INDUSTRIAL TRAINING

COURSE CODE: ME-300

TOPIC
Study on Production process and Maintenance system
Held In
Beximco Textile Limited.
Sarabo Kashimpur,Gazipur, Bangladesh

Submitted To
Mustafizur Rahman
Lecturer, Department of Mechanical Engineering
City University

Prepared & Submitted by

Md. Ali Anwar
ID No: 2010713128
7th Batch, Section-C

Department Of Mechanical Engineering

City University
 Table of Contents

Name Page No
Table of Content…………………………………………………..….. (1)

CHAPTER 1: Information
11. About Beximco Textile Ltd……...........……………..….…………
1.2 Company overview………………………………………..……………….
1.3 Vision and Mission……...………...……………………………….……….
1.4 Main product…………...……………………………………………………….
1.5 Location………………………………………………………………………...
1.6 Factory layout plan……………………………………………………………..
1.7 Factory layout description……………………………………………………...
1.8 List of major buyers……………………………………………………….…

CHAPTER 2: Sewing Machine

2.1 Introduction…………………………………………………………………….
2.2 Types of parts…………………………………………………………………..
2.3 Sewing Machine used in factory……………………………………………...
CHAPTER 3: Knitting Machine
3.1 Introduction…………………………………………………….......................
3.2 Working process……………………………………………………….……...
3.3 Process flow of Knitting………………………………………….…………...
3.4 Flat knitting machine………………………………………………….………

CHAPTER 4: Description of the Attachment

4.1 Row Material……………………………………………………………...
4.2 Yard……………………………………………………………………….
4.3 Yarn required supplied from yarns………………………………………..
CHAPTER 5: Single Jersey Machine
5.1 End product process……………………………………………………….......
5.2 Faults and their causes in Knitting…………………………………….

CHAPTER 6: Batching Section

6.1 Introduction……………………………………………………………….
6.2 Sequence of operation…………………………………………………….
CHAPTER 7: Laboratory
7.1 Introduction……………………………………………………………….

CHAPTER 8: Garments Section

8.1 Garments manufacturing process……………………………………….…….

CHAPTER 9: Sample Section

9.1 Types of Sample………………………………………………………………
9.2 Types of Sampling and their details……………………………..…..…….
9.3 Sample making process………………………………………………...…
CHAPTER 10: Pattern making section
10.1 Introduction……………………………………………...…………………..
10.2 Marker Making Section………………………………………………..…….
10.3 Types of marker making……………………………………………..…..
10.4 Cutter Section………………………………………………………………..
10.5 Sorting & Numbering……………………………………………………
10.6 Quality Check……………………………………………………………
10.7 Bundling…………………………………………………………………
10.8 Sewing Section…………………………………………….……..………
10.9 Sewing Defects…………………………………………….………..……

CHAPTER 11: Finishing

11.1 Introduction…………………………………………………………..….…..
11.2 Thread Sucking…………………………………………………………..…..
CHAPTER 12: Ironing
12.1 Ironing process………………………………………………………………
CHAPTER 13: Packing
13.1 Packing Process……………………………………………………………

CHAPTER 14: Merchandising

14.1 Introduction…………………………………………………….……………
14.2 Merchandiser key responsibility…………………………..…………………
CHAPTER 15: Boiler
15.1 Introduction……………………………………………….…………………
15.2 Types of Boiler………………………………………………………………
CHAPTER 16: Chiller
16.1 Introduction………………………………………………….…………..
16.2 Types of Chiller…………………………………………………...……..
16.3 Working principle of chiller……………………………………………..
CHAPTER-17: Conclusion
17.1 Conclusion…………………………………………………………………...
 CHAPTER 1
Information

1.1 About Beximco Textile Ltd.

Beximco Textile Limited.(the "Company") was incorporated in Bangladesh as a Public Limited

Company with limited liability on 8 March 1994 and commenced commercial operation in 1995
and also went into the public issue of shares and debentures in the same year. The shares of the
Company are listed in the Dhaka and Chittagong Stock Exchanges of Bangladesh.

Bextex Ltd. is the most modern composite mill in the region. Bextex Ltd. has an installed capacity
of 288 high-speed air-jet looms in its weaving section and a high-tech dyeing and finishing section
with a capacity of 100,000 yards of finished fabric per day.
1.2 Company overview

Fig: Company Overview

1.3 Vision & mission:

 BEXIMCO Limited is a full-service vendor with strong vertical production facilities and creative and
analytical capabilities, which sets us apart from other South Asian vendors. Mass create the most
desirable, innovative, garments, affordable prices, use the best technology, use sustainable raw
materials and processes.

To Furthermore, the company has a cotton and polyester-blended yarn-spinning mill with 122,000
spindles, making it one of the largest spinning mills of the country. The mill was set up to feed the
country's export- oriented industries.

• 40,000 Employees From Many Nationalities

• Annual Turnover US$ 500 Million
• Full Vertical Infrastructure
• Global Footprints For Services & Manufacturing Collaborations
• Employer Of Choice
• Innovation & Speed For Multi Product Categories
• Strong Design Support.

1.4 Main Production

Basic T-Shirt, Tank top, Long Sleeve-Shirt, Polo Shirt, Shorts, Ladies and Kids Knitwear and all
kinds of knit garments and Knit fabrics.

1.5 Location
1.6 Factory Layout Plan

Fig: Factory Layout

1.7 Factory Layout Description:

1. Administration and Account.

2. Security.
3. Garments, Finished garments store, Medical and child care.
4. Under construction for garments.
5. Knitting, Cutting and Canteen.
 6. Finishing.
7. Sub-section and Generator room.
8. Finish fabric store and waste fabric store.
9. Chemical store.
10. Dyeing lab.
11. Dyeing floor.
12. Dyeing office.
13. Finished fabric inspection.
14. Maintenance and WTP.
15. Garments finishing.
16. Construction store.
17. Assembly.
18. Garments, Fabric and Yarn store.
19. Knitting and Finishing.
20. ETP.
21. Knitting office.
22. Loading and unloading.
23. Car parking.
24. Dyeing Batch

1.8 List of Major Buyers

Buyers Sign
American Eagle

Amazon

Bershka
Walmart

Target

Men’s WareHouse

PVH

Sams Club

Michael Kors

Zara

C&A

Best Seller
Next

Pull&Bear

Land’s Ends

Marks&Spencer

Fig: Buyers Name, Logo & Origin

 CHAPTER
Sewing Machine

2.1 Introduction:
A Sewing machine is a machine used to sew fabric and other materials together with thread. Sewing
machines were invented during the first Industrial Revolution to decrease the amount of manual sewing
work performed in clothing companies. Since the invention of the first working sewing machine, generally
considered to have been the work of Elias Howe, and Englishman Thomas Saint in 1790, the sewing machine
has greatly improved the efficiency and productivity of the clothing industry.

2.2 Types of Parts:

Flat Bed: The construction and design of the Flat Bed sewing machine is similar to the traditional sewing
machine. Because in this the arm and the needle extend to the flat base of the machine like the traditional
sewing machine.
Cylinder Bed: This is the opposite of flatbed. They have a narrow and horizontal column. Because of, this
the fabric pass around and under the column. The diameter of the cylinder varies from 5 cm to 16 cm. Post
Bed: These machines have vertical column arise above the flat base of a machine. The height of the vertical
column is 10 to 45 cm. These have bobbins, feed dogs/ loopers in the vertical column.

Of-the-arm: These are not much common. In this type of a machine, the worker needs to feed material along
the axis of a horizontal column. It is useful in seaming sleeves and shoulder.

Fig: Sewing Machine.

2.3 Sewing m/c used in this factory
Nos Origin
Name of the Machine 436 nos. Japan
1. Single needle Plain Machine
2. 2-needle, 5-thread over lock 08 nos. Japan
3. 2-needle, 4-thread, over lock 318 nos. Japan 4. 2-needle, 4-thread, lap seam 11 nos. Japan stitching
5. 3-needle, 5-thread, chain stitch 06 nos. Japan
6. 1-needle Button Hole 19 nos. Japan
7. 1-needle Button stitches 19 nos. Japan
8. Snap button machine 04 nos. Japan
9. Flat Lock Flat bed 78 nos. Japan
10. Flat Lock Cylinder bed 162 nos. Japan
11. Kansai Special(PMD) 02 nos. Japan
12. Bar tack Machine 02 nos. Japan
13. 3 Thread over lock 10 nos. Japan
15. Cutting machine 16 nos. Japan
16. Thread winder (Re-conning) 06 nos. Japan
17. Heater less steam iron 90 nos. Japan
18. Vacuum Table 90 nos. Indonesia
19. Strapping Machine, TOYO 04 nos. Japan
20. Thread Sucking Machine 05 nos. BD.
21. Metal Detector (SainTex ) 01 nos. Japan
22. Cutting Layer 01 nos. Thailand

………………………………………………………………………………………
Total:1306 nos.
 CHAPTER 3
Knitting Machine

3.1 Introduction:
A knitting machine is a device used to create knitted fabrics in a semi or fully automated fashion.

There are numerous types of knitting machines, ranging from simple spool or board templates with no
moving parts to highly complex mechanisms controlled by electronics. All, however, produce various types
of knitted fabrics, usually either flat or tubular, and of varying degrees of complexity. Pattern stitches can
be selected by hand manipulation of the needles, or with push-buttons and dials, mechanical punch cards, or
electronic pattern reading devices and computers.

3.2 Working process:

Early flat bed stocking frames had low carbon steel bearded needles where the tips were reflexed and could
be depressed onto a hollow closing the loop. The needles were supported on a needle bar (bed) that passed
back and forth, to and from the operator. The beards were simultaneously depressed by a presser bar.[1]

1. The needle bar goes forward- the open needles clear the web
2. The weft thread is laid on the needles
3. The weft thread falls loosely
4. The needle bar draws back, the weft is pulled in the open needles
5. The needle bar draws back, the presser bar drops, the needle loops close and the weft is drawn back
through the web
6. The needles open, a new row has been added to the web which drops under gravity
This basic process can still be recognized in all machines, but it has been refined as new technologies have
become available.
3.3 Process flow of Knitting

Take buyer order sheet

Analysis of order sheet

Analysis of compatibility of machine

Analysis of amount of raw material

Collect raw material m

Distribute raw material to specific machine

Make batch card according to the buyer requirement

Adjust machine pulley according to the F.GSM

Run machine

Inspect the fabric time to time

Finding out the fabric faults and take remedies

Cutting the fabric and batching

Inspection

Weighting

Sending to store

Transport to buyer

Fig: Process flow of Knitting

3.4 Flat Knitting Machine
SERIAL MACHINE MACHINE MACHINE
NO. TYPE DIA GAUGE UNIT BRAND ORIGIN
S
33 FLAT 68'' 14 G 2 JY-LEH TAIWAN
KNIT
34 FLAT 52'' 14 G 4 JY-LEH TAIWAN
KNIT
80'' KAUO
35 FLAT 14 G 4 HENG TAIWAN
KNIT
40'' AROUND
36 FLAT 14 G 14 STAR CHINA
KNIT
68'' AROUND
37 FLAT 14 G 4 STAR CHINA
KNIT
T0TAL 28

Fig: List of Flat knitting machine

Fig: Knitting Machine
 CHAPTER 4
Description of the Attachment

4.1 Raw Material

Raw material is a unique substance in any production oriented textile industry. It plays a vital role in
continuous production and for high quality fabric.

4.2 Yarn
The raw material for knitting is the yarn. Different types of yarn of wide range of different count are
used. The sources of yarn are also found. Both carded and combed yarn is used for

knitting.

Fig : Cotton polyester

4.3 Yarn required supplied from yarns are:

Yarn type Sources

Cotton Paradise spinning mill, Delta spinning mill,
Jamuna
Group
Polyester Yarn India

Lycra Singapore, Indonesia, Korea, Japan

Fig: Lycra Yarn

 CHAPTER 5
Single Jersey Machine

5.1 End Product process:

• End products of Circular Knitting
Machine Single Jersey M/C:

4.1.1.1 S/J Plain

4.1.1.2 Single Lacoste
4.1.1.3 Double Lacoste
4.1.1.4 Single pique 4.1.1.5
Double pique
4.1.1.6 Terry.
• End products of Flat Bed Machine: Knitting

a) Tripping collar
b) Plain collar/ cuff
c) Emboss collar/ cuff

5.2 Faults and their causes in Knitting

Hole Mark:
Causes:
Holes are the results of yarn breakage or yarn cracks.
If the yarn count is not correct on regarding structure, gauge, course and density.
Badly knot or splicing.
Use proper count of yarn.
Knot should be give slot.
Sinker:
Causes:
When sinker corrode due to abrasion then sometimes cannot hold a new loop as a result sinker
mark comes.
If sinker head bend then sinker mark Star
Mark:
Causes:

Yarn tension variation during production.

Buckling of the needle latch.
Low G.S.M fabric.
Maintain same Yarn tension during production.
Use good conditioned needles.

Drop
Stitch:
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.
• Needle should be straight & well.
• Proper feeding of yarn during loop formation.
• Correct take up of the fabric & correct fabric tension.
 CHAPTER 6
Batching Section

6.1 Introduction:

Batching is the process to get ready the fabrics that should be dyed and processed for a Particular lot
of a Particular order.

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.
Sometime Planning is adjusted according to m/c condition.

6.2 Sequence of Operation:

Grey fabric

Inspection Batching

Fabric Turning

Storing dyeing

Fig: Turning Machine in Batching Section

 CHAPTER 7
Laboratory

7.1 Introduction

Lab Dip: Lab dip is a process by which buyers supplied a swatch is matched with the varying dyes
percentage in the laboratory with r without help of “DATA COLOR”

Lab dip plays an vital role in shade matching and detaching the characteristics of the dyes and
chemicals are to be used in the large scale of production so this is an important task before bulk
production.

Available Stock Solutions:

• Red – 0.1%, 0.5%, 1.0%, 2.0% (very common)

• Yellow – 0.1%, 0.5%, 1.0%, 2.0% (very common)
• Blue - 0.1%, 0.5%, 1.0%, 2.0% (very common).

List of Machine in Lab Section:

Machine Type Quantity

Spectra Photo meter 1pcs
Lab Dyeing Machine 4pcs
Lab Washing Machine 1pcs
Dryer 2pcs
Weight Balance Mc 2pcs
Crock Meter 1pcs
ICI Pilling Tester 1pcs
Perspirometer 4pcs

Fig: List of Machine in Lab Section

 CHAPTER 8
Garments Section

8.1 Garments Manufacturing Process

Design
↓
Sample
↓
Pattern
↓
Grading
↓
Marker
Making
↓
Spreading Fabric
↓
Cutting
Fabric
↓
Sorting out & bundling cut fabric
↓
Print/ Embroidery
↓
Assembling the part sewing
↓
Sewing quality inspection
↓
Ironing/ Pressing

Fig: Garment Manufacturing Process

 CHAPTER 9
Sample Section

9.1 Types of Sample

• 1st pattern sample

• Development sample
• 2nd pattern sample
• Counter sample
• Salesman sample
• Photo sample
• Approval sample
• Pre-production sample
• Production sample
• Shipment sample

9.2 Types of Sampling & Their details:

First Pattern

Defined as the first physical version of any garment as per the artwork done by designer and/or
developer.

Human Hand Sktch Pattern Sample

Fig: Sequence of First Pattern Sampling

Second Pattern

Usually designer/ developer always ask for some changes to the first pattern. Second pattern is
made as per comments.

Counter Sample

Where first pattern is made on designers artwork, Counter sample is to make not on designer’s artwork,
has to follow another sample given by the merchandiser.

Salesman Sample
 Sample is made when PRICE is confirmed and order are on speculation, usually in ‘L size in
all color combination of expected order. Buyer held a meeting with its customer and records
their response on order quantity per COLOR, SIZE etc. and finally plac order to their vendor.

Photo Sample

Samples are made with actual color and material to be worn by models on the event of SHOOTING
for catalog.

Approval Sample

In any discrete period of time, whenever it required any revision in the sample, a new sample
is made (sometimes moke-up is workable too) as per new specification. It is sent to buyer for
his APPROVAL of the conformity that the revision is done correctly.

Size Set

Consists of 1 piece from each size for each color combination

Mock Up

Any part of the garment to make for particular purpose, not complete garment.

9.3 Sample making process:

• Studying working sketch, specifications, and construction details of the garment to be made.

• Material selection and making the first pattern.

• Sewing the first sample garment or prototype – proto sample to see if a design is successful;
sending sample to the buyer.

• Solving construction problems according to buyer‘s comments; fabric changing if needed.

• Sewing the first fit sample; fitting the garment on a model or a dummy, and sending the first
fit sample to the buyer.

• Making pattern correction based on buyer‘s comments.

• If the first fit sample is rejected the garment must be remade with all the necessary
corrections done.

• After the fit sample is approved by a buyer, the pre-production sample must be made using
all the actual fabrics and trims.
• Once the pre-production sample is approved by a buyer, the sealed sample must be sent to
the garments production factory along with graded pattern and CAD marker. Embroidery or
print placement must be marked.

• Sewing the lab test sample and sending it to an independent laboratory (test house). The
sample garment must meet minimum performance standards to ensure the product is suitable
for customers use.

• Sewing the production size-set sample using all the actual fabrics and trims. If there is
embroidery or print on the garment, approved artwork design must be followed strictly.

• Specification sheet is a record of finished garment measurements for all the sizes in which
the garment will be made. It is used by pattern master, supervisor, sample operator, and
quality controller to ensure that the garment meets company standards.
 CHAPTER 10
Pattern Making Section

10.1 Introduction:

Pattern making is an art. It is the art of manipulating and shaping a flat piece of fabric to conform
to one or more curves of the human figure. Pattern making is a bridge function between design
and production. A sketch can be turned into a garment via a pattern which interprets the design in
the form of the garment components.
In South East Textile group the development of a garment comprises of different process. Fit is
the most important factor leading to the final acceptance or rejection of a garment. Fit must be
designed into the original pattern through subtleties in the pattern that provide fullness
unobtrusively.
Appropriate locations to accommodate body bulges in a flattering manner (Hudson). Good
customized fit is dependent on the pattern drafting incorporating various shapes and proportions
of the individual customer. With the onset of the Industrial Revolution, standardized patterns
were essential to the success of ready-to-wear clothing.

Fig: Pattern Making

10.2 Marker Making Section:
Marker is a thin paper which contains all the pattern pieces of a garment. It is made just before
cutting and its purpose is to minimize the wastages. The width of a marker is equal to the width
 of the fabric and it should not be greater than the width of the fabric i.e. the width of the marker
is kept less than or equal to the width of the Fabric.

10.3 Types of marker making

• Manual Method of Marker

• Computerized Method

The factors which influence the Marker Efficiency

• Manufacturers of the marker

• Size of pattern pieces
• Length of the marker
• Pattern Engineering
• Nature of the fabric
• Method of marker making
• Marker width

Fig: Marker Making Section

10.4 Cutter Section:

Cutting is the operation by which fabric lay is cut with accuracy the parts of garments. The company provides
straight knife and bend knife for cutting. Fabric lay are cut rendering the outline of the parts drawn on the
marker by the straight knife. Bend knifes are used to cut more sharp corner parts like collars and cuff.
Sometime hand scissors are used for cutting when some parts are missing or lack in quality.

Cutting flow Process

Spread
↓
Place marker
↓
Cutting
↓
Numbering
↓
Bundling
↓
Quality inspection

Fig: Cutting flowchart process

 Fig: Straight knife cutting machine

10.5 Sorting & Numbering

After cutting the cut pieces are shorted out size and shade wise. All the components of the same size
are brought together. And they are numbered with

Takai machine Or Numbering Machine.

This numbering process is an important factor. As it prevents the garments parts form mix up. The
sorted pieces are now ticketed. Ticketing is the process of marking the cut components for shade
matching precision and sequence identification.
10.6 Quality Check
The following terms will be check after Cutting.

• Oil spot
• Dirty spot
• Crease mark
• Needle mark
• Foreign yarn
• Slub
• Contamination
• Hole
10.7 Bundling
Checked components of one style & in one size are now clubbed & bundled
using ties. The size of bundle depends upon the requirement of the production
plant. Each bundle will contain pieces of same style & same size only.
10.8 Sewing Section
The process of joining of fabrics by the use of needle and sewing thread or by other
techniques is called sewing.

Element of sewing
• Sewing thread
• Needle and
• Sewing machine

Fig: Sewing Section

10.9 Sewing Defects
Some basic sewing defects are

• Needle damage,
• Skip stitches,
• Thread Breakages,
• Broken Stitches
• Seam Puckering

Basic types of sewing machines for Knit

Garments

• Plain m/c
• Over lock m/c
• Flat lock m/c
• Kanshai m/c
• Button hole m/c
• Button join m/c
• Bar take m/c
 CHAPTER 11
Finishing

11.1 Introduction:
Finishing department is the department which comes after all the department & it
plays an equal important role in the final appearance of the garments. This
department includes majorly of the following steps.

11.2 Thread Sucking

This involves the removal of the extra threads from the garments of the stitch area

Fig: Thread Sucking

 CHAPTER 12
Ironing
12.1 Ironing process:
Ironing is the use of a heated tool (an iron) to remove wrinkles from fabric. The
heating is commonly done to a temperature of 180–220 °Celsius, depending on the
fabric. Ironing works by loosening the bonds between the long-chain polymer
molecules in the fibers of the material. While the molecules are hot, the fibers are
straightened by the weight of the iron, and they hold their new shape as they cool.
Some fabrics, such as cotton, require the addition of water to loosen the
intermolecular bonds.

Fig: Ironing
 CHAPTER13
Packing
13.1 Packing Process:
The packing is always done in the carton boxes & there are several criteria for a packing
of the garments.

Fig: Packing
 CHAPTER 14
Merchandising

14.1 Introduction:

Merchandising is the department which medicate marketing & production

department. It is Space optimization through effective Brand/Package
allocation, focusing on gaining first position, providing greatest exposure
of brand to all consumer, creating a consistent, orderly & clean appearance
for the products, maximizing the use of POS to increase consumer
awareness of brand & promotion.

14.2 Merchandiser key responsibility:

• Product development
• Market & product analysis
• Selling the concept
• Booking orders
• 7Confirming deliveries
• Designing & Sampling
• Costing
• Raw material
• Flow monitoring
• Production flow Ups
• Payments Follows
• Internal & external communication
• Sampling
• Lab dips
• Accessories & trims
• Prepare internal order sheet
• Advising & assisting production
• Advising quality department about quality department
• Prepare purchase order
• Giving shipping instruction & following shipping
• Helping documentation department
• Taking responsibility for inspection &
• Following up the shipment
 Chapter 15
Boiler
15.1 Introduction:

A boiler is an enclosed vessel that provides a means for combustion and transfers heat to water
until it becomes hot water or steam. The hot water or steam under pressure is then usable for
transferring the heat to a process.
Water is useful and cheap medium for transferring heat to a process. When water is boiled into
steam its volume increases about 1,600 times, producing a force that is almost as explosive as
gunpowder. This causes the boiler to be extremely dangerous equipment and should be treated
carefully.
Liquid when heated up to the gaseous state this process is called evaporation. The heating surface
is any part of the boiler; hot gases of combustion are on one side and water on the other. Any part
of the boiler metal that actually contributes to making steam is heating surface. The amount of
heating surface of a boiler is expressed in square meters. The larger the heating surface a boiler
has, the more efficient it becomes.

15.2 Types of Boiler:

1. Fire Tube Boiler:
A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or (many) more
tubes running through a sealed container of water. The heat of the gases is transferred through the
walls of the tubes by thermal conduction, heating the water and ultimately creating steam .
 Fig: Fire tube boiler.

2. Water Tube Boiler :

A water tube boiler can be defined as a Steam boiler in which the flow of water in the tubes, as well
as hot gases, enclose the tubes. Not like fire tube boilers, this boiler attains high-pressures, as well
as high-steam capabilities, can be achieved. This is because of condensed tangential pressure on
tubes which is known as hoop stress.
 Fig: Water tube boiler.

3. Smoke Tube Boiler :

The smoke tube boiler is used with low operating pressures up to around 40 bars and a power range
between 5 and 25 MW. Depending on the fuel, the combustion chamber can be used either cooled
or uncooled. The boiler can be used for hot water and saturated steam generation as well as for
superheated steam generation.
Fig 1: Smoke tube boiler.
Smoke Tube Boiler Diagram:

Fig 2: Smoke tube boiler diagram

In Beximco Textile Limited to generate steam they have three boilers, two fire tube boilers& one
smoke tube boiler. Fire tube boilers are generally used in process industry & can work low pressure
range.
In a smoke tube boiler exhaust gas is reused to generate steam. The exhaust gas temperature is about
500-550 degree. For smoke tube boiler, there have three generators. Two gas generator of 504 KW
capacity. Diesel generator of 1030 KW of capacity.
As fire tube boiler THERMAX III & THERMAX IV are used.

THERMAX III:
Capacity =12.1 Ton/hour
Working pressure = 12 bar
Maximum pressure = 18 bar

THERMAX IV:
Capacity =10.9 Ton/hour
Working pressure = 12 bar
Maximum pressure = 18 bar

Smoke Tube Boiler:

Capacity =1.5 Ton/hour
Working pressure =6.5 bar
Maximum pressure = 8 bar
Fig: Fire tube boiler (THERMAX III)
 CHAPTER 16
Chiller

16.1 Introduction:
A chiller is a machine that removes heat from a liquid via a vapor-compression or absorption
refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool equipment,
or another process stream (such as air or process water). As a necessary by product, refrigeration
creates waste heat that must be exhausted to ambient or, for greater efficiency, recovered for heating
purposes.

Chilled water is used to cool and dehumidify air in mid- to large-size commercial, industrial, and
institutional facilities. Water chillers can be water-cooled, air-cooled, or evaporative cooled.
Watercooled systems can provide efficiency and environmental impact advantages over air-cooled
systems.

16.2 Types of Chiller:

There are three different types of chillers:
• Air
• Water
• evaporative condensed chiller.

There are four subcategories in each of the above categories for industrial chillers:
• reciprocating
• centrifugal
• screw driven
• absorption chillers.
16.3 Working principle of Chiller:

Fig: Working of chiller.

Process chillers contain a chemical compound, called a refrigerant. There are many types of refrigerant and
applications depending on the temperatures required but they all work on the basic principle ofcompression and
phase-change of the refrigerant from a liquid to a gas and back to a liquid.The refrigeration cycle starts with a low-
pressure liquid/gas mix entering the evaporator. In the evaporator, heat from the process water or water/glycol
solution boils the refrigerant, which changes it from a low-pressure liquid to a low-pressure gas. The low-pressure
gas enters the compressor where it is compressed to high-pressure gas.

45
 CHAPTER-17
Conclusion

17.1 Conclusion:
Mechanical Engineering is based on industrial ground and others. Theoretical background is not sufficient so,
industrial training is an essential part of study to make a technologist technically sound in this field. Industrial
training provides us that opportunity to gather practical knowledge.
For every person who is fresher in the field of textile, industrial
Training works like learning route. This course given me the opportunity to move liberally in every
section of the industry to learn the industrial work & follow the process sequence virtually. From my two months
observation of the industry along with recoupment section specially, I can say that in the woven section in this
industry has very strong possibility because the industry is running with all modern machineries & very
knowledgeable persons are working all the time with their maximum power. I just think the capacity of the
industry should be developed with the amount of order the industry is being taking.