presentation of square knit fabrics ltd. by milon,mamun,plabon supervising teacher kazi sowrov

Welcome To Our Presentation on Industrial Attachment

At

Square knit fabrics ltd. (From 1st June to 30th July,2013)

Supervising TeacherKAZI SOWROV

Lecturer,Department of Fabric Manufacturing Engineering

Submitted By:

BANLADESH UNIVERSITY OF TEXTILESTEJGAON, DHAKA-1208Department of Fabric Manufacturing Engineering

SKFL AT A GLANCE

Factory:JAMIRDIAVALUKA,MYMENSING

Corporate Office: Mascot Plaza,(11th-12th Floor), Plot # 107/A,Sector # 7, SonargaonJanapath, Uttara Model TownUttara,Dhaka-1230,Bangladesh.

Location of SQUARE from BUTex Source- Google map

Location of square knit fabrics ltd.(SKFL)

YARN STORE DEPARTMENT YARN DYEING DEPARTMENT KNITTING DEPARTMENT PHYSICAL AND CHEMICAL LAB DYEING DEPARTMENT FINISHING DEPARTMENT QUALITY CONTROL

DEPARTMENT R & D (RESEARCH &

DEVELOPMENT)

• Finance & Accounting • H R D • Utility• Security• Administration• Marketing & Merchandising

DEPARTMENTS OF SKFL

Supporting Departments

Different utilities

1. Gas generator2. Boiler3. Air compressor4. Chiller 5. ETP (Effluent Treatment Plant) 6. CRP (Caustic Recovery Plant)7. Rain water collection8. Kitchen waste recycling Products

Knitted grey fabricYarn dyed (non mercerised) knitted fabricYarn dyed (mercerised) knitted fabricKnit Garments

AN OVERVIEW OF MACHINE

DAILY PRODUCTION CAPACITY

Section Prod/Day

Dyeing 24 ton

Yarn Dyeing 7 ton

Knitting 18-20 ton

Section No of Machine

Knitting 66

Dyeing 18

Yarn Dyeing 10

Lab & QC 35

Achievements

SQUARE Fashions Limited received Best Labor Friendly

Organization award by BKMEA, May 2009

SQUARE KNIT FABRICS LIMITED(SKFL) earned National Award for “National Environment Certificate” 2009

Receiving award from the prime minister SHEIKH HASINA

• Oeko tex standard 100 certified• Iso 9001:2008 certified

Manpower Organogram of SKFL

G.M ↓

D.G.M ↓

A.G.M ↓

Sr. Manager ↓

Manager ↓

Department Manager ↓

Asst. Manager ↓

Sr. Executive 1 ↓

Sr. Executive 2 ↓

Executive 1 ↓

Executive 2 ↓

Executive 3 ↓

Production Officer ↓

Asst. Production Officer ↓

Supervisor

Chairman Managing Director Executive Director

GENERAL SHIFT - 08:00AM – 05:00PM General Shift is provided only for General manager/ Assistant General Manager/Sr.Manager/Sr. ExecutiveShift changes after a week

SHIFT CHANGE

Section Wise Worker Distribution of SKFLSection No of Worker

Fabric Dyeing 75

Yarn Dyeing 30

Knitting 115

Finishing 60

Quality 75

Physical Lab 30

Chemical Lab 15

R&D 20

HR & Admin 25

Others 35

Total Worker & Stuff 750

SHIFT FROM TO

A 6 am 2 pm

B 2 pm 10 pm

C 10 pm 6 am

MACHINE DESCRIPTION

KNITTING MACHINERIES

The entire machines in the knitting floor are divided into 3 sections. These are following:

1. Circular knitting section2. Flat knitting section

Machines at a Glance

M/C Type No. of M/C

Circular

S/J 12

Fleece 3

E-Stripe 14

S/J jacquard 4

Rib 7

S/J Semi jacquard 3

Interlock 4

Flat 19

Total 66

GIRCULAR KNITTING FLOOR

4 53 9

3 4

3 83 3

3 73 2

4 03 53 6

4 14 7 4 6 4 24 4 4 3

2 7 2 6

1 8 1 7

9 8

2 51 6

2 41 5

2 31 4

7 6 5

2 21 3

4

2 11 2

3

2 01 1

2

1 91 0

1

3 1 3 0 2 9 2 8Q

CQ

C

Air

Com

pres

sor

Offi

ce

Layout Plan Circular Knitting section (SKFL)

layout

2 6543

15 19181716

7 1098

11 141312

1

Stock

Office

Layout Plan Flat Bed Knitting Section

layout

Flat knitting floor

Specification of Flat Knitting M/C

Full jacquard Semi jacquard

M/C Type Brand Gauge Bed Length No.of Needle No. of M/c Origin

Semi Jacquard Stoll 14 84" 1176 8 German

Semi Jacquard Shima Seiki 14 60" 840 9 Japan

Full Jacquard Shima Seiki 14 80" 1120 2 Japan

total 19

Specification of Circular Knitting M/C

M/C

No.

Brand Model Dia Gauge Origin No. of

Feeder

01 Mayer &Cie Relanit 3.2 ll 30’’ 24 Germany 96



04 Mayer &Cie MV4 3.2 30’’ 24 Germany 90

05 PAI LUNG PL-XS3B/C 30” 20 Taiwan 90



08 Mayer &Cie Relanit 1.6 R 30” 24 Germany 48


10 Mayer &Cie Relanit 4.0 36” 24 Germany 144



13 Mayer &Cie Relanit 3.2 ll 26” 24 Germany 84



16 Mayer &Cie Relanit 1.6 ER 30” 24 Germany 48



19 Mayer &Cie Relanit 3.2 ll 30” 24 Germany 96

20 Mayer &Cie Relanit SE 30” 22 Germany 72

MAYER & CIE S/J Circular Knitting M/C

.

PAILUNG S/J Circular Knitting M/C

m

Fleece Circular Knitting M/C E-stripeCircular Knitting M/C

Different circular knitting m/c

Rib Circular Knitting M/C (Mayer & Cie) Interlock Circular knitting m/c (Mayer &Cie)

Open Width M/C:For producing open width S/J fabric it is

used.

Dia*Gauge: 38*24

Brand: Mayer & Cie

Origin: Germany

Maximum Dia M/C:For required or large double jersey fabric width there the maximum dia rib m/c we have seen.

Dia*Gauge: 44*18

Brand: PAILUNG

Origin: TAIWAN

Different circular knitting m/c

Inspection machine

Raw material

m

Cotton yarn Carded yarn Combed yarn Compact yarn Organic cottonViscose Yarn Modal yarn Mélange yarn Ecru MélangeSynthetic Polyester Nylon Acrylic ElastomericBlend PC Mélange CVC

Brand and count and their origin used by SKFL

Count Brand Origin Type

10/s16/s20/s22/s24/s

26/s 28/s30/s32/s40/s50/s60/s

kamalSquarePrime

PahartoliMarkupThermex

AkbarMaksonsviellatex

Bangladesh

CottonPolyester

CVCViscose

Mélange

10/s16/s20/s22/s24/s26/s28/s30/s32/s40/s50/s60/s

Rajasthan

Bardhaman

Supper

India

CottonPolyester

CVCViscose

Melange

75/s

150/s200/s

PT Indoroma Indonesia

CottonPolyester

CVCViscose

Mélange

20D40D70D

Creora (spandex) China

Lycra

Research and development ( R & D)

Parts of v bed flat knitting m/c

Side tensioner

cam

Full jacquard m/c

Important Components of Circular Knitting M/C

m

.

Standing CreelPositive Feeder

NeedleCam

Important Components of Circular Knitting m/c

m

.

Yarn Guide Cylinder

m

VDQ Pulley Fabric Spreader

Important Accessories of Circular Knitting M/C

m

1. Start, Stop & inching Button2. Auto Stop Motion3. Sensors & Detectors4. Auto Counter5. Fabric Take up Mechanism6. Safety Guard Hatch7. Auto Lubrication8. Auto Fly Removing System9. Air Hose10.Nozzle(air & oil)

Auto stop motion List in knitting machine

In Case of Gate open. Yarn breakage. Fabric cut & fell down. Needle breakage. Oil & air pressure problem. Completion of selected target.Take up problem.

Gearing Diagram of Power Transmission of a Knitting m/c

m

.

Motor & motor pulley

Electronic Jacquard

m

.Fully electronic jacquard with for fast fashions.It is fully computerizedSoftware program is given as input in m/c according to fabric design by using laptop.New patterns are transferred to the machine by the electronic control system in a matter of secondsThe electronic individual needle selection produces reliably without pattern errorsNeedle , jack & vertical sinkers are used here.

Parts Of Electronic Jacquard

GSM & GSM Control

m

GSM is a technical term that indicates the weight of the fabric per square meter GSM is a buyer’s requirement; hence GSM control is very important. In older m/c s is controlled by VDQ pulley. By rotating the upper disk in positive. Direction will reduce the pulley diameter and GSM will increase. Pulley diameter Stitch length GSM Pulley diameter Stitch length GSM In modern m/c GSM is controlled automatically by the help of variable rpm motor and relanit technology.

GSM & GSM Control

Relanit Technology

The technology of using vertical sinker in circular knitting m/c.

GSM can also be controlled directly by this sinker.

Reduce the possibility of sinker mark.

Reduce yarn tension during knitting

Types of stripe produced

Feeder stripe: - In this, stripe effect is produced by

using different color yarns in different feeder in an

orderly manner according to repeat.

Engineering stripe: - In this, stripe effect is produced

by gradually adding different colored yarn in each

feeding position according to repeat with the help of a

device called ‘finger mechanism’.

E-Stripe Circular Knitting M/C

Producing Feeder Stripe

m

Red = 5 courseGreen = 3 courseBlack = 2 course__________________________

Total = 10 courseWhile producing this fabric in a 54 feeder m/c active feeder would be = 10x5 =50 The rest 4 feeder will be needle drop or, all miss cam.Yarn arrangement would be, Feeder (1-4) = miss Feeder (5-9) = Red Feeder (10-12) = Green Repeat Feeder (13-14) = Black Feeder (15-19) = Red Feeder (20-22) = Green Feeder (23-24) = Black. And so on.

Program for E-Stripe

Red = 10 courseGreen = 5 courseRed = 5 courseWhite = 5 coursePink = 10 courseWhite = 5 courseRed = 5 course

Finger1 = Red, Finger2 =Green, Finger3 =White, Finger4 =Pink

Then Program will be: Finger1 1-10 Finger2 11-15 Finger1 16-20 Finger3 21-25 Finger4 26-35 Finger3 36-40 Finger1 41-45

The mostly produced single jersey derivatives are 1. Plain single jersey2. Single Lacoste3. Double Lacoste4. Polo pique.The mostly produced double jersey derivatives are5. 1 x 1 rib6. 2 x 2 rib7. Interlock

KNITTED FABRIC ANALYSIS

SINGLE JERSEY PLAIN

x x x x

x x x x

NOTATION DIAGRAM

Back Side K= Knit cam

CAM ARRANGEMENT

1 12 2

NEEDLE ARRANGEMENT

1= Position 1 butt2= Position 2 butt

o o o o

o o o o

Face Side

SINGLE LACOSTE FABRIC

NOTATION DIAGRAM

= Knit cam= Tuck cam

CAM ARRANGEMENT

1 12 2

NEEDLE ARRANGEMENT


DOUBLE LACOSTE FABRIC

NOTATION DIAGRAM

= Knit cam= Tuck cam

CAM ARRANGEMENT

1 12 2

NEEDLE ARRANGEMENT


1 x 1 RIB FABRIC

NOTATION DIAGRAM

= Knit cam

CAM ARRANGEMENT

1 12 2

NEEDLE ARRANGEMENT


Dial

Cylinder

2 21 1

Dial

Cylinder

2 x 2 RIB FABRIC

NOTATION DIAGRAM

= Knit cam

CAM ARRANGEMENT NEEDLE ARRANGEMENT


Dial

Cylinder

Dial

Cylinder

1 1

2 2

2 2

1 1

INTERLOCK FABRIC

NOTATION DIAGRAM

= Knit cam= Miss Cam

CAM ARRANGEMENTNEEDLE ARRANGEMENT

S= Short butt needleL= Long butt needle

Dial

Cylinder

L L L

S S S

S S S

L L L

Face Back

Face Back

SINGLE JERSEY (JACQUARD)SOME OTHER FABRICS PRODUCED IN SKFL

SINGLE JERSEY (JACQUARD)

Face Back

Back Face

Face BackMOOR SWEAT (3 Thread Fleece)

WAFFLE RIB

Products of v bed m/c

stripe

Sweater partTwo part

Stripe two npart

Knitting Parameter

m

.Machine diameter.Machine gauge.Number of feeds or feeder in use.Machine RPM.Count of yarn.M/C running time.Running efficiency.

PRODUCTION CALCULATION

m

Production per shift of 8 hours in kg

Efficiency

2.2046countYarn 840 36 2.54 10

8 60 SL(mm) Needle of No. Feeder of No. RPM

EfficiencyGaugeDia

2.2046countYarn 840362.5410

8 60 SL(mm) Feeder of No. RPM

FABRIC GSM CALCULATION

msqgmGSM ./100

Tex length(mm)Stitch cmper Wales cmper Course

msqgm ./9158.0Ne

length(mm)Stitch WPI CPI

Fibre dyeing

YARN MERCERIZINGAND HANK DYEING

Hank dyeingYarn mercerizing m/c

Lab (physical & chemical)

Physical lab

Chemical labHumidity controller

• SLUB : 1 POINT• ANY HOLE : 4 POINT• NEEDLE/SINKER LINE : 4 POINT• NEEDLE BREAKAGE : 4 POINT• PRESS OF : 4 POINT

THICK, THIN, DIRT, OIL SPOT, CONTAMINATION:• Up to 3’’ in length: 1 Pt• 3” to 6’’ in length: 2 Pt• 6” to 9’’ in length: 3 Pt• Above 9’’ in length: 4 Pt

Cut fabric role

Carried to Inspection machine

Inspect Fabric Fault

Specified on the basis of 4-Points system

Quality assurance procedure

QUALITY Pts. per 100 square meter = (Total point x GSM) / (Roll weight x 10)

<40 Pts 41-60 61-80 Above 80

A Class B Class C Class RejectedQUALITY CLASSIFICATION

Causes & Remedies of Knitting Fault

m

.

1.Hole Causes: Take up in improper tension Remedies: Adjusting proper take up tension

2.Knot: Causes: After thread breakage or bobbin end,

Twisting to join thread ends; therefore Hand dust get incorporated with yarn.

Remedies: Knotting should be done in proper way.


m

.3.Dirty SpotCauses: Externally incorporated dirt, lint, grease etc . Remedies: By keeping the work place and m/c clean.

4.Sinker Mark: Causes: Due to sinker decayed.Remedies: Change the sinker.


m

.

5.Lycara OutCauses: If lycra yarn missed or breakage happened. Remedies: Operator should be more cautious to make

necessary adjustment or replacement or joining the lycra yarn.

6.Oil Spot: Causes: Excessive supply of oil at different friction

point. Remedies: Proper lubrication system is must.

MAINTENANCE

Routine

Activities per shift

Hammer

Adjustable wrench

L-key

FUNCTION OF TOOLS Maintenance tools Functions

1. Adjustable wrench Used for setting nut & bolts

2. Air suctioner For cleaning machine

3.Spanner Fixed Spanner for nut & bolts fitting

4.Socket spanner Handle system for nut & bolt fitting

5. hammer To apply load where required

6. Screw driver To release any screw

7. Punch Used to fit any worn out shaft

8. Lock opener To open the clip of bearing

9. Hack saw To cut any metallic thing

10. Outside calipers To measure outside dia

11. Inside calipers To measure inside dia

12. Cutting pliers To cut thin wires

13. Pulley key To loosen pulleys

14. Chain ton To lift heavy load

15. Welding machine To join metallic parts

16. Grinding machine To make the smooth fabrics

17. Tester To test electric circuit

18. Pliers To grip anything & cut anything

19. Star driver Screw unlocking

22. L-key For loosen & tighten the screw

Utility Service

Different Utilities

1. Gas generator

2. Boiler

3. Air compressor

4. Chiller

5. ETP (Effluent Treatment Plant)

6. CRP (Caustic Recovery Plant)

7. Rain water collection

8. Kitchen waste recycling

Electrical control unit

m

.

SOURCE OF UTILITY

1. Water- Own supply (Pump)

2. Steam- Own supply (Boiler)

3. Electricity- Generator & PDB

4. Gas- Titas Gas Transmission & Distribution Co. Ltd.

5. Compressed air- Own supply (Air compressor)

• Raw water hardness: 18-20 (Generally 30 ppm)• Boiler water hardness: 0 • M/c used: Water conditioner • Submergible pump : 2 (For SKFL) & 1 (Dormitories)• Process water: 200m3/hr and 150 m3/hr• Domestic use: 150 m3/hr• Company: Cleaver Brooks • Country of origin: USA. • Water consumption: 4500-5000m3/day• Water pressure: 6-6.5 ba

•Boiler Steam: 10.2 tons/hr. & 2.3 tons/hr. •Steam pressure: 7.5-8 bar•Steam temp: 150-160 C •M/c used: Fire tube type Gas Boiler & Exhaust Gas Boiler•Piece: 02 (Fire tube type Gas Boiler) & 01 (Exhaust Gas Boiler).•Capacity: 10.2 tons/hr. & 2.3 tons/hr.

Steam

Fig: Fire tube type gas boiler

Water Conditioner

• Supply: Titas Gas Transmission & Distribution Co. Ltd.• M/c used: Electricity Gas Generator• Brand: Cater Pillar• Origin: USA• Piece: 05• Total Capacity: 5.6 MW (1 MW+1 MW+1 MW +1 MW+1.6

M• There is an emergency standby of power supply run by

disel

Power Supply

Electricity Gas Generator Cooling Tower

Use in: Generator Country of origin: Thailand Piece: 12

Cooling Tower

Air Compressor

No.of Air compressor: 07 Brand: BOGE (No. of machine 6) Brand: ROLL AIR (No. of machine 1). Country of origin: Germany Capacity: 6 m3 /hr.

Chiller

Hot water chiller Vapour absorbent chiller

Vapour compression chiller (Centrifugal Chiller)

Flue gas with steam absorption Chiller (Dual core chiller)

Brand: Prochill Thermax Brand: Prochill Thermax Brand: Mc Quay Brand: Shuang Liang

Capacity: 400 rt/hr. Capacity: 400 rt/hr. Capacity: 400 rt/hr Capacity: 661 rt/hr.

Origin: India Origin: India Origin: USA Origin: China

ETP( Effluent Treatment Plant)

Biological ETP

pH meter

Treated water

Mixing tank

ETP 1

Treatment process Biological

Treatment capacity 1200 m3 per day

Tank capacity

1 Collection sump 4 X 4 X 2.89 m3 = 46.16 m3

2 Homogenous tank 13.6 X 18 X 5 m3 = 1148 m3

3 Neutralisation tank 1.9 X 3.1 X 5 m3 = 29.45 m3

4 Distribution tank 3 X 3.1 X 5 m3 = 46.5 m3

5 Oxidation tank 27.3 X 18 X 5 m3 = 2457 m3

6 Clarifier tank 3.14 X (15/2)2 X 2.45 m3 = 432m3

7 Slug return tank 0.5 X 2.5 X 3.1 X 4 m3 = 15.5 m3

8 Slug thickener 4.5 X 3.1 X 4 m3 = 55.8 m3

9 Chemical dosing tank 1 m3 (3 piece), 2 m3 (1 piece)

ETP 1

ETP 2

Treatment process Biological

Treatment capacity 3000 m3 per day

Tank capacity

1 Collection sump 8 X 4 X 4 m3 = 128 m3

2 Homogenous tank 20 X 18 X 5.5 m3 = 2115 m3

3 Neutralisation tank 3 X 2.6 X 5.5 m3 = 42.9 m3

4 Distribution tank 9 X 2.6 X 5.5 m3 = 128.7 m3

5 Oxidation tank 58 X 21.5 X 5 m3 = 6235 m3

6 Clarifier tank 3.14 X (22/2)2 X 2.85 m3 = 1083 m3

7 Slug return tank 2 X 2 X 4 m3 = 16 m3

8 Slug thickener 5.4 X 6 X 6 m3 = 194.4 m3

9 Chemical dosing tank 2 m3 (2 piece)

ETP 2

Different things checked in ETP

Parameter Unit Quantity Std. Value

PH 7.5 6-8

COD mg/lt 39 150-200

BOD5 mg/lt 23 29-50

Color APHA/Pt.Co 335 220-250

Phosphate mg/lt 3.2 5-15

Sulphate mg/lt 560 1000

Ammonia mg/lt 2.50 5-10

Chloride mg/lt 120 500-600

Nitrate mg/lt 6.16 08-10

TSS mg/lt 80 60-80

TDS mg/lt 2075 2100

Chlorine mg/lt 0.1 1

Nitrite mg/lt 0.21 >1

Sludge (wet) ml / ½ hr 800-820 700-800

They have a caustic soda recovery plant. Yarn

& Fabrics mercerization machine discharge

weak lye at average 5o Be (32gm/lt) as waste,

collect the weak lye separately from

machines and pumped in Caustic Recovery

Plant (CRP) storage tank. Caustic Recovery

Plant is recovered strong lye at 300Be

( 296.8gm/Lt) by the process.

Caustic Soda Recovery Plant

Receiving waste

recovery

Presently they are using rain water in Boiler by

establishing rain water harvesting plant in their

complex. Their present storage rain water capacity

8389 m3. Their Treatment Capacity: 360m3/day.,

Their Present Rain water Catchment’s area

1,00,000 sqft, but we are thinking to increase their

catchment’s area up to 3,42,000sq.ft. We will use

this rain water in their dyeing process.

.

Rain water Harvesting

Rain water

pond

Kitchen waste recycling

• All kitchen wastes are collected and recycled to fertilizer which is used in the tea garden of SQUARE

Tea garden

They are progressing forward to

considering the concept of zero discharge,

we have already established caustic soda

recovery plant ( CRP) to recover the caustic

soda from waste liquor. They also

developed some infrastructure to recover

salt and water from dye.

Chemical Recovery

Security

SKFL has its own security agency named Aegis

Central Yarn Store:Capacity: Around 1200 Metric Ton.In yarn store yarns are kept in cartoons.

Dye Stuff and Chemical store for Yarn Dyeing:This store situated in an extension room of Yarn Store 1.

Spare Parts and Accessories Store:Different m/c spare parts and daily necessaries like pen, stickers etc are kept in this store.

Grey Fabric Store:After Knitting fabrics are collected in roll forms, then quality passed rolls are stored in Grey fabric store

Different Inventories

Dye Stuff and Chemical store

Yarn store

Knitting Charge Of Different Fabrics

Fabric name Charge per kg(Tk)

Single Jersey 9

Single Jersey with Lycra 34

Single locoste PK 16

Double lacoste PK 16

Single PK 18

Double PK 18

1X1 rib 18

1X1 rib feeder stripe 30

Design rib 50

Lyc 1X1 rib 35

2X2 rib 30

2X2 rib Lycra 40

Interlock 35

Fedeer stripe 30

Auto stripper 110

Auto striper with Lycra 140

Fleece 30

J/Q 200

Dyeing Cost:

Finishing charge of different fabrics:

PROCESSING TYPE PRICE PER KG

Light shade 75

Medium shade 90

Dark 95

Extra dark 110

Royal /Reactive black 130

White 30

CVC /TC (white) 130

CVC/TC (white) 50

Exceptional color (more than 8%) 120

Normal wash 25

NAME OF FABRIC PROCESS CHARGE PER KG(TK)

Slitting only 5

Stenter only 25

Compacting only 15

Stenter + Compacting 35

Stenter + Compacting+ wash 50

Tube Compacting 10

Marketing dept.

Major Buyers

Puma

G. Star

Esprit

M & S

S. Oliver

Mexx

H & M

Street One

Promod

Kitaro Etc.

EXPORT VALUE-2011

m

PUMA28%

G-STAR11%

S. OLIVE

R8%

H & M7%

MEXX4%

STRAUSS4%

OTHERS9%

ESPRIT29%

EXPORT VALUE-2012

PUMA32%

G-STAR7%

S. OLIVE

R8%

H & M11%

MEXX5%

STRAUSS3%

OTHERS7%

ESPRIT27%

What Next?

1.Green Factory2.Zero Discharge Plant3.School Project in Valuka

presentation of square knit fabrics ltd. by milon,mamun,plabon supervising teacher kazi sowrov

Data & Analytics