Acknowledging Support During an Industrial Attachment

ACKNOWLEDGEMENT:
We are extremely delighted to express our indebtedness and deepest sense

of gratitude to our supervisor Md. Dewan Mahbub Kamran(Sr.Executive,
Dyeing).for his able guidance, untiring efforts, stimulating influence and
valuable comments during the training period .
We would like to offer sincere thank to the DGM (Dyeing) Engr. Md.
Shamim Rahman for his invaluable suggestions regarding this training
period.
The authority of the VIYELLATEX GROUP who gave us the opportunity to

complete our industrial attachment with great success is remembered with
honor. Thanks are due to all Engineers, officers, technicians, employees,
stuffs, all section in-charges for their cordial behavior. We are really lucky
that we have gotten such helping hand without whom, this attachment
could not be completed.
We also like to thank Dr. Shah Mohammad Fatah-ur-Rahman,

department of Wet Processing Technology for his encouragement, valuable
suggestion, and for the completion of this Industrial attachment
successfully.
Last but not least, thanks goes to my precious family for their never-ending
support and loves in every stages of my life which has motivated me to do
such type work.
INDUSTRIAL ATTACHMENT ON VIYELLATEX

Page 2
EXECUTIVE SUMMARY
The internationally recognized Buyers or clients are looking for those

countries for producing their apparel products where different types of
mills have established as a one stop source for the global apparel market,
satisfy and meet customer's expectation by developing and providing
products and services on time, which offer value in terms of Quality,
Price, Safety & Environmental impact. And also assure complete
compliance with the international quality standards and also to provide
the employees internationally acceptable working condition/standards. In
Bangladesh, there are different types of Textile Industry those are
producing high quality textile and apparel product. VIYELLATEX GROUP is
one of them.
VIYELLATEX GROUP is a Knit Composite Garments, having all state of the

art facilities with the annual turnover US$ 106.6 Million (2006-2007). They
have different types of Knitting, Dyeing, Cutting, Sewing, and Finishing
machines supplied by mostly Germany, Japan, Taiwan, China, U.K, U.S.A,
Singapore, etc. which are very latest. It has high production where 30 Metric
tons of dyed and finished fabrics are produced per day. The production is
controlled by technical persons. All of the decision makers of production
sector in VIYELLATEX GROUP are textiles graduates. All the chemicals and
dyes use for dyeing and finishing are well branded.
They produce their product for their buyer and client those are coming from
international market like U.K, Sweden, Netherland, France, U.S.A, Germany
and Spain. Their customer profile is big and top end such as Esprit, M&S, S-
Oliver, Puma, G-star, Gap, Tesco and Grew waver etc. They follow all the
system for their machines maintenance so production can not hamper.
In this report, we have tried to give some information about VIYELLATEX

GROUP and we have observed that VIYELLATEX GROUP produce high
quality fabric and fulfill the special requirements from the different types of
buyers by following different internationally recommended standard
method.

Page 2
INTRODUCTION
The industrial attachment is the process, which builds

understanding, skills and attitude of the performer, which improves his
knowledge in boosting productivity and services. University education
provides us vast theoretical knowledge as well as more practical
attachment, in despite of all these industrial attachment helps us to be
familiar with technical support of modern machinery, skillness about various
processing stages.
By means of practical knowledge it’s not possible to apply the

theoretical knowledge in the practical field. For any technical education,
practical experience is almost equal important in association with the
theoretical knowledge.
It also provides us sufficient practical knowledge about production

management, work study, efficiency, industrial management, purchasing,
utility and maintenance of machinery and their operation techniques etc.
the above mentioned can not be achieved successfully by means of
theoretical knowledge only. This is why it should be accomplished with
practical knowledge in which it is based on. Industrial attachment makes us
reliable to be accustomed with the industrial atmosphere and improve
courage and inspiration to take self responsibility.
Textile education can’t be completed without industrial training.

Because this industrial training minimizes the gap between theoretical and
practical knowledge and make us accustomed to industrial environment. I
got an opportunity to complete two-months long industrial training at
VIYELLATEX GROUP, which is a 100% export-oriented composite Knit
Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and
garments units in addition to facilitate knitting and knitwear manufacturing.
.

Page 2
TABLE OF CONTENT
TOPIC NUMBER TOPIC NAME PAGE NUMBER

01 GENERAL INFORMATION 5-11
02 KNITTING SECTION 12-40
03 BATCH SECTION 41-43
04 LAB SECTION 44-59
05 DYEING SECTION 60-98
06 FINISHING SECTION 99-121
07 INSPECTION SECTION 122-124
08 GARMENTS SECTION 125-137
09 WASHING SECTION 138-146

10 PRINTING SECTION 147-153
11 EMBROIDERY SECTION 154-157
12 MAINTENANCE SECTION 158-163
13 UTILITY SECTION 164-175
14 CONCLUSION 176-177

Page 2
GENERAL INFORMATION ABOUT THE FACTORY
Name of Company : VIYELLATEX GROUP.
Factory: VIYELLATEX GROUP.

297 Khortoil, Tongi,
Gazipur-1712.,Dhaka
Bangladesh.
Tel : 880-2-9813001, Ext: 110
Fax : 880-2-9811400
http//www.viyellatexgroup.com
VIYELLATEX LTD. is a well established knit composite industry. The industry

stands on industrial area of Gazipur. VIYELLATEX GROUP. is a Group of Companies,
Viyella spinning, Youngone’s fashion LTD. Viyella knitting and dyeing~ VIYELLATEX
LTD. is going to prove its own standard about product quality in world market as they know
that their reputation depends on its quality. VIYELLATEX LTD. is a profitable project and
contributes the economy of our country.

Page 2
LAYOUT FOR GOING TO THE VIYELLATEX FROM DHAKA
M asco
KA I
In d u stries A lluminim
Co.Lt.d
Ltd .
V IYELLATEX
M asco
In d u stries
Ltd .
SM P
Design
Pvt. Ltd.
G A J IPU R A BO ARD BAZAR

TO N G I
DH A KA
-M AYM A N SH IN G H IG H W AY

Page 2
PROJECT DESCRIPTION
Name of the Company : VIYELLATEX GROUP

Status : Private Ltd. Company
Type : 100% Export oriented composite knit
Dyeing
Year of establishment : 2001
year of starting production : 2002
Location : Gazipura, Tongi
Address:
Factory: 297, Khortoli, Tongi, Gazipur-1712

Head Office : 297, Khortoli, Tongi, Gazipur-1712
Tel : No: 88192812
Fax No: 880-2-8810445
E-mail: www.viyellatexgroup.com
Sponsors :Mr. Rezaul Hasnat
Product Mix
 100% cotton
 100% polyester
 Spun
 Filament
 Nylon
 Chief Value Cotton (CVC)
 Polyester Cotton (PC)
 Grey melange (15% Voscose 85% cotton)
 10% Voscose 90% cotton
 Ash melange (1% Viscose 99% cotton)

Page 2
Different Departments of VIYELLATEX knit dyeing
composite unit
a) knitting Section:
 Knitting
 Inspection
b) Dyeing section:
 Batch section
 Dye house
 Dyeing lab.
 Quality control
 Finishing
c) Garments section:
 Merchandising
 Sample
 Cutting Section
 Sewing Section
 Finishing Section
d) Maintenance section:
 Electrical
 Mechanical
e) Store Section
f) Administration Section
g) Security Section
h) Marketing Section
i) Production Planning & Control
j) Human Resource & Development Section

Page 2
VIYELLATEX GROUP INFORMATION:
Nature of company: 100% Export Oriented Knit composite Factory.

Certification : FARE TRADE
As a textile conglomerate having, 40320 spindle
spinning. Given by, FLOCERT GmbH of Germany in
2007.
Qualify Certification: ISO 9002

Marks & Spencer
NANOTEX
TUV
DuPont Teflon
Puma
DOTS by Cu (Control union)
OE by CU (Control Union)
Award: BGMEA Gold Medal-2007.

For Outstanding performance on corporate social
Responsibility & knit export.
Bangladesh Business Person-2007

Organized by DHL & the Daily Star.
PVH Gold Medal – 2007

For in time shipmen of qualify goods.
CSR Award – 2008

By Standard Chartered bank & Financial Express
& so many from nation & international bodies.
Turn Over:Viyellatex Garments - US$ 41.5 Million (2006-2007)

Viyellatex Fabrics - US$ 30.0 Million (2006-2007)
ISML - US$ 15.5 Million (2006-2007)
FPPL - US$ o1.6 Million (2006-2007)
VSL - US$ 18.0 Million (2006-2007)
Buyer:

Page 2
Name of The Buyer Country
Marks & Spencer U.K
S.Oliver Germany
Tesco U.K
Gap U.S.A
Puma Germany
Esprit Germany
G-Star Netherland
PVH U.S.A
Woolworths -
Celio France
Abercrombie& Fitch U.S.A
Gerry Weber Germany
.
CSRP:
Run ETP to treat dyeing water before release to environment Donate Blood
transfusion Thalassaemia Hospital.
Donated Kidney Dialysis Machine by Rotary Club Dhaka North-West.
Scholarship to meritorious students.
A Local school runs by Viyellatex Welfare Trust.
Projected 80 bedded general Hospital.
Carbon Footprint Project by BASF.
Reuse of Generator exhaust to run chiller & Boiler.
Preserve Rain water.
Free Eye Camp & health Campaigns for local community.
+ Take part on others social & national activates, disaster etc.

Page 2
Sources of mellange:
• Patartoli
• Prime
• Shohag pur
• Thermax
Sources of polyester:
• Kader Synthetic.
• China.
• Count: 75den, 100den, 150den.
Sources of Lycra:
* Brand : Roica
Country : Taiwan.
* Brand : Texlon
Country : Korea.
*Brand : Acelen
Country: China
*Brand : Creora
Country: Japan
*Brand : Lioli (In Viyellatex used mostly)

Country: China
• Count: 20 den, 40 den, 70 den.
Price list of different types of yarn:
Cotton:
Yarn Count Combed Yarn Carded Yarn

40/1 3.65 $/Kg 2.65-2.7 $/Kg
34/1 3.00 $/Kg 2.5-2.6 $/Kg
32/1 2.90 $/Kg 2.30 $/Kg
30/1 2.70 $/Kg 2.30 $/Kg
28/1 2.70 $/Kg 2.25 $/Kg
26/1 2.65 $/kg 2.25 $/Kg
24/1 2.60 $/Kg 2.25 $/Kg
22/1 2.55 $/Kg 2.20 $/Kg
20/1 2.50 $/Kg 2.15-2.2 $/Kg

Page 2
Page 2
Organogram of Knitting Section
DGM / AGM
Manager /Asst. Manager (Production & Plan)(02) Manager/

(Technical)
Asst. Manager(01)
Sr. Executive (Production, Plan & Sample)(02)
Sr. Feeder/Feeder(07)
Executive / Jr. Executive (Prod. & Sample)(05)
Asst. Feeder(04)
Sr. Supervisor/Supervisor(06) Sample Supervisor(02)

Needle Man(03)
Sr. Operator/Operator(135) Sample Asst.(05)

Servicing Man(06)
Asst. Operator(33)
Servicing Helper(06)
Production Helper(21)
Manager / Asst. Manager (Store)(01)
Sr. Executive / Executive (02)
Jr. Executive (Yarn)(02) Jr. Executive (Grey Fabric)(03)
Store Asst.(Yarn)(03) Store Asst.(Grey Fabric)(07)
Loader (Yarn)(26) Batch Helper/Loader (35)

Page 2
`
Oil tank Worker Toilet Officer Toilet Stuff Sitting Room 1st floor-(Officeroom)
Office
Enter
Area
Gray Fabric &
Temporary
Temporary Yarn store

Exit Yarn Store Room
Store
Yarn
Office
69 70 71 72 Area
=Single jersey
65 66 67 68 Office =Rib
Area
Temporary
=Interlock
Yarn
Store
59 60 61 62 63 64
=Autostrip(S/ J)
56 55 58 57 44 43 42 41 =Autostrip(Rib)
35 36
36 37
37 38
38 39
39 40
40
=Flat/ V-bed
54 53
=Inspection m/ c
34 33 32 31 30
33 32 31 30 29
52 51
=Wt. Balance
22 23 24 25 26 27 28
50 49
21
21 20 19
19 18
18 17 16 15
47 48
48
08 09 10 11 12 23 14

Page 2
KNITTING:
KNITTING IS THE PROCESS OF PRODUCING A FABRIC BY FORMING A
SERIES OF CONNECTED LOOPS FROM A SERIES OF YARN. IN THIS
METHOD FABRIC IS PRODUCED BY INTERMESHING OF LOOPS.
KNITTING TYPES:
warp knitting: each loop in the horizontal direction is made from a

different thread and the number of threads used to produce such a fabric
is at least equal to the number of loops in a horizontal row.
Weft knitting: a horizontal row of loops can be made using one

thread and the thread runs in horizontal direction.

Page 2
Raw Material for Knitting
The raw material for knitting is the yarn. Different types of yarn of wide
range of count are used. In yarn store section we had the chance to know
about different yarns of different count used in \/IYELLA TEX knitting. We
also have known different yarn manufacturer/suppliers name for this
knitting section i.e. sources of yarn. Both carded and combed yarn is used
for knitting.
Cotton 24S, 26s,30S,

32S,34S,40S
Polyester 75D, lO0D
=
Spandex yarn 20D,40D, 70D

Grey Mélange (C 24S,26S
Ecru Mélange (C-85% V-15%) 24S,26S,28S
Anthra Mélange (C-65% V-35%) 24S,26S,28S
PC (65%Polyester & 35% cotton)24S,26S,28S,30S
CVC 24S,26S,28S,30S

Page 2
Knitting section is divided in four sections,
1. Inspection section
2. Flat knitting section
3. Circular Knitting section
4. Store section
I. Cloth Inspection Section:
In cloth inspection section two machines are available. Specification of

those machines is given below
Type Cloth Inspection Machine

Manufacturer name Uzu fabric Inspection
County Thailand
Model No. UZ 900.31
2. Flat Knitting Section:
Generally collar, cuff of knitted garments is produced in this section. In this

section there are 25 flat knitting machines. all of them are same type and
also have same specification. The specification of all machines is given
below:
Type Automatic Flat knitting machine

Manufacturer name Precision Fukuhara Works Ltd.
Country Japan
Model No. \l-100
Gauge G14
3. Circular Knitting Section:
This section contains 72 circular knitting machines. Circular knitting

machines are of different types, made by different manufacturer and also
have different specifications. In this section body fabric for knitted garments
is produced. The different specifications of different machines are given one
after another
4. Store section:
In this section knitted fabric and yarns are stored.

Page 2
Automatic Flat Bed M/C
Automatic Flat Bed M/C

Page 2
Machine List of Knitting Section in Viyellatex :
Machine name Machine Quantity
Circular Knitting(Single jersey) m/c 32
Circular Knitting(Rib) m/c 18
Engineering Stripe m/c 08
V-bed Knitting m/c 26
Grey Fabric Inspection m/c 03
Specification of Circular Knitting Machine:
Machine no: 01 Machine no:02

Machine type: Single jersey Machine type: Single jersey
Brand: Fukuhara (vxc-3s) Brand : Fukuhara (vxc-3s)
Origin: Kobe, Japan Origin : Kobe, Japan
Machine dia &Gauge: 30”; 24G Machine dia&Gauge:26”.24G
Extra cylinder: 30”; 20G No of Needle : 1932
\o of needle: 1860 No of feeder : 78
Machine no: 03 Machine no: 04
Industrial attachment Machine type: Single jersey
Machine type: Single jersey Brand: Fukuhara (vxc-3s)
Brand: Fukuhara (vxc-3s) Origin: Kobe, Japan
Origin: Kobe ,Japan Machine dia &Gauge: 30”; 24G
Machine dia &Gauge: 26”; 24G Extra cylinder:
Extra cylinder: No of needle: 2268
No of needle: 1932 No of feeder: 90
No of feeder: 78
Brand:Pai Lung Brand:Pai Lung
Origin: Taiwan Origin: Taiwan
Machine dia &Gauge: 36~ 24G Machine dia &Gauge:25”;24G
No of needle: 2712 No of needle: 1872
\o of feeder: 108 No of feeder: 74
Machine type: Single jersey(2 Machine type: Single jersey
truck) Brand: Pai Lung
Brand: Pai Lung Origin: Taiwan
Origin: Taiwan Machine dia &Gauge:30”;28G
Machine dia &Gauge:25”;24G Extra cylinder : 33”, 24G
No of needle: 1872 No of needle : 2236
No of feeder: 74

Page 2
Brand: Pai Lung Brand:Fukuhara (v.c-3.25)
Origin: Taiwan Origin: Kobe Japan
Machine dia &Gauge:30”;28G Machine dia &Gauge:30”;24G
Extra cylinder: 30”;24G Extra cylinder: 30”;20G
No of feeder: 90 No of feeder: 98
Brand:Fukuhara (B.c-3.25) Brand:Fukuhara (B.c-3.25)
Origin: Kobe Japan Origin: Kobe Japan
Machine dia &Gauge:30”;24G Machine dia &Gauge:30”;24G
Machine no: 13 14Machine no: 14
Machine type: Single jersey Machine type: Fleece
brand: Fukuhara (B.c-3.25) Brand: Terrot
Origin: Kobe Japan Origin: Germany
Machine dia &Gauge:30”-24G Machine dia &Gauge:30”~20G
No of needle: 2268
Noofneedle:~872
No of feeder: 98
No of feeder: 96
Machine no: 15 16. Machine no: 16
Machine type: Terrot Machine type: Rib\Interlock
Brand: Terrot Brand: Terrot
Origin: Germany Origin: Germany
Machine dia &Gauge:30”:20G Machine dia &Gauge:30”;18G
Noofneedle:1872 Extra cylinder: 30”~22G
No of feeder: 96 No of needle: 3368
No of feeder: 54
Machine no:17 Machine no: 18
Machine type: Rib Machine type: Rib
Brand: Terrot Brand: Terrot
Origin: Germany Origin: Germany
Machine dia &Gauge:34”-18G Machine dia &Gauge:36”; 18G
No of needle: 3840 No of needle : 4080
No of feeder: 60 No of feeder :64
Machine no :19 Machine no : 20

Machine type : Rib / Interlock Machine type : Single jersey
Brand : Terrot Brand : Mayer & Cie
Origin : Germany Origin : Germany
Machine dia & Gauge : 36 “ 28G
Machine dia & Gauge : 30: ; 28G
Extra cylinder : 36` 22G
No of needle : 4080
No of needle:980
No of feeler :64
Machine type: Single jersey Machine type: Rib
Page 2
Brand: Mayer & Cie Brand: Fukuhara(V-ER-22)
Origin: Germany Origin: Kobe Japan
Machine dia &Gauge:30”,28G Machine dia &Gauge:36”,18G
Extra cylinder: 30”,24G No of needle: 4078
No of feeder: 96
Machine no: 23 Machine no: 24.
Brand: Fukuhara (v.er-22) Brand: Fukuhara (v-er-22)
Machine no: 25. Machine no: 26
Brand: Fukuhara (v-er-22) Brand: Pai Lung (pl-xra\ce)
Origin: Kobe Japan Origin: Taiwan
Machine dia &Gauge:36”-l8G Machine dia &Gauge:38”18G
No of needle: 4078 Noofneedle:2160
Machine no: 27. Machine no: 28.

Brand: Pai Lung(pl-xr2b\ce) Brand: Pai Lung (pl-xr2b/ce)

Machine type: Rib Machine type: Single jersey
Brand: Pai Lung(pl-xr2b\ce) Brand: Pai Lung
Machine dia &Gauge:38”,18G Machine dia &Gauge:24”~24G
No of needle: 2124 No.of needle: 1800
Machine no: 31 Machine no: 32.

Machine type: Single jersey Machine type: Interlock
Brand: Pai Lung Brand: Pai Lung
Machine dia &Gauge:26”;24G Machine dia &Gauge:36”,22G
(Auto Stripe)(pl-xscsl 6) (Auto Stripe)(pl-xscsl 6)
Page 2
Machine dia &Gauge:30”,24G Machine dia
Extra cylinder: 30”,16G &Gauge:30’:24G
No of needle: 2256 Extra cylinder: 3O”~16G
No of feeder: 42x6 No of needle 22~6
No of feeder: 42x6
Machine No. 35 Machine No.

Type Auto striper Double jersey. 36
Brand PAL LUNG. TAIWAN
Origin TAIWAN. Type Auto striper Double
lodJ No PL-XDCS/6-U jersey
Machine Dia: 36 Brand PA! LUNG.
Gauge 18G Origin TAIWAN.
Model No. PL-XDCSI6-L
Machine Dia 36
Gauge 18G
PL
\F3B-—LP
Machine No. 37 Machine No. 38
Type Fleece Type Fleece
Brand PAl LUNG. Brand PAl LUNG.
Type Single jersey Type Single jersey
Brand PAT LUNG. Brand PAT LUNG.
Origin TAIWAN Origin TAIWAN
ModelNo. PL-XS4BACE. ModelNo. PL-XS4BACE.
Machine Dia 36” Machine Dia 36”
Gauge 24G Gauge 24G
Feeder No. 144 Feeder No. 144
Type Single jersey Tvpc Single jcrscv.
Brand PAT LUNG. Brand PAl LUNG.
Origin TAIWAN Origin TAIWAN.
ModelNo. PL-XS4BACE. Model No. PL-XS4B/AICE
Machine Dia 36” Machine Dia 23
Gauge 24G Gauge 24G
Feeder No. 144 Feeder No. 78

Type Double jersey Tvpe Doublc jersey.
Brand PAl LUNG Brand PAI- LUNG.
Machine Dia 38 Origin: TAIWAN
Gauge 18G Dia 38
Feeder No. 76 Gauge I 8G

Page 2
Fccdcr No. 76
Machine type: Single jersey. Machine type: Single jersey.
Brand:Fukuhara Brand: Fukuhara
Machine dia &Gauge:30x20
Machine dia &Gauge:30x20
No of feeder: 98
No of feeder: 98
Brand: Fukuhara Brand: Pai Lung
Origin: Kobe Japan Origin: Taiwan
Machine dia &Gauge:30x20 Machine dia &Gauge:36x24
No of feeder: 98 No of needle: 2850
No of feeder: 144
Brand: Pai Lung Brand: Fukuhara
Origin: Taiwan Origin: Kobe Japan
No of feeder: 144
Machine type: Single jersey(Auto Machine type Single
stripe) jersey(Auto strip)
Machine dia &Gauge: 3 0x247 Machine dia &Gawie:30x2
No of needle:2256 No of needle: 2256
No of feeder: 42x6 No of feeder: 42x6
Machine type: Rib(Auto stripe) Machine type: Rib(Auto stripe)
Machine dia Machine dia &Gauge:36x18
&Gauge:36x1 8 No of needle: 2040
No of needle:2040 No of feeder: 54x6
No of feeder54x6
Machine no: 53 Lachine no: 55
Machine type: Single Machine type: Single jersey(Auto
jersey (Auto stripe) stripe)
Machine dia & gauge : 30x24 Machine dia &Gauge:36x24
industrial attachment No of needle:2712
No opf needle : 2256 No of feeder: 50x6
no of feeder 42x6

Page 2
(Auto stripe) Brand: Fukuhara
Brand: Pai Lung Origin: Kobe Japan
Origin: Taiwan Machine dia &Gauge:26x24
Machine dia &Gauge:36x24 No of feeder: 86
No of needle: 27U
No of feeder: 50x6
Brand: Fukuhara Brand: Fukuhara


Machine dia &Gauge:30x20 Machine dia &Gauge8x24
No. of feeder: 30 No of feeder: 84


Page 2
Machine no: 68 Machine No: 69
Brand: Fukuhara Brand:Keumyong
Origin: Kobe Japan Origin:Koria
Machine dia &Gauge:36x4 M/C Dia&Gauge:30*20
No of feeder: 118 No of feeder:90
Machine No: 70 Machine No: 71

Machine type: Single jersey Machine type: Single jercy
Brand:Keumyong Brand:Keumyong
Origin:Koria Origin:Koria
M/C Dia&Gauge:30*20 M/C Dia&Gauge:30*20
No of feeder:90 No of feeder:90
Machine No: 72
Machine type: Single jersey
Brand:Keumyong
Origin:Koria
M/C Dia&Gauge:30*20
No of feeder:90
Specification of V-Bed Knitting Machine:
No. of V-Bed Knitting m/c: 26

Machine no-(01-15)
M/c type: Rib (collar)
Brand name: Matsuya
Origin: Japan
Manufacturing no: 8103
Gauge: 14
Date of manufacturing: 2004
Machine no-(16-25)
M/c type: Rib (collar)

Brand name: Strickmaschinen GMBH
Origin: Germany
Needle: 2040
Manufacturing no: 8103
Gauge: 16
Date of manufacturing: 2002

Page 2
Others Machines in Knitting Section:
1. Gray Fabric Inspection M/c
Brand: Uzu cloth inspection machine
Manufacturer: AATPR INDUSTRY CO.LTD.
Model: UZ – 900-3
Origin: Thailand.
No. of Machine: 03
2. Electric Balance for Fabric Weight.

3. Electric Balance for GSM check.
PROCESS FLOW CHART FOR KNITTING
YARN IN PACKAGE FORM
PLACE THE YARN PACKAGE IN THE CREEL
FEEDING THE YARN
SET THE M/C AS PER DESIGN &GSM
KNITTING
WITHDRAW THE ROLLED FABRIC AND WEIGHTING
INSPECTION
NUMBERING
Product Mix
SINGLE JERSEY
 S/J
 LYCRA S/J
 YARN DYED S/J
 POLO PIQUE
 SINGLE LACOSTE
 DOUBLE LACOSTE
 FLEECE
 LYCRA FLEECE

Page 2
DOUBLE JERSEY
 1*1 RIB
 1*1 LYCRA RIB
 YARN DYED RIB
 2*1 RIB
 2*2 RIB
 2*2 LYCRA RIB
 INTERLOCK
Type of Collar
 TIPPING COLLAR
 SOLID COLLAR
 RAISING COLLAR
 PEACOT COLLAR
 WAISY BAND / HEM
PRODUCTION CALCULATION:
A. Production/shift in kg at 100% efficiency
RPM × No. of Feeder × No. of Needle × SL(mm)

=
3527 .80 × Yarn count
B. Production/shift in meter
Course / min .
=
Course / cm
RPM × No. of Feeder × 60 × 12 × Efficiency
=
Course / cm × 100
C. Fabric width in meter:
Total no. of wales

=
Wales / cm × 100
Total no. of Needles used in knitting
=
Wales / cm × 100

Page 2
PRODUCTION PARAMETER:
1. Machine Diameter
2. Machine rpm (revolution per minute)
3. No. of feeds or feeders in use
4. Machine Gauge
5. Count of yarn
6. Required time (M/C running time)
7. Machine running efficiency
Production
 Calculated Fabric Production = 18 M. Ton

 Actual Fabric Production = 12-14 M. Ton
 Circular Knitting m/c production= 200 -500 kg per m/c/day

 Auto Stripper production = 60- 150 kg/mc
 Collar production= 11500-13500 pc/ day

Page 2
SAMPLE AND ANALYSIS OF VARIOUS TYPE OF KNITTED
FABRIC:
Fabric: Single jersey
SAMPLE
NOTATION DIAGRAM
× × × ×
× × × ×
× × × ×
× × × ×
× × × ×
CAM SETTING ARRANGEMENT
∆ ∆ ∆ ∆
∆ ∆ ∆ ∆
NEEDLE ARRANGMENT
1
2
N.B: 1 = One butt needle
× = Knit stitch 2 = Two butt needle
∆ = Knit cam

Page 2
Fabric: 1 × 1 Rib
SAMPLE
∆ ∆ ∆ ∆ ∆ ∆
∆ ∆ ∆ ∆ ∆ ∆ D
∆ ∆ ∆ ∆ ∆ ∆
∆ ∆ ∆ ∆ ∆ ∆ C
NEEDLE ARRANGMENT 1
L HL
LS 22 22
N.B:
∆ = Knit cam
H =High butt
needle
L = Low butt needle
1 = One butt needle
2 = Two butt needle

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Fabric: 2 × 2 Rib
SAMPLE
∆ ∆ ∆ ∆ ∆ ∆
NEEDLE
ARRANGMENT D
∆ ∆ ∆ ∆ ∆ ∆
LH
S ∆ ∆ ∆ ∆ 1∆ ∆
C
∆ ∆ ∆ ∆ ∆ ∆
22
N.B:
∆ = Knit cam
H = High butt needle
L= Low butt needle
C= Cylinder
D= Dial
1 = One butt needle
2 = Two butt needle
Fabric: Plain Interlock

SAMPLE

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∆ ―― ∆∆ ――
―― ∆∆ ―― ∆∆
―― ∆∆ ―― ∆∆
∆ ―― ∆∆ ――
NEEDLE ARRANGMENT
H
N.B:
∆ = Knit cam ― = Miss cam
H = High butt needle C = Cylinder
L = Low butt needle D = Dial
1= One butt needle

2 = Two butt needle

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Fabric: Single Lacost
SAMPLE
NOTATION DIAGRAM
× × × ×
• ×× •• ××
× × × ×
×× •• ×× ••
∆ ∆∆ ∆∆
∆ ∆ ∆
NEEDLE ARRANGMENT
1
2
N.B: 1 = One butt needle
× = Knit stitch 2 = Two butt needle
∆ = Knit cam
=Tuck cam
• = Tuck stich

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Fabric: Double Lacoste
SAMPLE
NOTATION DIAGRAM
× × × ×
×× •• ×× ••
× •• ×× ••
× × × ×
•• ×× •• ××
•• ×× •• ××
∆ ∆ ∆ ∆
∆ ∆ ∆ ∆
NEEDLE ARRANGMENT
1
2
N.B:
× = Knit stitch 1 = One butt needle
• = Tuck stitch 2 = Two butt needle
= Tuck cam
∆ = Knit cam

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Fabric: Terry/French Terry/Two Thread
SAMPLE
NOTATION DIAGRAM
× × ×
• ― ―
× × ×
― ― ••
1 2 3 4
∆ ∆
∆ ∆∆
∆ ∆∆
NEEDLE ARRANGMENT
1
2
3
NB: × = Knit stitch 1 = One butt needle
= Tuck cam 3 = Three butt needle
∆ = Knit cam ― = Miss stitch
• = Miss cam

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Fabric: Fleece (Three Thread)
SAMPLE
NOTATION DIAGRAM
× × ×
× × ×
• ― ―
× × ×
× × ×
― •• ―
× × ×
× × ×
― ― ••
1 2 3 4 5 6 7 8 9
∆ ∆ ∆ ∆ ∆ ∆
∆ ∆ ∆ ∆ ∆ ∆
∆ ∆ ∆ ∆ ∆ ∆
NEEDLE ARRANGMENT
1
2
3
NB: × = Knit stitch 1 = One butt needle
= Tuck cam 3 = Three butt needle
∆ = Knit cam ― = Miss stitch
= Miss cam
FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:

1. Hole Mark
Causes:
 Holes are the results of yarn breakage or yarn cracks.
 During loop formation the yarn breaks in the rejoin of the needle
hook.

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 If the yarn count is not correct on regarding structure, gauge, course
and density.
 Badly knot or splicing.
 Yarn feeder badly set.
Remedies:
 Yarn strength must be sufficient to withstand the stretch as well as
uniform.
 Use proper count of yarn.
 Correctly set of yarn feeder.
 Knot should be given properly.
2. Needle Mark
Causes:
 When a needle breaks down then needle mark comes along the
fabrics.
 If a needle or needle hook is slightly bends then needle mark comes
on the fabrics.
Remedies:
 Needle should be straight as well as from broken latch.
3. Sinker Mark
Causes:
 When sinker corrode due to abrasion then some times can not hold a
new loop as a result sinker mark comes.
 If sinker head bend then sinker mark comes.
Remedies:
 Sinker should be changed.
4. Star
Causes:
 Yarn tension variation during production.
 Buckling of the needle latch.
 Low G.S.M fabric production.
Remedies:
 Maintain same Yarn tension during production.
 Use good conditioned needles.
5. Drop Stitches

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Causes:
 Defective needle.
 If yarn is not properly fed during loop formation i.e. not properly laid
on to the needle hook.
 Take-down mechanism too loose.
 Insufficient yarn tension.
 Badly set yarn feeder.
Remedies:
 Needle should be straight & well.
 Proper feeding of yarn during loop formation.
 Correct take up of the fabric & correct fabric tension.
 Yarn tension should be properly.
6. Oil stain
Causes:
 When oil lick through the needle trick then it pass on the fabrics and
make a line.
Remedies:
 Ensure that oil does not pass on the fabrics.
 Well maintenance as well as proper oiling.
7. Rust stain
Causes:
 If any rust on the machine parts.
Remedies:
 If any rust on the machine parts then clean it.
 Proper maintenance as well as proper oiling.
8. Pin hole
Causes:
 Due to break down or bend of the latch, pin hole may come in the
fabric.
Remedies:
 Change the needle
9. Grease stain
Causes:

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 Improper greasing
 Excess greasing
Remedies:
 Proper greasing as well as proper maintenance
10. Cloth fall- out
Causes:
 Cloth fall- out can occur after a drop stitch especially when an empty
needle with an empty needle with closed latch runs into the yarn
feeder and remove the yarn out of the hook of the following needles.
Remedies:
 Make sure all the latches of needle are closed with feeding yarn after
a drop stitch.
11. Barre:
A fault in weft knitted fabric appearing as light or dark course wise

(width wise) Stripe.
Causes:
 This fault comes from yarn fault.
 If different micro near value of fiber content in yarn.
 Different lusture, dye affinity of fiber content in yarn.
 During spinning different similar classes of fiber is mixed specially in
carded yarn & these fibers have similar characteristics.
 In draw fame different similar classes sliver is mixed and make one
sliver.
Remedies:
 We can use this fabric in white color.
12. Fly dust:
Causes:
 In knitting section too much lint is flying to and fro that are created
from yarn due to low twist as well as yarn friction. This lint may
adhere or attaches to the fabric surface tightly during knit fabric
production.
Remedies:
 Blowing air for cleaning and different parts after a certain period of
time.

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 By cleaning the floor continuously.
 By using ducting system for cleaning too much lint in the floor.
 Over all ensure that lint does not attach to the fabric.
13. Yarn contamination
Causes:
 If yarn contains foreign fiber then it remains in the fabric even after
finishing,
 If lot, count mixing occurs.
Remedies:
 By avoiding lot, count mixing.
 Fault less spinning.
14. Yarn Faults:
 Neps.
 Slubs.
 Yarn count variations.
 Thick/Thin place in yarn.
 Hairiness.

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Batching is the process to get ready the fabrics which should be dyed
and processed for a particular lot of a particular order.
Function or Purpose of Batch Section
- To receive the grey fabric roll from knitting section or other source.
- Turn the grey fabric if require.
- To prepare the batch of fabric for dyeing according to the following
criteria –
• Order sheet (Received from buyer)
• Dyeing shade (color or white, light or dark)
• M/C capacity
• M/C available
• Type of fabrics(100% cotton, PE, PC, CVC)
• Emergency
- To send the grey fabric to the dyeing floor with batch card.
- To keep records for every previous dyeing.
Proper batching criteria
- To use maximum capacity of existing dyeing m/c.

- To minimize the washing time or preparation time & m/c stoppage
time.
- To keep the no. of batch as less as possible for same shade.
- To use a particular m/c for dyeing same shade.
Batch management
Primarily batching is done by dyeing manager taking the above

criteria under consideration. Batch section in charge receives this primary
batch plan from dyeing manager. Some time planning is adjusted according
to m/c condition or emergency.

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Machines in batch section
M/c quantity: 02
M/c Specification:
Machine Name : Air turning m/c

M/c No : 01
Brand Name : Taida
Origin : China
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company :Shandong Taida Dyeing &
Finishing
Machinery Co.Ltd
Machine Name : Air turning m/c

M/c No : 02
Brand Name : Taida
Origin : China
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company :Shandong Taida Dyeing &
Finishing
Machinery Co.Ltd.

Page 2
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LABORATORY
LABORATORY MACHINERIES WITH ITS SPECIFICATION
1. Tearing Strength Tester:

 Brand Name :Elmatear
 Origin : U.K
2. Button Strength Tester:

 Brand Name : Titan
 Origin : U.K
 Max.Pressure: 10 bar
 Capacity : 3000N
3. Bursting Strength Tester:

 Brand Name : TruBurst
 Origin : U.K
4. Pilling Resistant Tester:

 Brand Name : Impulse
 Origin : U.K
5. Sprectra Flash:
 Brand Name : Data Color
 Origin : U.S.A
Test Name: Colorfastness to Washing, Dry cleaning.

Name of the m/c : Rota Wash
 Origin : U.K
 Test Method :ISO105-C06, ISO105-D02
Test Name: Dimensional Stability, Spirality, Appearance after

washing.
Name of the m/c : Eltrolux wascator.
 Origin : U.K
 Test Method : ISO 6330, ISO 26330

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Test Name : Shrinkage Test.
Name of the m/c : Eltrolux
 Origin : U.K
Test Name : Color Fastness to Wash Test.

Name of the m/c : Gyro wash
 Origin : U.K
 Test Method : ISO 105-C06
Lab Dip m/c:

No.of m/c: 02
M/C NO- 01
 Brand name : Ahiba Nuance Lab Dip Dyeing m/c
 Origin : U.S.A
M/C NO- 02
 Brad name : Ahiba Nuance Lab Dip Dyeing m/c
 Origin : U.S.A
Color Matching Cabinet (Light box):
No. of Light Box: 02
Light Box no: 01

 Brand : Spectralight-111
 Origin : U.S.A
Light Source:
 Day Light (D-65)
 Cool White
 Horizon
 UV
 TL-84
 A (F11-10 degree)
Light Box no: 02

 Brand : Verivide

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 Origin : U.K
Light Source:
 Day Light (D-65)
 UV
 TL-84
 A (F11-10 degree)
Laboratory is the heart of dyeing Industry. An efficient laboratory can

increase the efficiency of dyeing. So, laboratory in-charge is sometimes
called pilot. Before bulk production a sample is sent to buyer for approval.
Laboratory supplies the recipe to the floor.
Purpose of Laboratory:
 Get color approval from buyer.
 Recipe supply to the floor.
 Shade correction.
 Minimize the deviation between bulk and laboratory.
Laboratory line:
Standard sample:
At first recipe % of standard sample is measured by CCM (computer color
matching) system.
Laboratory Trial:
Then by taking those recipe laboratory officers produce laboratory trial
and match with standard according to buyer requirement.
Approved Sample:
Then sample swatch, which is matched with the standard, is send to
buyer for approval.
Off-Line Tests:

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Off-Line tests for finished fabrics are divided into two groups. These are as
follows:
 Physical tests
 Chemical tests
Scope for Quality control, quality assurance and testing
1 Testing lab
2.Machine auditing system
3.A good training system
4.Excellent analytical back up
5.Technical expertise
QUALITY ASSURANCE SYSTEM

The Quality assurance Department is assigned to maintain consistently
uniform quality of the material in process and various stages of its
manufacturing. VIYELLATEX LTD is more about concern about quality. In
this factory quality assurance is more preferred than quality control, but
both are in advancement.
Objects of Quality Control:

1.Research.
2.Selection of raw materials.
3.Process control.
4.Process development.
5.Product testing.
6.Specification test
Quality management system in viyellatex:
QA
On-Line Off-Line

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Online Quality control:
There are two types of online quality control. These are as follows: -
• Raw material control:
Raw material control means control the quality of raw materials (e.g.-
Quality of Grey fabric, Dyes, Chemicals and Auxiliary)
• Process control:
Process control means the selection of right process and controlling of some
parameters. Such as PH, Water hardness, water volume, Temperature, Reel
Speed, Pump pressure, etc.
Online Tests:
 Dyed fabric.
 Shade check.
 Wash fastness.
 Water fastness.
 Crocking fastness.
Off-Line Tests:
Off-Line tests for finished fabrics are divided into two groups. These are as
follows:
 Physical tests
 Chemical tests
Physical Tests:
 GSM of Fabric.
 Abrasion resistance / Pilling.
 Dimensional stability test.
 Spirality test.
 Color fastness to rubbing test (Dry / Wet).
 Bursting strength test (For Knitted fabric).
 Tensile Strength test (For Woven fabric).
Chemical Tests:
 Color Fastness to washing.
 Color Fastness to light.

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 Color Fastness to heat.
 Color Fastness to actual laundering
 Color Fastness to Chlorinated water.
 Color Fastness to water spotting.
 Color Fastness to perspiration.
 Color Fastness to Seawater.
 Flammability test.
 Fibre analysis.
 PH test.
 Spray test (water repellency).
 Phenolic yellowing.
RESPOSIBILITY OF OFF-LINE QUALITY CONTROL:

To check the following things:
 Inspection of fabric in the inspection M/C under 4-point system.

 Yarn count and lot no.
 Buyer.
 Design.
 Stitch length of grey fabric.
 Shade of grey fabric with in one order.
RESPOSIBILITY OF ON LINE QUALITY CONTROL

To check the following things:
M/C Dia/Gauge
 Buyer
 Design
 Grey fabric GSN & Stitch Length
 Yarn count & Lot no
 Yarn whether approved or not by Q.C. Department
 Finished dia & grey dia.

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 Fabric quality checking under 4-point system.
RESPONSIBILITY OF IN CHARGE OF QUALITY CONTROL
 Making report.
 Supervise the grey Q.C.
 Check machine is running according to program or not
 Check program can meet the requirement. Which is mentioned in
the order sheet or not.
 Check yarn is approved by Q.C. or not.
RESPONSIBILITY OF THE FINISHING Q.C.
Finishing Q.C. (shade):

 After unloading from dyeing cut small piece, check shade with
std/approved lab dip/production sample & previous production batch
(if any).
 Then instruction to finishing for finish by mentioning specific
temperature in dryer.
 After finish again cut sample & check same way like before at dry
state.
 Keep the record of every lot after dry & after finished state.
 If any batch is not OK at any stage then make the re-process card for
dyeing.
 If any batch is closer to standard but not exactly pass with standard,
then make trial for that batch in finishing to make it OK.
 Maintain the resister of all batches.
 Check the shade of Body to Rib, Body to Collar & Cuff.
In charge:
 Supervise the trainee Q.C. & Q.C.
 Make report every day.
 Cross check whatever shade already checked by Q.C.
Q.C. (Finishing):

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 Make the R2R continuity of each dye lot by cutting small piece from
each roll of dye lot.
 Inspect 30-40 % of each dye lot under 4-point inspection system &
report accordingly.
 If found any problem then re-inspect 100% of that dye lot and make
report & re-process card (if re-process able) for dyeing. If it is knitting
faults then immediately inform to officer asking decision.
 Check the evenness of a dye lot by checking R2R continuity.
 Check the shade of body to rib, body to collar & cuff.
In charge:
 Monitor the all Q.C.’S (finishing) work including shade Q.C.
 Take decision when asking advise from his subordinate.
 Make daily problematic batch report.
 Make daily production report.
 Maintain resister khata.
 Make daily batch re-process job card.
RESPOSIBILITY OF QUALITY ASSURANCE MANAGER:

 Responsible for all quality matter of fabric.
 Yarn selection.
 Monitoring product development.
 Organize Laboratory.
 Control grey and finished fabric inspection under 4- point system.
 Documentation after shade check of every lot.

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Quality Assurance Procedure
1) Body & Rib Inspection:

All rolls are kept in front of the inspection m/c time to time and are
inspected over the inspection m/c visually in a pre-set speed against light.
For any major or minor faults like thick-thin, barre mark, fall out,
contamination, fly, holes, oil lines, needle line, stubs etc are recorded in
inspection report to classify the fabric based on the four point system.
2) Collar cuff Inspection:

Collar& cuff are inspected visually under the tight box, any major or minor
faulty collar/cuff like having wrong ply, hole, needle line, stubs, wrong
design, first round problem etc properly counted and recorded.
Quality Standard:
VIYELLA TEX Ltd. maintains the ISO: 9002 standard in case of quality.
Therefore the four point system is followed to inspect the body & rib fabric.
The defects found and points given against are recorded in the inspection
sheet. Following table shows the four point grading system followed by
inspection at VIYELLA TEX Ltd.
Four point grading system

Size of defects Penalty
3 inches or less 1 point
‘ 2 point
Over 3 inch but not over 6 inch
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point

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Following table shows common body and rib faults and response by
inspection section at VIYELLA TEX Ltd.
Acceptance Calculation
Factory: Roll yardage (A) Total points founds(B)
Formula : X100 =points per 100 yard
Classification:
← 40 points =A type
41-60 =B type
61-80 =C type
Above 8Opoin = Reject
Tests
There are two types of tests are done in Quality Assurance Department.
They are —
1. Physical Tests
2. Chemical Tests
Physical Tests:
 Yarn Grade
 GSM test
 Shrinkage test
 Spirality test
 Tensile strength
 Abrasion resistance
 Button Strength Testing
 Lycra% determination
 Crease resistance
Chemical Tests:
 Fastness to washing.
 Fastness to light

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 Fastness to actual laundering
 Fastness to sea water
 Fastness to water
 Fastness to perspiration
SOME TEST PROCEDURE

Color fastness to rubbing (wet & dry):
Procedure:
At first take a sample of size (14 × 5) cm at Wales & Course wise. Put the
crocking cloth on to the finger & stag by finger clip & run 10 times in 10
seconds manually & assess the crocking cloth with gray scale.
Place the crocking cloth on the water, it will sucked some water and then
squeeze the crocking cloth. Then place the wet rubbing cloth on to the
finger and stag with finger clip and run 10 times in 10 seconds manually.
Then assess the crocking cloth by gray scale for wet rubbing. Wet and dry
rubbing are checked according to buyer’s requirement.
Color fastness to washing(ISO/05-CO6):
Procedure:
1. Size of specimen: Cut sample & multifibre at (10 × 2)cm then stitch.
2. Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in distilled
water & cooled at 20°C & measured PH (where necessary).
3. Run the program in the following way: -
Test no. Temp°C Liq.volume ml Time min. Steel balls Adjust pH
C2S 60°C 50 30 25 10.5±1
4. Rinse the sample twice with cold water.
5. Dry at 60°C by hanging or by flat iron pressing but temperature should not less
more than 150°C.
Pilling test:
Procedure:

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Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using
template. Then sewn the fabric so that it can be firmly fit in the tube a
moulded polyurethane tubes. Then four tubes are placed in a box & start
60±2 rev/min for 5 hrs or according to buyer requirement. Here mainly
used 3hrs(1100 cycle). Then assess the pilling by putting tested
specimen on the viewing cabinet & compare with standard photographs.
Shrinkage & Spirality test:
Buyer’s requirements:
Template size: 50cm & 35cm, 25.5cm &18cm (use after quick wash).
Shrinkage: length wise--- 5%
Width wise----5%
Spirality: Left -------- 5%

Right -------- 5%
Procedure:
At first take two ply of fabric & put the template (50cm) on to the fabric. The
template has 8 holes. Both length & width wise the template holes can
measure 35cm at 3 places. Then we mark the 8 holes by permanent marker
& also at the edges of the template.
Then sewn the fabric & it is given to the washing m/c for run at 60°C for
60minutes with water. After that dry the sample & then measure the fabric
Spin speed --- 500rpm
Drum speed--500rpm
Calculation:
 Shrinkage Test:
Lengthwise:
After wash – Before wash
= ----------------------------------×100
Before wash
Width wise:
After wash – Before wash
= ----------------------------------×100
Before wash


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
Spirality test:
Left side + Right side

= 2 × 100 %
Length(width for H & M)
Color fastness to water (ISO 105 EO1& EO2):
1. Sample size: Cut the specimen & multi-fiber at 10×2cm & sewn
together.
2. Solution: Wet in distilled water at room temperature & it will suck
water.
3. Place it in acrylic resin plates & put the weight on to the plates.
4. Keep it in oven & keep the temperature at 37± 2°C for 4hrs.
5. Open the specimen & dry it in the air hot exceeding 60°C.
6. Assess the staining & shade change with gray scale.
Color fastness to perspiration Alkaline & Acid solution
(Method: ISO 105 E04):
1) Procedure:
Cut the specimen & multifibre at 10×2cm & sewn together.
2) Prepare solution:
Alkaline Solution:
 0.5g/l of 1-histadine mono hydrochloride monohydrate
 5g/l of sodium chloride
This solution is brought to pH -8 with 0.1 mole/l caustic solution.
Acid solution:
 0.5 g/l of 1-histadine monohydrochloride monohydrate

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 5g/l of sodium chloride.
 2.2 g/l of sodium dihydrogen orthophosphate dehydrate.
This solution is brought to pH-5.5 with 0.1 mole/l caustic solution.
3) M: L = 1: 50
4) Wet the specimen in flat dish containing acid & alkaline solution & keep
for 30min. Then take the specimen & squeeze the excess solution by two
glass rods.
5) Put the specimen in to the acrylic resin plates & put wt. on the plates.
6) Keep it in the woven at 37°C ± 2°C for 4hrs.
7) Open the specimen 6 multi fibre & dry separately in the air temperature
not exceeding 60°C.
8) Access the staining & shade change with grey scale.
PH Test:
Procedure:
Take 2gm sample fabrics and cut into small pieces. Then put it conical flax
with 100cc water (M: L -1:50). Then shake it 15 min, then place it in a
shaker m/c for 1 hour. Then check PH by PH meter.
GSM TEST:
Procedure:
GSM is the most important factor. There is a GSM cutter. The sample
cut by the GSM cutter is weighted in the electronic balance. The reading (in
gm) from the balance is multiplied by 100 to get the value of GSM.
Remarks:
They have a well-equipped Testing laboratory called Textile Testing Services
limited for all kinds of Textile Testing. The laboratory of viyellatex is
approved by world renowned buyer Marks & Spenser and also Puma. Now
they are just testing their internal tests but they are trying to develop their

Page 62
laboratory. So that external author can send their textile material for testing
by suitable testing fees.

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Organogram of Dyeing Section:
C.E.O (Fabric)
G.M / D.G.M / A.G.M (01)
Manager (01)
Assistant Manager (02)
Senior Executive (03)
Executive (03)
Production Officer (03)
Senior Supervisor
Supervisor / Jr. Supervisor
Production Operator
Production Helper

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Responsibility of production officer
o Overall supervision of dyeing & finishing.
o Dyes & chemicals requisition issue & check.
o Program making, sample checking color measurement.
o Control the supervisor’s operators & helpers of machines.
o To give dye-line or the program slip according to daily
production plan, batch preparation & PH check.
o To rectify the finished fabric which rejected from quality control
department
o To check daily production report.
o To study dye & chemicals nature delivery by the manufacture &
applied them correctly to the production to get best product
Job Description:
Title: Production officer.
Dept: Dyeing
Report to: Senior production officer.
Job summary: To plan execute & follow up the production
activities & control the quality production with related activities.
Title: Senior production officer.

Dept: Dyeing.
Report to: Dyeing manager.
Job summary: To plan execute & follow up the production
activities & control the quality production with related activities.
Duties & Responsibilities :

 Overall supervision of dyeing, finishing production.
 Checks the different log books of different areas & report to
management.
 Checks the sensitive parameters of different machine for smooth
dyeing.
 Checks out the plan to control the best output from supervisor &
workers.
 To trained up & motive the subordinates how to improve the quality
production.
 Maintenance of machine & equipment. Any other works & when
required by the management.
 Control the supervisors, operator, asst. operator & helpers of dyeing
m/c.
REMARKS:
The manpower management system VIYELLATEX GROUP is well arranged.
Every officers & stuffs are responsible for their duty. But there are only six

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textile engineers in the industry 11 for dyeing & 1 for Finishing. It is
sufficient for Finishing). It is sufficient for fluent production. The efficiency of
the \\orker should be increased for more quality production.
Dyeing Machine Capacity
Bulk Dyeing Machine
Machine Number Capacity in Kg

Machine Number: 01 500
Total Capacity= 11,360
Sample Dyeing Machine Capacity

Machine Number Capacity in Kg

Page 62
Total Capacity=
350
Total capacity of Bulk dyeing & Sample dyeing machine=

11,710 Kg

Page 62
Bulk Dyeing Machine Specification
Dyeing Machine: 01(FONGS)
Machine name Fongs( Atmospheric m/c)

Machine NO. ECO-38-2T
NO. of nozzle 2
Origin CHINA
Dyeing Machine: 02(THIES)
Machine Name Thie’s (High temperature m/c).

Type Farbekessel eco- soft Plus
Origin Germany
Capacity 1000 kg
Model 45506
Number of nozzle 04
Max. working Temperature 140°C
Max. Liquor Capacity 17696 liter
Working Pressure 0.35 Mpa
Test pressure : 0.55 Mpa
Year of Construction 2004

Origin Germany
Capacity 1000 kg
Model 43891
Number of nozzle 04
Test pressure 0.55 Mpa

Page 176

Origin Germany
Capacity 250 kg
Model 41346
Number of nozzle 01

Origin Germany
Capacity 500 kg
Model 41350
Number of nozzle 02
Machine Name Thie’s (High temperature machine).

Origin Germany
Capacity 750 kg
Model 41354
Number of nozzle 03
Max. Liquor Capacity 13901liter

Machine Name Fongs (High temperature machine).

Page 176
Origin CHINA
Capacity 200 kg
Model No. SHI 0515416/25
Number of nozzle 01
Design code PD 5500 2003 CAT2
Design Temp. 140°C
Design Pressure 380 KPa
Hydraulic Test pressure 585KPa
Safety Valve Set 380 KPa
Manufacturer Fongs National Engineering
(SHENZHEN)Company Ltd
Origin CHINA
Capacity 250 kg
Number of nozzle 01
Design Temp. 140°C
(SHENZHEN) Company Ltd
Origin CHINA
Capacity 750 kg
Number of nozzle 03
Design Temp. 140°C
Origin CHINA
Capacity 1120 kg

Page 176
Number of nozzle 04
Design Temp. 140°C
Origin CHINA
Capacity 840 kg
Number of nozzle 03
Design Temp. 140°C

Origin CHINA
Capacity 560 kg
Number of nozzle 02
Design Temp. 140°C
Origin CHINA
Capacity 1680 kg

Page 176
Number of nozzle 06
Design Temp. 140°C

Origin CHINA
Capacity 840 kg
Number of nozzle 03
Design Temp. 140°C
Origin CHINA
Capacity 1120 kg
Number of nozzle 04
Design Temp. 140°C
Specification Of Sample Dyeing Machine
Dyeing Machine: 01 (FONGS)

Origin CHINA
Capacity 25 kg

Page 176
Number of nozzle 01
Design Temp. 140°C
Dyeing Machine: 02 (THIES)
Machine Name Thies (High temperature machine).

Origin GERMANY
Capacity 25 kg
Number of nozzle 01
Max. Operating Pressure 0.35MPa
Max. Operating Temp. 140°C
Liquor Capacity 523 lit.

Origin CHINA
Capacity 30 kg
Number of nozzle 01
Design Temp. 140°C

Origin CHINA
Capacity 120 kg
Number of nozzle 01

Page 176
Design Temp. 140°C

Origin CHINA
Capacity 30 kg
Number of nozzle 01
Design Temp. 140°C

Origin CHINA
Capacity 60 kg
Number of nozzle 01
Design Temp. 140°C

Origin CHINA
Capacity 60 kg
Number of nozzle 01
Design Temp. 140°C

Page 176
Bulk Dyeing Machine
Machine No. Loading/Nozzle Controller
1 250*2 FC 28
2 250*4 T 737xL
3 250*4 T 737Xl
4 200*1 T 737xL
5 250*2 T 737xL
6 250*3 T 737xL
7 200*1 FC 22
8 250*1 FC 22
9 250*3 FC 22
10 280*4 FC 22
11 280*3 FC 22
12 280*2 FC 22
13 280*6 FC 22
14 280*3 FC 22
15 280*4 FC 22
Sample Dyeing Machine
Machine NO. Loading/Nozzle Controller

1 25*1 FC28
2 25*1 T505
3 30*1 FC22
4 120*1 FC22
5 30*1 FC22
6 60*1 FC22
7 60*1 FC22
Raw materials for dyeing
Raw materials used in the dyeing section are:

1. Grey fabrics
2. Dyes
3. Chemicals.
Grey fabrics

Page 176
Following types of gray fabrics are dyed in ViyellaTex:
 Single jersey
 Single jersey with lycra
 Polo pique
 Back Pique
 Single lacoste
 Double Lacoste
 Fleece
 Rib
 Rib with lycra
 1Χ1 rib

Page 176
List of dyes used in VIYELLATEX LTD.
Name of the Dyes Type Source Origin
Ciba Yellow FN2R Reactive Dye Swiss Color GERMANY
Ciba Red FNR Reactive Dye Swiss Color GERMANY
Ciba Red FN2BL Reactive Dye Swiss Color GERMANY
Ciba Blue FNR Reactive Dye Swiss Color GERMANY
Ciba Br. Blue FNG Reactive Dye Swiss Color GERMANY
Ciba Red FN3F Reactive Dye Swiss Color GERMANY
Ciba Yellow F4G Reactive Dye Swiss Color GERMANY
Ciba Scarlet F3G Reactive Dye Swiss Color GERMANY
Ciba Yellow WR Reactive Dye Swiss Color GERMANY
Ciba Red WB Reactive Dye Swiss Color GERMANY
Ciba Navy WB Reactive Dye Swiss Color GERMANY
Ciba Dk. Blue WR Reactive Dye Swiss Color GERMANY
Ciba Red HF Reactive Dye Swiss Color GERMANY
Ciba Orange HR Reactive Dye Swiss Color GERMANY
Ciba Navy H2G Reactive Dye Swiss Color GERMANY
Ciba Black WHF Reactive Dye Swiss Color GERMANY
DrimarineYellow HFR Reactive Dye Clariant SWITZERLAND
Drimarine Red HF2B Reactive Dye Clariant SWITZERLAND
Drimarine Blue HFRL Reactive Dye Clariant SWITZERLAND
DrimarineYellowCLR Reactive Dye Clariant SWITZERLAND
Drimarine Red CL5B Reactive Dye Clariant SWITZERLAND
Drimarine Navy CLB Reactive Dye Clariant SWITZERLAND
DrimarineOrangCLR Reactive Dye Clariant SWITZERLAND
Drimarine Yellow GL Reactive Dye Clariant SWITZERLAND
DrimarineTurquisCLB Reactive Dye Clariant SWITZERLAND
DrimarineTurquisK2B Reactive Dye Clariant SWITZERLAND
Drirnarin Blue CLBR Reactive Dye Clariant SWITZERLAND
Drimarin Blue K2RL Reactive Dye Clariant SWITZERLAND
Remazol Yellow~RR Reactive Dye Dyestar EUROPEAN/ASIAN
Remazol Red RR Reactive Dye Dyestar EUROPEAN/ASIAN
Remazol Blue RR Reactive Dye Dyestar EUROPEAN/ASIAN
RemazolBrBlue(RSPL) Reactive Dye Dyestar EUROPEAN/ASIAN
Remazol Blue BB Reactive Dye Dyestar EUROPEAN/ASIAN
Remazol T/Blue G Reactive Dye Dyestar EUROPEAN/ASIAN
Remazol Yellow 3RS Reactive Dye Dyestar EUROPEAN/ASIAN
Remazol Red 3BS Reactive Dye Dyestar EUROPEAN/ASIAN
Dianix Yellow SEG Disperse Dychufix EUROPEAN/ASIAN
Dianix Red CC Disperse Dychufix EUROPEAN/ASIAN
Dianix Blue ER Disperse Dychufix EUROPEAN/ASIAN
Dianix Black CCR Disperse Dychufix EUROPEAN/ASIAN
Dianix Navy CC Disperse Dychufix EUROPEAN/ASIAN
Sunfix Yellow EXF Reactive Dye Sumitomo KORIA
Sunfix Red EXF Reactive Dye Sumitomo KORIA
Sunfix Blue EXF Reactive Dye Sumitomo KORIA
Sunfix Blue BRF Reactive Dye Sumitomo KORIA

Page 176
Sunfix Yellow S3RD Reactive Dye Sumitomo KORIA
Sunfix Red S3BD Reactive Dye Sumitomo KORIA
Bezactive Red VBN Reactive Dye Bezema SWITZERLAND
Bezactive Yellow V2R Reactive Dye Bezerna SWITZERLAND
BezactiveTurquisVC Reactive Dye Bezema SWITZERLAND
Bezactive Red S2B Reactive Dye Bezerna SWITZERLAND
Bezactive blue-SLF Reactive Dye Bezerna SWITZERLAND
Imcozyn Black VB Reactive Dye Impo color GERMANY
Imcozyn Red 3BF Reactive Dye Impo color GERMANY
Imcozyn Yellow E3R Reactive Dye Impo color GERMANY
Irncozyn Blue V3R Reactive Dye Impo color GERMANY
Imcozyn T. Blue VG Reactive Dye Impo color GERMANY
ImcozynBr.OrangeVR Reactive Dye Impo color GERMANY
Terasil Yellow W4G Disperse Swiss Color GERMANY
TerasilG.Yellow W3R Disperse Swiss Color GERMANY
Terasil Navy WRS Disperse Swiss Color GERMANY
Terasil Red W4BS Disperse Swiss Color GERMANY
Terasil Blue WBLS Disperse Swiss Color GERMANY
Terasil Black WNS Disperse Swiss Color GERMANY
Terasil Black BFE Disperse Swiss Color GERMANY
Levafix Blue CA Reactive Dye Dyestar EUROPEAN/ASIAN
Levafix Rubine CA Reactive Dye Dyestar EUROPEAN/ASIAN
Levafix Amber CA Reactive Dye Dyestar EUROPEAN/ASIAN
Ciba Yellow HG Reactive Dye Swiss Color GERMANY
Ciba Blue HRN Reactive Dye Swiss Color GERMANY
Ciba Red HBL Reactive Dye Swiss Color GERMANY
Ciba Orange EBR Reactive Dye Swiss Color GERMANY

Page 176
Different Types of Chemicals Used In Viyellatex With
Their Brand Name
CHEMICAL NAME BRAND NAME COUNTRY NAME

Wetting agent Feloson NOF Germany
Levelling agent A-41 China
Anti-creasing
agent Kapavon CL Germany
Kapazon H-53
Per Oxide
CBB Germany
Stabilizer
Rucorit Wez
Caustic Caustic China
Soda Ash Soda Ash China
H2O2 H2O2 China+ Korea
Uvitex-BAM
Optical Uvitex-BHV GERMANY
Brightening Agent Uvitex-BBT
Syno White 4Bk
H2O2 Killer Kapatex-PKS Germany
Acitic Acid Acitic Acid India
Securon-540
Sequestering China
CS
Agent
Polyclean-SP India
Bio-ACE China
Enzyme
Biopolish-B41 Srilanka
Sodium Sulphate Anhydrose
Electrolyte / Salt India
Glubar Salt
Rukozen-WBL Germany
Detergent
Diwet PIUS India
Rukozen-NZA Germany
Soaping Agent Dekol ISN
China
Cyclonon XCW
Nerosoft-JS(an-ionic)
China
Softener Nerosoft-NI(non-ionic)
Purrustol-IMA Germany
Sandofix-EC
Fixing Agent Germany
Protan FCE-375

Page 176
DYEING CURVE FOR LIGHT SHADE
Linear dosing 70%progressive

Leveling agent 35 minutes 15 minutes Check pH Check pH
50 minutes
Level in
Check pH Color dosing Salt dissolving Soda dosing

Runtime20′ Runtime20′
Runtime10′
10′
60°C
Sample check
MIR 10′
In case of s/j low gsm fabric anti-creasing agents have to use in scouring & with R- hot.
In case of s/j low gsm fabric heating and cooling during scouring & R- hot have do with gradient.
Heating-2.5°C/min.
Colling-1.5°C/min
It is 60°C isothermal dyeing.

Bath
drop
Page 176
DYEING CURVE FOR MEDIUM/ DARK SHADE
Check pH Linear dosing 70%progressive

10 minutes Check pH 30 minutes 50 minutes Check
Check pH
pH
Level in
Color dosing Soda dosing
Leveling agent Salt dissolving Runtime20′
MIR 10′
10′
60°C Runtime10′ Runtime15′
Sample check
Bath
drop
In case of s/j low gsm fabric anti-creasing agents have to use in scouring & with R- hot.
In case of s/j low gsm fabric heating and cooling during scouring & R- hot have to do with gradient.
Heating-2.5°C/min.
Colling-1.5°C/min

It is 60°C isothermal dyeing.
Page 176
Some sample with recipe
Color: White
Nature of fabric: S/J SAMPLE

GSM: 160
M:L-1:7
Feloson NOF=0.5%
Kapazon-H53=0.75%
Caustic-3 g/l
H2O2 -12 g/l
BAM (OBA) – 0.8400%
4BK=0.6180%
Acetic Acid=1 g/l
Securon-540=0.5%
Color= Black
Nature of fabric=PC(Fleece)
GSM= 280
M:L=1:6
For Polyester part dyeing
Feloson NOF=1%
AB-45=1%
T Yell W-3R=0.16800%
T Red W 4BS=0.3400%
T Black SNRL=2.3880 %
For Reduction Cleaning
Hydrous=3 g/l
Caustic=3 g/l
Pretreatment
WBL=0.7%
CBB=0.5 g/l
Caustic=2 g/l
H2O2=2.5 g/l
PC=0.75 g/l
Acetic Acid=1
Enzyme

Page 176
Acid=0.8
B11=0.75
Securon-540=0.5
Cotton part dyeing
A41=0.5%
SUN Yell MF3RD=0.73%
SUN Red MF3BD=0.3365%
RS Black-WM=5.6416%
Salt=90 g/l
Soda ash=5 g/l
Caustic=1.75 g/l
After treatment
Acetic Acid=0.8 g/l
JS100=1.5%
SAMPLE

Page 176
Taurquies color
Nature of fabric: S/J
GSM= 160
Pretreatment
NOF=0.5%
CL=0.5%
Feloson NOF=0.7% SAMPLE
KAPAZON-h53=0.5%
KAPAVON –CL=1%
Caustic=2 g/l
H2O2=2.5 g/l
ROCORIT-WEZ=0.75 g/l
Acetic Acid=1
Acetic Acid=0.8
Biopolish-B11=1.5 g/l
Securon-540=0.5%
Dyeing
CS=0.5%
KAPAVON –CL=0.5%
SV=1.5%
ADM=1%
IM BR YELL V-4GL=0.8060%
TURQ V-G=0.6800%
BLUE VCR=0.0132%
Salt=50 g/l
Soda=ash=14 g/l
After treatment
Acetic Acid=0.8%
Sapamine C.W.S=1.5%

Page 176
FLOW CHART FOR DYEING
BATCHING
SELECT M/C NO.
FABRIC LOADING
SELECT PRODUCTION PROGRAMME
PRETREATMENT
SELECT RECIPE FOR DYEING
RECIPE CONFIRMED BY DM/PO
DYEING
POST TREATMENT
UNLOAD
Process Flow Chart for Machine Wash

NOF
↓
Caustic
↓
Hydrous
Run time 20´ at 130ºC
Process Flow Chart for Deminaralization

Page 176
Fabric load
↓
Water fill
↓
NOF + A. Acid (Run time10´)
↓ At 60ºC
Drain bath
Process Flow Chart for Scouring & Bleaching
Water fill( From PT)
↓
Detergent/wetting agent + Stabilizer +Anticreasing agent (inject)
↓ At 60ºC
Caustic (Linear dosing 5´)
↓At 60ºC
H2O2 dosing
↓At 70ºC
Then temp. raised to 105ºC & run 30´
↓
Water drain
↓
H2O2 Killer hot wash (800C X10 min)
↓
HOT WASH (10´)
↓
Water Drain & Water fill
↓
Acetic Acid (Run 10´ at 60ºC)
↓
Water drain
Enzyme wash
As per Buyer requirement Enzyme wash is given.
Water fill + fabric load
↓
Temp. raised to 55ºC
↓
A.Acid(inject)
↓PH check (4.5-4.7)
Enzyme (Dosing for 10´ )
↓Run 60´ at 55ºC
Sequestering agent at 90ºC
↓ Run 10´
Water drain
Process Sequence of Dyeing (for different types shade)
Flow Chart for OBA Treatment

Page 176
Water fill + fabric load
↓
Temp. raised to 70ºC
↓
Detergent/wetting agent + Stabilizer
↓ (Inject)
Caustic dosing 10´ at 70ºC
↓ Run 10´
H202 Dosing 10´
↓Run 10´
OBA dosing 10´
↓Temp. raised to 105ºC & run 50´
Cooling to 78ºC
↓
Water drain & Water fill
↓
Normal hot wash at 80ºC
↓
Bath drain & water fill
↓Temp. controlled at 55ºC
Acetic Acid inject & run 10´
↓
↓
CS hot wash at 90ºC
↓ Run 10´
↓
Normal wash at 45ºC 10´
↓
Fabric unload
Dyeing Sequence for Light Shade
Level In (Water from PT at 600 C)& Fabric load

Page 176
Check ph 6.5-7
Leveling agent injection
Run 10 min
Color dosing linear (600 c x 35 min)
Run 20 min
Salt dissolving (600 c x 15 min)
Run 20 min
Soda dosing (70% Progressing) (600 c x 50 min)
Check ph 11.5
Sample check
MIR rising 10 min
Bath drop
Dyeing Sequence for Dark Shade
Level In (Water from PT at 600 ) & Fabric load

Check ph 6.5-7
Leveling agent injection
Run 10 min
Salt dosing (600 c x 10 min)
Run 20 min
Color dosing (600 c x 30 min)
Run 20 min
Check ph 11.5
Sample check
MIR rising 10 min
Bath drop
Process Flow Chart for After treatment

Water fill
↓

Page 176
MIR wash 10´
↓
Normal hot 70ºC
↓Run time 15´
MIR wash 15´
↓
Acetic Acid inject at 45ºC & run 10´
↓
Hot with NOF + Soaping agent
↓ At 80ºC & run 10´
Sample check
↓
Wash at 90ºC for 10´
↓
Sample check at 78ºC
↓
Rinsing
↓
Fixing agent + Softener
↓
Sample check
↓
If OK , Then bath drain
↓
If not OK, Then Addition is given
Addition
Dye dosing for 20´
Sample taken
↓
If ok, Then Bath drain
↓
If not ok, Then Topping is Done
Flow Chart for CVC (blended fleece fabric) Dyeing
Pre-wash
Fabric load + Water fill
↓
Wash with NOF at 80ºC & run10´

Page 176
↓
Rinsing
↓
Bath drain
Polyester part dyeing
Water fill
↓
Acetic Acid (Injection) Run time (10 min x 450C)
PH Check (PH- 4.5)
Color dosing (15min x 450C)
Raising Temp at 1300C & Run time 45 min

↓
Cooling at 78ºC
Sample Check
Drain
Normal hot wash
Drain
Reduction cleaning
Water fill
↓
Caustic Dosing (700C X 5 min)
Run 20´
Raising Temp at 900C
Hydrose dosing
Run time (20 min)
Bath Drain
↓
Normal wash
Drain
Cotton part dyeing

Level In (water from P.T)
Levelling agent injection

Page 176
Salt dosing (10 min x 60˚C)
Run time 20 min
Color dosing (30 min x 60˚C)
Run time 20 min
Soda dosing (50 min x 60˚C)
Run time 10 min
Caustic dosing (30 min x 60˚C)
Check ph
Sample check
Normal hot wash
Drain
MIR rising 10 min
Bath drop
After Treatment
Water fill
↓Temp. raised
Acetic Acid inject at 45ºC & run 10´
↓
J.S100 at 80ºC & run

Page 176
Dyeing Sequence for migration:
Level In (Water from p.t at 600 )

Check ph
Leveling agent injection (600 c)
Color dosing linear (600 c x 35 min)

Run 20 min
Salt dosing (60 c x 15 min)
0
Check ph
Raise temp 800
Run 20 min
Down temp 600
Sample check
MIR rising 10 min
Bath drop
About Machine
In VIYELLATEX two Brands of machines are used-
THIES (GERMANY)
FONGS(CHINA)
Comparison between Fongs And Thies dyeing m/s
Parameter Thies Fongs

1 .Manufacturer Germany China
2.No of additional 01 02
tank
3.Heat exchanger
Vertical Horizontal
4.OperatingTSystem
737 XL FC 22/FC 28
2 nozzle/lid,So
5.Nozzle& Production 1 nozzle/lid, Less
pro
dn.

Page 176
6.Chemical
Has Vibrating
Tank Compressed air
Types of M/CS according to Temperature
 High Temperature M/C
 Atmospheric M/C
Main Parts Of The Machines

 Main tank
 Preparation tank
 Pump
 Filter
 Heat Exchanger
 Additional tank
 Lid
Filter
 The filter eliminates the loose fibres in the dye bath,
 consequently it reduces the loose fibre loads on the fabric.
 Changing and cleaning the filters is sometimes forgotten, with the

result that the dyeing machine's nozzle pressure decreases, with the
effect that running is disturbed and tangles can occur.
automatic self cleaning filter system

 No cleaning of filter.
 No pressure variation in the nozzles due to lint buildup due to

automatic regulation system.
 No lint on fabric due to 100 % filtration of the circulation liquor.

Page 176
Additional Tank
Addition tank is used for-
 Color dosing
 Salt dosing
 Chemical dosing
 Auxiliaries injection
 Salt dissolving
Heat exchanger
Theory of Application
 Two fluids, of different starting temperatures, flow through the heat
exchanger.
 One flows through the tubes (the tube side) and the other flows
outside the tubes but inside the shell (the shell side).
 Heat is transferred from one fluid to the other through the tube walls,
either from tube side to shell side or vice versa.
 The fluids can be either liquid or gases on either the shell or the tube
side. In order to transfer heat efficiently, a large heat transfer area
should be used, so there are many tubes. In this way, waste heat can
be put to use. This is a great way to conserve energy.
Function of dissolution pump

 Dissolution pump makes the chemical concentration
(salt,soda,dye,auxiliaries) low before passing it to the main tank.
 This concentration is reduced in 1:4 ratio(liquor from additional tank:

liquor from main tank).
 As a result rate of chemical dosing become slow which gives better

fixation.
 Thus better color yield and even dyeing can obtain.
Advantages of variable chamber setting

 Better alignment of the fabric

Page 176
 More loading facility
 Less Entanglement
Ways of liquor flow from additional tank

TWO WAYS-
1. Injection
2. Dosing
• Linear dosing
• Progressive dosing
• Decreasive dosing
FEATURES OF FONG’S ATMOSPHERIC M/C
 The M/C is designed for the pre-treatment, dyeing and after-

treatment under atmospheric condition.
 Nozzle is sized for smooth passing through by the fabric and

extensive exchange with the dyeing liquid.
 Two standard nozzle sizes with sufficiently large diameter are

available.
 Circulation pump is sized for heavy fabric
 Production capacity:500kgs
 Max temperature:98◦C
 Max pressure:1atm
Features of high temperature machine
 The M/C is designed for the pre-treatment, dyeing and after-

treatment which can provide temperature up to 140◦c
 nozzle lead get interlock after temperature
 exceed 80◦C
 Loading per nozzle 250kg
 Design pressure:350-550kpa
 Design Temp :140◦C

Page 176
 Hydraulic Test Pressure:585Kpa
 Manufacturer: Germany(Thies),Taiwan(Fong’s)
 No of nozzles:1-6
Features of FONG’S(HSJ) machines
 Variable Loading (VL) storage chamber design gives extra capacity to

carry loading up to 280 kg per tube
 Heat Exchanger of extreme efficiency gives the largest heating rate

with minimum heat loss to the environment
 Multi Saving Rinsing System (MSR) shortens the dye cycle and
reduces the water consumption
 Advanced Intelligent Rinsing System (MIR) controls the rinsing water

consumption and shortens the rinsing process
 Highly optimized machine structure reaches the lowest possible

liquor ratio of 1:4.5 to run the machine .
 Dissolution pump for proper circulation of liquor.
 safety valve test:350kpa
 Maximum fabric speed: 400 m/min.
 Maximum working temperature: 140 °C
 Design pressure:350kpa
 Hydraulic test pressure:510kpa
MIR RINSING
 Multi-function intelligent rinsing system
 If the temperature is below 80°C It is a Low Level Continuous Rinsing

Shorten Rinsing Time
 Save Rinsing Water
 Fill and Drain at the same time at low level
MSR Rinsing
 MULTI- SAVING RINSING SYSTEM

Page 176
 If the temperature above 80°c It is Combined Cooling and Rinsing at
high temperature
 Save Steam in Hot Rinsing
 Rinsing efficiency at higher temperature is faster, so rinsing time is

shortened
The factors to feed and check before loading-
 Variable Chamber setting according to the linear density and loading.
 Calculate and feed the exact MLR and feed in batch Data
 Ensure the MSR level and MIR level and flow.
 Ensure the pH of Dyeing
The factors to concentrate during dyeing-
The operator should change the filter-

 After Enzyme wash
 After Drain dyeing Bath
 After Rinsing Bath
DYEING PARAMETER CONTROL CHART
 Water level before fabric loading(Lit)

 Loading Time(min)  
 Water level after fabric loading(after running 05 min)
 Dosing time of caustic 
 Run time   
 Dosing time of per-oxide 
 Total time need to raise temp.of 105:
 Gradiant (Degree/min)  
 Total run time(min)  
 Total time need to cooling at 80c 
 Gradiant (Degree/min)  
 Total MIR /Rinsing time to 50c 
 Total run time after acid dosing 
 Check PH  

Page 176
 Total runtime after peroxide killer dosing
 Check residual per-oxide(ppm) 
 CheckPHbeforeenzymedosing 
 Total run time during enzyme 
DYEING
 Water level (Lit)

 Check PH before color/salt dosing
 Total time for color dosing
 Total run time
 Total time for salt dosing
 Total run time
 Check PH after salt dosing
 Total time for soda dosing
 Check PH after soda
dosing(Afterrunningthem/c05min)
 Total time need to B/D
 Drain the m/c
 Total time for MIR/ Rinsing
 Drain the m/c
 Total time for
acid
 Check PH and TDS(ppm)
 Temp for soaping
 Soaping time
 Drain the m/c
 2ndsoapingtemp
 Soapingtime
 Drain the m/c
 Total MIR/Rinsing time
Common dyeing faults with their remedies
Uneven dyeing
Causes:
 Uneven pretreatment (uneven scouring & bleaching).
 Improper color dosing.

Page 176
 Using dyes of high fixation property.
 Uneven heat-setting in case of synthetic fibers.
 Lack of control on dyeing m/c
Remedies:
 By ensuring even pretreatment.
 By ensuring even heat-setting in case of synthetic fibers.
 Proper dosing of dyes and chemicals.
 Proper controlling of dyeing m/c
Batch to Batch Shade variation
Causes:
 Fluctuation of Temperature.
 Improper dosing time of dyes & chemicals.
 Batch to batch weight variation of dyes and chemicals.
 Dyes lot variation.
 Improper reel speed, pump speed, liquor ratio.
 Improper pretreatment.
Remedies:
 Use standard dyes and chemicals.
 Maintain the same liquor ratio.
 Follow the standard pretreatment procedure.
 Maintain the same dyeing cycle.
 Identical dyeing procedure should be followed for the same depth of

the Shade. .

Page 176
 The pH, hardness and sodium carbonate content of supply water
should check daily.
Patchy dyeing effect
Causes:
 Entanglement of fabric.
 Faulty injection of alkali.
 Improper addition of color.
 Due to hardness of water.
 Due to improper salt addition.
 Dye migration during intermediate dyeing.
 Uneven heat in the machine, etc
Remedies:
 By ensuring proper pretreatment.
 Proper dosing of dyes and chemicals.
 Heat should be same throughout the dye liquor.
 Proper salt addition.
Roll to Roll variation or Meter to Meter variation:
Causes:
 Poor migration property of dyes.
 Improper dyes solubility.
 Hardness of water.
 Faulty m/c speed, etc
Remedies:

Page 176
 Use standard dyes and chemicals.
 Proper m/c speed.
 Use of soft water
Crease mark:
Causes:
 Poor opening of the fabric rope
 Shock cooling of synthetic material
 If pump pressure & reel speed is not equal
 Due to high speed m/c running
Remedies:
 maintaining proper reel sped & pump speed.
 Lower rate rising and cooling the temperature
 Reducing the m/c load
 Higher liquor ratio
Dye spot:
Causes:
 Improper Dissolving of dye particle in bath.
 Improper Dissolving of caustic soda particle in bath.
Remedies:
 By proper dissolving of dyes & chemicals
 By passing the dissolved dyestuff through a fine stainless steel mesh

strainer, so that the large un-dissolved particles are removed
Wrinkle mark
Causes:
 Poor opening of the fabric rope

Page 176
 Shock cooling of synthetic material
 High temperature entanglement of the fabric
Remedies:
 Maintaining proper reel sped & pump speed.
 Lower rate rising and cooling the temperature
 Higher liquor ratio
Softener Mark:
Causes:
 Improper mixing of the Softener.
 Improper running time of the fabric during application of softener.
 Entanglement of the fabric during application of softener
Remedies:
 Maintaining proper reel sped & pump speed.
 Proper Mixing of the softener before addition.
 Prevent the entanglement of the fabric during application of softener

Page 176
Page 176
Finishing:
Textile finishing, in a restricted sense, is the term used for a series of

processes to which all bleached, dyed, printed and certain grey fabrics are
subjected before they are put on the market. In fact, finishing includes the
final treatment of every kind of fabric made from every kind of fiber
Objective of finishing:
 Improving the appearance Luster, whiteness, etc
—
 Improving the feel, which depends on the handle of the material and
its softness suppleness fullness, etc.
, ,
 Wearing qualities, none soiling, anticrease, antishrink, comfort, etc.

—
 Special properties required for particular uses water proofing, flame

— —
proofing, etc.
 Covering of the faults in the original cloth.
 Increasing the weight of the cloth.
Types of finishing:
1) Chemical finishing:
a) Chemical reaction of auxiliaries with fibers.
b) Application of the handle modifying products / additives.
2) Mechanical finishing:
• Mechanical treatment with machines
Finishing effects:
• Easy - care
• Crease recovery.
• Dimensional stability.
• Good abrasion resistance.
• Improved tear strength.
• Good sew ability
• Soft or stiff handle.
• Shine or luster

Page 176
Organogram of Finishing Section:
Executive Director (E.D)
Manager / Asst.Manager
Sr. Principle officer (P.O)
Finished Fabric Finished Collar / Cuff
Sr. Supervisor / Supervisor /

On line System Off line system Jr. Supervisor
Sr. Supervisor / Supervisor Sr. Supervisor / Supervisor Quality Controller

/ Jr. Supervisor / Jr. Supervisor
Asst. Quality Controller

Quality Controller Quality Controller
Asst. Quality Controller Asst. Quality Controller

Page 176
INSPECTED
FABRIC
SLITTING & SLITTING &

DEWATERING DEWATERING DEWATERING DEWATERING
M/ C M/ C M/ C M/ C
ROLLING
STENTER M/ C
TUBE OPEN TUBE

DRYER COM PACTOR
COMPACTOR COM PACTOR
WEIGHTING
M/ C
OPEN STENTER & TUBE

COM PACTOR STENTER
DRYER
FABRIC
INSPECTION
TABLE
RAISING TOILET
RAISING
M/ C
M/ C
RAISING SUEDIN G
FABRIC
M/ C M/ C INSPECTION
M/ C

Page 176
Flow chart of finishing section :
Finishing Section
Open fabric Tube fabric
Slitting machine Dewatering machine
Stentering Drying Machine
Compacting Tube compacting

machine machine
Final Final
Inspection inspection
Flow chart:
For Peach finish/Brush:
Slitting
↓
Stenter
↓
Sueding/Raising
↓
Stenter
↓
Compacting
For Lycra:
Slitting
↓
Heat Setting
↓
Sewing
↓
Drying
↓
Slitting
↓
Stenter
↓
Compacting

Page 176
SLITTING MACHINE
Slitting Machine specification:

No of Slitting m/c : 02
Slitting m/c-1:
Brand name- Corino(SH)
Country- Italy
Year of manufacturing-2007
Slitting m/c-2:
Brand name- Bianco(SH)
Country- Italy
Year of manufacturing-2007
Velocity maximum-90m/min
Slitting:
Slitting is a process that is applied for cutting the tubular fabric through the
intended break Wales line on lengthwise direction prior to stenter
processing.
Machine parts:
1. Rotary blade: To cut the fabric through break Wales line.
2. Ring: To help cutting.
3. Guide Roller: To guide the fabric to plaiting.
4. Plaiting: To plait the fabric.
5. Sensor: Sense for cutting through break Wales line.

Page 176
Slitting Machine

Page 176
Working principle:
The slitting m/c has 4 units - initial squeezer, de-twisting, slitter

and padder. After dyeing completed and falling of water from fabric the
fabric is fed in slitting m/c. So it is necessary to remove some water initially
for the case of further processing in this m/c. The initial squeezer does this
work. The de-twisting unit removes twists that may present in tubular rope
form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2
feeler rollers with sensors. By these rollers it detects twist in fabric and
removes by rotating rope fabric in opposite direction. Before slitting there is
a blower which blows air to open the tubular fabric & makes it easy to pass
over cigger. The cigger can be extended in circumference and opens the
tubular fabric in full circumference. Slitting is done by using open mark
detecting golden eye by around knife. Then the fabric passes through the
padder where washing or chemical treatment is done. Squeezer is used to
remove 60-70% of water. After removing water width is controlled by
stretcher and fabric is delivered by folding device.
Operational parameter:
-Set the padder pressure as required (3-7bar)

-Set the speed as much as possible (30-80m/min).
Function of the Machine:
 Used to remove excess water after pretreatment and dyeing.

 To slit the tube fabric by the knife for opening of the fabric and
ready for stentering.
 Delivered fabric in crease free state.
 Before squeezing balloon is formed with the help of compressed
air passing by a nozzle or air sprayer.
 It can control the diameter of fabric and GSM and shrinkage by
over feeding mechanism.

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DEWATERING MACHINE
Dewatering Machine specification:
No of Dewatering m/c : 02
Machine no : 01
Machine name : Dewatering
Brand name : Heliot
Country : France
Padder pressure : 1-1.5 bar
Pressure capacity : 4 bar
Machine no : 02
Machine name : Dewatering
Brand name : Heliot
Country : France
Padder pressure : 1-1.5bar
Pressure Capacity : 4 bar
Function:
 Reduce water content.

 Apply chemicals.
 Apply over feed to give some compaction.
 Open the fabric from the rope form.
 Width wise stretch the fabric.
 Plait the fabric.

Page 176
Dewatering Machine
Fabric path in Dewatering Machine

Page 176
Working principle of Dewatering:
After completing the dyeing process from the dyeing m/c then the fabrics
are ready for de-watering. In de-watering m/c tubular fabrics are mainly
processed. There is a magnetic sensor which scene the twist of the fabric
and its direction and turn the fabric in opposite direction to remove twist
automatically. Here dewatering is performed De-watering is the process to
remove the water from the fabric completely by squeezing and it is done by
the padder. A suitable expander is used before the fabric is passed through
the nip of the padders, which expands the fabric flat wise and adjust the
width. The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%,
Lacoste-40% wider than the required width. There is a pair of rubber coated
padder, where water is removed from fabric when passed through the nip of
it.
Normally squeezer contain single or double padders where,

- One for removing water and
- Other for applying finishing chemicals such as softener.
But this finishing is done only for the tubular fabric. Open width knitted
fabrics are applied finishing treatment later in stenter.
Here present the compressor which given compress air to form ballooning
before passing through the padder. This balloon remove crease mark but
not form the maximum balloon otherwise shrinkage increase

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DRYER
Machine specification :
No. of Dryer : 02
Dryer no -1
Brand name- Heliot
Origin- France
Chamber-3
Year of construction – 2006
Ratiomatic Burner:
Brand name:ECLIPSE
Year-03/2002
Capacity-300 kw
Voltage-230/400 v
Frequency-50Hz
Fuel- Natural gas
Pressure- (150-500) m bar
Dryer no- 2
Brand name-Santex AG
Origin – Switzerland
Type-SANTASHINK
Chamber -5
Year of construction- 2008
Fuel combustion chamber:

Fuel- Natural gas
Fuel pressure-7.2m bar
Capacity-300kw
Voltage-240/400v
Frequency-50Hz
Year-12/2007

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Dryer
Working principle of dryer:
After de-watering then the fabric through the dryer. The main function of
the dryer is given below,
- To dry the fabric.

- To control the overfeed system.
- To control the vibration which increase the G.S.M.
This machine contains two chambers. Two mesh endless conveyors are
placed lengthwise to the chamber named conveyor net and filter net, each
chamber contain a burner, which supply hot air .This hot air is guided
through the ducting line by suction fan .There are nozzles placed in between
filter net and conveyor net .When the fabric pass on the conveyor net, hot
air is supplied to the wet fabric to dry it. There are exhaust fan which such
the wet air and deliver to the atmosphere through the ducting line.
The speed of the dryer depends on the temperature of the m/c & the G.S.M
of the fabric. If the m/c temp. is high then m/c speed also high and the m/c
temp. is low then m/c speed also low . The vibration speed of the m/c for
heavy fabric is 730 m/min and normal fabric is 480 m/min.

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STENTER
Machine specification :
No. of Stenter : 02
Stenter m/c no - 01
Brand name - Sun-Super
Country of origin -South Korea
Manufacturing date-: 2006
Width Range -2700
Maximum Speed - 100m/min
Chamber - 8
Stenter m/c no – 2
Brand name - BRUCKNER
Country - Germany
Manufacturing Year – 2004
Chamber – 5
Maximum steam pressure – 2bar
Maximum air pressure – 10bar
Ratiomatic Burner for Fuel Combustion:

Origin - Germrny
Year-11/2003
Capacity-200 kw
Voltage-230/400 v
Frequency-50/60Hz
Fuel- Natural gas
Pressure- 50 m bar

Page 176
Important parts of stenter
-Burner (12)
- Exhaust air fan (16)
-Over feed roller.
- Suction fan (12)
-Nozzle
-Chain arrangement.
Stenter machine

Page 176
FUNCTION OF STENTER:
- Drying
- Shrinkage control.
- Heat setting.
- Width control Finishing chemical application.
- Loop control.
- Moisture control.
- Spirility control.
STANDARD OPERATING PARAMETER FOR DIFFERENT

FABRIC IN STENTER:
Fabric Type GSM Dia Tempera Over Padder Speed Blower

ture Feed Pressue (rpm) rpm
Single 115-150 2”+ 110-140 40- 2 bar 30-35 1100-
jersey 45% 1300
Single 160-220 2”+ 120-170 40- 2.5 bar 25-30 1200-
jersey 45% 1400
Lycra Single 160-200 4”+ 130-160 50% 2 bar 25-30 1200-
jersey 1400
Lycra Single 200-250 4”+ 140-160 50% 2 bar 24-28 1200-
jersey 1400
Pique 160-200 3”+ 130-160 40- 1.5- 25-30 1200-

45% 2bar 1400
Lycra Pique 190-220 4”+ 130-160 50% 2 bar 20-25 1200-
1400
Fleece/Terry 260-300 4”+ 140-170 40- 2 bar 20-25 1300-
45% 1400
1x1 Rib 160-220 2”+ 130-160 45% 2 bar 24-28 1300-
1400
2x2 Rib 190-220 2”+ 140-160 45% 2 bar 20-25 1200-
1400
Interlock 190-220 3”+ 130-160 50% 2 bar 20-25 1200-
1400
*S/J fabric feed at 3-5 degree angle.

*Others fabric feed, straight.

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COMPACTOR
Machine specification of compactor:

No. of Compacting m/c: 02
Tube Compactor:
Machine name – Tube compactor
Brand name – Heliot
Country - France
Tube Compactor machine
Open Compactor:
Machine name – Open compactor
Brand name – FERRARO
Country – Italy
Open Compactor machine

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Function
• To control shrinkage.
• To control width.
• To control GSM.
• To smooth fabric.
• Heat seating of fabric for lycra.
Important parts
- Over feed roller.

- Expander.
- Blanket(2)
Operational parameter:
-Set the temperature at 120 °C (as required)

-Set the speed as much as possible (15-25 m/min).GSM m/c speed.
-Set the overfeed % as required; to increase GSM, overfeed need to
increase to a certain limit.

Page 176
STANDARD OPERATING PARAMETER FOR DIFFERENT
FABRIC IN OPEN COMPACTOR
Fabric Colour Speed Over Temperatur Blanket Teflon

type Feed e Pressur Pressur
e e
Single White 15-18 25-30 90-110 1.5- 36psi
jersey Colour 15-18 25-30 110-120 2bar
Pique White 15-18 30-35 100 1.5- 36psi

(s/j,d/j) Colour 15-18 30-35 110-120 2bar
Lycra s/j White 12-16 Full 100-110 1.5- 36psi

Colour 12-16 over 100-120 2bar
feed
1x1 Rib White 15-20 20-30 100 1.5- 36psi
Colour 15-20 20-30 110-120 2bar
2x2 Rib White 12-15 25-30 100 1.5- 36psi

Colour 12-15 25-30 110-120 2bar
Interloc White 12-16 Full 100 1.5- 36psi

k Colour 12-16 over 110-120 2bar
feed

Page 176
*S/J fabric feed at 3-5 degree angle.
*Others fabric feed, straight.

Page 176
RAISING MACHINE
Machine specification of Raising Machine :

No. of Raising m/c : 02
Raising m/c - 01(Single drum)

Brand name - Lafer
Country - Italy
Cylinder -1
Drum Speed - 110
Drum Dia - 68 inch
Machine Speed - 40 m/min
Pile Roller - 12
Counter Pile Roller - 12
Manufacturing Year –2002
Fabric path in Raising m/c (Single drum)

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Raising m/c-02(Double drum)
Brand name – Lafer
Country – Italy
Cylinder- 2
Drum Speed - 110
Drum Dia - 68 inch
Machine Speed - 40 m/min
Pile Roller - 24
Counter Pile Roller - 24
Manufacturing Year –2002
Fabric path in Raising m/c (double drum)
FUNCTION OF RAISING MACHINE:

≈ To produce the brush effect.
≈ To produce the fleece fabric.
≈ To raise the fibre on the fabric surface.

Page 176
SUEDING MACHINE
A sueder is sometimes referred to a s a sander since the machine

consists of one or more rolls covered with sand paper as the abrasive.
Fabrics traveling over these rolls develop a very low pile and the materials
surface can be made to feel like suede leather. The hand will depend on the
fiber composition, the filament count in the yarn and the intensity with
which the fabric is worked.
Filament fabrics can be made to feel like a spun fabric and all fabrics will
have a softer hand.
Machine Specification of Sueding Machine:

No.Of Sueding m/c: 01
Brand name : Lafer

Country :Italy
Cylinder :1
Company name : SPA Machine Tessili
Model : GSI 106
Drum Speed : 110
Drum Dia : 72 inch
Machine Speed : 40 m/min
Manufacturing Year :2002

Page 176
Sample of Raised & Sueded Fabric:
SAMPLES:
Single Drum Raised Fabric Double Drum Raised Fabric
Single Drum Raised Fabric Double Drum Raised

Fabric
Sueded Fabric

Page 176
Page 176
Process Flow Chart of Final Inspection :(Q.A.D)
After completing finishing process here firstly check the shade as per buyer
standard with dimensional stability from lab.
Secondly check dia / width fabric weight or G.S.M
Thirdly check fabric surface or appearance as per buyer standard.
The every roll with every meter check as per four (04) point system.
Make a report.
If OK then ready for delivery.
If not OK then identify the fault.
If it is knitting fault then inform the knitting department by job card and
mail, & requested the fabric for replacement.
If it is dyeing fault & If make sure that it is reprocess able then give job card
to dyeing department correction. And if is not reprocess able then reject the
fabric & inform the dyeing department to replace the rejected quantity.

Page 176
FABRIC FAULTS, CAUSES AND REMIDIES
FAULT CAUSE REMIDIES

HOLE DUE TO YARN USE GOOD QUALITY
BREAKAGE AND YARN OF YARN
FAULT
RUB MARK IF THE DUST OF FLOW CONTINUOUS
ENZYME IS NOT AIR TO FABRIC
CLEAN PROPERLY DURING COMPACTING
OIL STAIN OIL STICK ON FABRIC USE SOLUBLE OIL
FROM NEEDLE, AND KEEP THE M/CS
SINKER OR CYLINDER CLEAN
DYE STAIN DYES POWDER FALLS STORE THE FABRICS
ON TO THE WET BY COVERING
FABRICS
WATER SPOTS BEFORE INSPECTION BY WASHING AND
IF FABRIC STORED IN STORE FABRIC IN DRY
WET FLOOR PLACE
FLY YARN DIFFERENT TYPES OF COVER THE KNITTING
YARN MIXED DURING M/C DURING KNITTING
KNITTING
YARN DIFFERENT DUST OR KEEP THE M/C AREA
CONTAMINATION SLUBS MIXED CLEAN
DURING KNITTING
SOFTENER SPOT IF SOFTENER IS USED USE SOFTENER
UNDER 45ºC UNDER REQUIRED
TEMP.
PATCHES IF SODA IS NOT USED USE SODA PROPERLY
PROPERLY
HAIRY IF THE ENZYME WASH GIVE ENZYME WASH
IS NOT PROPERLY PROPERLY
DONE
NEEDLE LINE FOR FAULTY NEEDLE REPLACE THE FAULTY
NEEDLE
DEAD COTTON FOR IMMATURE FIBRE USE YARN OF
MATURED FIBRE
CREASE MARK FOR THERMAL SHOCK, INCREASE DYEBATH
UNEVEN TEMP.
NOZZLEPRESSURE SLOWLY,MAINTAIN
AND BAD QUALITY NOZZLE PRESSURE
LEVELLING AGENT AND USE GOOD
QUALITY LEVELLING
AGENT

Page 176
Page 176
Sample Development :
Sample is the prototype or model o the garment, upon what the buyer can
decide on how and whiter to confirm the order or not.
Organ gram of sample department :
There are about 175 total employees working in the Viyellatex Group
sample department including executives and workers. There are also some
supervisors and coordinators to stimulate and take care the sample job. Let
us see the organogram below to know more about the sample department
Manager
Patten Master Officer/Coordinator Officer. QC
Pattern asst. Fabric Coordinator QC/AQC
Sample man Folding Man
Accessories Issue Man
Cutter man
Iron Man
Purchase/Marketing man
Sample Asst.
Sample Input man
Sample Operator

Page 176
Sampling Process Flowchart :
Receiving Tec Pak from buyer (Via Merchandiser)
CAD & Pattern Making (Styling & Measurement)
Sample Making
Approval Failed
Size Setting (One Development Stage) Re Sample Making
Evaluation the Sample
Pre Production Meeting (Decides on when to produce) Sending Sample

to the Cutting Section
Grading of sample Market Making Production stats
Sending sample to the buyer Approval Grading of Sample
Brief Description of the Sampling Processes:
1. Tec Pack Receiving: This is the firs stage of the sampling processes.
In this stage Tec Pack or the technical pack is received from the buyer,
via merchandiser. Tec pack contains all the specifications to produce a
garment.
2. CAD & Pattern Making: In this stage pattern is made through CAD.
Sometimes pattern is made manually, but CAD is more popular and easy.
Computer-aided design (CAD) is the use of computer technology for
the design of objects, real or virtual. The design of geometric models for
object shapes, in particular, is often called computer-aided geometric
design (CAGD).However CAD often involves more than lust shapes. As in
the manual drafting of technical and engineering drawings, the output of
CAD often must convey also symbolic information such as materials,
processes. dimensions, and tolerances, according to application-specific
conventions. CAD may be used to design curves and figures in two-
dimensional (“2D”) space; or curves, surfaces, or solids in three-
dimensional (“3D”) objects. Viyellatex pattern section uses OptiTex CAD

Page 176
software for pattern making.
3. Sample Making: Sample making is the ultimate goal of this
department. After making the pattern, the sample is made by using the
pattern set.
4. Size Setting: After making the sample, size is set according to the Tec
Pack. If there is any fault, the sample is redone
5. Pre Production (PP) Meeting: after the buyer has inspected the
sample, a preproduction meeting is called. In this meeting buyer or his
agent, merchandiser, sample manager. all remain present. They decide
on how to and when to start the production. If the decision Okayed. the
sample is ready to go for final production.
6. Grading of Sample: After finalizing the sample. grading is done to
separate the samples and patterns from each others.
7. Marker After grading the samples. the design is inputted into the
marker software. This software specifies how to set the pattern in the
actual fabric. By using the marking software efficiently, fabric can be
saved. Viyellatex uses Gerbar Garment Technology (GGT) for marker
making.
8. Cutting: After making the pattern is delivered to the cutting unit and
the fabric is cut for final production.
Sample Procedure
There are some standard sample procedures after pattern making, the are
as follows,
Sourcing the Fabric and Accessories for making the Garment
Cutting (For Sample Only)
Emblishment
Sewing
Iron
Quality Control (QC)
Pre check from
Buyer QC
Forwarding form the merchandiser
Sending sample to the buyer

Page 176
Types of sample and their use
Serial no. Sample Use
01 Proto/ Development Sample To converts pattern in to actual garment.
02 Size set/Grad / Fitting To fit the styling of the garments

Sample
03 Additional Sample (White All these samples are made to how the
only magazine , Photo) garments no the rack
04 Contract Seal / Seal sample To gain approval before the bulk

production
05 Per Production (pp) sample To gain approval before the bulk
production
06 Production Sample To gain approval for shipping the
garments
07 Sales Man Sample (SMS) To gain approval for shipping the garment
08 Rack Sample To show the garment on the rack
Pattern Making Flowchart
Tec Pack Deceived
Sketching Pattern
Printing / plotting
Pattern Cutting
Hardware & Software used in Pattern Making

1 CAD Software . Gerber Garments Technology (GGT)
2 Maker Making software - PCs
3 Gerber Plotter – 3 pcs
4 Pattern design software (PDS ) , opti Tex 4 PCs

Page 176
Types of Machine
Sampling process is the most important department in a garment factory .

With proper sample, one can not achieve enough order. Do there is several
number of machine are used in the sampling section and craftsmanship in
also very important
Serial Type of machine Qty in Use
no pcs
01 Single needle Lock Stitch 52 Single Stitch
02 4 Thread Over Lock 20 Using 4 treads to
lock the joint
03 Flat Lock 17 Normal Stitch
04 Blind Lock 1 Straight Overlock
Hem
05 Chain Stitch Machine (Single 2 Making chain stitch
Needle) in the garment
06 Over Lock Open stitch 1 Over Lock
07 PMD Kansai 1 Attaching Parts
08 Bar tack 1 Heavy Stitch
09 Button Attaché 1 Attaching button
in the garment
10 Button Hole 1 Making button hole
11 Shade stick 1 Straight sewing
12 Thread Recone 1 Thread transferring
between bobbins
13 snap button 1 Metal button
Attachment
14 Plain Machine Zig Zag 1 Crosses sewing
15 Back Neck beck tape attack 1 Attaching back
neck tape
Total 102

Page 176
Garments Cutting Section
M/C Specification:
Auto Spreader (4):
M/C No.: 01
Brand Name: Jutex
Country: Germany
Year of Manufacturing: 2006
M/C No.: 02
Brand Name: Gerber
Country: Germany
M/C No.: 03
Brand Name: Gerber
Country: Germany
M/C No.: 04
Brand Name: Gerber
Country: Germany
Hand Cutter (20):

Brand Name: Mack (10)
Country: Japan
Speed: 3000/3600
Volt: 220
Frequency: 50/60 Hz
Phase:1
Blade: Straight bar blade
Brand Name: Blue Streak (10)

Country: USA
Speed: 2850
Volt: 220
Frequency: 50Hz
Phase:1
Blade: Straight bar blade
Auto Cutter (1):

Brand Name: Gerber
Country: Germany

Page 176
STANDARD OPERATING PROCEDURE OF CUTTING
SECTION
Cutting department receives Tech Pack from merchandiser and PP sheet of

a style from IE.
Cutting department checks whether sample, master pattern and fabrics are
ready or not.
If ready cutting department collect sample, marker and fabric (for size set)
from the sample section, CAD section and fabric store.
Cutting department gives a lay for size set sample, cut, sew in the size set
line, print, wash, embroidery all are done and measurement are taken in all
the steps.
If it is found that an adjustment is required in the master pattern, than

cutting manager, buyer QC and pattern master check and make necessary
correction as per grading and informs pattern and CAD section.
Then cutting department collects fabrics for bulk production from store and
checks whether the GSM of every roll is fine or not and check the width of
fabric for that lot.
If fabric GSM is ok, cutting department sends information to CAD section

containing in which width and ratio of fabric they are going to cut that
particular cutting.
CAD prepares marker and sends it If in that style self fabric for neck is
required,
to the cutting section. Cutting in charge informs the
spreading
machine operator to keep particular amount
of fabric from each roll.
Spreading starts and completed.

Page 176
Marker is placed on the lay and then costape is attached.
Cutting starts and completed.
Cuttin g parts are transferred to

stickering A spread sheet containing number of
Table. layer in that cutting, how many parts
in a garment goes to the ckering
sti
Section by ps reader machine operator.
Stickersare made ready. Bundle cards are made ready.
Stikering starts and completedand

sticker attached parts are send to Bundle cards
omecto bundle area.
bundling area.
Bundling starts and completed.
Rejection cutting starts

and completed.
If other operations are needed such

as Print, Embroidery , cutting
departmentsends the cut panels to Solid parts.
the storeand later collects them
from the store and checks whether
there is any alte
r or not.
Print and Embroidery panels are

checked and if some alter and
rejects are foundthe bundle cards Store in the cutting input rack.
are re-written making necessary
adjustments.

Page 176
SEWING SECTION
List of machines in Sewing Unit:
Machine name M/C quantity

Plain Stitching m/c 1290
Over Lock Stitching m/c 600
Flat Lock m/c 400
Button Hole m/c 25
Button Stitching m/c 25
Bar Tack m/c 40
Picoting m/c 02
Plain zig zig m/c 04
Kansai m/c 10
Two Needle Chain Stitching m/c 40
Two Needle Lock Stitching m/c 06
Suttle Stitching m/c 04
Fusing m/c 09
Heat Transfer m/c 13
Machine Specification:
Brand Name Country
Juki Japan
Pegasus Japan
Kansai Japan
Brother Japan
Pup Japan
Sun Star Korea

Page 176
Garments Finishing Section
Process Sequence of Garments Finishing:
1. Quality inspection after sewing
Check hole body of the garments i.e., inside & outside , stitch, neck,
placket, 4 point etc.
Reject Q. I. Pass Spot Alter

(Red (Green carrier) (Blue (Yellow
carrier) carrier) carrier)
Audit check lot- wise with Spot room

measurement Return sewing
section
Spot lifter
Q.I. check
for alter ok
Again Q.I.
check
Q.
Pass Q. Q. Q.
Q. Q. Fail Pass Fail
Pass Fail
Recheck
2. Thread Sucker
Folding (Body turning)

Page 176
3. Running Iron
4. Quality check
(finishing)
Reject Q. Pass Spot Alter
Spot room Take necessary action
Q. check Q.
Check
Pass Fail
5. Measurement
check
Alter Measurement
Pass Reject problem
Return to the sewing section

for necessary action Measurement
iron
Q.
check Again Measurement
check
Fail Pass
6. Get-up Pass Fail

check

Page 176
Pass Fail
7. Sleeve and shoulder check
Alter Pass Fail/reject
Return to sewing section

for necessary action
8. Hang tag attach
9. Getup iron (If appearance is not

good)
10. Metal detector
11. Q. check (only appearance check due to

new buyer or buyer requirement but all
body are passed )
12. Folding Hard tag attach (if buyer requirement)
13. Poly pack
14. Assorting
15. Blister (According to buyer requirement)
16. cartoning
17. Carton sticker attach
18. SHIPMENT

Page 176
Page 176
ORGANOGRAM
CEO
↓
COO
↓
DGM
↓
EXECUTIVE
↓
PRODUCTION OFFICER
↓
SUPERVISOR
↓
↓ ↓
↓ SHIFTSUPERVISOR QUALITY SUPERVISOR STORE
SUPERVISOR
↓ ↓
↓
OPERATOR Q.I
STORE STUFF
↓
↓
HELPER
LOADER

Page 176
Page 176
Page 176
MACHINE CAPACITY
DRYING MACHINE:
COSMOTEX:
CAPACITY=50-60 KG
TEMP= 150ºC
ORIGIN = SPAIN
GREENMAC:
CAPACITY=40-50 KG
TEMP = 70-75ºC
ORIGIN = CHINA
DYEING MACHINE:
COSMOTEX:
CAPACITY=150 KG
TEMP.= 100ºC
ORIGIN = SPAIN
SAMPLE DYEING MACHINE:

COSMOTEX:
CAPACITY=30 KG
TEMP.= 100ºC
ORIGIN = SPAIN
HYDRO-EXTRACTOR:
GREENMAC:
R.P.M= 2000
ORIGIN= CHINA

Page 176
Flow Chart for Garments dyeing (Light Shade)
Water fill + garment load M:L= 1:8
↓
NOF
Normal wash two times at normal temp.
↓
Dyeing water fill
↓Check PH 6.5
Levelling agent
↓ Run time 10´
Temperature raised at 80ºC
↓
Color dosing 10´
↓ run 10´
Salt dosing 10´
↓ run 10´
Soda dosing 10´
↓ Run until desired shade
Bath drain
↓
Normal wash two times
↓
Acetic Acid dosing 2´ & run 5´ at normal temp.
↓
Bath drain
↓
E.C(Fixing agent) dosing 5´ & run 10´ at 45ºC
↓
Softener dosing 5´ & run 10´ at 45ºC
↓
Bath drain
CHEMICALS USE IN WASHING

Page 176
CHEMICA BRAND PURPOSE MANUFAC ORIGIN
L NAME NAME TURER
WETTING FELOSON- increases the spreading CHT SWITZERL
AGENT NOF and penetrating AND
properties of a liquid by
lowering its surface
tension
LEVELLING DBC low foaming, ensure
AGENT smooth dyeing process.
Are slowing down the
exhaustion speed of the
dyestuffs
ANTI BACK CYCLONEAN REDUCE COLOR BASF GERMANY

STAIN BLEEDING
FIXING SANDOFIX- TO FIX THE DYE
AGENT EC MOLECULES INTO
THE FIBRE
SOAPING CIBAPONE-R FASTNESS
AGENT IMPROVEMENT,
REDUCE UNFIXED
DYE
SOFTENER ROCOFIN FEELING SOFT OF CHEMI GERMANY
GWE THE FABRIC WORLD
NEONSOPH UNICON ITALY
T RESOURCE
STIFFENIN INCREASES THE
G AGENT STRENGTH OF THE
FABRIC
A.ACID to create acidity medium TEX TAIWAN/
and to control the PH. CONCERN INDIA/
KOREA
BLEACHIN OCEAN TO CHANGE THE CHINA
G AGENT MAGIC ORGINAL COLOR
ENZYME BIOPOLISH- TO REMOVE MULTI SRILANKA
B14 HAIRINESS CHEMI
PRE- DENIMCOL TO CONVERT THE
CATIONIZA FIX GF FABRIC INTO ANIONIC
TION FORM TO CATIONIC.
BINDER DENIMCOL to bind the pigment
GFC particles and develop
adhesion to a surface
TYPES OF WASH
1. GARMENT WASH
Page 176
2. ENZYME WASH
3. ACID WASH
4. NORMAL WASH
5. VINTAGE WASH
GARMENT WASH
WATER FILL + GARMENT LOAD
↓
DETERGENT DOSING (5 MIN. AT 45°C)
↓ RUN 5 MIN.
BATH DRAIN
↓
NORMAL WASH TWO TIMES
↓
WATER FILL
↓
SOFTENER DOSING (5 MIN. AT 45°C)
↓ RUN 5 MIN
BATH DRAIN & UNLOAD
↓
HYDRO-EXTRACTOR
↓
DRYER
ENZYME WASH
↓
NOF DOSING (3 MIN. AT 55°C)
↓
A. ACID DOSING (3 MIN. AT 55°C)
↓CHECK PH=4.5
ENZYME DOSING (3 MIN. AT 55°C)
↓RUN UNTIL DESIRED RESULT
BATH DRAIN
↓
↓
↓ RUN 10 MIN
BATH DRAIN & UNLOAD
↓
HYDRO-EXTRACTOR
↓
DRYER
VINTAGE WASH

Page 176
↓
SODA+ DETERGENT, DOSING (5 MIN. AT 60°C)
↓ RUN 20 MIN.
BATH DRAIN
↓
A. ACID DOSING (3 MIN. AT NORMAL TEMP.)
↓RUN 5 MIN.
↓ RUN 10 MIN
BATH DRAIN & UNLOAD
↓
HYDRO-EXTRACTOR
↓
DRYER
ACID WASH
↓
POTTASH DOSING (10 MIN. AT 45°C)
↓ RUN UNTIL REQUIRED
RESULT
BATH DRAIN
↓
META DOSING (10MIN. AT 45°C)
↓RUN 10 MIN.
BATH DRAIN
↓
↓ RUN 10 MIN
BATH DRAIN & UNLOAD
↓
HYDRO-EXTRACTOR
↓
DRYER
NORMAL WASH
Page 176
↓
DETERGENT DOSING (5 MIN. AT 45°C)
↓ RUN 5 MIN.
BATH DRAIN
↓
↓
BATH DRAIN & UNLOAD
↓
HYDRO-EXTRACTOR
↓
DRYER
Check Points
 Require of shade
 Hand feeling
 Printing
 Embroidery
 Fabrics fault
 Washing effects
 Spirality
 Label
 Zipper
 Bleeding
 Reject
Faults found in garments after washing
 Needle damage

Page 176
 Fabric damage
 Print problem
 Spot

Page 176
PRINTING
General Overview
Area Covered=50,000 sft( 2 flo0r)

Manpower=450
Per table=12-13
Auto screen m/c=7-8
Heat press m/c=3-4
Curing m/c=2-3
Capacity of Printing= 40,000-45,000 pcs per day
Machine Type Machine information NO. of M/C

Screen shot Auto screen shot 4
Manual screen shot
Drying Auto dryer 4
Hand dryer 100
Expose shot Auto expose shot 1
Manual expose shot 3
Heat press Depends on pressure & 6
temp. range
Curing Depends on temp. & 7
belt speed
Printing System
Hand screen printing

Sereen Printing Automatic Flat (Revolving) screen printing
Specification (Automatic Flat screen printing)
M/C no -1
Brand name: Diamond back Red chili
Country : USA
No. of Head :6
Max. Color used :5
Drying head :1
M/C NO:2
Brand name : Diamond back Red chili
Country : USA
No. of Head :8
Max. Color used : 6
Drying head :2
M/C NO:3
Page 176
Country : USA
No. of Head : 12
Max. Color used : 8
Drying head :2
M/C NO:4
Country : USA
No. of Head :8
Max. Color used : 6
Drying head :2
Flow chart of Printing section
Artwork from merchandiser
↓
Design input
↓
Design development
↓
Positive/film
↓
Print taken
↓
Requisition by merchandiser
↓
Panel(cutting fabric parts)
↓
Expose(frame adjusted)
↓
Fila and frame adjusted
↓
Water spray
↓
Panel send to buyer
↓
Buyer approval
↓
Sale sample
↓
Counter sample
↓
P P production
↓
Accessories booking
↓
Requisition by merchandiser for fabric
↓
Fabric received and store
Page 176
↓
Count the fabric
↓
Inspection the fabric
↓
Fabric adjusted
↓
Bulk production start
↓
Hydro extractor from dryer
↓
Inspection
↓
Finishing
↓
Delivery
Types of print
Rubber print
Pigment print(Water base print)
Foil print
Discharge print
Puff print
Glitter print
Afsan print
High density print
Plastisol print
Crack print
Gel print
Sticker/transfer print
Reflective
Design
Artwork receive from development
↓
Detail design perform & analyze by Adove photoshop & illustrate
↓

Page 176
Prepare individual film for different color by work express software
↓
Send to expose room
Screen Preparation:
Mesh fabric tight with frame
Applied chemical TXR (sensitizing emulsion) on the mesh & dried 8 min in
air.
Placed design paper under the mesh.
Light passes through the design paper & mesh fabric for 3-4 min.
Remove the colored TXR from the design area by water spraying.
Sequence of printing
Count garment parts
Screen preparation
Printing paste preparation
Applied garment part on the printing bed by (adhesive) gum in the marked
portion
Printing the garment part by using screen
Drying the printed portion by hard dryer applying hot air flow
Curing the printed portion by passing through the conveyor dryer at 1600 -
1800 c
Inspection is done in qualify control department
Process for Foil Printing
Add adhesive on the require design by screen

Page 176
Place the fabric part on to the Pressing M/C
Pressing the upper part of the M/C at 100PSi, Temp-1500 For-6 Sec
Expose Room
Mesh fabric NO. Print Type

10,12 Glitter
14 Afsan, Discharge pigment
16,20 Rubber,Puff, High density, Foil, Gel,
Plastisol, Reflective, Crack
Print wise curing
Print type Temperature Belt speed Duration(sec)

m/min
Rubber 150-160 4-6 30-45
Pigment 140-150 4-6 30-45
Plastisol 180-200 4-5 36-45
Discharge 180-200 3.5-4 45-52
Puff 170-180 3.5-4 45-52
Glitter 150-160 4-6 30-45
Reflective 160-170 4-6 30-45
High density 180-200 3.5-4 45-52
Gel 170-180 4-5 36-45
Afsan 150-160 4-6 30-45
Common print defects

 Measuring fault
 Print missing
 Wrong color
 Hand feel not correct
 Color migration problem

Page 176
 Not properly attach
 Dirty marks
 Uneven print
 Air bubble
 Air hole
 Shade variation
Major causes of print defects

1. Screen & print body are not in same axis
2. Irregular wash of screen frame
3. Wrong color recipe
4. Insufficient drying of previous color
5. Inaccurate composition of fixture
6. Improper heat & pressure
7. Dirty environment
Auto screen shot

1. Faster production
2. High color combination
3. Immediate drying between two consequetive print
Not suitable for-
Large & complete body print
High density, flock & multiple color, discharge print.
Manual screen shot

Page 176
1. Generally all types of print are performed
2. More time consuming
3. Drying performed by hand or auto dryer
HEAT PRESS M/C
1. GENERALLY USED FOR Foil & Sticker print
2. Matt & glossy appearance also provide by this technique
3. Print performed at a certain temp. & pressure
Drying
1. Hand drying
2. Auto drying
It is performed to dry previous color temporally
Color migration occurred due to improper drying of previous

color
Curing
Curing is the ultimate drying of print
Proper curing is the vital issue for a quality print
Curing also liable for fabric shade change due to high temp.

Page 176
Page 176
EMBROIDERY
ORGANOGRAM OF EMBROIDERY
CO (Embroidery)
Embroidery manager
Assistant manager (designer)
Supervisor ( A.Q.C) Sample

man
Q.I senior
operator
Helper Helper
Senior operator
Assistant operator
Frame men
M/c men
Helper
Iron men
Embroidery Machine Specification
Electronic multi-head automatic Embroidery M/C
Brand: Tajima
Country: Japan
Model: TFGn-920
No. of head: 20
No. of Needle per head: 9
No. of Embroidery M/C: 7 M/Cs for Bulk production

: 1 M/C for Sample
Machine RPM= maximum 950

Page 176
Bobbin winding M/C
Brand: Tajima
Country: Japan
No of m/c: 2
Embroidery stitching type
 Sartin Stitch
 Tatami Stitch
 Run Stitch
 Motif Stitch
 Cornoly Stich
 Loop Stich
Method
1. By Bed
2. By Ring
Bed: Needle fixed but Bed movable
Interlining:
Four types of interlining are used in Viyellatex-

3. Soft
4. Hard
5. Dot line
6. EB-50(PUMA)
Design Analysis
Art work from buyer
Input to ES-65(Software)
Design analysis

Page 176
↓
Send to buyer
Recommendation & correction from buyer
Sample prepare
Send to buyer
If approved then for bulk production
Thread used in Embroidery
Brand Name Country

• Madera Germany
• Metal Germany
• Well Bangladesh
• Force Bangladesh
• Coats Bangladesh
• Basic Bangladesh
 Thread Count – 135 x 2 Dtex

 Thread contain in bobbin - 2500m
Embroidery Faults
 Stitch gap
 Bobbin out
 Oil spot
 Thread loose
 Embroidery position wrong
 Needle hole
 Over stich

Page 176
Production per day:
• 20,000 piece per day

Page 176
Page 176
Maintenance
Maintenance is a procedure by which we can maintain active functioning in
operation according to the behavior and utility of a particular element.
Machine, buildings and other facilities are subjected to deterioration due to
their use and exposure to environmental condition. Process of deterioration,
if unchecked. culminates in rendering these service facilities unserviceable
and brings them to a standstill. In Industry, therefore has no choice but to
attend them from time to time to repair and recondition them so as to
elongate their life to the extent it is economically and physically possible to
do so. In engineering, we use this terminology for maintaining smooth and
uninterrupted performance of machines, tools and metallurgical
characteristics in practical uses
Objective of maintenance:
 To keep the factory plants, equipments, machine tools in an optimum
working condition.
 To ensure specified accuracy to product and time schedule of delivery
to customer.
 To keep the downtime of machines to the minimum thuds to have
control over the production program.
 To keep the production cycle within the stipulated range.
 To modify the machine tools to meet the need for production.
Three types of maintenance are performed in Viyellatex

Group.
1. Preventive Maintenance.
2. Routine/ Schedule Maintenance.
3. Breakdown Maintenance.
Preventive Maintenance: Preventive maintenance is a
predetermined routine actively to ensure on time inspection checking of
facilities to uncover conditions that may lead to production break downs or
harmful description.These actions are performed to prevent or reduce
consequences of failures.
Schedule maintenance: Maintenance of different machines are
prepared by expert engineer of maintenance department. It is time-based
maintenance and pre-planned to perform on machine and equipments
Normally in case of dyeing machine maintenance after 30 days complete
checking of different important parts are done.

Page 176
Breakdown maintenance: In this type of maintenance when the
machine remains stop that time the maintenance is done.
SL. NO. Items need to be checked & Serviced

1. Check and tightening all motor terminals.
2. Check and clean pressure sensor and tightening
terminals
3. Clean the ventilation fans of panel board and
circular fan on top machine.
4. Check and clean the interfacing and data cables.
5. Check and tightening the proximity switch
terminals.
6. Inspection, cleaning and tightening all the
terminals in the panel.
7. Check and tightening limit switch, safety door
guard and emergency switch.
8. Functional test of the yarn detector.
SL.NO items need to be checked & Serviced

1. Check and tightening all motor terminals and clean the
motor (3odays).
2. Check activity of wide and sensor and pneumatic
regulator.
3. Check and clean pressure sensor and tightening terminals
4. Clean the A/C ventilation fans of panel board
5. Check the fan and the heat sink o the inverters in the
panel board.
6. Check and tightening the edge sensors.
7. ~ Check and tightening the photo sensor terminals.
8. Check and tightening the safety light barrier and
tightening terminals.
9. Inspection, cleaning and tightening all the terminals in the
panel.
10. Check and tightening limit switch, safety door guard and
emergency switch.

Page 176
Check List of Different Parts
Maintenance : Mechanical
Machine : Dyeing machine
SL. Items need to be checked & Serviced

No.
1 Clean the m/c bearing.
2 Complete cleaning of machine
3 Cleaning of drain valves, replace seals if required.
4 Check air supply filters, regulators auto drain seals
5 Clean filters element and blow out.
6 Greasing of unloading roller bearing.
7 Checking of oil level and bolts of unloading roller
gearbox.,
8 Checking of unloading roller coupling and packing.
9 Checking & cleaning (if required) of main vessel level
indicator.
10 Check the oil level of pump bearing and refill if
required.
ii Check the function of heat and cool modulating valves
12 Check all door seals.
Maintenance : Electrical
Machine : Dyeing Machine
SL No. Items need to be checked & Serviced

1. Check & clean fluff and dirt at 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 its filter
5. Clean main pump inverter and its cooling fan.
6. Check all circuit breaker, magnetic conductors and relays.
7. Check current setting of all circuit breaker & motor over load.

Page 176
8. Visual checking of all power & control cables.
9. Check calibration of main vessel & all addition tank
10. Check all pneumatic solenoids
11. Check calibration of heating/cooling modulating value
12. Check setting of tangle sensor.
13. Check setting & operation of lid safely switches.
14. Check all emergency switches
15. Check all indicating lamps
16. Check all on/off switches
17. Check all signal isolators.
Maintenance Tools & Equipments:
1. Combination tools / spanner
Function: Tightening & loosening of nuts & bolts.
2. Socket ratchet set
Function: Tightening of nuts & bolts.
3. Slide range
Function: Tightening & loosening of nuts & bolts.
4. Monkey pliers
Function: Tightening & loosening of nuts & bolts. 5. Pipe
threat cutting tools
Function: To cut the threat in pipe.
6. Bearing puller
Function: To assist the opening of bearing from shaft. 7. Pipe
range
Function: Tightening & loosening of pipe joint.
8. Pipe cutting tools
Function: For pipe cutting.
9. Hole punch
Function: Punching the hole.
10. Divider
Function: For circle marking on metal & wood.
11. Easy opener
Function: To open the broken head bolt.
12. External threat die
Function: For external threat cutting.
13. Heavy scissor
Function: Cutting of gasket & steel sheet.
14. Oil can
Function: Oiling of moving parts.
15. Drill machine and drill bit.
Function: For drilling.
16. Grease gun
Function: For greasing of moving parts of rn/c.
17. Grinding m/c
Function: For grinding & cutting of mild steel.
18. Welding m/c

Page 176
Function: For welding & cutting.
19. Spirit leveler
Function: For perfect leveling.
20. File
Function: For smoothing the surface.
21. Hammer
Function: For scaling & right angling.
22. Circlip tools
Function: Circlip opening & closing.
23. Hacksaw blade
Function: For metal cutting.
Maintenance Procedure:
Preventive Maintenance: They always follow preventive
maintenance.
Breakdown Maintenance: When a problem occurred the operator
informed the supervisor, then the supervisor informed the production
officer, then the production officer called the maintenance officer. The
maintenance officer visits the problem and takes necessary steps to solve
the problem.
Flow chart of maintenance
Problem occurred
Operator
Supervisor
Production officer
↓
Maintenance officer
Solution
Remarks:
Maintenance of m/c’s are very essential to prolong the m/c life and good
maintenance is important consideration. It is necessary to check that all
routine maintenance is being done regularly and properly otherwise
efficiency of each department will be reduced.

Page 176
Page 176
UTILITY SERVICES
Introduction:
VIYELLATEX GROUP LTD. is a big project and so of course having a vast project of utility
service. Here the total account of utility facilities are available. The utilities are
 Water
 Gas
 Electricity
 Compressed Air
 Steam
Generator house
The list of machine:
1. Generator
2. Panel
3. Distribution Board
4. Generator Control Panel
Number of Generator= Four
Capacity= 4.25MW
Manufacturer= Jenbacher (AUSTRIA)
1. Generator:
To generate the power (volts & amps) for every section in the Factory.
2. Panel:
To store the power (volts & amps) from the generator for every
section in the factory.
There are two types of panel:
 PFI (Power Factor Improvement) panel
 LT panel

Page 176
PFI panel:
To store the power (volts & amps) from the generator for the boiler house, finishing
section & dyeing section in the factory. Supply AC current. 4 Amps & 400 volts
LT panel:
To store the power (volts & amps) from the generator for the boiler
house, finishing section & dyeing section in the factory. According there
need. Supply AC current. 4 Amps & 400 volts.
3. Distribution:
To supply the power (volts & amps) for the light, AC, fan etc in the different section.
Supply AC current. 4 Amps & 400 volts.
4. Generator control panel: To control the generator for generate power.

Page 176
BOILER
Boiler:
The equipment used for producing steam from water is called steam
generator or boiler. The boiler used for producing steam in GKL is Cochran
boiler which is a fire tube type boiler. This produced steam is supplied by
the steam line in different section. Simple vertical boiler of fire tube type is
mainly used in small plant requiring small quantity of steam and where floor
area is limited.
Classification of boilers:
1) Fire – tube boiler( gas ) : Low pressure , low running cost , less chance
of busting but greater risk of damage .
2) Water – tube boiler: High pressure, high running cost high chance of
bursting & don’t damage the whole boiler.
As this factory used fire tube boilers and its description is given below.
In boiler house, steam is produced at high temperature and pressure. This produced steam is
supplied by the steam line in different section.
Uses: Steam use for –

 Power generation ( steam engine / turbine ) .
 Processing in industries (dyeing & finishing mill, sugar mill, paper mill etc.).
 Heating purposes ( houses , offices , hospitals etc in cold countries ).
 Hot water supply.
Essentials of a good boiler
 Required pressure and quality at minimum fuel .
 Initial installation and maintenance cost low .
 Parts approachable for repairs .
 Quick starting capacity .
 Conform to the safely regulations of boiler act .
Working principle:
The gas is fed through the front side to the furnace where fire created by
electric spark. The blower move the fire into the flue pipe by compress air
and then the flue gases enter through the combustion chamber which is
lined with fire bricks on the outer wall of boiler. The hot gases passing
through the horizontal smoke tubes give their heat to the water and convert
water into steam. This steam gets accumulated in the upper portion of shell
from where it can be supplied to the users. Finally, the flue gases are
discharged to the atmosphere through the smoke box and chimney.

Page 176
Feed water tank
Gas Burner Boiler Blower
Steam
Factory house
Figure: Steam produces procedure mechanism
The list of machineries:

 Three Boilers
 Boiler water softener plant
 De-alkalize
 Four Condensed pump
 One hot water tank
 One water feed tank.
Capacity= 17ton
Boiler Specification
Boiler No : 01
Machine Name (Functional) : Steam Generate
Boiler Type : Fire Tube Boiler
Brand Name : OMNICAL BOILER
Model Name : 20424
Max. Steam Output : 6 t /h
Test Pressure : 20.5 bar
Volume : 12540 L
Year of Manufacture : 2008
Country Name : Germany.
Boiler No : 02
Page 176
Brand Name : SCHNEIDER-KESSEL BERLIN
Model Name : HDD-P5000-10
Max. Working Pressure : 10 bar
Minn. Steam Temp. : 20˚C
Max. Steam Temp. : 185˚C
Volume : 5200 L
Manufacturer's Name : German Thai Boiler Manufacturing Ltd.
Boiler No : 03
Boiler Type : Fire Tube Boiler
Brand Name : OMNICAL BOILER
Model Name : 20424
Max. Steam Output : 6 t /h
Volume : 12540 L
Country Name : Germany.
COMPRESSED AIR
Compressed air is produced by air compressor.
There are four air compressors for producing compressed air.
Manufacturer= GERMANY(KAESAR)
STEAM
Steam is produce by Boiler.
From the Water Treatment Plant, water is stored in a reserve tank and from
there water goes
to boiler & steam is produced.
GAS
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section (Boiler- for heating
water) from the main line of the TITAS GAS LTD.
Sources of Electricity:
Page 176
Electricity : PDB & Generator
Steam : Boiler
Water : Pump
Compressed air : Compressor
Gas : TITAS GAS LTD.
Remarks:
As the biggest project the VIYELLATEX GROUP., so the vast utility
systems. There is a skill manpower group of engineers and other technical
staffs to look after these utility services. They have to remain aware of
solution on a great sense of responsibility for any type of problem due to
utility supply.

Page 176
WATER TREATMENT PLANT
There are two deep tubeweel by the two side of the treatment plant.
There are also two submersible pumps in the deep tubeweel one is 100 ft
deep and another is 140 ft deep. The submersible pump transfer raw water
in the water tank by creates force. The formation of oxidation of the water
by showering with the help of another two pimps in the water tank. Iron
content removes by the oxidation.
Two circular transfer raw water in the (vessel no-1) Multigrade filter
unit. The large size plastic, iron that means solid content are removed in the
multigrade filter unit. The water is transferred to the (vessel No-2) Activated
carbon filter unit. In the (vessel No-2) Activated carbon unit to remove
chlorine that means bad smell. The water then transfer in to the (vessel No-
3) softener unit from the activated carbon unit at the presence of cationic
resin (Zeolite) is reacted with water to remove the hardness of water.
The water is transferred in to the reserve tank from the softener unit.
The soft water is supplied from the reserve tank by the 7 Boosting pump in
the different section of the factory.
The back wash & regeneration process

The back wash process to clean the vessel no-1,2 & 3. The back wash
process should be done after 8-12hrs. After 40-48 hrs later the regeneration
process should be done. It should be done after back wash process. After
back wash the common salt dissolved with water in to the STT (salt
saturated tank) the solution of common salt is ringing the resin by the
injector. The use of 18% salt in the total solution. (Suppose, 5000 lit of
solution the amount of salt 600kg). The resin is activated by the salt rising.
Here used cationic resin (NaHSO3). If the PH of the water increase or
decrease it should be control by the dosing chemical (Sodium Hypochlorite)
from the chemical tank.
A B C D E
Figure: Water treatment plant
Where,
A=Hard water storage tank
B=Stone filter
C=Carbon filter
D=Resin filter
E=Soft water storage tank
F= Pump

Page 176
Standard water quality for dye house
Minimum Permissible concentration
standard
Color Colorless
Smell No bad smell
Water hardness < 50
PH Value 7-8 Neutral
Dissolved solid < 150 mg/1
Inorganic salt < 500 mg/1
Iron (Fe) < 0.1 mg/1
Manganese (Mn) < 0.01 mg/1
Copper (Cu) < 0.005 mg/1
Nitrate (NO3) < 50 mg/1
Nitrite (No2) < 5 mg/1
Chlorine <0.i mg/1
Filterable solids < 50 mg/1
ammonia < 0.5 mg/1
Hardness check
The hardness should be checked after every 6 hrs. It should be
checked by the hardness test kits. The using hardness test kits are Hanna
Instrument. Made in Italy. If the hardness is going to be 0.5 on the syringe
scale. Then have to do the regeneration process.
The capacity of WTP= 200m3/ hr

Page 176
EFFLUENT TREATMENT
PLANT
Flow chart of ETP:
Effluent Equalizer Reaction PH Floccula- Prmary

Water from Tank Tank Control tion clarifier
Dyeing Tank Tank
Sludge
Discharge bed
Effluent
Multifilter Chlorintion Secondary Aeratio

Tank clarifier n
Tank
Reserve tank
For Re-using
Water
Effluent treatment plant (ETP)

Process:
i. Chemical
ii. Biological.
In Viyellatex Biological process is used

Capacity: 100 m3 / hour.
The major sources of liquid discharge are:
 scouring.
 Bleaching.
 Dyeing.

Page 176
 Washing.
Dye wastes content:

- Carbon, nitrogen, phosphorus.
Bleaching:
- Dilute hypochlorite solution.
- H2O2
Raw materials:
1. main raw material:
 Cotton yarn.
 mixed yarn
 Dyes
 Chemical
2. dye include:
 Reactive.
 Disperse.
3. Chemical includes:
 Detergent
 Soda ash
 Caustic soda.
 H2O2
 Stabilizer.
 Acetic acid.
Step wise function of different unit of E.T.P
Equalizer Tank:
Air circulation is occurred in this tank to reduce the temperature of the
water.
Reaction Tank:
Use chemical: Soda Lime.
Function: To remove the various color.
PH Control Tank:
Use chemical: FeSo4, Fitcary.
Function: To control PH.(6.0-6.5).
Flocculation Tank
Use chemical: Polyelectrolyte & alum.
Page 176
Function: To produce flock.
Primary Clarifier:
Function: To monitor performance of flocculation clarifier & separate solid waste.
Sludge Bed:
Function: Solid waste dried & send to outside for burial
Aeration Tank:
Use chemical: Urea, Phosphoric acid.
Function: Bio logical oxygen demand & Chemical oxygen demand reduced here &
diffused aeration system ensures high oxidation efficiency.
Secondary Clarifier:
Function: Remaining solid waste separate here. Reduced total solid.
Chlorination Tank:
Used chemical: Sodium hypochloride
Function: Disinfection done here.
Multi filter:
Function: Extra suspended impurities separation by passing into the sand.

Here removed suspended solution and correction the water color.
The characteristics of waste water assumed at

VIYELLATEX as follows:
 pH = 11
 BOD = 300 mg/L
 COD=200 mg/L
 Suspended solid (SS) = 200 mg/L
 Color = dark
Final treated Quality of VIYLLATEX discharge is

 PH = 6-9
 BOD = 35 mg/ L
 COD = 170 mg / L
 Suspended solid = 50 mg/L
 Color = color less.
BSTI’S standard:
 Ph = 6-9
 BOD = 50 mg/L
 COD= 200 mg/L
 Suspended solid = 150 mg/L
Page 176
 Color = Light brownish.

Page 176
CONCLUSION :
We have completed our industrial attachment successfully by the grace of Allah.
Industrial attachment sends us to the expected destiny of

practical life. The completion of the two months Industrial attachment at
VIYELLATEX GROUP, we have got the impression that factory is one of the
most modern export oriented knit composite complex in Bangladesh.
Though it was established only a few year’s ago, it has earned “very good
reputations” for its best performance over many other export oriented
textile mills.
During our training period, talking with the clients of this mill we
knew that the mill is fulfilling the country’s best export oriented white
finished fabric as well as very good colored fabric due to its modern
machinery & good management system.
Mill is settled with utility to give all convenient supports to the

productions for twenty-four hours. It had self-power generator system to
satisfy total power consumptions of the mill.
We are enough fortunate that we have got an opportunity of

having a training in this mill. During the training period we are received co-
operation and association from the authority full & found all man, machines
& materials on appreciable working condition. .\ll stuffs & officers were very
sincere & devoted their duties to achieve their goal.
There are some suggestions from us within our limited knowledge
Some Suggestions:
 The dyeing floor is watery most of the time: it should be cleaned all
the time.
 To increase overall efficiency, more skilled labor should be used in a
project.
 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) and routine maintenance should be carried out
regularly.
 There should be a yarn dyeing project.
 Sitting arrangement of production officers should be improved.

Page 176
Lastly:
We tried our best to gather all necessary information but it is true that
within this short period it is quite impossible to achieve 100% success but
as a whole this industrial training was a satisfactory one and once again
wed would like to thank the authority of VIYELLATEX GROUP. as well as
our honorable teachers far their altruistic help and advice. We are fortunate
enough that we have got an opportunity to have training in this mill. During
the training period we have received enough co-operation and association
from the authority and found all personnel. All stuffs and officers were very
sincere and devoted their duties to achieve their goal.

Page 176

Acknowledging Support During an Industrial Attachment

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ACKNOWLEDGEMENT:

We are extremely delighted to express our indebtedness and deepest sense

The authority of the VIYELLATEX GROUP who gave us the opportunity to

We also like to thank Dr. Shah Mohammad Fatah-ur-Rahman,

INDUSTRIAL ATTACHMENT ON VIYELLATEX

The internationally recognized Buyers or clients are looking for those

VIYELLATEX GROUP is a Knit Composite Garments, having all state of the

In this report, we have tried to give some information about VIYELLATEX

INDUSTRIAL ATTACHMENT ON VIYELLATEX

The industrial attachment is the process, which builds

By means of practical knowledge it’s not possible to apply the

It also provides us sufficient practical knowledge about production

Textile education can’t be completed without industrial training.

INDUSTRIAL ATTACHMENT ON VIYELLATEX

TOPIC NUMBER TOPIC NAME PAGE NUMBER

09 WASHING SECTION 138-146

INDUSTRIAL ATTACHMENT ON VIYELLATEX

Name of Company : VIYELLATEX GROUP.

Factory: VIYELLATEX GROUP.

VIYELLATEX LTD. is a well established knit composite industry. The industry

INDUSTRIAL ATTACHMENT ON VIYELLATEX

G A J IPU R A BO ARD BAZAR

INDUSTRIAL ATTACHMENT ON VIYELLATEX

Name of the Company : VIYELLATEX GROUP

Factory: 297, Khortoli, Tongi, Gazipur-1712

 Chief Value Cotton (CVC)

 Polyester Cotton (PC)

 Grey melange (15% Voscose 85% cotton)

 10% Voscose 90% cotton

 Ash melange (1% Viscose 99% cotton)

INDUSTRIAL ATTACHMENT ON VIYELLATEX

INDUSTRIAL ATTACHMENT ON VIYELLATEX

Nature of company: 100% Export Oriented Knit composite Factory.

Qualify Certification: ISO 9002

Award: BGMEA Gold Medal-2007.

Bangladesh Business Person-2007

PVH Gold Medal – 2007

CSR Award – 2008

Turn Over:Viyellatex Garments - US$ 41.5 Million (2006-2007)

INDUSTRIAL ATTACHMENT ON VIYELLATEX

INDUSTRIAL ATTACHMENT ON VIYELLATEX

*Brand : Lioli (In Viyellatex used mostly)

• Count: 20 den, 40 den, 70 den.

Price list of different types of yarn:

Yarn Count Combed Yarn Carded Yarn

INDUSTRIAL ATTACHMENT ON VIYELLATEX

Manager /Asst. Manager (Production & Plan)(02) Manager/

Sr. Supervisor/Supervisor(06) Sample Supervisor(02)

Sr. Operator/Operator(135) Sample Asst.(05)

Manager / Asst. Manager (Store)(01)

Sr. Executive / Executive (02)

Jr. Executive (Yarn)(02) Jr. Executive (Grey Fabric)(03)

Store Asst.(Yarn)(03) Store Asst.(Grey Fabric)(07)

Loader (Yarn)(26) Batch Helper/Loader (35)

INDUSTRIAL ATTACHMENT ON VIYELLATEX

Temporary Yarn store

INDUSTRIAL ATTACHMENT ON VIYELLATEX

warp knitting: each loop in the horizontal direction is made from a

Weft knitting: a horizontal row of loops can be made using one

INDUSTRIAL ATTACHMENT ON VIYELLATEX

Cotton 24S, 26s,30S,

Spandex yarn 20D,40D, 70D

INDUSTRIAL ATTACHMENT ON VIYELLATEX