INDUSTRIAL ATTACHMENT OF YASSMA KNITTING & DYEING.

Dec. 9
1


INDUSTRIAL TRAINING
Course Code: Tex
-4036


INDUSTRIAL ATTACHMENT OF
YASSMA KNITTING & DYEING.

Dec. 9
2





CHAPTER-1













INTRODUCTION




Dec. 9
3

INTRODUCTION
Industrial training is one of the most essential parts of engineering & technical education. This
industrial training is included in our syllabus to acquaint us with the practical implementation of
the technology studied within the industrial environment. Though it is very helpful & lays the
milestone for starting the carrier for fresh Textile graduates.

Wet processing which occupies a vast field in modern Textile technology is undergoing many
stages of processing. Many problems are generally being encountered during each operation
stage starting from desizing to finishing section. Finally from mill training, I learn practical wet
processing under industrial environment. I think it will be helpful in my future carrier life.

Industrial training is an indispensable part to study of practical knowledge of an industrial unit
for student of textile Engineering. YASSMA KNITTING & DYEING Ltd. is the 100% export
oriented industry in Bangladesh. The factory is concerned about knitting, yarn dyeing and knit
garments. Due to the changing environment the textile sector faced with challenge, But the
YASSMA KNITTING & DYEING Ltd. will fully prepare to face the situation.
I have completed my 6 weeks long industrial training in dyeing and finishing section of
YASSMA KNITTING & DYEING Ltd. These training enable me to avoid the gap between
theoretical and practical knowledge. The incumbent is deputed to YASSMA KNITTING &
DYEING Ltd. for practical industrial training program.




Dec. 9
4

CHAPTER-2










COMPANY
PROFILE



Dec. 9
5


Company Profile:

Factory Name : YASSMA KNITTING & DYEING Ltd.
Type : 100% Export Oriented Yarn Dyeing Industry.
Year Of Establishment : 01 January 2009
Investors : Md.



Address:

Factory Address : Plot/23-25,Adamjee-EPZ,Siddirgonj, Narayangonj.

Head Office & Corporate Office : Baridhara –DOHS, Banani, Dhaka.


Sponsors : Islami Bank, HSBC Bank.













Dec. 9
6


Vision:

To establish as a one stop source for the Global knit Apparel market and to satisfy and meet
customers expectation by developing and providing products and services on time, which offer
value in terms of Quality, Price, Safety and Environmental impact.
Assuring complete compliance with the international quality standards and also providing the
employees internationally acceptable working condition and standards. To promote the

development and to use human talent and equal opportunity of employment.

Mission:

YASSMA KNITTING & DYEING Ltd. realizes the need to take out a competitive segment in
the changing global market of today through technological excellence and human expertise.
YASSMA KNITTING & DYEING Ltd. is committed to transpose its local success to the world
scene.

LOCATION:
The Project is located at Adamjee,EPZ,Siddirgonj,Narayangonj. It is about 40
kilometers away from Primeasia University,Banani,Dhaka.



Main Products:
 Dyed cotton yarn
 Viscose yarn
 Acrylic-cotton blend.




Dec. 9
7

Major Buyers & Fashion Labels:


H & M ESPRIT

C & A DECATHLON


MQ
PUMA






Dec. 9
8


CHAPTER-3

MANPOWER
MANAGEMENT






Dec. 9
9


Management System:
The company has skilled administration, management and marketing team guided by proficient,
dexterous & experienced leaders of offer right solution for the consumers with the right
eminence & with the shortest lead-time for the export market in Bangladesh.
The best use of continuous development of human resources by providing them International
standard equal opportunity is the keys for achieving comprehensive competence in all level of

the organizational hierarchy.


Total Shift :
2 shifts per day.

Shift
Duration
General
9.00 am- 6.00 pm
A
8.00 am- 8.00 pm
B
8.00 pm-8.00 am










Dec. 9
10

Organogram of Dyeing Section:
General Manager


Deputy General Manager

Manager

Deputy Production Manager

Asst. Production Manager

Sr. Production Officer

Production Officer

Supervisor

Asst. Supervisor

Sr. Operator

Operator

Asst. Operator

Helper

Dec. 9
11
Responsibilities of Production Manager :

1. To plan the production schedule with capacity & volume of order.
2. To observe dyeing finishing.
3. To supervise senior production officer & production officer.
4. To rectify any kinds of problems during dyeing.
Responsibilities of Production Officer :
1. To check recipe.
2. Batch preparation & p
H
check.
3. Control of supervisor, operator, astt. Operator & helper of dyeing floor.
4. To match shade as required.
5. To find out dyeing & yarn fault as early as possible.
6. To recover the finished yarn this is rejected from quality department.
7. To register each batch dyeing condition.
8. To check daily production report.
9. To check water level in dyeing stage.
10. To maintain connection with finishing & quality control department.
11. To maintain connection with maintenance department etc.

Remarks :
There are a sufficient number of Efficient Textile Engineers & Technical persons. This is why
they achieved a very good reputation in Knit Dyeing Sector.

Dec. 9
12
CHAPTER-4

MACHINE
DESCRIPTION



Dec. 9
13

MACHINE DESCRIPTION

For yarn dyeing process,YASSMA KNITTING & DYEING Ltd. uses state-of-the-art machinery
of SSM Brand from Switzerland, FADIS and DETTIN from Italy, and STRAYFIELD from
England.
Yarn Dyeing Capacity: 20 Tons/day
Machine List:
TYPE
BRAND
MC. QTY.

TOTAL
86 Nos.
Yarn Dyeing M/C
Fongs, China
48 Nos.
Yarn Printing M/C
Laip, Italy
01 Nos.

Soft Winding M/C
Fadis, Italy
02 Nos.
Soft Winding M/C
SSM, Switzerland
13 Nos.
Hard Winding M/C
Fadis, Italy
02 Nos.
Hard Winding M/C
SSM, Switzerland
10 Nos.
Hydro
Dettin, Italy
04 Nos.
Dryer
Stryfield, England
02 Nos.
Dryer
Stalam, Italy
02 Nos.
Sewing Thread
SSM (Hacoba), Switzerland
01 Nos.
Auto Dosing

Dec. 9
14


CHAPTER-5

RAW MATERIALS
AND CHEMICALS




Dec. 9
15

Type of Raw Materials :

Grey Yarn:


 Single Ply cotton yarn
 Double Ply cotton yarn
 Tree Ply cotton Yarn
 AC blend yarn.etc

Commonly Used Dyes :

Name of Dyes
Synozol G,Yellow HF 2GR
Synozol Red HF 6BN
Synozol Black B
Synozol Orange SHF RR
Synozol Br,Blue R-SPCL
Synozol Turquise Blue HFG 266%
Synozol Yellow K-3RS
Synozol Red K-3BS
Synozol Navy Blue K-BF
Synozol Yellow 4GL
Synozol Yellow 4GR
Synozol Red SHF GD
Name of Dyes



Dec. 9
16
Synozol Blue K-BR
Synozol Ultra Black DR
Synozol B/Red BB
Synozol Yellow HB
Synozol Navy Blue HB
Synozol Deep Red HB
Synozol Red K-GD
Synozol Black HF GR
Sun White BVB
Syno White 4BK

Leucophor BBU
Rifazol Orange RN
Rifazol G,Yellow 4GR
Rifazol Turquise Blue G-165%
Rifazol Br,Blue R-SPCL
Rifazol Deep Black ED Conc
Drimaren Navy CLR
Drimaren Yellow HFR
Drimaren Blue HFRL
Remazol Yellow RR
Remazol Blue RR
Remazol Orange RR
Remazol Turquise Blue G




Commonly Used Chemicals & Auxiliaries:



Dec. 9
17

Agent of-
Name of items
Chemicals of KBC Co.(Pvt).
2UD
Eco
Scouring & Bleaching agent

Imerol PCLF
TF-129B
Perlavin NDA
Sabilezer
TF-122B

Causic Soda

Hydrozen peroxide

Acetic acid
Peroxide Killer
Bactasol Sap
Lavelling agent
Sarabid MIP
TF-210 B
Sequestering Agent
Sirrix 2UD
ladiquest-1097U
TF-510B
Periquest BSV
Antifoaming Agent
Antimussol UFD
Periwet WDP
Salt
Glober Salt
Refined salt

Soda Ash
Soaping Agent

Ladipur RSK
Parlavin SR/SN
Fixing agent
Optifix EC
Perifixan RS
TF-234 B
Color Softner
Cepreton UCP
GTF-445C
Perifil 210 Liq
White Softner
Nass-T ( Local )
GTF-442

Sodium hydrosulfite





Dec. 9
18


Source of Raw Materials:
Grey yarn is collected from buyers.
Dyes & Chemicals are imported from Germany , Switzerland , Singapore , Turkey , India , China
etc.

Remarks:

Price & Monthly consumption are unavailable.




Dec. 9
19
CHAPTER-6


















PRODUCTION
PLANING, &
OPERATIONS

Operations





Dec. 9
20

Production Parameters:
P
H
:
For Scouring & Bleaching : 10-11
Before Enzyme : 4.2-4.5
Before Leveling : 5.5 (All Color)
6 for Black, Red, Deep Color.
After Leveling : 5.5 (All Color)
6 for Black, Red, Deep Color.
Before Dyes : 5.5 & 0.2
After Salt : 5.5 & 0.2
After Soda : 10.5-11.5
After Acid wash : 5.5-6.5
Before Softener : 5.5

Temperature:

For Scouring & Bleaching : 105°C
For Cold Wash : 40-55
0

C
For Hot Wash : 80-95
0
C
For Cotton Dyeing : 80-90
0
C (For Hot Brand)
60
0
C (For Cold Brand)
For Polyester Dyeing : 130
0
C

Time:
For Scouring & Bleaching : 30-40 minute for Normal color
50 minute for Critical Color
For Reactive Dyeing : 60-90 minute.


Remarks:

Critical colors are Green , Turquoise Blue , Brown , Dark grey .

Material &Liquor ratio:
For Reactive Dyeing Material & Liquor Ratio is maintained in Between 1:8



Dec. 9

21

Production Flow Chart:
Grey yarn Collection from Grey store
▼
Winding on hard package
▼
Yarn loading to m/c
▼
Scouring & Bleaching
▼
Bio polish ( Enzyme Treament)
▼
Dyeing
▼
Soaping
▼
Fixing
▼
Softening
▼
Unloading from dyeing m/c
▼
Drying
▼
Inspection
▼
Winding on soft package
▼
Final inspection

▼
Packaging.


Grey yarn inspection section:
Object of inspection:
 To check the actual count of yarn
 To identify the yarn faults
 To ensure about the yarn quantity




Dec. 9
22

Yarn fault:
1. Slub
2. Neps
3. Thick & thin place
4. Patta / Barre
5. Yarn contamination
6. Yarn hairiness

Batch Section

Function or purpose of the batch:
 Order sheet (Received from buyer)
 To receive the grey yarn package from soft section or other source
 To send the grey yarn to the dyeing floor by trolley with batch card

 To prepare the batch of yarn on the carrier
 Dyeing shade (Color or white, Light or Dark)
 M/C capacity
 Yarn structure.
 Yarn type, etc
 To keep records for every previous dyeing.
 Keeping the no. of batch as less as possible for same shade, etc.
 Minimizing the m/c washing time or preparation time.


Batch management:
Primary batch is done by the dyeing manager. Batch section in charge receives this primary
batch plan from dyeing manager. Then the works is adjusting, according to m/c condition.

Remarks:
Proper batch can minimize the batch to batch shade variation. It can near or same dyeing
condition for every batch of same shade. Thus it improves the dyeing quantity & minimizes a lot
of dyeing cost.



Dec. 9
23

Scouring-Bleaching Process:
Scouring-Bleaching is carried out in the same bath and at the same time simultaneously.

Scouring-Bleaching Chemicals Used in a batch:

Agent

Brand Name
g/l
Wetting agent
TF-129 B
0.70
Sequestering agent
TF 510
1.0
Stabilizer
TF 122
0.5
Antifoaming agent
Alkafoam AF-10
1.0
Alkali
Caustic soda
1.8
Bleaching agent
H
2
O
2

2.5
Peroxide Killer
Bactasol Sap
o.85
Acid
Acetic Acid
0.6

N.B : Amount of Chemical varies according to yarn consumption .














Dec. 9
24

Procedure of Scouring-Bleaching :
 At first required amount of water is taken into the m/c.
 Then the yarn is loaded
 Then Wetting, Sequestering, Stabilizer is added by inject at 50
0
C.
 Then Temperature is raised to 60
0
C.
 Then Caustic soda is added by linear dosing for 6 minutes.

 Then temp rised to 70°c .Then H
2
O
2
is added by linear dosing for 8 minutes.
 Then. Temp raised to 105
0
C. Runtime 60 minutes.
 Then temp.is decreased to 90
0
C.Rinse at 90
0

 Then Hot wash at 90
0

 Then Rinse at 90
0
-
 Then Bayreduct PRN is added by transfer at 90
0
C × 10΄
 Then Rinse at 90
0

 Then Drain out.
 Fill water. Acid treatment for neutralization at 70°c °× 10´ & P
H
is checked.
 Then rinse at 55°c× 10΄

 Then Primafast-100 is transferred at 55°c. Run time 20-50 minitues.
 Then Hot wash at 80
0

 Finally drain out

N.B :
1. In case of critical color after loading water & yarn first hot process is carried out with
sequestering agent & detergent to get better result. Rest of processes are same as usual.













Dec. 9
25


White dyeing process:
Batch No : 27942 Machine No : 02
Batch Date : 22.04.09 Water : 5600 Lit
Liquor ratio : 1:7 Yarn Weight : 1000.00 kg

Customer : United Count : 32/2
Color : White 10-100




Recipe :
















Name of the Chemicals
Amount (g/l)
Feloson NOF
0.40
Exstab BRH
0.40
Feloson NOF

0.50
Exstab BRH
0.40
Antisil CONZ
0.60
Caustic soda
2.50
Hydrogen per Oxide
6.00
Singo white-2BX
0.10 %
Singo white-BHV
0.33 %
Invatex-CS
0.10 %