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. 01 NAME UDAY RAY
IDENTIFICATION NO.

2008-1-046

02
03 04

ELIAS KHALIL
QMD. IMRAN HASSAN MD. SAMSUL ALAM

2008-1-048
2008-1-073 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 ASST. MANAGER SENIOR OFFICER OFFICER

DYEING

FINISHING

IN-CHARGE

PRODUCTIO N OFFICER FLOOR INCHARGE SHIFT INCHARGE SUPERVISO R ASST. SUPERVISO R OPERATOR

PRODUCTIO N OFFICER FLOOR INCHARGE SHIFT INCHARGE SUPERVISO R ASST. SUPERVISO R OPERATOR

ASST. IN CHARGE SR. SUPER VISOR SUPER VISOR ASST. SUPER VISOR

ASST. OFFICER TECHNICIA N

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

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

CIRCULAR KNITTING MACHINE

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. Mlange -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:

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
. Maximum

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

2) Temperature
For cotton fabric scouring: 105C 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

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

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 4 Batch to batch shade variation 5 Crease mark 6 Roll to Roll 7 Soda spot 8 Others

30%

30%

Uneven Dyeing

Dye Spot

Soda 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)

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.

Knit fabrics are finished in 2 forms

1.Tubular form 2.Open form

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

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

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

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 L-Key Air suctioner Screw driver Spanner Star driver Pliers Pulley Key Functions Loosen and tighten the screw Clean machines by suctioning Loosen and tighten the screw Loosen and tighten nut & bolts Screw unlocking Cutting, Holding, Joining of wire, Gripping 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
H2SO4 & HCl
Lime Alum Polyelectrolyte H3PO4 Urea

Chemical Used
25 Kg/Day
250Kg/shift 250Kg/Day 1 Kg/day 1 Kg/shift 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.
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Serial No.
1 2 3 4 5 6 7 8

Price quotation of finishing

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

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

Types Of Shade
Light Color Light Color Medium Color Medium Color Dark Color Dark Color Black Color Or Extra Dark Black Color Or Extra Dark Deep Black Or Deep Royal Deep Black Or Deep Royal Only Wash Only Wash White White

Type Of Finishing
Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish Tube Finish Open Finish

Price/Kg
65 Tk 75 Tk 75 Tk 85 Tk 85 Tk 95 Tk 110 Tk 125 Tk 115 Tk 125 Tk 25 Tk 35 Tk 40 Tk 50 Tk

Knitting Cost
Serial No. 1. 2. 3. 4. 5. 6. 7. 8.

Fabrication
Single Jersey Lacoste/PK Terry Fleece 1x1 Rib Interlock Single Jersey E. Stripe Lacoste/PK E. Stripe

Knitting Price(Tk./Kg)
8-10 14 14 18-20 14 18 100 120

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.