Presentation on Industrial Attachment at Metro Knitting & Dyeing Mills Ltd. - Uday Ray

Report on Industrial Attachment At

METRO KNITTING & DYEING MILLS LTD. (From 01 July to 31 August, 2012) Supervising Teacher RASHEDA BEGUM DINA

(Lecturer) Dept. of Wet Processing Engineering Bangladesh University of Textiles Submitted by SERIAL NO.

NAME

IDENTIFICATION NO.

01

UDAY RAY

2008-1-046

02

ELIAS KHALIL

2008-1-048

03

QMD. IMRAN HASSAN

2008-1-073

04

MD. SAMSUL ALAM

2008-1-104

sister Concerns • Metro Knitting & Dyeing Mills Ltd (Factory-2) • Bea-Con Knitwear Ltd • Mercer Design Tex Ltd • KB Traders ltd • AAA Textile Mills Ltd • Panam Agrovet Ltd

Export Growth Turnover

Man power Management(Dyeing Section) GENERAL MANAGER SENIOR PRODUCTION MANAGER PRODUCTION MANAGER

LAB (QAD)

LAB (COLOR MATCH

DYEING

FINISHING

IN-CHARGE

ASST. MANAGER

PRODUCTIO N OFFICER

PRODUCTIO N OFFICER

ASST. IN CHARGE

SENIOR OFFICER

FLOOR INCHARGE

FLOOR INCHARGE

SR. SUPER VISOR

OFFICER

SHIFT INCHARGE

SHIFT INCHARGE

SUPER VISOR

ASST. OFFICER

SUPERVISO R

SUPERVISO R

ASST. SUPER VISOR

TECHNICIA N

ASST. SUPERVISO R OPERATOR

ASST. SUPERVISO R OPERATOR

HELPER

HELPER

Machine Description THIES Machine

Dyeing

Origin: Germany Maxm Temperature: 130-135oC Loading per nozzle: 250kg Capacity: 250-750kg

SCLAVOS DYEING MACHINE ORIGIN : GREECE QUANTITY: 10 MAXIMUM CAPACITY: 1500 KG MAX TEMPARATURE:142oC MAX NOZZLE: 6

WORKING PRESSURE: 2.8 BAR

FONG DYEING MACHINE

CIRCULAR KNITTING MACHINE

ORIGIN:CHINA MAXTEMPERATURE: 140oC NO OF NOZZLE: 1~8

BRAND: MAYER& CIE PAILUNG, JUINN LUNG, LISKY QUANTITY: 106

STENTER MACHINE BRAND: BRUCKNER ORIGIN: GERMANY SPEED: 4-100 M/MIN PADDER PRESSURE: 0.7-10 BAR MAX. PRODUCTION: UPTO 10 TON / MACHINE

GARMENTS MECHINERIES

COMPACTING MACHINE BRAND: TUBETEX ORIGIN: USA SPEED: 5-35M/MIN MACHINE PRESSURE: 20-35 BAR TEMPERATURE:90-120oC

BRAND:JUKI, PEGASUS, YAMATOBROTHER, UZU, OSHIMA, TOYO LOCK, HASHIMA LEEWAI, NISSIN

TOTAL :1229

Raw Materials Types of raw material used: 1. Yarn 2. Fabric 3. Dye stuff 4. Chemical and auxiliaries

Sources of yarn: 1. Cotton (Both Carded & Combed) - Loyal, Malek, N.ZJabber, KeyaS.Q Gill, Mix, Israq, Negreeka, Multizim 2. Polyester - India 3. Mélange -Shamim spinning mill -Prime spinning mills -Thermex spinning mill 4. Lycra -Korea, Vietnam, china

FABRICS USED COMMONLY •Single Jersey •Lycra Single Jersey •1x1 Rib •2x1 Rib •2x2 Rib •Fleece •Terry

COMMONLY USED DYES •Begacron (China) •Novacron (China) •Remazol (Germany) •Levafix (Germany)

•Supra (India)

MOSTLY USED CHEMICALS • Caustic Soda • Soda Ash • Hydrogen Peroxide • Glauber Salt • Hydrose

•Sumifix(China) •Dianix (Germany) •Terasil (China)

Production per day: • Maximum

Loading capacity 100% (11.36 tons) • Possible maximum loading 80% (9.088 tons) • Total production per days (3 shifts) = 9.088 x 2.5 (considering 2.5 batch in 3 shifts) = 22.72 tons .

Dyeing Parameter PH • • • • • • • •

Scouring PH – 10.5-11 During H2O2 bleaching PH 10.5-11 Enzyme PH – 4.5 Before dyeing (Leveling) PH – 6.5 Salt PH – 7-8 During reactive dyeing PH 10.5-11.5 During disperse dyeing PH 4.5-6.0 Softener PH – 6.5

3) Time: -For white shade 4-5hrs -For 100% cotton 8-10hrs -For 100% polyester 5hrs -CVC 2 parts 13-14 hrs.

4) M: L ratio: -For reactive dyeing M: L ratio maintained within 1:6

2) Temperature For cotton fabric scouring: 105ºC  During NaOH addition 65oC  During H2O2addition 70oC  Peroxide killing at 80oC  Sequestering at 90oC  Bio-polishing at 55oC For cotton dyeing:  Low brand – 45oC  Medium brand - 600C  Hot brand – 80oC o Migration for turquoise color at – 90oC o Optical brightening agent (OBA) atb 80oC o Polyester dying: 1000-1300C o Softener at – 45oC

Cycle Time 2-3 mins

Reel Speed 250-300 m/min

Dyeing Faults 3%

1% 2% 1% 1%

1 Uneven dyeing 2 Running shade 32%

3 Dye spots

30%

4 Batch to batch shade variation 5 Crease mark

30%

6 Roll to Roll 7 Soda spot 8 Others

Uneven Dyeing

Soda spot

Dye Spot

Hole

Resist spot

Finishing Types of Finishing: 1. Mechanical Finishing (Used to control dimension to improve appearance & handle) 2. Chemical Finishing (Used to make glossy protection. To improve performance or serviceability)

Knit fabrics are finished in 2 forms 1.Tubular form 2.Open form

Effects of Finishing -Easy care. -Crease recovery. -Dimensional stability. -Good abrasion resistance. -Improved tear strength. -Good sew ability. - Soft or stiff handle. -Shine or luster.

Machine used in finishing section: •Dewatering machine •Slitting machine •Dryer •Compactor (Open/Tube) •Stenter •Raising machine •Sueding machine •Padder

Flow diagram of open & tube fabric finishing

Quality Control system mainly two types: 1. Online QC Raw material Control Process Control Laboratory test

2. Offline QC

A. Physical tests GSM test Shrinkage test Spirality test Tensile strength Abrasion resistance Pilling resistance Button Strength Testing Crease resistance Dimensional stability Bursting strength test

B. Chemical Test Color Fastness to washing. Color Fastness to light. Color Fastness to Chlorinated water. Color Fastness to water spotting. Color Fastness to perspiration. Color Fastness to Sea-water. Fiber analysis. PH test. Spray test (water repellency

Fabric Inspection Grey Fabric Inspection Grey Fabric Inspection is performed according to 4-point system.

Finished Fabric Inspection Uneven Shade Crease Mark Oil Spot Spirality

Maintenance Maintenance of Machinary Routine/Schedule

Preventive

Breakdown

Maintenance Tools and their Functions Name of the Tools

Functions

L-Key

Loosen and tighten the screw

Air suctioner

Clean machines by suctioning

Screw driver

Loosen and tighten the screw

Spanner

Loosen and tighten nut & bolts

Star driver

Screw unlocking

Pliers

Cutting, Holding, Joining of wire, Gripping

Pulley Key

To loosen pulleys

Utilities Utilities services available in Metro Industries Ltd Electricity Water Gas Steam

Source of utilities: Electricity Steam Water Gas

: PDB & Generator : Boiler : Pump : Titas gas Ltd

Types of Generator: A.Gas Generator (Running) 1.Brand: Perkins, England Capacity: 400 KW 2.Brand: Waukesh, USA Capacity: 900 KW B. Diesel Generator (Backup) Brand: Perkins, England Capacity: 200 KW Fig:Gas generator 1

Diesel generator

Gas generator 2

Boiler

Brand: COCHRAN , Scotland Maximum Temperature: 188 Maximum Steam Output: 10 ton/hr Steam pressure: 7.5 bar Boiler

Store & Inventory Control Objectives Financial activities

Property protection

Operating

Scope of Inventory Control Grey Fabric Store

Dyes & Chemical Stores

Spare Parts

Finished Goods

Others

Effluent Treatment Plant Types of ETP PhysioChemical

ChemicalBiological

Biological

Metro has Combined Bio-chemical ETP in the factory premises. The output of the ETP is about -200CBM/Hr) Consumption of the chemical used

Chemical Name

Chemical Used

H2SO4 & HCl

25 Kg/Day

Lime

250Kg/shift

Alum

250Kg/Day

Polyelectrolyte

1 Kg/day

H3PO4

1 Kg/shift

Urea

1 Kg/shift

Discharge water quality of Metro Industries: pH = 6-9 BOD = 50 mg/ L COD = 220 mg / L Suspended solid = 145 mg/L Color = color less.

Functions of different chemicals used in ETP: H2SO4 & HCl: Neutralize the water from alkaline state. Ferrous Sulphate & Lime: To remove the color of the effluent. Alum & Polyelectrolyte: To agglomerate the smaller particles. For sedimentation of the smaller particle. H3PO4/Urea: For increasing the production of the bacteria.

Finishing Cost Dyeing Cost Along with Dyes and Chemical Sl. No.

Types Of Shade

Type Of Finishing

Price/Kg

1 2 3 4 5 6 7

Light Color Light Color Medium Color Medium Color Dark Color Dark Color Black Color Or Extra Dark

Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish Tube Finish

65 Tk 75 Tk 75 Tk 85 Tk 85 Tk 95 Tk 110 Tk

8

Black Color Or Extra Dark

Open Finish

125 Tk

9

Deep Black Or Deep Royal

Tube Finish

115 Tk

10

Deep Black Or Deep Royal

Open Finish

125 Tk

11 12 13 14

Only Wash Only Wash White White

Tube Finish Open Finish Tube Finish Open Finish

25 Tk 35 Tk 40 Tk 50 Tk

Serial No.

Price quotation of finishing

Price

1 2 3 4 5 6 7

ONLY STENTER ONLY OPEN COMPACTING STENTER + OPEN COMPACTING ONLY TUBE DRY TUBE COMPACTING ONLY SUEDING SUEDING+ STENTER+ OPEN COMPACTING ONLY BRUSH

20 TK/KG 15 TK/KG 30 TK/ KG 8 TK/KG 8 TK/KG 25 TK/KG 55 TK/KG

8

15-20 TK/KG

Knitting Cost Serial No. 1.

Fabrication

Knitting Price(Tk./Kg)

Single Jersey

8-10

2.

Lacoste/PK

14

3.

Terry

14

4.

Fleece

18-20

5.

1x1 Rib

14

6.

Interlock

18

7.

Single Jersey E. Stripe

100

8.

Lacoste/PK E. Stripe

120

Marketing Activities

Exporting countries: Germany Netherland Japan UK Singapore Canada USA

Conclusion So, that was the very brief of our Industrial attachment program. It excludes so many subjects and facts. In this short presentation its very hard to include everything we did and learned in that program. Thanks for giving us the opportunity to do this presentation.