
 Check belt tension
 Check steam or water system & air supply
 Check chemical pump
 Machine clean
Weekly:
 Bearing & belt check
 Check leakage of air, steam &
 Water line
 Greasing bearing points
 Add gland packing at pump
Monthly:
 Greasing bearing points
 Replace bearing points (if required)
 Gaskrt check
 Clean steam trap
 Lubricating all chemical pump
Quarterly:
 Replace belts
 Repairing of pulley, shaft & bearing housing
 Painting m/c & pipe line
 Clean steam trap
 Replace seals (if leakage)
 Change gasket of steam of water lines
Half yearly:
 Replace belts
 Repairing pulley, shaft & bearing housing
 Painting m/c, pipe line
 Replace seals
 Machine body repairing
Half yearly:
 Replace belts
 Repairing pulley, shaft & bearing housing
 Painting m/c, pipe line
 Replace seals
 Machine body repairing
Yearly:
 Machine overhauling
Page no: 47
Hydro extractor Maintenance
Daily:
 Machine clean
 Belt checking
Weekly:
 M/c clean
 Belt clean
 Greasing & lubricating of all points
Monthly:
 M/c clean
 Check gear oil quality
Quaterly:
 Change of gear oil
 Belt change
Half yearly:
 Change of gear oil
 Belt change (if required)
Yearly:
 Machine overhauling
Page no: 48
TENSIONLESS DRYER MAINTENANCE
Daily:
 Check belt tension
 Check steam supply & air system
 Machine clean
Weekly:
 Check fabric drying quality
 Greasing bearing points
 Clean airfilter & regulator
Monthly:
 Clean radiator & m/c cabinet
 Greasing bearing points
 Clean air filter and regulator
Quarterly:
 Replace belt
 Replace gear oil
 Duct clean
Half yearly:
 Check roller condition
 Greasing & lubricating all points
Yearly:
 Machine overhauling
Page no: 49
TUMBLER DRYER MAINTENANCE:
Daily:
 Check belt
 Steam leakage area
 M/c clean
Weekly:
 Heat exchange clean
 Greasing & lubricating of all points
 Belt check
 M/c clean
Monthly:
 Filter clean
 Steam trap clean
Quarterly:
 Replace belt
 Replace gear oil
 Duct clean
 Gasket & valve change
Half yearly:
 Gasket & valve change
 Yearly:
 Machine overhauling
Page no: 50
SOFT SET M/C MAINTENANCE:
Daily:
 Check belt tension
 Check Steam supply & air system
 M/c clean
Weekly:
 Check fabric quality
 Greasing bearing points
Monthly:
 Greasing bearing points
 Clean air filter & regulator
 Clean steam trap
Quarterly:
 Replace belts
 Replace gear oil
 Painting m/c & pipeline of the total system
 Replace seals
Half yearly:
 Check roller condition
 Greasing & lubricating of all points
 Check bearing condition
Yearly:
 Machine overhauling
Page no: 51
Maintenance tools/equipments & their functions:
Maintenance tools/equipments Functions
1. Adjustable wrench Used for setting nut & bolts
2. Pipe Spanner For pipe fitting
3.Spanner Fixed Spanner for nut & bolts fitting
4.Socket spanner Handle system for nut & bolt fitting
5. hammer To apply load where required
6. Screw driver To release any screw
7. Punch Used to fit any worn out shaft
8. Lock opener To open the clip of bearing
9. Hack saw To cut any metallic thing
10. Outside calipers To measure outside dia
11. Inside calipers To measure inside dia
12. Slide calipers To measure very small dia
13. Vernier scale To measure very small dia
14. Chain ton To lift heavy load
15. Welding machine To join metallic parts
16. Grinding machine To make the smooth fabrics
17. Tester To test electric circuit
18. Pliers To grip anything & cut anything
19. Avometer/Voltmeter To measure voltage
20. Steel tape To measure length, width & height
21. Chisel To cut any metal
22. Gasket cutter For gasket cutting
23. File To smooth the rough surface
REMARKS:
The maintenance department of The Delta composite Knitting Ind Ltd is well equipped. It has sufficient
maintenance manpower including mechanical and electrical engineers. They do the maintenance of the m/cs
during the Eid vacation. Otherwise, they do the breakdown maintenance. To increase the lifetime of the
machineries and ensure the proper running of the machinery.
Page no: 52
UTILITY SERVICES
CHAPTER - 8
Page no: 53
WATER TREATMENT PLANT:
(Water Softening Method – Base Exchange Process)
Technical
Details
Raw water tank Softener tank Soft water
tank
Brine tane
Size Length - 40´
Width - 20´
Height - 15´
Diameter – 6´
Height - 15´
Diameter - 20´
Height - 20´
Salt reqd:
190
kg/day/tank
Regeneration
time 1.30 hr
Capacity 360 Ton 45 Cubic
meter/hour/tank
180 Ton
Source Natural source
Deep tubewell
R.W.T S.T. Salt price
10tk/kg
Project cost Total Project Cost : 113 Lacks
BOILER:
Specifications:
1. Type : Fire Tube Boiler
2. Brand Name : Cleaver Brooks, USA
3. Type No. : DDH 15.0 – 10
4. Serial No. : 18709
5. Year of manufacturing : 1996
6. Max. Working pressure gauge : 10 bar
7. Max Temperature : 183
0
C
8. Max heat capacity : 3.25 MW
9. Water content up to ‘NW’ : 9.62 cubic meter
10. Max steam out put : 5.0 ton/hr
11. Gas pressure in line : 1 bar
12. Gas pressure (in boiler) : 010 bar
13. Gas consumption : 34 cubic meter/day
14. Steam pressure : 7.5 bar
15. Steam header pressure : 120 PSI
16. Blow down line : 4 times/day
17. Soft water supply pipe dia : 1 inch
18. Establishment cost : 60 lacks
Page no: 54
Electricity
Electricity is supplied by:
 WAUKESHA (GAS GENERATOR)
Amp : 1565
KVA : 1125
KW : 900
 CATER PILLAR (GAS GENERATOR)
Amp : 702
KVA : 487
KW : 390
 CAMINS (DIESEL GENERATOR)
Amp : 139
KVA : 100
KW : 80
Electricity consumption – 50KW/day
(A substation of voltage control – 1100 KV)
Utility cost:
01. Gas bill (Titas) : 7-8 lacs / month
02. Electricity Bill (REB) : 8-9 lacs / month
03. Others : 5-6 lacs / month
Page no: 55
STORE & INVENTORY CONTROL
CHAPTER - 9
Page no: 56
CHAPTER-IX
Store & Inventory Control
Inventory system for Raw material:
The Delta composite Knitting Ind Ltd. there are different inventory systems for different raw
materials.
Grey fabrics Store: All the grey fabrics arc stored in the fabric store, near the batch section.
Different types of fabrics arc listed in the sheet according to the fabric types, quantity &
consumer’s requirements. Fabrics GSM, shrinkage, diameter & other properties are also taken
into consideration. The batches are prepared by taking the required fabrics from the grey store.
At present the grey fabrics store of The Delta composite Knitting Ind Ltd. containing the
following types of fabrics-
 Single jersey
 1 x 1 Rib
 2 x 2 Rib
 2 x 1 Rib
 Fleece
 Melange..
 Pique
 Single jersey (with lycra attachment)
 1 x 1 Rib (with lycra attachment)
Dyes & Chemicals Store:
There is a different time for dyes & chemicals_ Various types of dyes & chemicals arc stored
here according to the dyes & chemical company.
Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity of dyes
& chemicals are also included. Everyday the sheet is updated & a copy of this sheet is supplied
to the AGM (production), Dye house & lab section.
Spares:
The Delta composite Knitting Ind Ltd. required amount of spares of different machines are
stored in the mechanical store room. All the spares are listed in a sheet which is controlled by the
mechanical & maintenance personnel. Spares are arranged in the store room according to there
size, quantity & requirements. There are shelfs in the store room to keep the small spare parts.
Finished goods:
The Delta composite Knitting Ind Ltd. supplies its finished dyed fabrics to its garments section
So. dyed finished fabrics are stored for short time in the finishing section. All the delivered
fabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter, buyers
name, color & considering other technical parameters.
Others:
There is a central store at the Ind Ltd. In that store the various types of forms, papers,
stationary & other necessary goods are kept.
Page no: 57
Remarks:
The Delta Composite Knitting Ind. Ltd. has individual stores for raw materials, finished goods
etc. the sotre of dyestuff & chemicals arc not so clean. There is no enough space to store the
finished goods. It requires to increase the store area.
Page no: 58
COST ANALYSIS
CHAPTER - 10
Page no: 59
COSTING OF THE PRODUCT
The following points are considered for costing any dyed product in The Delta Composite Knitting Ind.
Ltd.
1. Total dyes & chemical cost
2. Total utility cost
3. Salary
4. Payment
5. Transport cost
6. Lunch
7. Entertainment cost
8. Miscellaneous cost
9. Government cash incentive
Price of the product: Not available.
Costing of the product: Not available
REMARKS:
The costing of the product is a secret matter of the Ind. They are not interested to flash up the
cost related data. So we could not collect the price of product & costing of the product.
Page no: 60
MARKETING ACTIVITIES
CHAPTER - 11
Page no: 61
CONSUMERS OF PRODUCT:
The Delta composite Knitting Ind. Ltd. is a 100% export oriented industry. All the goods produced in
this industry are exported into various foreign countries. Name of the main buyers are given below-
NAME OF THE BUYER:
01.Tom Tailor
02.H&M
03.Echo Sourcing
04.Well Lord
05.Mono Prix
Importing countries:
There are some countries which are importing goods from The Delta composite Knitting Ind. Ltd.
The name of the countries are given below-
 Spain
 Germany
 Denmark
 Europe
 Denmark
 Europe Union
 United State of America
Manpower of marketing:
Marketing plays a vital role in the field of displaying / showing the goods criteria of the products to the
buyer & to communicate with the buyer. There are about 15 people in the marketing section of the
industry.
Marketing Strategy:
Marketing strategy is a very important factors to sale the products to the buyer. If the
marketing strategy is not so developed, it will be very hard to reach the goal. In case of garments
marketing the dealings with the buyer is a very important factor.
The Delta composite Knitting Ind. Ltd. mainly senior marketing officers, merchandiser &
higher officials deal with the buyer. There are some fixed buyers of the industry. The buyers give their
orders continuously all over the year. The marketing officers & the merchandisers communicate with
the buying houses to collect the orders.
By both side understanding the rate & the order quantity are fixed.
Duties & responsibilities of marketing officer:
Dealing with the buyer & convince the buyer is the main duty of marketing officer. A
marketing officer also has some other duties. The main duties & responsibilities of a marketing officer
are given bellow-
 To prepare cost sheet by dealing with the buyer
 To take different steps by discussing with the high officials & merchandisers
 To maintain a regular & good relationship between commercial officer & merchandisers
 To maintain a communication with the buyers and buying houses
 Communicate with better criteria of the products
Page no: 62
Actually the responsibilities & duties of marketing officer begins from getting order of buyer &
ends after receiving foods by the buyer. So, he should be always smart, energetic & sincere.
REMARKS:
The Delta composite Knitting Ind Ltd. has a well learned marketing & merchandising team. They
always communicate with the buyers. The Delta composite Knitting Ind Ltd. has some fixed
buyers. The marketing section also looks the quality & quantity buyers.
Page no: 63
CONCLUSION
CHAPTER - 12
Page no: 64
The Delta Composite Knitting Industries Ltd. is a well-planned versatile project. The
administrations, management, chain of command – all are well organized. They are
devoted to satisfy the customer by their activities. However, some of the point we
want to mention for the good of Delta Composite Knitting Industries Ltd. .
SOME SUGGESTIONS:
- During the transport of the fabric in the dyeing floor and also during the
loading of the m/c, fabrics are soiled for the contact with floor. This makes
the fabric/part of the fabric dirty. It may require more scouring/bleaching
agent or may create stain making it faulty.
- The dyeing floor is watery most of the time: it should be cleaned all the
time.
- The illumination of the dyeing shade should be enhanced. It may exert the
worker fatigue ness.
- More skilled labour should be used in a project as Delta Composite Knitting
Industries Ltd.. Many time the dosing pipelines are clogged due to the
careless dosing of chemicals.
- The m/c stoppage time should be analyzed and minimized. The
maintenance should be carried out when the m/c is out of action
(wherever possible)
Page no: 65
LIMITATIONS OF THE REPORT:
- Because of secrecy act, the data on costing and marketing activities has
not been supplied & 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 chapter are not described as these were not
available.
- The whole process is not possible to bind in such a small frame as this report,
hence our effort spent on summarizing them.
Lastly
What special in this report is that the information, data & description very much
subjective & practical. So, one can easily have an idea about the whole dyeing unit
of Delta Composite Knitting Industries Ltd. at a single look on it.
The newcomer can use this report for further detailed study or can know Delta
Composite Knitting Industries Ltd. without much work. But what should be
remembered the chemical, some process steps may be modified within the period
this papers goes to the readers.