industrial attachment of fakhruddin textile mills limited

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTFAKHRUDDIN TEXTILE MILLS LIMITED

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Chapter-1

Introduction

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Chapter-1

Introduction

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Chapter-1

Introduction

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The textile and clothing (T&C) industries provide the single source of economic growthin Bangladesh's rapidly developing economy. Exports of textiles and garments are the principalsource of foreign exchange earnings. By 2002 exports of textiles, clothing, and ready-madegarments (RMG) accounted for 77% of Bangladesh’s total merchandise exports. By 2013, about4 million people, mostly women, worked in Bangladesh's $19 billion-a-year industry, export-oriented ready-made garment (RMG) industry. Bangladesh is second only to China, the world'ssecond-largest apparel exporter of western brands. Sixty percent of the export contracts ofwestern brands are with European buyers and about forty percent with American buyers. Only5% of textile factories are owned by foreign investors, with most of the production beingcontrolled by local investors. It can be emphasized that among the entire textile sector knitcomposite is the most fast growing sector in Bangladesh because of smaller investmentrequirement, greater backward linkage facility and higher profit. We are very fortunate at suchtype of present situation we have completed our industrial training at a reputed 100% exportoriented knit composite factory “FAKHRUDDIN TEXTILE MILLS LIMITED.”

“FAKHRUDDIN TEXTILE MILLS LIMITED” is fully concerned about knitting, knitdyeing and knit garments which vertically setup well planned textile unit in 2005. From thebeginning of production it has earned lot of reputation due to its quality product and approval ofseveral multinational inspection firm i.e. Oeko Tex, SGS, WRAP as well as renowned buyer i.e.MARKS & SPENCER, S.OLIVER. At “FAKHRUDDIN TEXTILE MILLS LIMITED” we havecompleted eight weeks long industrial training on knitting, knit dyeing and finishing. Duringentire training period we had tried as much as possible to keep ourselves at actual workingcondition by implementation our knowledge, thoughts and ideas and this report is mainly a littleeffort to express such experiences gathered in training.

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1.1. Profile of Fakhruddin Textile Mills Ltd.:

Primary Profile

Company Name : FAKHRUDDIN TEXTILE MILLS LTD.

BKMEA Membership Number : 678Membership Type : Ordinary Member

Year Of Registration : 09.03.2003

General Profile

Status : Private Limited CompanyType : Fakhruddin Textile Mills Ltd is a 100%

export oriented knit composite millYear Of Establishment : 2005

Year Of Starting Production : 2005Location : Sreepur, Gazipur

Factory Address : 1036/1 Ghorghoria master bari, Kewa,Sreepur, Gazipur

Head Office : 235/A, Tejgaon Industrial area,DhakaSponsors : Urmi Group

Owner : Asif AshrafRaw materials : 100% Cotton

100% Polyester 100% Viscose 95% Cotton 5% Lycra 95% Polyester 5% Lycra 95% Viscose 5% Lycra 60% Cotton 40% Polyester 48% Cotton 48% Modal 4% Lycra Nylon

Different Departmentsa) Knitting section :

b) Dyeing section :

c) Garments section :

- 2 Knitting section- Inspection

- Batch section- Dyeing lab- Dyeing section- Quality control- Finishing

- Cutting- Sewing- R.N.D. / Sample- Finishing & Packing

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d ) Merchandising & Marketing :

e) Maintenance section :

f) Store section :

- Quality control- I.E.N. & Planning- Store

- Electrical- Mechanical

Supporting Departments : - Security department- HRD- Procurement- Finance & accounting- Personnel administration

Total Manpower :Major customers : Marks & Spencer (M&S)

S. Oliver Auchan Vert Toray Japan Triton Bengal Tex

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1.2. Site layout :

W

S

Entrance

Security, Medical, Mosque, Administration, Knitting section, Car parkGarments 1&2 Packaging Canteen Dyeing sec. ETP Power house

1.3. Location of Fakhruddin Textile Mills Ltd. :

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1.2. Site layout :

W

S

Entrance



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1.2. Site layout :

W

S

Entrance



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Chapter-2

Manpower MANAGEMENT

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Chapter-2

Manpower MANAGEMENT

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Chapter-2

Manpower MANAGEMENT

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2.1. Organogram:

Managing Director

Chief Operating officer, Administration Director

Manager -Compliance

Sr. Manager-Admin, HR &Security

Manager-Stores

GM-Production

DGM-Commercial

AGM-Accounts &Purchase

QualityManager

QualityController

Quality Auditor

Quality Inspector

WorkstudyManager

FactoryManager

DyeingManager

KnitManager

Knitofficer/ In-charge

KnitOperator,Knit Asst.

ProductionManager

APM/Floor In-charge

Supervisors &line In-charge

Operator &Helper

CuttingManager

CuttingIn-charge

CuttingSupervisor

Cutter/Maker

man,Cut asst.

FinishingManager

FinishingSupervisor

Poly/iron/Packer,finishingasst.

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2.2. Management System:

Buyer sample is sent to G.M.

Matching is done by lab in charge.

Sample is prepared by asst. dyeing master.

Sample is resent to the buyer for approval.

Approved sample is returned and taken as standard. sample for bulk production.

Asst. dyeing master gives responsibilities to production officer

Then production officer, with the supervisors start bulk production

On-line and off-line quality check is done by lab in charge and asst. dyeing master.

After dyeing finishing in charge controls the finishing process with the supervision ofproduction officer

After finishing, the material is checked by asst. dyeing master

Finally G.M. checks the result with asst. dyeing master and decision is taken for delivery

2.3. Shift Change:

Three shifts (A, B, C): each of 8 hrs A Shift: 7 A.M to 2 P.M. B Shift: 2 P.M. to 10 P.M C Shift: 10 P.M. to 7 A.M General Shift: 9 A.M to 5 P.M.

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2.4. Overall Man Power of FTML :

Departments No. Of EmployeesKnitting 240

Garments-1 566Garments-2 349

Sample 35Project Implement 12

Printing 118Fabric dyeing 135

Human resources 10Planning 10Security 32

Maintenance 22Cutting 110

Store 21Accounts & Finance 11

Lab & QC 10Quality Assurance 21

Finishing 43Total 1750

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Chapter-3

Knitting section

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Chapter-3

Knitting section

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Chapter-3

Knitting section

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3.1. Raw Materials Used In Knitting:

Cotton 18s,20s,24s,26s,28s,30s,32s,34s,40sViscose 18s,20s,24s,26s,28s,30s,3s,34s,40sPolyamide 20D, 40D,75D, 100DPolyester 75D, 100DSpandex 20D, 40DGrey mélange (C-90%, V-10%) 24s,26sEcru mélange (C-85 %, V-15%) 24s,26s,28sAnthra mélange (C-60%, V-40%) 24s,26s,28sPC(65% Polyester 35% Cotton) 24s,26s,2s,30sCVC(40%Polyester & 60% Cotton) 24s,26s,28s,30s

3.2. Sources Of Yarn For Knitting :

Yarn Count Yarn Type Brand Name28/1 Combed Cotton NRG30/1 Carded slub Thermax40/1 Polyester-Viscose SQR40/1 Carded slub Bangol28/1 Carded slub Thermax40/1 Combed Cotton NRG40/1 CVC NRG36/1 Combed Cotton AA32/1 Grey Mélange Thermax32/1 Combed Cotton Thermax34/1 Organic Cotton Nahar24/1 Combed Cotton AA24/1 Combed Cotton NRG28/1 Grey Mélange Thermax16/1 Grey Mélange Thermax26/1 Carded slub Thermax24/1 Carded slub UniTex24/1 Carded slub Bangol20/1 Carded slub Anwara16/1 Polyester-Cotton SQR

75/72 Polyester Thermax24/1 Grey Mélange Thermax28/1 Carded slub Kamal32/1 Viscose Liberty30/1 Carded slub Techno27/1 Combed Cotton NRG

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3.3 Product Mix :

# Single Jersey # Double Jersey

1. Single Jersey (plain) 1. 1×1 Rib

2. Polo pique 2. 2×1 Rib

3. Single lacoste 3. Interlock

4. Double lacoste

5. Fleece

3.4 Knitting Machine:

Fakhruddin Textile Mills Ltd. is well equipped modern export oriented industry. It has highquality machinery with large production. There are 2 types of machines in this industry. Theseare:-

Circular knitting machine Single jersey machine Double jersey machine

Flat bed machine (cuff & collar)

Machine at a Glance:

Machine type Machine name Total no.Circular knitting machine

Flat knitting machine

Single jersey 53Double jersey 11Collar, Cuff 10

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Circular Knitting Machines:M/c No. M/c

TypeM/c Dia(inch)

M/cGauge

No. ofFeeder

No. ofNeedle

Brand Origin

1,2,3 S/J 28 24 84 2112 JIUNN LONG Taiwan4,5,6 S/J 30 24 90 2256 JIUNN LONG Taiwan7,8,9 S/J 32 24 96 2400 JIUNN LONG Taiwan

10,11,12 S/J 34 24 102 2544 JIUNN LONG Taiwan13 S/J 36 24 108 2412 JIUNN LONG Taiwan14 S/J 36 24 72 2712 JIUNN LONG Taiwan15 S/J 36 18 72 2040 JIUNN LONG Taiwan16 S/J 34 24 72 2544 JIUNN LONG Taiwan17 S/J 34 18 72 1920 JIUNN LONG Taiwan18 S/J 38 24 90 2856 KEUMYONG Korea19 Rib 40 18 80 2256 PAILUNG Taiwan

20* . . . . . . .21 Rib 42 18 84 2376 PAILUNG Taiwan22 Rib 42 18 84 2376 KEUMYONG Korea

23,24 S/J 24 24 72 1800 PAILUNG Taiwan25,26 S/J 26 24 78 1944 PAILUNG Taiwan27,28 S/J 28 24 84 2112 JIUNN LONG Taiwan

29 Rib 40 18 80 2256 PAILUNG Taiwan30 Rib 36 18 72 1992 PAILUNG Taiwan31 Interlock 32 18 64 1800 PAILUNG Taiwan32 Fleece 32 24 64 2400 PAILUNG Taiwan33 Honey

comb30 24 60 2256 PAILUNG Taiwan

34 S/J 40 24 120 3000 KEUMYONG Korea35 Interlock 38 24 114 2856 KEUMYONG Korea36 S/J 36 24 108 2712 KEUMYONG Korea37 Interlock 36 24 108 2712 PAILUNG Taiwan38 Interlock 38 24 102 2544 PAILUNG Taiwan39 S/J 30 24 90 2256 JIUNNLONG Taiwan40 S/J 30 24 90 2220 PAOLO ORIZIO Italy41 Fleece 30 20 46 1872 PAILUNG Taiwan42 Fleece 26 24 78 1944 PAILUNG Taiwan

43,44 Philip 30 20 46 1872 PAILUNG Taiwan45,47 Fleece 32 24 96 2400 PAILUNG Taiwan

46 Philip 32 24 96 2400 PAILUNG Taiwan48 S/J 34 24 102 2568 KEUMYONG Korea

49,50 S/J 24 24 72 1812 JIUNN LONG Taiwan51,52,53,

54,55S/J 30 24 90 2256 JIUNN LONG Taiwan

56,57 S/J 38 24 114 2880 JIUNN LONG Taiwan58,59 S/J 28 24 84 2112 JIUNN LONG Taiwan

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60,61,62 S/J 26 24 78 1968 JIUNN LONG Taiwan63,64** Stripe*under repair **newly arrived under setup

Flat Bed Knitting Machines:

M/C No. Brand Name Origin Model M/C Type Gauge No. ofFeeder

1, 2 MATSUYA Japan 100 Fully automatic flatknitting m/c

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3, 4, 5, 6 JY-LEHINDVSRIAL

Taiwan JY-303 Computerized Flatknitting m/c

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7, 8, 9,10

MATSUYA Japan M-17283 Fully automatic flatknitting m/c

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Important Parts of Knitting Machine and Their Functions:

1. Needle: The needle is the primary knitting element .Needle is a thin metal bar.

Function: It is used to produce a loop.

2. Sinker: The sinker is the second primary knitting element .It is a thin metal plate.

Function: Holding down knocking over

3. Knitting Cam: Cam is the devices which convert rotary machine drive in to a suitablereciprocation action for the needle.

i.Knit Cam

Function: To produce knit loop.

ii.Tuck Cam

Function: To produce tuck loop.

iii.Miss Cam

Function: To produce miss loop.

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4. Cam Box

Function: To set cam on the slider.

5. Quality Adjustments Pulleys

Function: It is used to control GSM.

6. Memminger Positive Feeder

Function: It is use to apply positive feed of the yarn.

7. Lycra Feeder Device

Function: It is used to apply positive feed of the spandex.

3.5 Knitting Process:

Knitting is the process to develop a fabric by intermeshing of loops when commercially aknit fabric is produced it contain it some specification i.e. structure/design, GSM, dia/width thatdetermine the characteristics of a finished fabric. As Fakhruddin Textile Mills. is an exportoriented industry its knitting section has to follow some knitting parameters strongly to meetthose specifications .In this segment we have tried to give a basic concept on the implementationof knitting process.

Process Flow of Knitting:

Yarn in cone Form

Feeding the yarn Cone on the Creel

Feeding the yarn in the feeder via positive feedingArrangement

Tension Device

Knitting

Withdraw the Rolled Fabric and Weighting

Inspection

Numbering

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3.6 Production Parameter:

1. Diameter of the machine2. RPM of the machine3. No. of feeders4. Machine gauge5. Efficiency of production

3.7 Quality Assurance System:

After collecting fabric rolls from different machine it becomes necessary to ensure requirequality. Fakhruddin Textile Mills Ltd. maintains ISO: 9001 standard in case of quality. Thereforeit ensures quality through four point system, where fabric are inspected and give againstrespective defect.

4-Point System

Maximum point for any fault is 4. One meter fabric should not mark over-4 point system whatever the faults are. Rejected if faults point/100 yards is 40 or over. 4- Point Grading System

Fault Length Penalty point3 inches or less 1

3-6 inches 26-9 inches 3

Over 9 inches 4

Body and Rib Inspection

Faults ResponseLoop/Drop stitch Give 4 point

Wrong design RejectSlub Give 1 pointHole Give 4 point

Thick/thin place Give 1 pointStar mark Give 4 point/1 point(for small point)Pin holes Give 4 point

Barre RejectNeedle mark Major needle line is rejectedSinker mark Major sinker mark is rejected

Birds eye Give 1 pointOil drop Give 4 point

Contamination &fly Give 1 point

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Collar & Cuff Inspection

Faults ResponseWrong ply Reject

Hole RejectMissing Yarn RejectWrong tipping Reject

Wrong tube Reject

3.8 Fabric Faults and Their Causes:

There are various type of faults is occurred in the section of knitting .But during our training wefound the following types of faults.

1. Thick Yarn Course

Causes: Lot mixing Negligence of worker etc.

2. Hole

Causes: Bad needle Knots in yarn Take down mechanism too tight High tension on the yarn Bad yarn etc.

3. Missing Yarn

Causes: Yarn breakage Faulty stop motion etc.

4. Lycra Out

Causes: Incorrect position of yarn guide Improper sinker ring setting etc.

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5. Barre/Patta

Causes: Uneven dial &cylinder relationship Lot missing Yarn count mix etc.

6. Sinker Mark

Causes: Old sinker Sinker mixing Dust in sinker ring etc.

7. Needle Line

Causes: Bad needle Needle mixing Dust in needle track etc.

8. Drop Stitch

Causes: Bad needle latch.

3.9 Ways of Increasing Production:

Production of knitting can be increased by the following ways:

By increasing machine speed By increasing the number of feeder By using higher machine gauge By introducing auto motion

3.10 Production Calculation:

Production/shift in kg at 100% efficiency:

No. of feeder x No of needle x Gauge x S.L.(mm) x 60 x 8=

1000 x 840 x 2.2046 x Yarn count (Ne)

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3.11 Maintenance in the Knitting Section:

To get maximum efficiency is it necessary to ensure smooth running of a machine and atFakhruddin textile mills ltd it is carried out by m/c servicing. At this case main objectives are:

To ensure required quality of the fabric To minimize the fabric fault Removal of dust from the machine Cleaning of different parts of the machine

Turning is a process to turn the fabric roll and it is done those fabric which are not similar in bothface and back side .The main objectives of turning is:

- To protect the side of the fabric from any dust, spot, staining and friction of machine

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Chapter-4

Dyeing section

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Chapter-4

Dyeing section

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Chapter-4

Dyeing section

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4.1 Machine Description of Dyeing Section:

M/cNo.

Brand Type Origin Capacity(Kg)

M:L Max.Temp(0C)

Max.

Pressure(bar)

1, 2 DILMENLER DMS15HT-sample

dyeing m/c

Turkey 15 1:6 135 3

3 DILMENLER DMS50HT-sample

dyeing m/c

Turkey 50 1:6 135 3

4 DILMENLER DMS 11HTJumbo Jet

Flow

Turkey 175 1:6 135 3


Flow

Turkey 225 1:6 135 3


Flow

Turkey 450 1:6 135 3


Flow

Turkey 675 1:6 135 3


Flow

Turkey 350 1:6 135 3


Flow

Turkey 1050 1:6 135 2.5

10 TONGGENG TGURV-NUV-6-900

China 900 1:!0 98 Low


China 600 1:10 98 Low


China 300 1:10 98 Low


Flow

Türkiye 1400 1:6 135 2.5

16 THEN DMS 11HTJumbo Jet

Germany 1500 1:4 140 3

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Flow17 J & X China 100 1:8 98 Low18 EA (BD) Bangladesh 25 100 Low19 THEN DMS 11HT

Jumbo JetFlow

Germany 1600 1:4 140 3

20 THEN DMS 11HTJumbo Jet

Flow

Germany 1600 1:4 140 3

21 GuandongHeshan Hongfa

China 10 1:10 140 High


Flow

Turkey 175 1:6 135 2.5


Flow

Turkey 350 1:6 135 2.5

24 EA (BD) Bangladesh 15 100 Low25 EA (BD) Bangladesh 50 100 Low27 EA (BD) Bangladesh 15 100 Low28 EA (BD) Bangladesh 15 100 Low29 EA (BD) Bangladesh 25 100 Low

***M/c No. 14, 15, 26 were removed from the floor.

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4.2 Chemical & Auxiliaries Used in Fakhruddin Textile Mills:

S/L No. Name of Chemical Common Name1 Gradprep Hooley Detergent2 Nearpon BWLF Detergent3 Geis QSE Sequestering agent4 Optavon 4UD-QSE Sequestering agent5 Lubrifil TFV- P Anti-creasing agent6 Geistabe RS Stabilizer7 Danilube P Anti-creasing agent8 Gyszyme PR Peroxide Killer9 Caustic Soda (NaOH) Alkali

10 Hydrogen Peroxide Oxidizing agent11 A. Acid Acid12 Glauber Salt Salt13 GSS Multifunctional agent14 Gradtech RDLB Leveling agent15 Corscolor ADM Leveling agent16 Setavin RCO Leveling agent17 SkiantanNW Soaping agent18 Hydroprotec COMP B Softener (for stenter)19 NearcandPC 15 Viscose Scouring agent20 Biopolish B 600N Enzyme21 Retro cell PLEX Enzyme22 Jinsoft ECO ECA Anti-creasing agent23 Softener SA 1000 Softener (color)24 Jintexalate SQ 117CA Sequestering agent25 Benlon 5020 Color softener26 Benlon 3525 Silicon softener27 Benlon 3526 Silicon softener28 Aristan PSR Polyester Softener29 Nuva TTC Stenter softener30 Grosoft SCA Silicon softener31 Zetesal 2000 Fixing agent32 Croscolor OZ Polyester leveling33 Croscolor PLD Polyester leveling34 Croscolor PCD Polyester buffer35 Finscour OSP Detergent36 Setavin PA/SANZ Leveling37 Antimussol UDF Antifoaming38 Setasel PNT/LSP Leveling39 Zetesall NR/NRF Fixing Agent40 Oleophobol CO Stenter softening41 Bilsoft 200 White softener

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4.3 Dyes:

The following dyes are used:1. Reactive2. Disperse

S/L No. Name of Dyes Manufacturer1 Remazol RedRR Dystar2 Remazol Yellow RR Dystar3 Remazol Blue RR Dystar4 Remazol Orange RR Dystar5 Remazol Yellow 3GL Dystar6 Remazol T/Blue G Dystar7 Remazol BR Blue RSP Dystar8 Bemacron Rubine SERDL Bezema9 Bemacron orange SERDL Bezema

10 Bemacron Red SERDL Bezema11 Bemacron Yellow SERDL Bezema12 Bemacron Blue SERDL Bezema13 Bemacron Turqse SERDL Bezema14 Bemacron Black SERDL Bezema15 Bemacron Navy SERDL Bezema16 Bemacron Carmine HP3R Bezema17 Bemacron Blue HP3R Bezema18 Solazol T/Blue SPVG SOLAR FINE CHEMICAL CO.19 Solacion Red SOLAR FINE CHEMICAL CO.20 Solacion Orange SOLAR FINE CHEMICAL CO.21 Solazol Orange SP3R SOLAR FINE CHEMICAL CO.

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4.4 Process Flow Chart:Production Flow Chart For 100% Cotton Fabric:

Fabric Load

Water Level - As Required

Raise temp to 60°C

Add detergent, stabilizer, sequestering agent, H2O2

Add Caustic at 70°C - Dosing time 10 min

Raise temp to 105°C and run 40 min (pH - 10.5-1 1)

Cooling 80°C

Rinse

Drain

Fill with water

Peroxide killer inject & temperature rise 80°C & run l5 min

Rinse

Drain

Water Level - As required

Add Acetic Acid for neutralization

Add enzyme at 55°C and run 45 min (pH - 4.5 to 5.5)

Temp rise 80°C

Run l0 min

Drain

Rinse for l0 min


Add Leveling agent and run l0 min at 55°C (pH 5.5 to 6)

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Add salt run l0 min

Add colour and dosing time 10 min

Machine Run time - 20 min

Add Soda at 55°C - Dosing time 45 min

Machine Run & after 20 min Sample Cutting & Shade Matching

Run the machine as required to match the shade

If shade match

Drain (Bath Drop)

Rinse until unfixed dyes are removed


Drain

Add Soaping chemical & run 30 min at 80°C

Add Fixing agent at 40°C and run for 10 min

Drain

Add Water

Cold Wash

Unload Fabric

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Production Flow Chart For 100% Polyester Fabric:

Fabric Load


Hot treatment at 80°C 20 min

Wash at 30°C 10 min

Drain

Add Acid to adjust pH

Leveling at 60°C 10 min (pH 4 - 4.5)

Color dosing at 60°C 20 min (Run time 20 min)

Raise the temperature 1.5°C /min =100°C Raise the temperature 1°C /min =130°C

Color steaming at 130°for 60 min

Dropped the temperature 1°C/min =100°C

Dropped the temperature 1.5°C /min =80°C

Sample cutting for shade matching

If the shade is OK

Reduction clearing

For dark shade at 90°C 30min

Cooling

Wash

Drain

Softener dozing at 50°C

Unloading

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Production Flow Chart For 100% Viscose Fabric:

Fabric Load


Raise temp to 70°C

Add detergent, stabilizer, sequestering agent, H2O2

Add Caustic at 98°C - Dosing time 40 min

Raise temp, to 105°C and run 40 min (pH - 10.5-11)

Cooling 80°C

Rinse

Drain

Fill with water

Peroxide killer inject & temperature rise 80°C & run l5 min

Rinse

Drain



Add enzyme at 55°C and run 45 min (pH - 4.5 to 5.5)

Temp rise 80°C

Run l0 min

Drain

Rinse for l0 min


Add Leveling agent and run l0 min at 55°C (pH 5.5 to 6)

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Add salt run l0 min

Add color and dosing time 10 min

Machine Run time - 20 min

Add Soda at 55°C - Dosing time 45 min

Machine Run & after 20 min Sample Cutting & Shade Matching

Run the machine as required to match the shade

If shade match

Drain (Bath Drop)

Rinse until unfixed dyes are removed


Drain

Add Soaping chemical & run 30 min at 80°C

Add Fixing agent at 40°C and run for 10 min

Drain

Add Water

Cold Wash

Unload Fabric

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4.5 Different Problem and Remedies in Wet Processing of Knit Fabric:

Problem Possible Cause Possible remediesUneven dyeing inrope

- It can be due to fastaddition dyes/ chemicals

- Check dyestuff dissolution isproper and uniform dosing inmachine. - Control rope speed - Usesuitable leveling agent to improvedye migration

Dye spots - Improper dissolution ofdyestuff - Inadequate saltsolubility of the dyestuff -Metal ion sensitivity causingprecipitation of dye metalcomplex.

-Ensure proper dissolution ofdyestuff and filter through finecloth. -Linear/progressive dosing ofalkali as per dyestuff class used

Tailing effect oncritical shades likekhaki/olive/grey

- Due to poor migration ofdyestuff

- Use of suitable leveling agent -Proper selection of tri-chromaticcombination of dyestuff

Poor washing offfastness

-Improper fixation ofdyestuff - Improper washingoff of hydrolyzed dyestuff -Use of poor quality salt andhard water in washing off

- Use suitable soaping agent to washout unfixed hydrolyzed dyestuff -Use of soft water during washingoff

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Chapter-5

Finishing section

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Chapter-5

Finishing section

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Chapter-5

Finishing section

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5.1 Process Flow of Finishing Section:

The finishing section is divided into two lines and each line have own process flow:

Fabric unload

Finishing section

Open line Tube line

Slitting Dewatering

Stentering Drying

Compacting by open compactor Compacting by tube compactor

Inspection Inspection

Delivery Delivery

5.2 Machine Description of Finishing Section:

Machine Name Brand Origin QtySlitting Machine Bianco Italy 02

Dewatering Machine Bianco Italy 01Stenter Sun-Super Korea 02

BRUCNER Germany 01Open Compactor m/c Ferraro Italy 02Tube Compactor m/c Fab-con USA 01

Brushing m/c Kuang Taiwan 03Dryer M/C Dilmelner Turkey 01

Air Turning m/c Dong num Korea 03Bag Sewing m/c Hsing Chebg Taiwan 01

Total 17

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Fabric Slitting Machine:Machine Name: Slitting Machine for open Fabric.Brand name: BIANCOCountry of Origin: ItalyYear of Manufacturing: 2004Speed of Machine: Maximum 90m/minMachine Capacity: 10 Ton

Tubular Fabric Slitting Machine / Dewatering Machine:Machine Name: Dewatering Machine for Tube Fabric.Brand name: BIANCOCountry of Origin: ItalyYear of Manufacturing: 2006Speed of Machine: Maximum 80 m/minMachine Capacity: 8 Ton

Stenter Machine 1:Machine Name: Stentering machineMachine Type: SST-6GP (V1.1)Year of Manufacturing: 2004Brand Name: SUN SUPERSSpeed: 100 m/minCountry of Origin: SOUTH KOREAWidth Range: 2700 cmChamber of Flame: 06

Stenter Machine 2:Machine Name: Stentering machineType: VN-SFP-26/8-999Year of Manufacturing: 2009Brand Name: BRUCNERCountry of Origin: GERMANYWidth Range: 2800 cmChamber of Flame: 08

Tube Compacting Machine:Machine Name: Compacting machineMachine Type: SST-6GP(V1.1)Year of Manufacturing: 2006Brand Name: FABCONSpeed: 75 m/minCountry of Origin: U.S.A.Capacity of Machine: 10 Ton

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Open width Compacting Machine:Machine Name: Compacting machineYear of Manufacturing: 2006Brand Name: FERRAROSpeed: 80 m/minCountry of Origin: ItalyCapacity of Machine: 8 Ton

Dryer Machine:Machine Name: Dryer machineBrand Name: DILMENLERCountry of Origin: TurkiyeYear of Manufacturing: 2006Speed: 50 m/minCapacity: 12 TonPower Consumption: 139.25 KWWorking Width: 2400 mm

5.3 Process Description on Tube Line Finishing:

1. Dewatering

The removal process of excess water through squeezing by means of pressure(applied by twocylinders).

Function of the Machine: Use to remove excess water after pretreatment and dyeing Delivered fabric is crease free state It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism To impart soft finish to the fabric by using required softener.

Important Parts: Stretches (to control width) Over feeding wheels (to control GSM) De –watering device (to deliver the fabric roll in untwisted form) Folding device (to deliver the fabric in folded form) Squeezing roller Air injector to form balloon

Controlling Parameter: Overfeed Speed Padder pressure Stretch

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2. DryingDrying is defined as a process where the liquid portion of the solution is evaporated from thefabric.

Function of the machine in drying: To control GSM To control the shrinkage To prepare for next subsequent process To dry tubular fabric without tension

Important parts:- Over feed roller- Conveyor belt- Heating chamber(3)- Blower- Burner- Exhaust fan- Filter net- Folding device- Vibrator

Controlling Parameter:

Temperature: It depends on GSM and shade % of a fabric. Normally following temperature ismaintained depending on the shade%

- Dark shade: 140-170°C- Medium shade: 130-150°C- Light/ white shade: 110-130°C

2. Speed: Normally 6-18 m/min speed is maintained.

3. Overfeed (%): It depends on construction of fabric.

- Plain/single Jersey: 18-20%- Rib: 14-16%

Checking Parameter:

1. Shade checking: After running the machine the shade is checked with approved swatch atdelivery side.

2. Width checking: Required width is measured at delivery side.

3. GSM Checking

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3. CompactingCompacting is a method whereby the course loops are compressed upon themselves. The fabric

is steamed to add moisture and then introduced to the compacting zone. The compactionmechanism, along with heat and moisture, forces the length stitches(courses) to be compacted.

Function of compactor Shrinkage control GSM control Width control

Important parts Over feed control Steam sprayer Stretcher Cylinder Blanket Teflon covers

Controlling parameter1. Temperature2. Speed3. Blanket pressure4. Overfeed

5.4 Process Description on Open Line Finishing:

SlittingSlitting is a process that is applied for cutting the tubular fabric through the intended break walesline on length wise direction.

Function of slitting machine:1. De-twisting2. Extraction3. Slitting4. Opening5. Plaiting

Important parts: Squeezing roller (to remove water) Stretcher (to control width) Over feeding wheels(to control GSM) De-twisting device (to deliver the fabric roll in untwisted form) Plaiting device (to deliver the fabric in folded form)

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Controlling parameter: Pressure Speed

Checking parameter Cutting line check Faults check

Stentering Function: Drying Heat setting Width control Chemical finishing GSM control

Different parts/ zone at stenter frame:

1. Feed zone: fabric feeding.

2. Chemical padding zone: Here fabric is washed or padded with required chemical and excessmaterials are removed by squeezing.

3. Over feed roller: Depending on GSM over feeding or under feeding is given by over feedroller.

4. Selvedge detector: It detects the selvedge, prevent the curling and adjust the rail for propergripping of the fabric in the pin arrangement.

5. Brush roller: For attaching the fabric with the pin of the chain.

6. Drying zone: Each chamber of stenter contains two burners, two blowers, two ducting line,nozzle, and suction fan attached with suction line. The burner produces hot flue gases whichthrough the ducting line by the help of blower. There are nozzles placed above and below therail. When the fabric is passed through the rail then hot air is sprayed to the above and bellowsthe fabric with the help of nozzle. The hot air is circulating in the chamber and moisture of fabricwhich is evaporated ; leave the chamber with the help of suction fan through the ducting line.Temperature of each chamber can control automatically by controlling the intensity of burner.

7. Cooling zone

8. Delivery zone

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Controlling points:a) Temperatureb) Over feedc) Fabric width settingd) Speed

Compacting Function:1. Shrinkage control2. Width control3. GSM control

Important parts: Overfeed roller Blanket Steam sprayers Cylinder Teflon covers

Controlling parameter: Overfeeding Blanket pressure Steam pressure Temperature Speed

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Chapter-6

Quality assurance

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Chapter-6

Quality assurance

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Chapter-6

Quality assurance

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In textile industry; quality is assured in different stage of production. From the rawmaterials to the finished goods, quality is assured by the quality control department. Quality isassured in fiber selection, yarn production, fabric manufacturing, wet processing and apparelmanufacturing. Also, quality is checked for dyestuff and chemicals which is used in dyeing,printing and finishing. Most of the times, quality control department gives a quality passcertificate before export. In this section we have tried to provide activities of quality assurance atFakhruddin textile mill Ltd.

6.1 Quality Control

Quality control is a process to ensure quality product by following standard inspection andtesting system. At this case Fakhruddin Textile mill Ltd. maintain following standard to ensurequality product:

ISO standard AATCC standard M&S standard

The quality assurance system at Fakhruddin Textile mill Ltd. is maintained by two ways:1. Online Quality control2. Offline Quality control

Online Quality control:The functions of Online Quality control are:

a) Raw material control- Selection of materials and supplies- Maintaining proper specification of materials- Checking /Inspection of incoming materials

b) Process control- Proper controlling of process parameter I .e .time ,temperature ,speed, pressure, addition, ordischarge of dyes, chemicals liquors.- Checking /monitoring of process parameter.- Ensuring require quality at every process

c) Finished goods Inspection

The finished goods inspection is carried out through four point grading system.

Offline quality control:

Offline quality control generally comprises different tests of final product so that it is possible toidentify whether it pass against the norms given by buyer.

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The following test are generally done-

- GSM test- Shrinkage test- Spirality test- Shade check- Wash fastness test- Fastness to water- Perspiratipn test- Rubbing fastness test- Durability test- Dimensional stability

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Chapter-7

Lab-dip unit

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Chapter-7

Lab-dip unit

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Chapter-7

Lab-dip unit

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7.1. Function/Activities:

Color measurement, recipe formulation &correction by computer color matching system To carry out lab dyeing Maximization of “right-first- time” dyeing and minimization of re-dyeing, color addition/

topping.

7.2. Computerized Color Matching System:In case of color measurement, recipe formulation & correction Fakhruddin Textile mill Ltd.use following instrument and program:

SpectrophotometerSpecification:

Brand Name: Spectrophotometer SF600 CT PLUSMade by: Data color InstitutionWavelength range: 400-700 nmWavelength interval: 10 nmDual beam Light source: Pulsed xenon lamps

Functions:Measure the reflectance of colored sample in at least 16 wavelength in the visible spectralregion 400-700 nm.

The wavelengths are measured at 10 nm interval.

Uses: The reflectance value of a sample can be used to calculate the tri-stimulus values ofthat sample under the given illuminant.

Program

Data color software M & S standard software

Function:

Colorant recipe formulation and correction Color difference assessment in various light source Predict mesmerism ,cost , and fastness of each recipe Give the decision of pass/fail of a dyed sample by assessing color difference at tolerance

limit.

Personal computer All the CCM system is controlled & observed by this computer

PrinterIt give hard copy of formulated recipe , color difference , reflectance value /curve

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Lab dyeing process

In case of lab dyeing Fakhruddin Textile mills Ltd. have developed following programs depending onthe shade % and type of substrate which is always perform on 10 gm of sample.

Dyeing program for light shadeDyeing program for medium shade.Dyeing program for dark shade.Dyeing program for turquoise colorDyeing program for polyester.

7.1 Material Testing:

Fakhruddin Textile Mills Ltd. has well equipped quality control lab. There lab is recognize byMarks & Spencer. They follow Marks & Spencer testing procedure for testing fabric and rawmaterials. There are two types of materials are tested in Fakhruddin Textile Mills Ltd. laboratoryfor the purpose of quality control.

This are- A. Fabric testingB. Raw materials testing

A. Fabric testing:

To control the quality of the fabric two types of tests are mainly done-

1. Physical test2. Chemical test or color fastness test.

1. Physical test:

- G.S.M- Spirality test- Shrinkage test- Durability test- Level wash test- Garments durability test- Print durability test

2. Chemical test / color fastness test:- Color fastness to water- Color fastness to wash- Color fastness to rubbing- Color fastness to perspiration

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B. Raw material testing:

a. Water : pH & Hardness testb. Glauber’s salt : Purity testc. Acetic Acid : Strength testd. Caustic soda : Strength teste. Soda ash : Strength testf. Hydrogen per oxide : Strength test

7.4 List of the Test Performed in the Dyeing Laboratory:

Name of The Test Purpose MethodColor Fastness test to

WashTo check color fastness after

washing.ISO 105 C03

Color Fastness test toPerspiration

To check color fastnessagainst perspiration

ISO E04:1994

Color Fastness test toWater

To check color fastnessagainst hot and cold water

ISO E01:1991ISO E08

Color Fastness test toCrocking

To check color fastnessagainst rubbing

AATCC-08ISO-105 X12

Color Fastness test toLight

To check color fastnessagainst light

AATCC-16

Dimensional Stability To check the DimensionalStability after finishing.

AATCC-135/150

Torque To determine the Spirality AATCC-179Bursting To determine the bursting

strength of a finished fabricASTM-D3786

Pilling To determine the pillingproperty of a finished fabric

ASTM-D3512AATCC-18000

ISO-3000

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Color Fastness Test to Wash (ISO 105 C03):

Test Specimen:

1) Colored Sample:Type: FabricSize: 10cmx40cm

2) Multi-fiber Fabric:Type: DWSize: 10cmx4cm

Recipe:

Soap: 5g/L

Soda ash: 2g/L

Temperature: 600C

Time: 30 Minute

M:L :1:50

Color Fastness Test to Perspiration (ISO E04:1994):

Test Specimen:

1) Colored Sample:Type: Fabric, Size: 10cm x 4cm

2) Multi-fiber Fabric:Type: DW, Size: 10cm x 4cm

Recipe:

Chemicals ConditionsAcidic Alkaline

l-histadine monohydrochloridemonohydrate

0.5 gm 0.5 gm

NaCl 5 gm 5 gmDi-sodium hydrogenorthophosphate dehydrate

2.2 gm 2.5 gm

Distilled water 1000 ml 1000 mlpH 5.5 8.0

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Color Fastness Test To Water (ISO 105-E01:1991) Cold:

Test Specimen:

1) Colored Sample:Type: FabricSize: 10cm x 40cm

2) Multi-fiber Fabric:Type: DWSize: 10cm x 4cm

Recipe:

Immersion:

Distilled Water : 250ml

Temperature: Room Temperature

Time: 15Minute

Pressure: Pressure: 12.5 Kpa

Temperature: 370C

Time: 4 hours

Color Fastness Test To Water (ISO 105-E08) Hot:

Test Specimen:

1) Colored Sample:Type: FabricSize: 10cm x 4cm

2) Multi-fibre Fabric:Type: DWSize: 10cmx4cm

Recipe:

1) M:L : 1:50

2) pH: 6

3) Temperature: 68-720C

4) Time: 30 Minutes

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Color Fastness Test O Crocking (ISO 105 X 12):

Test Specimen:

1. Colored Sample:Type: FabricSize: 14cm x 5cm

2. Rubbing Cloth:Size: 5cm X 5cmProperties: Desized, scoured, bleached, mercerized but not finished.

Apparatus:I. Crock MeterManufacturer: James H. HealOrigin: England

II. Grey Scale for stainingGrey Scale for Shade Change

Spirality Test / Skewness Change In Fabric & Garments Twist ResultingFrom Automatic Home Laundering (AATCC-179):

PRINCIPLE: Change in skewness in fabric or twist in garment specimens resulting fromprocedures typical of home laundering practices is measured using benchmarks applied to thespecimens before laundering.

Apparatus & Materials Used:

1. Indelible ink marking pen2. Right triangle, L-square or marking template3. Tape or rule marked in mili-meters, tenths of an inch or similar increments.4. Conditioning or drying racks with pull-out screens or perforated shelves.5. Automatic washing machine.6. AATCC standard reference Detergent.7. Automatic tumble dryer.8. Facilities for drip drying & line drying.9. Digital imaging system.

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Chapter-8

Maintenance management

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Maintenance is a process by which equipment is looked after in such a way that troublefree. Services and increased machine life can be ensured and specific product quality required bythe customers is sustained. Machine, building & facilities are subjected to deterioration due totheir use & exposure to environmental condition. Process of deterioration, if unchecked,culminates in rendering these service facilities unserviceable & brings them to a standstill. Inindustry, therefore has no choice but to attend them from time to time to repair & reconditionthem so as to elongate their life to extent it is economically & physically possible to do so. It isin this in the context that maintenance assumes important as an engineering function. It is maderesponsible for provision of a condition of these machines, buildings & service that permituninterrupted implementation of plans requiring their use. Maintenance of machineries is veryimportant for any type of industries and it is a must for a knit composite mill. All machines andmachines parts of knitting, dyeing and garments are maintained with extreme care. Becauseproduction quality and quantity, both depends on the maintenance with regularity

8.1 Objectives of Maintenance:

1. To keep the factory plants, equipments, machine tools in an optimum working condition.2. To ensure specified accuracy to product and time schedule of delivery to customer.3. To keep the downtime of machines to the minimum thus to have control over the productionprogram.4. To keep the production cycle within the stipulated range.5. To modify the machine tools to meet the need for production.

Flowchart of maintenance:

Problem

Inform to maintenance department

Detect problem

Problem can be repairing or replacing

Repair can be solved immediately, replacing requires time (parts needed to buy & then solvedthe problem)

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8.2 Maintenance System:

Maintenance

Preventive Breakdown

Electrical Mechanical Electrical Mechanical

8.3 Maintenance Procedure of Different Machineries:

1. Dyeing machine

Maintenance: MechanicalItems need to be checked & Service

Grease the winch bearing. Complete cleaning of machine. Cleaning of drain valves, replace scale if required.

Checking air supply filters, regulators and auto drain scales Cleaning filter element and blow out. Greasing the unloading roller bearings. Checking oil level and bolts of unloading roller gear box. Checking of unloading roller couple and packing. Checking and cleaning of main vessel level indicator. Check the oil level of pump bearing and refill if required. Check the function of heat and cool modeling values. Check all belts and belt tension

1. Dewatering machine


Grease padder bearing & expender device unit by Staburg NBU Complete cleaning of m/c. Checking oil level and bolts of unloading roller gear box. Check oil level of hydraulic system. Check all belts, all chain and belt tension. Check gear box plotting and its oil. Check main line air pressure and air pressure gauge.

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Check pneumatic belts, brushes, if required tight them properly. Check in feed motor. Check squeeze roller hydraulic cylinder. Check turn table, belt tension, and gearing.

3. Dryer machine


Clean filter net of the machine. Clean hot air ducting of the machine Burner blower impeller cleaning. Complete cleaning of the m/c Greasing of all the bearing Conveyor net checking & repairing if required Inside chamber all fiber rail checking Exit conveyor checking properly & repair if required Plaiter checking

4.Tube compactor


Check & clean fluff & dirt at all motors fan covers. Clean panel’s vs cards & inverter by using compressed airs. Check photocell & adjust if required. Check all safety limit switches. Check all on/ off& emergency switches. Check all indicating lamp. Check steam solenoids. Check all circuit breakers, magnetic contractors & relays. Visual inspection of all control & power cables. Check all motor terminals. Check the potentiometer of main speed. Check temperature controllers of cylinder. Check compensator for speed synchronization of 1st and 2nd cylinder. Check carbon brash for 1st & 2nd cylinder heating system.

5. Bianco Slitting m/c

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Grease padder bearing (staburg NBU-12 energrease 1002) Complete cleaning of m/c Check turns table and grease with BP energrease LS-2 Check turn V –belt & adjust its tension if required Check all belts and chain tension Check oil level of turn table gear box Check basket roller drive ,gearbox ,and grease as required Check all roller rubber gripping tape Check alignment of all chains ,check tensions, and give oil if required Checking turn table Checking knife Checking all scroll rollers and its bearing

6. Stenter machine


Grease all bearing with stuburg NBU-12 energrease 1002 Complete cleaning of the machine Check all belt and belt tension Check all door silts Check gear box of platting and its oil Check all pin bars and clean Check chain and give oil if required Clean exhaust blower and duct All chamber blowers check and clean Chamber nozzle cleaning Check gas pressure , adjust if required

7. Open CompactorMaintenance: MechanicalItems need to be checked & Service

Check steam pressure and adjust it if required Complete cleaning of m/c Check steam and pneumatic pipeline for any leakage and service/repair if required Check the function of all pneumatic cylinders and service/repair if required Check all pneumatic solenoids

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Check all talons for visible damage , foreign particles and check its position Check all motors ,gearbox, roller and its bearing for any defect and grease the bearing Check all the belts for tension , visible damage and position on roller Check impellers of suction & exhaust blower for clogging with foreign particles and clean Check all chain and sprockets for alignment ,tension and lubrication Check the exit conveyor for smooth running and visible damage Check all belts and belt tension Check plaiter for smooth operation Check loading device Check steam trap

8. Boiler


Check and clean fluff & dart at all machine Feed pump servicing Main boiler servicing Check all temperature & pressure gauge meter Check gas strainer Clean gauge glass & change if required Clean feed tank Clean fire tube Clean all safety values Check all steam values (ball value, glove value, pneumatic value etc.) Check all gas regulator Auto blow down operation check

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Chapter-9

Utility services

As Fakhruddin Textile Mills Ltd. is large manufacturing unit obviously it has some utilityservice. The available utilities are:

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Chapter-9

Utility services


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Chapter-9

Utility services


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a. Water

b. Steam

c. Electricity

d. Compressed air

e. Gas

Water :

Source of water is land water which is pumped by deep tube well.

Water treatment plant: Small, medium, & big size industries use treated water to differentmachine like boiler, dyeing, washing machine. They collect this water from land by deep tubewell. But raw water content different types of foreign materials like oil or gummy substances.Iron ,Copper, Manganese & their salt, etc. The hardness of raw water is 100 ppm or more. To useit in dyeing and in boiler this water needs to be softened & foreign materials needs to beremoved. Otherwise this may create problem in processing like precipitation of soap, redepositon fabric & scale formation on pipe line etc. There is no WTP at Fakhruddin Textile Mills Ltd.Supply water is used there for every process as the hardness of water is very low.

Steam:

Steam is produced by boiler .From the Water Treatment Plant, water is stored ina reserve tank and from there water goes to boiler & steam is produce.

Speciation of Boiler:

Boiler No: 01

Serial 23/3599Brand Name CochranType Fire tube boilerCountry of Origin UKYear of Manufacturing 2006Maximum Allowable Pressure 11 barMaximum Allowable Temperature 188 0 cHydraulic test date 28-04-04Maximum Heat output 2820 KWSafety Value set Pressure 10.9 barHydraulic test pressure 16.50 bar

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Boiler No.: 02

Serial 23/4171Brand Name CochranType Fire tube boilerCountry of Origin UKYear of Manufacturing 2006Maximum Allowable Pressure 11 barMaximum Allowable Temp. 188 0 cHydraulic test date 26-06-06Maximum Heat output 2820 KWSafety Value set Pressure 10.9 barHydraulic test pressure 16.50 bar

Source of electricity:1.Gas generator2.Diesel generator

Generator specification:

M/c No: 01

Model MTG 846Serial BZ5L 4895

Brand Name LS2000Origin USAType Gas generatorManufacturing date 2004KVA prime 200KWKVA prime 250KVAPower factor 0.8Volts 415AMPS 1304Frequency 50 HzRPM 1000Phase 3Temp Rise 105ocMaximum Ambient Temp 40oc

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M/c No: 02

Model G3516BSerial SWNO 2962

Brand Name CATOrigin U.KType Gas generatorManufacturing date 2004KVA prime 1145KWKVA prime 1431KVAPower factor 0.8Volts 400AMPS 2066Frequency 50 HzRPM 1500Phase 3Temp Rise 105ocMaximum Ambient Temp 40oc

M/c No: 03

Model GEH 275-2Serial OLY PMPN O2584

Brand Name OLYMPIANOrigin U.KType Diesel generatorManufacturing date 2009KVA prime 250KWKVA prime 200KVAPower factor 0.8Volts 415AMPS 2066Frequency 50 HzRPM 1500Phase 3Temp Rise 105ocMaximum Ambient Temp 40oc

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Chapter-10

Inventory management

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Chapter-10


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Chapter-10


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Inventory is stock or store of good. Inventory management is a vital part for any factorybecause smooth production as well as cost of storage depends on it.

10.1 Scope of Inventory Control:

- Raw materials inventories

- In process inventories Finish good inventories

- Maintenance, repair and operational inventories

- Miscellaneous inventories

10.2 Function of Inventory:

- To smooth production requirement

- To meet anticipate demand

- To protect against stock outs

- To take advantages of order cycles

- To take advantages of quality discounts

10.3 Inventory Store System for Raw Material:

In Fakhruddin Textile Mills Ltd. there is different inventory systems for different rawmaterials.

Grey Fabric Store:

All the grey fabrics are stored in the fabric store near the batch section. Different types of fabricare listed in the sheet according to fabric types, quantity and consumer's requirement.

Dyes and Chemicals store:

There is a different store for dyes and chemicals. Varies types of dyes and chemicals are storedhere according to dyes and chemicals companies. Different types of dyes and chemicals arelisted in a sheet. In the sheet the stored quantity of dyes and chemicals are also included. Everyday the sheet is updated and a copy of this sheet is supplied to the dyeing manager, dye houseand lab section.

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Finished goods store:

In Fakhruddin Textile Mills Ltd. supplies its finished dyed fabrics to its garments section. So,dyed finished fabrics are stored for short time in the finished fabric store section. All thedelivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter,buyer's name, Color & considering other technical parameters.

Spares part store:

In Fakhruddin Textile Mills Ltd. required amount of spears of different machines arestored in the mechanical store room. All the spears are listed in a sheet which is controlled by themechanical & maintenance personnel. Spares are arranged in the store room according to theirsize, quantity & requirements. There are shelves in the store room to keep the small spare parts.

Store capacity:

Items AmountDyes 10- 15 tons

Chemicals 40-50 tonsYarn storage 60 tonsGrey fabric 140 tons

Frequency of Inventory control:

Daily inventory control Monthly inventory control - Yearly inventory control

Re-order point:

The re order point is stated in terms of level of inventory at which an order should be placed forreplenishing the current stock of inventory. Re order quantity depends on the lead time of theproduct with some additional safety period. It also depends on the store capacity of factory. Forexample if the lead time of a product is two month then normally re ordering quantity may be fortwo and half months.

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Chapter-11

Marketing

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Chapter-11

Marketing

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Chapter-11

Marketing

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In an uncertain world market Fakhruddin Textile Mills Ltd. doubled their effortswith our design team leading the way; they increased their calls as the customers & looked forways to add new ones also. Having established a strong relationship with Buyer and becomingone of their core suppliers, Fakhruddin Textile Mills Ltd. targeted Europe & USA also andmade inroads there. Fakhruddin Textile Mills Ltd. added new and dynamic designers to theexisting team & can proudly say that their spring and autumn collections were hailed as some ofthe best to be presented. These meetings boosted the confidence of existing buyers and attractednew customers. Fakhruddin Textile Mills Ltd. continued with their strategy to market valueadded products like dyed fabrics with special finishes. This is reflected in the increase in averageprice per linear meter.

11.1 Product & Customer:

As it is an apparels manufacturing industry, its main product are fashion T-shirts, Poloshirts, knitted shorts, Leggings, Nightwear and school wear, Trousers, Fleece Jacket, Vest.Ladies dresses etc. The factory ensures safe/metal free garments as per customer requirements,through practice of metal detection & needle/metal control procedures. All kinds of S/J, Rib,Interlock, Pique ,French Terry, Brushed Fleece, Dobby Pique, Drop Needle etc of:

100% Cotton & Different blend of Cotton and Polyester. 95% Cotton, 5% Lycra. 100% Organic Cotton. Blend of Organic and normal Cotton. 100% Modal. T/C & CVC

Special Fabrics: Category Mix:

• Coolmax. > Men's -25%

• Soil / Stain Release. > Ladies -45%

• Water Repellent. > Children -20%

• Silver Finish (Anti Bacterial) > Infant -10%

• UV Finish.

• Viscose- Elastane

• Polyamide- Elastane

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BUYER NAME:

TritonAuchanS.oliverTescoV-texHoly promLa redouteVertH & MEllosSonnetLidl GermanyBrylante USAKiabiRegatta UKAvenue USAM & S

11.2 Exporting Countries:

The major countries where Fakhruddin Textile Mills Ltd Export their goods are given below:

Germany Spain Denmark Europe USA

11.3 Buyers Compliance:

The factory is full compliance with ILO and Bangladesh Labour Law. Their companypolicy is as follows:

No child labour. No forced labour. Transport facilities for worker. Hours of work. Voluntary over time. Intervals for rest. Weekly holidays. Annual leave. Festival holidays & leaves with bonus. Maternity protection. Worker's welfare committee.

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Mineral drinking water. Sanitary facilities. First aid box. Canteen services. Day care centre. Health care activities for the worker & employ company doctor. Fire extinguisher each & every floor & conduct fire drill at least 12 times a year. We are

giving a top priority on prevention of fire and eventual evacuation. Other safety department (no discrimination). Compensation cases department. The development of compliance programmer. Environmental developer. Smoking free zone.

11.4. Marketing Strategy:

Marketing strategy is a very important factors to sale the products to the buyer. If themarketing strategy is not so developed , it will be very hard to reach the goal . In case ofgarments marketing the dealings with the buyer is a very important factor.In Fakhruddin Textile Mills Ltd. mainly senior marketing officers, merchandiser & higherofficials deal with the buyer. There are some fixed buyers of the industry. The buyers give theirorders continuously all over the year. The marketing officers & the merchandisers communicatewith the buying houses to collect the orders. By both side understanding the rate & the orderquantity are fixed.

11.5. Duties & Responsibilities of Marketing Officer:

Dealing with the buyer & convince the buyer is the main duty of the marketing officer. Amarketing officer also has some other duties. The main duties & responsibilities of a marketingofficer are given below:

To prepare cost sheet by dealing with the buyer . To take different steps by discussing with the higher officials & merchandisers To maintain a regular & good relationship between commercial officer & merchandisers To maintain a regular communication with the buyers & buying houses . Communicate with the new buyers. Display the better criteria of the products.

Actually the responsibilities & duties of marketing officer begins from getting order of buyer &ends after receiving goods by the buyer . So he should be always smart, energetic & sincere tohis duties.

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11.6 Marketing Information:

The declining retail sales and the losses shows by big retailers worldwide andconsequent drop in order in the world wide garment industry proved to be a major challenge toour marketing efforts and strategy. In an uncertain world market, Fakhruddin Textile Mills Ltd.doubled their efforts with our design team leading the way; they increased their calls as thecustomers & looked for ways to add new ones also. Having established a strong relationship withBuyer and becoming one of their core suppliers, Fakhruddin Textile Mills Ltd. targeted Europe& USA also and made inroads there. It. added new and dynamic designers to the existing team &can proudly say that their spring and autumn collections were hailed as some of the best to bepresented. These meetings boosted the confidence of existing buyers and attracted newcustomers. Fakhruddin Textile Mills Ltd. continued with their strategy to market value addedproducts like dyed fabrics with special finishes. This is reflected in the increase in average priceper linear meter.

Remarks:

Fakhruddin Textile Mills Ltd. has a well learned marketing & merchandising team. Theyalways communicate with the buyers. This has some fixed buyers. The marketing section alsolooks for the quality and quantity buyers.

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Chapter-12

Environmental information

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12.1 Environment Management System of Fakhruddin Textile Mills Ltd:

Fakhruddin Textile Mills Ltd. recognizes that its activities impact upon theenvironment through its routine internal operations, its infrastructural development and throughits influence and effects on the wider community. It acknowledges a responsibility for andcommitment to, protection to the environment at all levels and try to minimize the potentiallyharmful effects of such activity wherever and whenever possible. They comply fully withenvironmental legislation application in garments industry. As part of their continuing drive forquality in all things they therefore develop a comprehensive policy system which will enablethem to set a target which will enable them to measure and monitor their efforts on sustainableenvironmental improvement on regular basis. Sources of environmental hazard in the factorycomplex:

Wastages of fabric and accessories and other storage. Electrical wastage and other storage. Empty chemical container. Effluent (Factory waste water).

12.2 Fabric and Accessories Wastage Management System:

Wastage baskets are placed in the production floor. During the working hour cleanersand loaders keep the floor wastage in the basket. Once the basket is about to be full loader carryall the wastage to waste designed area which is 100 yards out side of the main factory building.When 80% of waste stores filled up, then the waste is sold to the customer.

12.3 Electrical and Mechanical Wastage Management System:

Electrical wastage will be stored in the designed area of the factory complex andmaintenance department disposed of the wastage by burning or selling.

12.4 Empty Chemical / Dye Container Management System:

Empty chemical containers are stored in designed chemical wastage area and sold tooutside people or disposed of by burning in the desire area on weekly basis.

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Chapter-13

Effluent treatment plant

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Chapter-13


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Chapter-13


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Effluent means liquid waste from the wet processing industry. Dyeing, printing andfinishing- industries produce a large amount of liquid waste.

The characteristics of effluent are summarized as follows-

1. pH and alkalinity.

2. Suspended solids (SS).

3. Dissolved solids (DS).

4. Total solids (TS).

5. AOX (Adsorbable organic halogen).

6. BOD (Biological oxygen demand).

7. COD (Chemical oxygen demand).

8. Color

9. Metal ion.

Effluent Parameters (Bangladesh Standard):

Flow Rate 30 m3/hrpH 7-8

BOD < 50 PPMCOD <250 PPMTSS <100 PPMTDS <2000 PPM

Oil & Grease <10 PPMColor Clean

Temperature <300C

Types of effluent treatment plant:

1. Physico-chemical treatment plant.

2. Biological treatment plant.

3. Physico- chamical- biological treatment plant.

In ETP of FTML biological treatment plant is used.

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Machine Used In ETP Plant:

1. Equalization tank (where air supplied through a blower)

2. ECR (Electro contaminant removal)

3. Flash mixer tank

4. Flocculation tank

5. Tube settler 1

6. FAP 1

7. pH control tank

Capacity of ECR:

There are two ECR in this plant. Capacity of each ECR is 60 m3/hr.

Flowchart for ETP:

Drainage water (after dyeing)

Equalization tank (where air is inserted through a blower which makes oxygen)

(Pumping)

ECR (Electro contaminant removal)

Flash mixer tank

Flocculation tank (where polymer is added which worked to thicker the sludge which isproduced due to waste)

Tube settler 1(Here several tube is present for keep the sludge below the liquor)

FAP 1(Where air is added to produce O2)

pH control tank(where HCl is used & kept pH 7)→Discharge Water

Aeration Tank

Clarifier Tank→ Treated Effluent

Excess sludge recycle tank

Dispose/Brick fire

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Chemical Used:

1. Polymer (Electrolyte)

2. HCl (to keep pH at 6-8)

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Conclusion

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Industrial training is an essential part for textile education because it minimizes the gapbetween theoretical and practical knowledge. Undoubtedly, this industrial training helped us a lotabout textile technology, production process, machineries, and industrial management and madeus comfortable with industrial life. Besides it give us the first opportunity to work in industry.During our two month industrial training at Fakhruddin Textile Mills Ltd. we have got theimpression that this factory is a modern export oriented knit composite industry. Though it wasestablished 5 years ago, it has achieved a very good reputation in foreign market for its bestquality product over many other export oriented textile mills by establishing on-line and off-linequality control system of each product. They have well equipped and modern textile testinglaboratory. They do all the chemical & physical tests of dyed good and the results are very goodand within the buyer’s acceptance limit. During our training period we have rarely saw manyfaulty dyeing. If there was any problem it was quickly removed with the help of experienced andskilled manpower. During this period we have never seen any stripping of color from fabric.Moreover they use good quality yarn, dyes, and chemicals in production. The administration &management are well organized. In our training period, talking with the clients of this mill weknew that the mill is fulfilling the country’s best export oriented white finished fabric as well asvery good colored fabric due to its modern machinery & good management system. Mill issettled with utility to give all convenient supports to the productions for twenty-four hours. Weare enough fortunate that we have got an opportunity of having a training in this mill. During thetraining period we are received co-operation and association from the authority & found all man,machines & materials on appreciable working condition. All stuffs & officers were very sincere& devoted their duties to achieve their goal.

industrial attachment of fakhruddin textile mills limited

Engineering