SIM Fabrics LTD - Tex36

DEPARTMENT OF TEXTILE ENGINEERING
Course No.: Tex 500

Course Title: Industrial Training
Academic Semester: Spring 21
Industrial Training Report at

SIM Fabrics Ltd.
Submitted by
Students No. Name of the student

170206097 Abidur Rahman Lisun
170206102 Arindam Dey Gourav
170206104 Saima Hossain Shanta
170206142 MD. Zamil Hasan Talukder
170106130 Mahim Karmaker Mugdha
Supervised by
Mr. Md. Koushic Uddin

Assistant Professor
AHSANULLAH UNIVERSITY OF SCIENCE AND TECHNOLOGY
October 2022
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Industrial Training at SIM Fabrics Ltd
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Table of Contents
Chapter-1 Introduction ........................................................................................................... 1

1.1 Introduction ...................................................................................................................... 2
1.2 Objectives ......................................................................................................................... 2
Chapter-2 General Information about the Company........................................................... 3
2.1 Brief background .............................................................................................................. 4
2.2 The mission of SIM Fabrics Limited ............................................................................... 4
2.3 The vision of SIM Fabrics Limited .................................................................................. 4
2.4 Core Values of SIM Fabrics Limited ............................................................................... 4
2.5 Company profile ............................................................................................................... 6
2.6 Location of factory ........................................................................................................... 7
2.7 Certification ...................................................................................................................... 8
2.8 Working-Time Schedule of the Factory ........................................................................... 8
2.9 Manpower setup (Department wise) ................................................................................ 9
2.10 Major Buyers ................................................................................................................ 10
2.11 Organogram .................................................................................................................. 11
Chapter-3 Lab section ........................................................................................................... 12
3.1 Lab Dip development procedure: ................................................................................... 13
3.2 Process sequence of Lab Dip: ........................................................................................ 14
3.3 Sample Dyeing Methods: ............................................................................................... 15
3.4 Specifications of Machine Used in Dyeing Lab: ........................................................... 18
3.5 Shade checking machinery: ............................................................................................ 21
Chapter 4 – Pretreatment ..................................................................................................... 23
4.1 Introduction .................................................................................................................... 24
4.2 Objective ........................................................................................................................ 24
4.3 Process flowchart ........................................................................................................... 25
4.4 Layout plan of Pretreatment ........................................................................................... 25
4.5 Pretreatment Processes ................................................................................................... 26
Chapter-5 Dyeing ................................................................................................................... 34
5.1 Dyeing Section: .............................................................................................................. 35
5.2 Layout of Dyeing Section: ............................................................................................. 36
5.3 Vat Dyeing Process: ....................................................................................................... 39
5.4 Reactive Dyeing Process: ............................................................................................... 42
5.5 Different dyeing machines: ............................................................................................ 44
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Chapter-6 Finishing ............................................................................................................... 46
6.1 Finishing ......................................................................................................................... 47
6.2 The machines are used in woven dyeing:....................................................................... 48
6.3 Stenter machine .............................................................................................................. 48
6.4 Sanforising machine ....................................................................................................... 52
6.5 Peach machine: ............................................................................................................... 54
Chapter-7 Quality Control .................................................................................................... 56
7.1 Quality Control System: ................................................................................................. 57
7.2 Objectives of Quality Control: ....................................................................................... 57
7.3 Types of Quality Control System:.................................................................................. 57
7.4 Online quality control: ................................................................................................... 57
7.5 Offline Quality control: .................................................................................................. 59
7.6 Layout of Offline Quality section ................................................................................. 62
7.7 Inspection ....................................................................................................................... 63
7.8 Types of inspection: ....................................................................................................... 65
Chapter- 8 Utility ................................................................................................................... 69
8.1 Origin of utility: ............................................................................................................. 70
8.2 Boiler: ............................................................................................................................. 70
8.2.1 Boiler operation principle: .......................................................................................... 71
8.3 The Standard of Natural Water: ..................................................................................... 71
8.4 Steam: ............................................................................................................................. 71
8.4.1 Uses: ............................................................................................................................ 72
8.5 Compressed Air: ............................................................................................................. 72
8.6 Electricity: ...................................................................................................................... 73
8.7 Water Treatment Plant ................................................................................................... 74
8.7.1 Flowchart:.................................................................................................................... 75
8.7.2 SIM Group Water Treatment Plant's process flow: .................................................... 76
8.7.3 Water Treatment Plant of SIM Group: ........................................................................ 77
8.8 Effluent Treatment Plant: ............................................................................................... 78
8.8.1 Purpose: ....................................................................................................................... 78
8.8.2 Flow Chart Of ETP: .................................................................................................... 79
8.8.3 ETP's Operational Process: ......................................................................................... 81
8.8.4 ETP of SIM Group: ..................................................................................................... 82
Chapter-9 Compliance........................................................................................................... 83
9.1 Compliance Policy of the group: .................................................................................... 84
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9.2 Infrastructure and Security: ............................................................................................ 84
9.3 Some Other Facilities: .................................................................................................... 87
Chapter-10 Conclusion .......................................................................................................... 88
10.1 Challenge observed during the training period: ........................................................... 89
10.2 Conclusion:................................................................................................................... 89
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List of tables
Table 2.1 Factory information ................................................................................................... 6
Table 2.2 Company certifications .............................................................................................. 8
Table 2.3 Manpower setup ......................................................................................................... 9
Table 3. 1 Vat dyeing recipe .................................................................................................... 15

Table 3. 2 Reactie dyeing recipe .............................................................................................. 17
Table 3. 3 Mini Padder specification ....................................................................................... 18
Table 3. 4 Horizontal Padder specification .............................................................................. 18
Table 3. 5 Mini Dryer specification ......................................................................................... 19
Table 3. 6 Mini Pad steam ....................................................................................................... 20
Table 3. 7 Spectrophotometer specification............................................................................. 21
Table 3. 8 Different light sources ............................................................................................ 22
Table 4. 1 Recipe for desizing ................................................................................................. 27

Table 4. 2 Recipe for scouring ................................................................................................. 29
Table 4. 3 Recipe for bleaching: .............................................................................................. 30
Table 4. 4 Recipe for mercerization ......................................................................................... 32
Table 5. 1 Vat dyeing recipe: ................................................................................................... 41

Table 5. 2 Reactie dyeing recipe: ............................................................................................. 43
Table 5. 3 Thermosol machine specification ........................................................................... 44
Table 5. 4 Pad steam machine specification ............................................................................ 45
Table 6. 1 Machine specification of Stenter machine .............................................................. 50

Table 6. 2 Machine specification of Sanforising machine ....................................................... 53
Table 6. 3 Machine specification of Peach machine................................................................ 55
Table 7. 1 Inspection Machine specification ........................................................................... 66

Table 7. 2 4 Point system ......................................................................................................... 67
Table 8. 1 Air compressor Specification.................................................................................. 72

Table 8. 2 Generator Specifications: ........................................................................................ 73
Table 8. 3 WTP of SIM group ................................................................................................ 74
Table 8. 4 ETP Standard parameters in SIM Group: ............................................................... 80
Table 8. 5 Specification of ETP plant in SIM group ............................................................... 80
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List of figures
Figure 2.1Factory premises ........................................................................................................ 5
Figure 2.2 Factory Location ....................................................................................................... 7
Figure 3. 1 Mini Padder ........................................................................................................... 18

Figure 3. 2 Padding machine ................................................................................................... 19
Figure 3. 3 Mini dryer .............................................................................................................. 19
Figure 3. 4 Mini Pad steam ...................................................................................................... 20
Figure 3. 5 Spectrophotometer ................................................................................................. 21
Figure 3. 6 Light box ............................................................................................................... 22
Figure 4. 1 Layout plan of Pretreatment section ...................................................................... 25

Figure 4. 2 Singeing Machine. ................................................................................................. 26
Figure 4. 3 Desizing Machine. ................................................................................................. 28
Figure 4. 4 Scouring Machine.................................................................................................. 29
Figure 4. 5 Bleaching Machine ................................................................................................ 32
Figure 4. 6 Mercerizing Machine............................................................................................. 33
Figure 5. 1 Layout plan of Dyeing section .............................................................................. 36

Figure 5. 2 Thermosol Machine ............................................................................................... 37
Figure 5. 3 Vat dyeing ............................................................................................................. 41
Figure 5. 4 Reactive dyeing ..................................................................................................... 43
Figure 6. 1 Layout plan of Finishing section ........................................................................... 47

Figure 6. 2 Stenter machine ..................................................................................................... 51
Figure 6. 3 Sanforising machine .............................................................................................. 53
Figure 6. 4 Peach machine ....................................................................................................... 55
Figure 7. 1 Online Quality Control .......................................................................................... 57

Figure 7. 2 Online quality control ............................................................................................ 58
Figure 7. 3 Shade check ........................................................................................................... 58
Figure 7. 4 Offline quality control ........................................................................................... 59
Figure 7. 5 Pilling tester ........................................................................................................... 59
Figure 7. 6 Tensile tester .......................................................................................................... 60
Figure 7. 7 Rubbing tester ........................................................................................................ 60
Figure 7. 8 Gsm cutter ............................................................................................................. 60
Figure 7. 9 Shaker machine ..................................................................................................... 60
Figure 7. 10 Shrinkage scale .................................................................................................... 60
Figure 7. 11 Washing machine ................................................................................................ 61
Figure 7. 12 PH tester ............................................................................................................. 61
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Figure 7. 13 Layout of Offline Quality section........................................................................ 62
Figure 7. 14 Layout of Inspection Section ............................................................................... 63
Figure 7. 15 4 point system ...................................................................................................... 64
Figure 7. 16 Fabric Inspection ................................................................................................. 65
Figure 7. 17 Fabric Inspection room ........................................................................................ 66
Figure 7. 18 Fabric Inspection machine ................................................................................... 66
Figure 8. 1 Boiler ................................................................................................................... 70

Figure 8. 2 Water boiler .......................................................................................................... 71
Figure 8. 3 Air compressor ..................................................................................................... 73
Figure 8. 4 Generator .............................................................................................................. 73
Figure 8. 5 WTP of Sim Fabrics Ltd....................................................................................... 75
Figure 8. 6 Water Treatment plant .......................................................................................... 77
Figure 8. 7 ETP of SIM Group ............................................................................................... 78
Figure 8. 8 ETP of SIM Group ............................................................................................... 82
Figure 9. 1 Mechanical Maintenance ....................................................................................... 85

Figure 9. 2 Medical Center ...................................................................................................... 86
Figure 9. 3 Child Care Room ................................................................................................... 86
Figure 9. 4 Civil Department ................................................................................................... 87
Figure 9. 5 Fire Extinguisher ................................................................................................... 87
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Acknowledgment
First, we want to thank the Almighty ALLAH for his divine blessing which made us possible
to complete our internship at SIM Fabrics Ltd. successfully.
We feel grateful to Dr. Lal Mohan Baral, Professor & Head, Department of Textile Engineer-
ing, Ahsanullah University of Science & Technology (AUST) for giving us all the support
concerning the internship.
We are very much thankful to our respected teacher & supervisor of internship Md. Koushic
Uddin, Assistant Professor, Department of Textile Engineering, Ahsanullah University of Sci-
ence & Technology (AUST) for his encouragement and valuable suggestions, and necessary
information.
We would like to express our sincere gratitude & appreciation to, Engr. Mozaffar Hoss-
ain Managing Director, SIM Fabrics Ltd. Our hearts are full thanks to him for allowing us to
perform our industrial attachment in SIM Fabrics Ltd.
We are also very grateful to Engr. Md Sohel Rana, General Manager, Dyeing, SIM Fabrics
Ltd. for guidance, encouragement & keen interest in delivering thoughtful advice during the
period of industrial training.
Finally, we would like to acknowledge that we remain responsible for the inadequacies and
errors, which doubtlessly remain.
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Chapter-1 Introduction
1
1.1 Introduction
Internships are required for all Textile students to complete their bachelor's degree since they
provide students with the opportunity to learn about the intricacies of the real world. As a result,
students profit from being able to apply the knowledge they've gained to the real world. When
we work in an organizational setting, we learn how to apply theoretical information to real-
world situations, which helps us become more effective as professionals.
It is the most effective process of achieving practical experience. It provides us with enough
practical knowledge about production management, productivity, evaluation, work-study, ef-
ficiency, industrial management, production planning & control, production cost analysis, in-
ventory control, purchasing, utilities, and Maintenance of machinery and their operation tech-
nique, etc.
Industrial attachment is an essential part of four years of B.Sc. in Textile Engineering courses
at Ahsanullah University of Science & Technology. We had the opportunity to perform the
industrial attachment with SIM Fabrics Limited.
At SIM Fabrics Limited, cutting-edge technologies merge seamlessly with human ingenuity
and deep-seat recommitment to ensure excellence in every stage and area of their activities.
1.2 Objectives
• To comprehend theoretical knowledge along with practical knowledge.
• To observe the workflow of a Textile Industry.
• To see different departments of a Textile Industry.
• To learn about the operations of different machines and purposes.
• To be adopted with the atmosphere of factories.
• To prepare ourselves for future working life with these practical experiences.
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Chapter-2 General Information about the Company
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2.1 Brief background
SIM GROUP, a large contributor to the manufacturing and economic development of Bangla-
desh, displays admirable performance in the field of battle.
It entered the business arena as a manufacturer and exporter in the year 2000. Since then they
have never looked back. By dint of their hard work and sincerity, They have been capable to
expand the confidence of highly dignified buyers of the United Kingdom, USA, and other
members of the European Union. Now they have several factories having 3000 workers and
employees, working in an excellent atmosphere.
It is a 100% export-oriented Composite Factory. SIM Fabrics is designed and equipped with
the most modern types of machinery in the Knitting, Dyeing, Garments, Washing, and Dry
Finishing Division also strictly maintains the International Compliance Standards prescribed
by various World is known Certification Authorities. They have a team of dedicated, experi-
enced professionals taking care of every division to meet the requirements of their valued cli-
ents along with a skilled primary workforce which made It exclusively a “Buyer Friendly"
company.
2.2 The mission of SIM Fabrics Limited
• Exceed our customer’s expectations with better quality products.

• Effective Quality Management System.
2.3 The vision of SIM Fabrics Limited
To Achieve Quality Goal Through Continuous, Improve In Process And Long Term Sustain-
able Customers Satisfaction.
2.4 Core Values of SIM Fabrics Limited
• Constant focus and development on the product & valuable Quality offered.
• Commitment towards staff training & development.
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• Encouraging open work culture.
Figure 2.1 Factory premises
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2.5 Company profile
Table 2.1 Factory information
Name of the Factory SIM Fabrics Ltd
Type Private Limited Company
Year of Establishment 2000
Factory location Thakurbari Teac, Masumabad, Vulta, Rupganj , Nara-

yanganj.
Head office House # 315, Road # 04, Baridhara D.O.H.S., Dhaka.
Total Employee 3000 persons
Exponential growth $20 Million (USD)
SIM Fabrics Ltd. (Weaving)

Sister Concern SIM Fabrics Ltd. (Dyeing, Finishing & Printing)
Mozaffar Hossain Spinning Mills Ltd.
Authentic Colors Ltd.
Azlan Denim Ltd
Suntech Energy Limited
Azlan Agro Foods Ltd
Azlan Knitting
Phone numbers +88-02-8415961
E-mail info@simgroup-bd.com
Website https://www.simgroup-bd.com/
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2.6 Location of factory
SIM Fabrics Limited is located at Thakurbari Teac, Masumabad, Vulta, Rupganj , Narayan-
ganj.
Figure 2.2 Factory Location
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2.7 Certification
Table 2.2 Company certifications

SL Certification Logo
1 OEKO-TEX® STANDARD 100
2 Global Recycled Standard (GRS)
3 GOTS (Global Organic Textile Standard)
2.8 Working-Time Schedule of the Factory
The factory runs 24 hours a day. It maintains a tight work schedule. It follows mainly 3
schedules. i.e.
• A-shift: 6 a.m. - 2 p.m

• B-shift: 2 p.m. - 10 p.m
• C-shift: 10 p.m. - 6 a.m &
• General shift: 9.00 a.m to 6.00 p.m
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2.9 Manpower setup of SIM Group Ltd
Table 2.3 Manpower setup
Department Manpower
Quality Control 197
Maintenance 149
HR 45
Store 179
Accounts 25
Knit Dyeing 183
Weaving 376
Woven Dyeing 176
Spinning (Rotor) 183
Spinning (Ring) 359
Printing 123
Medical 08
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2.10 Major Buyers
SIM Fabrics Ltd is 100 % export-oriented industry. All the goods produced in this industry
are exported into various foreign countries. Name of the main buyers of this mill are given
below:
Table 2.4 Buyer’s name list
Buyer’s Name Logo
H&M
(Sweden)
Lee
(USA)
Inditex
(Spain)
Next plc
(UK)
OVS
(Italy)
Matalan
(UK)
ZARA
(Spain)
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2.11 Organogram
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Chapter-3 Lab section
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3.1 Lab Dip development procedure:
Lab Dip: A lab dip is a swatch of fabric test dyed to hit a color standard. It is a process by
which the buyer’s supplied swatch is matched with the varying dye percentage in the laboratory
with or without the help of a spectrophotometer. Lab dip plays an important role in shade
matching & this is an important task before bulk production.
Objective of Lab Dip:
The main objectives in lab dip are as follows:
1. To calculate the recipe for sample dyeing.

2. To compare a dyed sample with a swatch by light Box or Spectrophotometer.
3. Finally approved Lab Dip (Grade: A, B, C & D).
The procedure of labwork to bulk: Lab dip plays an important role in the Dyeing process. The
bulk dyeing process completely depends on the lab dip development work. Lab dip is com-
pletely managed as the following sequence:
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3.2 Process sequence of Lab Dip:
Lab dip requisition from buyer
Swatch recipe generation from spectrophotometer
Recipe is given by swatch Or pantone number
Dyeing process followed by recipe (Padding, Drying, fixation by cps,

Washing, Drying)
If the shade match go for the further process If the shade doesn’t match
Grading of sample nearby three shades that

are- same shade, lighter, deeper
Send for Buyer’s approval
Approved by Buyer’s
Order for bulk production
Sample dyeing for trail
Production card with approved sample and

recipe send to dyeing floor
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3.3 Sample Dyeing Methods:
There is a different sample dyeing process followed in the lab for the buyer’s approval. They
are as given below:
• Vat dyeing.
• Reactive dyeing.
1. Vat dyeing:
Method: Pad dry pad steam
Machine: Thermosol & Pad steam.
Dye Stuff: Vat Dyes.
Material: 100% Cotton.
Table 3. 1 Vat dyeing recipe
Serial no Chemical Amount

01 Dyes As per required
02 Hydrose 50-65 gm/l
03 Caustic 50 gm/l
04 Soda ash 5gm/l
05 Dispersing agent 10gm/l
06 Wetting Agent 2gm/l
07 Levelling Agent 10 gm/l
08 Hydrogen Peroxide 3-5 gm/l
09 Glauber’s Salt 20gm/l
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Process Sequence:
Vatting (Dyes solution preparation)
Padding with prepared dye solution in Mini Padder

Machine
Drying in Mini dryer at 113°-115°C for 1min
Padding with H2O2
Steaming at 101°-102°C for 1-2min in Mini pad steam
Soaping at 90°C with 3-5gm/l soaping agent
Hot wash at 90°C
Neutralization at 60°C with 1 gm/l acetic acid for 1

min
Cold wash
Dry
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2.Reactive dyeing:
Method: Pad dry pad steam
Machine: Thermosol & Pad steam
Dye Stuff: Reactive Dyes.
Material: 100% Cotton
Table 3. 2 Reactie dyeing recipe
Serial no Dyes & Chemical Amount

02 Wetting Agent 2 gm/l
03 Levelling Agent 10 gm/l
04 Caustic soda 15 gm/l
05 Glauber’s salt 250 gm/l
06 Soda ash 20 gm/l
07 Acetic acid 1gm/l
Process Sequence:
Pading with dyes in Mini Padder Machine
Drying in Mini dryer at 100°C
Padding with fixing chemical
Steaming at 103-105ºC, 1 min in mini pad steam
Soaping (2 min) at 90°C
Hot wash
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Neutralization with acidic acid at 60°C
Cold wash
Dry
3.4 Specifications of Machine Used in Dyeing Lab:
1.Rapid (Mini) Padder:
Table 3. 3 Mini Padder specification

Brand Rapid
Origin China
Speed 0-20 rpm
Standard Speed During Dyeing 10rpm
Standard Pressure Applied by Padder 2 bar
Voltage 220 V
Model PA-1
Figure 3. 1 Mini Padder
2.Horizontal Padding Mangle:
Table 3. 4 Horizontal Padder specification
Brand Daclim
Origin Korea
Speed 0-20 rpm
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Standard Speed During Dyeing 10rpm
Standard Pressure Applied by Padder 2 bar
Voltage 220 V
Model DL-2005
Figure 3. 2 Padding machine
3.Lab Mini Dryer:
Table 3. 5 Mini Dryer specification

Brand Testex
Origin China
Circular fan Speed 700-2500 r/min
Dry time 1 sec, 99min
Specimen size 1400×730mm
Voltage 380 V
Model TD-610
Temperature 250ºC
Figure 3. 3 Mini dryer
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4. Mini Pad steam:
Table 3. 6 Mini Pad steam
Brand Rapid
Origin China
Speed 0.2-5 m/min
Time 12s-15 min
Steam generator goods capacity 1-3 m
Voltage 400 V
Temperature Drying- 150 ℃ ,Curing- 200 ℃
Figure 3. 4 Mini Pad steam
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3.5 Shade checking machinery:
1. Spectrophotometer:
A spectrophotometer is used for the quantitative measurement of the reflection or trans-
mission properties of a material as a function of wavelength. It measures reflected or
transmitted light across a light spectrum. The resulting data creates a visual curve. Spec-
tral measurements ensure that color is consistent across varying substrates and produc-
tion processes. It detects the percentage of coloring material in a substance.
Functions:
1. Recipe Formulation
2. Shade Matching with a standard.
3. Grey Scale Assessment.
4. Whiteness Assessment.
Figure 3. 5 Spectrophotometer
Table 3. 7 Spectrophotometer specification
Machine Name: Spectrophotometer

Model: X-rite Color -Eye-7000A
Software Data Color
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2. Light Box:
A lightbox is a physical emitter of light where different light sources are present. It is used
for visual shade matching of dye particles under different light sources because in today’s
complex color requirements a shade cannot always be assumed under one light source.
Functions:
1. Visual assessment of color by reflectance & transmission.

2. Mainly used for shade matching.
3. To check the Metamerism of the fabric.
Figure 3. 6 Light box
Different Types of Illuminants:
Table 3. 8 Different light sources
Symbol Full meaning Functions Buyer’s Name
UV Ultraviolet Used for check white

color matching
TL84 Fluorescent light Check the metamerism ZARA
of the fabric
TL83 Tube light (Tungsten fluores- Check the metamerism H&M
cent light) of the fabric
D65 Artificial daylight Used for color match- H&M, ZARA
ing
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Chapter 4 – Pretreatment
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4.1 Introduction
In the dyeing industry, the pre-treatment section is considered the main part of the dyeing pro-
cess. The textile pretreatment process can help eliminate sizing agents, oils, waxes, seed hulls,
soils, pectin, and other impurities while improving the whiteness and feel of the fabric. Pre-
treatment means any treatment, which is done before the actual process. Pretreatment processes
include desizing, scouring, and bleaching which make subsequent dyeing and softening pro-
cesses easy. Pre-treatment is the process that is used to remove impurities from fibres or fabric
to make it dyeable or printable. Natural fibres and synthetic fibres contain primary impurities
that are contained naturally and secondary impurities that are added during spinning, knitting,
and weaving processes. Textile pre-treatment is a series of cleaning operations. All impurities,
which causes adverse effect during dyeing and printing, are removed in the pre-treatment pro-
cess.
4.2 Objective
The basic objective of pretreatment processing is the removal of added or natural impurities
present in textile fibres to improve absorbency. This prepares the textile substrate for down-
stream processes like dyeing, printing, finishing, etc.
• To remove natural and added impurities

• To impart certain desirable properties (water absorbency)
• To improve the appearance of fabric
• To make it suitable for a subsequent processes like dyeing, printing, finishing
• To achieve the degree of desire for whiteness
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4.3 Process flowchart
Grey fabric collection

Singeing & Desizing

Scouring & Bleaching

Mercerizing
4.4 Layout plan of Pretreatment
E W
Scouring
Mercerizing & Mercerizing
2 1
Bleaching
Singeing
& Desiz-
ing
Figure 4. 1 Layout plan of Pretreatment section
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4.5 Pretreatment Processes
Singeing: Singeing is an important part of pretreatment. This is the burning off of protruding
fiber ends from the surface of the fabric. Singeing is a process applied to both yarns and fabrics
to produce an even surface burning off projecting fibres, yarn ends, and fuzz. This is accom-
plished by passing the fibre or yarn over a gas flame at a speed sufficient to burn away the
protruding material without scorching or burning the yarn or fabric. Singeing can be done by
various methods such as plate singeing, roller singeing, and gas singeing. In Sim fabrics ltd.
Gas Singeing Machine is used for singeing.
The objective of singeing:
1. To remove hairy fibres projecting on the surface of the cloth.
2. To increase luster in the finished fabric.
3. To give a smoothen surface.
Figure 4. 2 Singeing Machine.
26
Desizing: Desizing is the process of chemically eliminating sized material from fabric. It is a
process by which size materials from warp yarn in the woven fabric are removed. In Sim fabrics
ltd. enzymatic desizing is used which uses an enzyme that degrades the size material of the
fabric.
Objective of desizing:
• To remove starch from the fabric.
Table 4. 1 Recipe for desizing

Serial no. Chemicals Amounts
1 Enzyme 4 g/l
2 Wetting agent 5 g/l
3 Sequestering agent 2 g/l
Temperature 70 - 80c

pH 6-6.5
27
Figure 4. 3 Desizing Machine.
Flowchart for singeing & desizing:
Fabric preparation
↓
Fabric is combed by combing roller
↓
Fabric is burned by the burner
↓
Chemical preparation for desizing
↓
Fabric is padded with desizing chemicals
↓
Delivered fabric is kept to a minimum of 8 hours at continuous rotation
28
Scouring: Scouring is a process for removing the impurities e.g. oil, fat and waxy materials
from the fabric by chemical treatment.
Objective of scouring:
1. To make the fabric highly hydrophilic & to remove impurities such as oil, waxes, gum, etc.
2. To increase the absorbency of fabric without undergoing physical & chemical change.
Table 4. 2 Recipe for scouring

1 Caustic 50-55 g/l
2 Wetting agent 5-6 g/l
Temperature 90-100c
pH 10.5-11
Figure 4. 4 Scouring Machine.
29
Bleaching: Bleaching is the process by which textile material becomes white by the destruc-
tion of natural color matters of fiber.
Objective of bleaching:
1. To ensure a pure and permanent basic white color fabric.
2. Destruction of natural coloring matters from the fabric.
3. To increase absorbing for dyeing operation.
4. To ensure level dyeing property.
Table 4. 3 Recipe for bleaching:

1 Hydrogen peroxide 18-30 g/l
2 Caustic 5-6 g/l
3 Stabilizer 3-6 g/l
Temperature 95-100c
pH 10.5-11
30
Flowchart for scouring & bleaching:
Fabric preparation
↓
Pre-wash at 90° -95°C
↓
Fabric is passed into a chemical bath of scouring
↓
Steam chamber at 95°-100°C for 8-10 minutes
↓
Hot wash (4 bath at 80°C)
↓
Cold wash
↓
Fabric is passed into a chemical bath of bleaching
↓
Fabric is kept for about 20 minutes in a heat chamber where the temperature is 95˚-100˚C.
↓
Hot wash (4 bath at 80˚C)
↓
Cold wash
↓
Fabric is dried on the cylinder dryer.
↓
Batching
31
Figure 4. 5 Bleaching Machine
Mercerization: Mercerization is the treatment of pure cotton fabrics or yarn with string caustic
soda solution to improve strength, dye substantively, strength and smoothness. Sufficient wash-
ing is required after this step to remove any traces of caustic soda.
Objective of mercerization:
1. To increment the luster of a fabric.

2. To improve the whiteness of a fabric.
3. To develop the absorbency of a fabric.
Table 4. 4 Recipe for mercerization

1 Caustic 24-30 Be’
2 Acetic acid 5% of total water
3 Wetting agent 3 g/l
Compressed air As required

Steam/water As required
32
Flowchart for mercerization:
Fabric is drawn into a machine

↓
Padding in alkaline liquor (2-3Bar) for 10-12sec at 50-60℃
↓
Squeezing by squeezer roller (2.25-2.5 Bar)
↓
Washing at 85℃ temperature
↓
Neutralization in acid solution at 60℃
↓
Drying by cylinder dryer at 95°-100℃
↓
Cooling by cooling cylinder at 25-40℃
↓
Drawing fabric in batch
Figure 4. 6 Mercerizing machine.
33
Chapter-5 Dyeing
34
5.1 Dyeing Section:
Dyeing is the most important stage in Textile processing. Without it, we can’t get a proper
colorful textile material. Because dyeing is “the process of coloring fibers, yarns or fabrics by
using a liquid containing coloring matter for imparting a particular hue to a substance.
Organogram
Chief Operating Officer
General Manager
Manager
Assistant Manager
Executive
Jr. Executive
Supervisor
Operator
Worker
35
5.2 Layout of Dyeing Section:
Exit 2
South
East West
Entry 1
North
Office
Pad Steam Machine- 1 Thermosol Machine- 1

Exit 1
Pad Steam Machine -2

Entry 1
Thermosol Machine -2
Figure 5. 1 Layout plan of Dyeing section
36
Dyeing of fabric can be done by a different procedure. In SIM Fabrics Ltd, The Major Woven
Dyeing processes are:
1. Vat Dyeing
2. Reactive Dyeing
& these processes are to be performed in different machines with different working principles.
The machines are:
Thermosol & Pad Steam Machine
Method: Pad Dry Pad Steam
Figure 5. 2 Thermosol Machine
37
SIM Fabrics Ltd
Thakurbari Tech, Masumabad, Rupganj, Narayangonj
Department: Dyeing & Finishing
Process Flow-Chart (General)
Grey Fabric Lay-In
Singeing & Desizing
Scouring
Bleaching
Mercerizing
Heatset (Only for Lycra)
Peach Non Peach
Washing
Thermosol
Pad Steam
After checking
Shade
If Shade, Listing, Test reports If Shade, Listing, Test reports

is OK, give approval for Next is Not OK, Need to inform
Process, Decision should be Dyeing incharge for taking ac-
taken with in 1hr after pad tion immediately
steam
Finishing
38
Stenter
Sanforize
Inspection
39
5.3 Vat Dyeing Process:
Process Sequence:
Preparation of dyes & chemicals in cooking tank

(Vatting)
Padding with soluble vat dyes in chemical bath at

20-30°C (Liquor pick up 50 – 80%, padder pres-
sure 2-3bar)
Drying (113°C-115°C)
Padding with H2O2 at 20°-30°C (Liquor pick up 70

– 80%, Machine speed 40m/min, Padder pressure
2-3 bar)
Steaming for Oxidation (101°-102°C) for 1.5 min
4 times Hot wash at 90°-100°C,Padder Pressure

3bar
4 times Cold Wash at 40°C, Padder Pressure 3bar
Neutralization with acetic acid at 60°C for 1-1.5min
Cold wash at 40°C
Drying with cylinder dryer 113°-115°C
Cooling with cylinder dryer
Batching
40
Table 5. 1 Vat dyeing recipe:
Serial No Vatting Chemical Amount
1 Vat dyes As per required
2 Hydrose 60 gm/l
3 Caustic 70gm/l
4 Soda ash 5 gm/l
Dyeing Chemicals
Solubilized Vat Dyes As per required
5 Wetting agent 2gm/l
6 Dispersing agent 2gm/l
7 Levelling agent 10gm/l
Oxidation Chemical
8 Glauber’s Salt 10gm/l
9 Hydrogen Peroxide-50% Conc 10gm/l
Washing Chemical
10 Detergent 2-5gm/l
Neutralization Chemical
11 Acetic acid 1gm/l
Figure 5. 3 Vat dyeing

41
5.4 Reactive Dyeing Process:
Process sequence:
Preparation of dyes & chemicals in cooking

tank
Padding dyeing chemicals at 20°-30°C (Pad

pressure 2-3 bar, pick up 50-80%)
Drying by IR (Chamber 1&2) at 110° -130°C
Padding with fixing chemicals (Pick up 70-

80%, Pad pressure 2-3 bar)
Steaming at 95°-100°C for 45 – 90s
4 times Hot wash at 90°-100°C,Padder Pressure

3bar
4 times Cold Wash at 40°C, Padder Pressure 3bar
Neutralization with acetic acid at 60°C for 1-

1.5min
Cold wash at 40°C
Drying with cylinder dryer 113°-115°C
Cooling with cylinder dryer
Batching
42
Dyeing recipe:
Dye Stuff: Reactive Dyes.
Table 5. 2 Reactie dyeing recipe:
Serial no Dyeing Chemicals Amount
2 Wetting Agent 2gm/l
3 Levelling Agent 12gm/l
Fixing Chemicals
4 Glauber’s salt 250gm/l
5 Caustic soda 10gm/l
6 Soda ash 20gm/l
Washing Chemicals
7 Detergent 2-5gm/l
Neutralization Chemicals
8 Acetic acid 1gm/l
Figure 5. 4 Reactive dyeing
43
5.5 Different dyeing machines:
Thermosol Machine:
Table 5. 3 Thermosol machine specification
Machine name Thermosol
Brand name Monforts Monfortex
Origin Germany
Production range 15000 m/day
M/C speed range 20-25 m/min. for heavy fabric

35-40 m/min. for light fabric
Temperature 180-1900C for heavy fabric

150-1600C for light fabric
Process selector switch Pad batch/continuous

IR section-1:
❖ Speed (0-100)m/min.%
❖ Intensity (20-100)P%
IR section-2:
❖ Speed (0-100)m/min.%
❖ Intensity (20-100)P%
Padder pressure 0-4 Bar
Speed(rpm) (0-120)m/min.
Pneumatic pressure of guiders 0-10 Bar
Pneumatic pressure of compensators 0-6 Bar
Gas pressure for IR-section 0-40 m/Bar or max. 20m/Bar

Gas pressure for burners 0-250 m/Bar
Air pressure 0-10 Bar
Used utilities Gas
Product quality check Shade check, cosmetic defects, shade variation
QC sample test QC checks the shade & listing test duration opera-
tion. QC also checks the parameters.
44
Pad steam machine:
Table 5. 4 Pad steam machine specification
Machine name Pad steam
Brand name Goller
Origin Germany
Production range 10000-25000 m/day

M/C speed range 28-35 m/min. or as required
Temperature 70-1000C
No. of padder 2
No. of chamber 4
Fabric position Face
Used utilities Gas
Product quality check Shade check, cosmetic defects, shade variation

QC sample test QC checks the shade & listing test duration opera-
tion. QC also checks the parameters.
45
Chapter-6 Finishing
46
6.1 Finishing
Layout of finishing section:
p.1 p.2
Sanf. m/c .1
Sanf. m/c .2
Stenter machine.3
.2 Stenter machine
Stenter machine.1
p.3
Figure 6. 1 Layout plan of Finishing section
Textile finishing is applied to different processes that the textile materials undergo after differ-
ent treatment to enhance their attractiveness and sale enlargement as well as comfort and ef-
fectiveness. The finish is done to a fabric after weaving to change its appearance, handle and
performance. Textile finishing involves treating the fabric in such a way that the product has
the desired aesthetic and functional properties required for its intended use and therefore has a
great market value.
The objectives of finishing:
➢ To improve fabric attractiveness

➢ To increase comfort
47
➢ To improve Performance
➢ To improve hand feel
➢ To improve serviceability
➢ To improve usefulness
6.2 The machines are used in woven dyeing:
1. Stenter machine
2. Sanforising machine
3. Peach machine
6.3 Stenter machine
Stenter is a transport device that carries fabric from one point to another continuously in open
width with precise width control.
Functions of stenter machine:
➢ Control the GSM of the fabric

➢ Control fabric shrinkage lengthwise and widthwise
➢ Control fabric width
➢ Control fabric length through overfeeding principle
➢ Drying the fabric
➢ Heat set of the fabric
➢ Control the spirality of the fabric
Parts of Stenter Machine:
I. Padder
II. Cooling Drums
III. Burners
IV. Circulator fan
V. Exhaust fan
VI. Heat recovery unit
48
VII. Weft Stretcher
VIII. Pins or clips
IX. Winder
X. Rollers of Attraction
Flow diagram of Stenter Machine:
Drawing fabric into the machine
Applying finishing chemicals
Controlling skew and bow
Width adjusting
Drying
Collecting fabric
Delivery
49
Table 6. 1 Machine specification of Stenter machine
Brand ICOMATEX
Origin Spain
Speed 50-80 m/min
Fabric length required to pass 120 m
through the machine
Capacity 6000 m/day

Pressure of padder 3 kg
Temperature of burners 130℃ − 170℃
No. of Machine 2
No. of Chamber 7
50
Figure 6. 2 Stenter machine
51
6.4 Sanforising machine
The purpose of the process is to shrink fabrics in such a way that the textiles made up of these
fabrics do not shrink during washing.
Functions of Sanforising machine:
➢ To minimize the after-washing fabric shrinkage

➢ To improve the dimensional stability of the fabric
➢ To increase the fabric GSM
➢ To increase the fabric cover in the fabric
➢ To soften the fabric handle
➢ To control bow and skewness
Parts of Sanforising Machine:
I. Draw cylinder
II. Water spray unit
III. Steaming drum
IV. Weft straightener
V. Clip type
VI. Rubber blanket shrinkage unit
VII. Felt calendar
VIII. Felt drying cylinder
Flow diagram of Sanforising machine:

Drawing fabric into the machine
Damping
Steaming to make the fabric soft
Shrinking
52
↓
Ironing
Coiling
Collecting fabric
Delivery
Table 6. 2 Machine specification of Sanforising machine

Brand MONFORTEX
Origin France
Speed 40-60 m/min
Steam pressure for damping 2-5 bar
Capacity 20000-30000 m/day
Steam pressure for felt belt 2-3 bar
Air-pressure for felt belt 4-5 bar
No. of Machine 2
Figure 6. 3 Sanforising machine
53
6.5 Peach machine:
The peach finish machine is the process where the peach fabric becomes smoother. By this
process especially for twill fabric, the diagonal line becomes lower with the application of
micro sandpaper or carbon wire brushing.
Functions of Peach machine:
➢ A wide range of brushing effects can soften the fabric

➢ Remove dust, neps
➢ Increase dye uptake
Flow diagram of peach finish:

Batcher
Upper roller
Drum
Air sucker
Brush roller
Bush chamber
Folding
Delivery
54
Table 6. 3 Machine specification of Peach machine
Brand LAFER SPA
Origin Italy
Speed 20 m/min
Drum speed 90 m/min
Capacity 20000-25000 m/day
Belt Pressure 2.6 bar
Drum Pressure 9 bar
No. of Machine 3
Figure 6. 4 Peach machine
55
Chapter-7 Quality Control
56
7.1 Quality Control System:
The quality department is assigned to maintain consistently uniform quality of the material in
process and various stages of its manufacturing. The quality control department checks the
quality of a sample through different tests and takes proper action to ensure the desired quality.
7.2 Objectives of Quality Control:
1. To produce the required fabric according to the standard procedure.

2. To maintain the total process.
3. To control the quality of raw materials.
4. To select the right process and control of same parameters
7.3 Types of Quality Control System:
1. Online Quality Control System.

2. Offline Quality Control System.
7.4 Online quality control:
In this system, different types of fabric faults can be

detected. Necessary tests before treatment & during
production (pre-treatment &dyeing) should be done ac-
cording to the proper procedure.
Figure 7. 1 Online Quality Control
57
This system includes the checking of –
Grey fabric faults:
• Miss pick
• Double pick
• Hole
• Oil spot
• Grease spot
• Broken selvage
• Miss yarn
• Iron spot
Grey fabric test: Figure 7. 2 Online quality control
• Width
• EPI/PPI
• GSM
• Boiler
• Pick up%
Scoured/Bleached fabric test:
• Fabric width
• Absorbency
• Size rating
• Ph
• GSM
• Shrinkage
• Pick up%
• Wicking
Mercerized fabric test: Figure 7. 3 Shade check
• Width
• Absorbency
• Ph check
58
• Whiteness
• Yellowness
• Shrinkage
• Pick up%
• BAN (Barium activity test)
Fabric shade check:
• Listing and Tailing
7.5 Offline Quality control:
Offline tests for finished fabrics are divided into two groups. These are as follows:
• Physical tests.
• Chemical tests.
Figure 7. 4 Offline quality control Figure 7. 5 Pilling tester
Physical tests:
• Tensile strength
• Tearing strength
• Pilling test
• Abrasion test
• Rubbing test
59
• Fabric width
• Fabric GSM
• EPI & PPI Count
• Seam Slippage
Figure 7. 6 Tensile tester
Figure 7. 7 Rubbing tester
Figure 7. 8 Gsm cutter
Figure 7. 9 Shaker machine
Figure 7. 10 Shrinkage scale
60
Chemical tests:
• Color Fastness to Water

• Color Fastness to wash
• Color Fastness to Perspiration
• Color Fastness to artificial light
• Absorbency Test
• Hardness of water
• Dimensional Stability (shrinkage)
• Ph Figure 7. 11 Washing machine
Figure 7. 12 PH tester
61
7.6 Layout of Offline Quality section
ENTRY
OFFLINE QUAL-
ITY CONTROL
MANAGER
OFFICE ROOM
R&D CHEMICAL
STORE ROOM
SECTION
COLOUR LAB
COLOUR LAB
LAB DIP
Figure 7. 13 Layout of Offline Quality section
62
7.7 Inspection
Layout of inspection section:
Exit
1
4
Roll fabric
Inspection machine
Inspection
(waiting for deliv-
room
ery)
5
Enter
Fabric storing section
Figure 7. 14 Layout of Inspection Section
63
Fabric inspection is a systematic fabric evaluation in which faults and defects are identified.
Fabric inspection is a crucial step that must be taken before garment manufacturing to prevent
rejects due to poor fabric quality and dealing with unanticipated manufacturing losses. The 4-
Points system is used for fabric inspection.
Figure 7. 15 4 point system
64
7.8 Types of inspection:
1. Grey inspection:
Inspection & grading of fabric quality is one of the important functions of quality control in
the grey or finished state. The grading of fabric is a difficult task, taking two primary consid-
erations: the frequency of effects & the seriousness of defects. Grading has two primary func-
tions: 1st to classify fabrics according to standard qualities based on the end use & customer
demands and 2nd is to supply information as to the qualities actually being produced.
Figure 7. 16 Fabric Inspection
2. Final Inspection:
➢ All pieces will be graded on the base of 4 points per 100 linear yards mapping will be
done on each piece to ensure proper grading. Do not count more than 4 points per yard.
➢ All defects must be recorded & marked in final inspection & an accurate account of points
made to ensure proper grading.
➢ All fabrics must meet specifications,
➢ At the end of each piece of fabric, the inspector will add up total points & decide
whether the piece can be shipped as first quality or not, reworked, placed in lower
65
quality, or cut & upgraded for shipment. Fifteen yards or more can be shipped as first
quality.
➢ The quality control supervisor must approve the grading of all quality levels & check
the lower quality.
➢ Major or unsightly defects in the first & last yard of a roll or piece will be cut. All
defects of one-yard length or more will be cut off the piece. Defects within the first 2
inches or the last 2 inches of a piece will not be cut out or counted in the grading,
➢ Open defects on the back of fabric such as drops runs & hanging picks are to be
included in the grading of the fabric,
➢ Pieces can be connected together, once each piece must be the same shade,
➢ All defects such as runs that extend more than a yard in length will be cut out.
Figure 7. 18 Fabric Inspection room Figure 7. 17 Fabric Inspection machine
Table 7. 1 Inspection Machine specification
Company Suntech Industrial (International) Ltd.

Model ST-WF1M-180
Year 2016
Origin ZHEJIANG, China
Capacity 5-60 m/day
Speed 20 rpm
Duration 2 hrs. for one operator per machine
No. of Machine 8
66
4-point system:
Table 7. 2 4 Point system
Defect size Points allowed
Up to 0-3 inches 1 point
Over 3-6 inches 2 points
Over 6-9 inches 3 points
Over 9 inches 4 points
Hole 4 points
Points Calculation: Roll points x 100 x 36
Individual roll points (Imperial system) = = points/100yds2
Inspected yds x cuttable width(inches)
Roll points x 100
Individual roll points (Metric system) = = points/100 m2
Inspected mtr x cuttable width(m)
Acceptable points (Imperial system):
For individual roll 10 points are allowed (points per 100 yds )2
For average shipment, 8 points are allowed (points per 100 yds )2
Acceptable points (Metric system):
For individual roll 12 points are allowed (points per 100 m )2
For average shipment, 10 points are allowed (points per 100 m )2
67
Faults are checked by inspection:
Dyeing faults:
➢ Crease mark
➢ Dye stain
➢ Oil spot
➢ White spot
➢ Color spot
➢ Joint mark
➢ Dye patta
➢ Uneven dyeing
➢ Shade variation
Yarn faults:
➢ Thick/thin yarn
➢ Slab
➢ Knot
➢ Foreign yarn
➢ Naps
Weaving faults:
➢ Broken yarn
➢ Double yarn/pick
➢ Miss yarn/pick
➢ Mixed yarn
➢ Hole
➢ Reed mark
➢ Damage yarn
➢ Stop mark
68
Chapter- 8 Utility
69
In Sim Group, the following utility amenities are available.
• Water
• Gas
• Steam
• Compressed Air
• Electricity
8.1 Origin of utility:
Natural gas is the primary utility used by SIM Group. Electricity is generated by a generator
using natural gas. From electricity and natural gas in conjunction with electrical and mechani-
cal equipment.
8.2 Boiler:
Typically, a closed steel vessel is used as a steam generator or boiler. The purpose of a boiler
is to transfer heat from the burning of fuel (gas) to water and then to make steam. The wet
processing section may use the created steam to power a heating cylinder dryer, staining during
steaming. Deep tube wells provide the water needed to produce steam.
Objective: To provide steam.
Figure 8. 1 Boiler
70
8.2.1 Boiler operation principle:
Gas is injected into the furnace's front side, where an electric spark starts a fire. The combustion
chamber, which is lined with fire bricks on the exterior wall of the boiler, is where the flue
gases enter after the blower moves the fire into the exhaust pipe by compressing air. The heated
gases that are moving through the lateral smoke tubes heat the water, turning it into steam. In
the top part of the shell, where it may be provided to the users, this steam builds up. Finally,
the smoke tray and chimney are used to release the flue gases into the atmosphere.
Figure 8. 2 Water boiler
8.3 The Standard of Natural Water:
A textile mill may receive water from a variety of sources. These consist of underground water
from wells as well as surface water from rivers and lakes. They use underground water collec-
tion. Various chemical species that might affect textile wet processing in general and dyeing,
in particular, may be present in natural and processed water.
8.4 Steam:
In the industrial setting, boilers provide steam.
71
8.4.1 Uses:
• Power production
• Applications for heating
• Providing hot water
• Industrial processing
8.5 Compressed Air:
From an air conditioner's air compressor, compressed air is delivered. Compressors are used in
the industry to supply compressed air.
Table 8. 1 Air compressor Specification
Brand FS Curtis
Product category GA30C
Origin India
Highest practical pressure 10 bar
Nominal shaft power 30 kW
Serial no. AII265397
Total weight 11.6 Tons
Rpm 3000
72
Figure 8. 3 Air compressor
Figure 8. 4 Generator
8.6 Electricity:
The factory receives electricity from the Electricity Board & Gas Generator.
Table 8. 2 Generator Specifications:

Brand Caterpillar machinery
Origin USA
Voltage 415 V
RPM 1500
Required Oil 2 Lt/day
Power element 0.8
Fuel Gas
No. of Generator 02
73
8.7 Water Treatment Plant
The water treatment facility, which is an essential component of the dyeing section, is where
the dyeing floor's supply of water is treated and prepared for dyeing. When dyeing knitted
fabrics, the supply water might contain dissolved particles, metal compounds, and other pollu-
tants that can cause fabric problems of all kinds.
75 cubic meters are processed by the facility each hour. The surface water serves as the water's
source. The raw water tank is supplied with surface water utilizing different pump and pipe
arrangements.
Table 8. 3 WTP of SIM group

➢ Total Plants 4
➢ Pumps attached with Softening 2
Plant
➢ Water Distribution • Woven Dyeing
• Knit Dyeing
• Towel Dyeing
➢ 1st & 2nd Vessel contains Resin & Stone
➢ Test Iron and Hardness test
➢ Maintenance Depends on the quality of the water
➢ Salt required for Washing 50 Kg
➢ Per Hour Plant Processing • 35 cubicmeter-2011
• 40/50 cubicmeter-2013/14
• 75 cubicmeter-2020
74
Figure 8. 5 WTP of Sim Fabrics Ltd
8.7.1 Flowchart:
Submersible pump
Motor (2)
Multigrade Stone Filter
Resin Filter
Motor (2)
Multigrade Stone Filter
Resin Filter
Booster Pump
Production Floor
75
8.7.2 SIM Group Water Treatment Plant's process flow:
Submersible Pump:
It brings groundwater.
Motor:
It helps to transfer the raw water to the Multigrade stone filter.
Multigrade Stone Filter:
Multi Grade Filters (MGF) are used in water treatment to remove water impurities.
Resin Filter:
Raw water contains various contaminants which are removed by a resin filter to make the water
soft.
Booster Pump:
This pump is used to supply the water in different sections.
Reserve Plant:
In the reserve tank, the processed soft water is kept. The water required for the dyeing and
finishing processes is deposited in a 20-foot-deep reserve water tank, from which water is
drawn using a water pump.
76
8.7.3 Water Treatment Plant of SIM Group:
Figure 8. 6 Water Treatment plant
77
8.8 Effluent Treatment Plant:
The stream of additional chemical liquid that is removed from the industry after being used in
the initial operation is known as effluent. Effluent treatment plant refers to the entire plant.
8.8.1 Purpose:
➢ To keep Biological Oxygen Demand (BOD) and Chemical Oxygen Demand (COD) at
their correct levels.
➢ pH regulation.
➢ To eliminate coloring materials.
Figure 8. 7 ETP of SIM Group
78
8.8.2 Flow Chart Of ETP:
Collection Pit
Equalization Tank
Dissolved Air Floatation
PVA Gel Tank
Anoxic Tank
Aeration Tank
Secondary Clarifier
Sludge recycle pump
Sludge Pit
Cavitation Air Flow
Wastewater out
Rest Sludge
Dry cake
79
Table 8. 4 ETP Standard parameters in SIM Group:
Standard COD 200 ppm

Standard BOD 50ppm
TDS 2100ppm
TSS 150
DO 4.5- 8
pH 6-9
Polymer Used for tank
H₂SO₄ Used for pH
Temperature 40°C
Pump Specification 4 Auto, 1 Manual
ETP 1800-2000 ppm
Table 8. 5 Specification of ETP plant in SIM group
Plant Capacity 75m3/hr
ETP run Through Gas Generator
Motor Specification 75 kw, 3 motors
80
8.8.3 ETP's Operational Process:
Collection Pit:
Collecting the dyeing water.
Equalization Tank:
Wastewater is highly alkaline, so here adding H2SO4 control the pH.
DAF (Dissolve Air Floatation):
Removal of oils & greases from wastewater.
PVA Gel Tank:
It features higher bacterial retention than ordinary carriers and enables more efficient
wastewater treatment with a compact system.
Anoxic Tank:
Anoxic zones in wastewater are useful for nitrogen removal. Some wastewater has a high ni-
trate and nitrite content, and the treatment process must break down those compounds to avoid
causing nutrient pollution when the plant discharges its effluent back into the environment.
Aeration Tank:
Wastewater aeration is the process of adding air into wastewater to allow aerobic bio-degrada-
tion of pollutant components.
Secondary Clarifier
Secondary clarifiers are used to remove the settlable suspended solids created in biological
treatment processes such as the activated sludge and trickling filter process.
Sludge recycle pump:
The purpose of the sludge recycle pump is to move sludge through sewer lines or other systems.
Sludge Pit:
The sludge pits are used for the disposal of excess active sewage sludge.
81
Cavitation Air Flow:
Removes suspended solids, fats, and colloids in water treatment.
Wastewater out:
Discharge the wastewater
Rest Sludge:
Dewatering process dry sludge is prepared
Dry cake
Sludge is stored for 6 months
8.8.4 ETP of SIM Group:
Figure 8. 8 ETP of SIM Group
82
Chapter-9 Compliance
83
9.1 Compliance Policy of the group:
Complying with a request, desire, or necessity is referred to as compliance. Others describe

compliance as adhering to laws, regulations, or requirements.
The senior management of SIM places great importance on interpersonal ties with its staff and
sees them as an essential part of the business. The organization helps to maintain a setting at
work where staff members may feel at home.
SIM is determined that high levels of organizational efficiency are required throughout the
board to achieve its corporate purpose. As a result, conformity, retraining, growth, and incen-
tives receive a lot of funding. Since it considers its human resources to be one of its most crucial
success elements and because it thinks that doing so will contribute to improving organizational
efficiency and production quality. It frequently provides training to its human resources.
A unique bonus, inducement, or award may be given by SIM without being mandated by the
relevant national legislation. Employee rights and responsibilities are better understood by em-
ployees thanks to a workers' welfare board.
Despite having a division dedicated to resolving what are typically known as compliance con-
cerns, SIM believes all of them to be good motivational efforts.
9.2 Infrastructure and Security:
Health:
• Register for the suggestion box

• The canteen has a water cooler and a heater
• Water source for drinking
• One time Cup availability
84
Mechanical Maintenance:
Figure 9. 1 Mechanical Maintenance
Safety Measure:
• Training Program regarding safety

• First-aid kit
• Medicine
• Doctor
• Child Care Room
85
Figure 9. 2 Medical Center
Figure 9. 3 Child Care Room
Fire:
• Fire-certified individual photograph

• Both English and Bangla fire signs
• Emergency exit
• Enough fire extinguishers
86
Figure 9. 4 Civil Department
Figure 9. 5 Fire Extinguisher
9.3 Some Other Facilities:
• Reimbursement for a vacation

• Committee for safety and health
• Policy about working hours
• Stance against child labor
• Holiday for a national festivals
• Register of accidents
• Record of daily cleaning
87
Chapter-10 Conclusion
88
10.1 Challenge observed during the training period:
• New Environment: For us, the new atmosphere presented difficulties. The temperature
was a little bit high in several areas, such as the dyeing and finishing. It took us some
time to adjust to these new surroundings because we were unfamiliar with them.
• Gas Shortage: A deepening energy crisis is hitting industries in Bangladesh hard and
SIM Fabrics Ltd is one of them. Sim Fabrics had to stop production for about 10 days
due to a gas constraint, which made it impossible for us to carry out our training as
planned.
10.2 Conclusion:
The eight-week-long industrial training truly helped us to reduce the gap between theoretical
and practical knowledge. Practical knowledge frequently takes precedence over theoretical un-
derstanding in textile education. Industrial training is an essential component of studies to make
a technologist technically sound in this sector because the theoretical background is insuffi-
cient. We get the chance to learn from experience thanks to industrial training. We have com-
pleted our industrial attachment from SIM Fabrics Ltd. We got the impression that this factory
is one of the modern export-oriented industries of our country. This factory does not compro-
mise in case of quality. This industrial training has greatly expanded our understanding of tex-
tile technology. Additionally, it prepared us for an industrial existence by teaching us a great
deal about industrial production methods, machinery, and administration. It provided us with
our first chance to work in the industry.
89

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DEPARTMENT OF TEXTILE ENGINEERING

Course No.: Tex 500

Industrial Training Report at

Students No. Name of the student

Mr. Md. Koushic Uddin

AHSANULLAH UNIVERSITY OF SCIENCE AND TECHNOLOGY

Chapter-1 Introduction ........................................................................................................... 1

Table 3. 1 Vat dyeing recipe .................................................................................................... 15

Table 4. 1 Recipe for desizing ................................................................................................. 27

Table 5. 1 Vat dyeing recipe: ................................................................................................... 41

Table 6. 1 Machine specification of Stenter machine .............................................................. 50

Table 7. 1 Inspection Machine specification ........................................................................... 66

Table 8. 1 Air compressor Specification.................................................................................. 72

Figure 3. 1 Mini Padder ........................................................................................................... 18

Figure 4. 1 Layout plan of Pretreatment section ...................................................................... 25

Figure 5. 1 Layout plan of Dyeing section .............................................................................. 36

Figure 6. 1 Layout plan of Finishing section ........................................................................... 47

Figure 7. 1 Online Quality Control .......................................................................................... 57

Figure 8. 1 Boiler ................................................................................................................... 70

Figure 9. 1 Mechanical Maintenance ....................................................................................... 85

2.2 The mission of SIM Fabrics Limited

• Exceed our customer’s expectations with better quality products.

2.3 The vision of SIM Fabrics Limited

2.4 Core Values of SIM Fabrics Limited

Figure 2.1 Factory premises

Table 2.1 Factory information

Name of the Factory SIM Fabrics Ltd

Type Private Limited Company

Year of Establishment 2000

Factory location Thakurbari Teac, Masumabad, Vulta, Rupganj , Nara-

Head office House # 315, Road # 04, Baridhara D.O.H.S., Dhaka.

Total Employee 3000 persons

Exponential growth $20 Million (USD)

SIM Fabrics Ltd. (Weaving)

Phone numbers +88-02-8415961

Figure 2.2 Factory Location

Table 2.2 Company certifications

1 OEKO-TEX® STANDARD 100

2 Global Recycled Standard (GRS)

3 GOTS (Global Organic Textile Standard)

2.8 Working-Time Schedule of the Factory

• A-shift: 6 a.m. - 2 p.m

Table 2.3 Manpower setup

Quality Control 197

Knit Dyeing 183

Woven Dyeing 176

Spinning (Rotor) 183

Spinning (Ring) 359

Table 2.4 Buyer’s name list

Buyer’s Name Logo

Objective of Lab Dip:

The main objectives in lab dip are as follows:

1. To calculate the recipe for sample dyeing.

Swatch recipe generation from spectrophotometer

Recipe is given by swatch Or pantone number

Dyeing process followed by recipe (Padding, Drying, fixation by cps,

Grading of sample nearby three shades that

Send for Buyer’s approval

Order for bulk production

Sample dyeing for trail

Production card with approved sample and

Method: Pad dry pad steam