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A Study on dyeing machine, Stenter machine

and ETP at AKH knitting and dyeing Ltd.
Dipayon Saha
ID-15107114
Program-BSME

Department of Mechanical Engineering

IUBAT—International University of Business Agriculture and Technology
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Contents:
 Objectives
 Company Profile
 Mission and Vision
 Dyeing machine
 Stenter machine
 Effluent treatment plant
 Problem Finding, Analyzing and Solution
 Conclusion
 Recommendation

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Objectives:
 To gain basic understanding of operation and maintenance of different
machineries and trouble-shooting procedures and the related aspects at
AKH knitting and dyeing Ltd.
 To have practical experience of job life.
 To find out the relevance and application of the theoretical knowledge
in practical life.

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 Company profile:
AKH was established in the year 1997, when export
continues to increase. AKH has now successfully
evolved into a highly integrated leading group in
exporting from Bangladesh. AKH is a one-stop
source for overseas buyers to buy their high quality
knit and woven garments from Bangladesh.

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Mission and Vision:
Mission:
 To operate as one of the best apparel sources in the global market.
 To satisfy the valued customers and meeting their expectation by
providing good quality product.
 To make green factory as much as possible.

Vision:
“AKH is committed to venture out into the changing and
challenging global market as a leading enterprise in the world
apparel industry by satisfying its valued customers.
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Location:
Head Office:
AKH Tower
133-134, Hemayetpur, Savar
Dhaka-1340, Bangladesh.
Tel: 00 88 02 7741727-8,
Fax: (880-2) 8155640 – 41
Mail: info@akhfashions.com

Factory Location:
AKH knitting and Dyeing Ltd.
92, Phulbaria, Tetuljhora, Savar,
Dhaka. Bangladesh
PHONE : 880-2-7741830-3

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Factory Organogram

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AKH GROUP
 AKH knitting and dyeing Ltd.
 AKH Fashions ltd.
 AKH Knit wear Ltd.
 AKH washing Ltd.
 AKH Apparels Ltd.
 AKH Trims Ltd.
 AKH Eco Apparels Ltd.
 AKH shirts Ltd.
 AKH Packaging & Accessories Ltd.
 AKH Cargo Services.
 AKH stitch Art Ltd.
 Angshuk Ltd. 9
Company Products:

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Buyers:

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Certificates:

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 Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is normally
done in a special solution containing dyes and other chemical material.
There are mainly two types of dye: natural and man-made.

Dyeing machines:
• Yarn dyeing machines
• Fabric dyeing machines

Fabric dyeing machine:

• Jet dyeing machine
• Jigger dyeing machine
• Winch dyeing machine

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Chemicals:
 Acids
 Alkali
 Salts
 Oxidizing agents
 Reducing agents

Utilities:
 Air
 Electricity
 Gas
 Compressed air

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 Jet Dyeing Machine:

Jet dyeing machine is a continuous dyeing machine. Which is used for fabric dyeing at textile mill.

These are the high temperature rope dyeing machine which may be classified as follows-
 Special high temperature winches.
 Jet dyeing machine with additional winch or drive roller.

Features:
 Modern continuous dyeing machine.
 Used for woven i.e. synthetic fabric.
 Both dye liquor and fabrics are circulated.
 The fabric dyed in rope form.

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For fabric dyeing, Jet dyeing machine is used at AKDL. Generally, There are
two types jet dyeing process :

 Overflow Dyeing process

 Airflow Dyeing process
Overflow dyeing process:

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 Airflow dyeing process:

Advantages:
 Uniform dyeing is possible.
 Knitted fabric can be used.
 Easy to maintain uniform temperature through the machine.
Disadvantages:
 Crease of fabric may be damaged.
 Slight dark mark is found of the fabric.
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 Main parts of Dyeing Machine:

Power Control Board: power control board are controlling voltage and ampere.
And supply actual voltage and ampere to the machine so that the machine run at perfect condition.
Components of power control board are given below:
 Main circuit breaker
 Temperature controller
 Inverter
 Power supply
Fig: Power control
board

Chemical Tank-1, 2: Chemicals are directly passed to the main tank by

injecting process. Injecting means pass chemical from dosing
tank to main tank.
Figure .: Chemical Tank of Dyeing Machine
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Monitor: Monitor is used to observe and control the process such as
water level, temperature, pressure, dosing time etc.

Main Tank: Main tank is the largest part of the dyeing machine.
The main tank contains the dye bath liquor and the fabric.

Panel Board:
Panel board is attached to the main tank. The panel board is used to control
the rpm, temperature, on-off of the machine.

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Nozzle :Nozzle is the main part of dyeing machine where dye pick up
of the maximum fabric. Winch passed the fabric through the
nozzle. Main motor is connected to the nozzle

Winch: Winch is used for moving the fabric through the whole dyeing machine.
Winch is rotated with the help of motor.

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Heat Exchanger:
Heat exchanger is made from stainless steel. Heat exchanger is used for heating
and cooling the dye liquor. Heat exchange process is achieved by
passing steam through the coiled pipe.

Reel: The fabric is loaded in the main tank by reel.

There is a motor attached to the reel. Reel is used in loading and
unloading time.

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Filter Tube: Filter tube is inside the circulating line and drain
line. Dyeing liquor is going to the filter tube to remove impurities.

Figure .: Filter Tube of SCALVOS Dyeing Machine

J-box: J-box looks like j shape. The fabric is running and circulating
to achieve the perfect dye in J box. The J-Box contains a tube line,
which guides the Fabric.

Main Pump: Centrifugal pump is used for circulating

the liquor in dyeing machine. Its capacity
depend on the motor.

Figure : J- BOX
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 Fig: Butterfly
Different types of valves and devices valve
Butterfly valve: A butterfly valve is used to control the flow of fluids;
a disk controls flow through the port.
 Steam line, Air line, Water line.
Fig: Steam Trap

Steam trap: Steam trap is mechanical device designed to remove

Condensate and non-condensable gases, such as air and carbon
dioxide, from a flow of steam.
 Steam line
Fig: Non-return
valve
Non-return valve: Valve which allows a fluid to pass in one
direction only. The flow can not come back.
 Steam line, Air line, Water line.
Fig: Piston
valve
Piston valve: A piston valve is a used to control the
motion of a fluid along a tube or pipe.
 Steam line, Air line, Water line. 23
 Fig: Globe
Valve
Globe Valve: A globe valve is used to control the regulating flow of fluid
in a pipeline, consisting of a movable disk-type element.
 Steam line, Air line, Water line.

Fig: Solenoid
Solenoid Valve: The valve is controlled by an electric current through valve
a solenoid: in the case , two-port valve used for on and off.
 Air line

Strainer: Strainers remove the suspended solids in fluids, and

protecting many equipment from their harmful effects.
Fig: Strainer
According to shape Strainer has two types :
Y-type and U-type.
 Steam line, Air line, Water line.

Air Regulator: A air regulator is a control valve that reduces the Fig: Air regulator
input pressure of a fluid to give a desired value at its output.
 Air line
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Maintenance of Dyeing Unit
 Cleaning of drain valves, replace seals if required.
 Check air supply filters, regulators.
 Checking of oil level and bolts of roller gear box.
 Grease the machine bearing.
 Checking and cleaning of main vessel level indicator.

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 Stenter Machine

The purpose of the stenter machine is to bringing the length and width to pre
determine dimensions, for heat setting, finishing chemical is applied and also
shade variation is adjusted.

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It can be used for the following functions:

 Width of the fabric

 Finishing chemical
 Loop of the knit fabric
 Moisture of the fabric
 Spirility of the fabric
 GSM of the fabric
 Shrinkage property of the fabric
 Fabric is dried

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Technical Ability of a Stenter Machine:

 Automatic fabric humidity

 Fabric weight(GSM)
 Non-stop operation
 Low energy consumption.
 Machine failure warning and record
 Fully automatic operation capacity using PLC.

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The main sections of a stenter machine are given below:

 Padder Section:
In the padder section, the fabric is treated with chemicals
especially with softener and acid in two tanks.
Fig: Padder section

 Weft Straightener:
This Chamber controls the bowing and Skewness
of the fabric.

 Width Setting Chamber:

Weft Straighter
This Chamber controls the width of the fabric by clip of pin.
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Heating Chamber:
 This chamber controls the shrinkage and the G.S.M of fabric.
Temperature Range:
Cotton 150°C~170°C.
Polyester 165°C~185°C.
With Lycra 175°C~190°C.

 Cooling Chamber:
This chamber cools the hot fabric before they reach
Fig: Heating Chamber
to delivery zone.
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 Exhaust Motor:
Exhaust motor is used to exit the steam that produce in the
heating chambers.

 Delivery Zone:
This chamber delivered the fabric in a
folded form. In this chamber, the fabric has to pass through several
rollers.

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 Operation of Stenter Machine:

Width setting Cooling

Chamber Chamber
Delivery zone

Heating
Paddder Weft Chamber
section Straightener
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 Different parts of the machine

 Padder: Padder is the attachment of two rubber roller. The Job of this to remove extra
water from fabric.(Padder section)
Fig: Padder

 Monitor: Monitor is used to control and observe the process such as temperature,
pressure, speed, width etc.(weft straightener)

Fig: monitor
 General Overfeeding: The overfeed system help to produce unshrinkable cloth
on stenter machine.(Heat setting chamber)

 Side Control Board : Side control boards fitted on both sides stenter machine.
It helps to control the machine.(Deliver zone and weft straightener) Fig: Side control board
Burner: A burner is a device for generating flame to heat up fabric by using
gaseous fuel such as acetylene, natural gas or propane.(Heating chamber) Fig: Burner

Pinning Wheels: Pinning wheels covered by special rubber with 2 motors

to adjust the left and right pinning.(Width setting chamber)
Fig: Pinning
Wheels
Fabric Guider Wheel: This wheel guide help to stuck the fabric in
the pinning device.(Width setting chamber)

Fig: Fabric guider wheel

Photocells: Photocells are sensor that allow you to detect light. They are small,
inexpensive, low-power, easy to use.(Width setting chamber)

Fig: photocells 34
Plaiter: Plaiter used to fold the dried fabric coming out
from the stenter machine. Plaiter contains 5 roller.(Deliver zone)
Fig: Plaiter

Textometer: Textometer control the amount of moisture has in a

fabric .It is measuring by its electrical resistance.(Heating chamber) Fig: Texometer

Permaset : Permaset is a heat setting control device which detect the Fig: Permaset
temperature of the fabric and automatically adjust
the speed of the stenter machine.(Heating chamber)

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 Maintenance of Stenter machine

 Bearings of overfeed cylinders are well greased.

 Bearings of the chain-wheels are well greased.
 Filters of the burners are kept clean.
 Nozzles are cleaned and free from excessive dust.
 Chamber compartments are free from excessive dust.

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 Effluent treatment plant:

 Effluent treatment plant is used to treat the waste water, which is coming from different
manufacturing industries where different types of chemicals, dyes are used. After
treatment, waste water is discharged to the environment directly.
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Types of ETP:

There are basically three types of effluent treatment plants. They are-
 The biological plant
 The biological-chemical plant
 The physio-chemical plant.

Biological Treatment Plant:

Biological waste water treatment is used worldwide. In Biological waste water treatment
plant, the bacteria and other microbes are eating small organic carbon molecules from
the waste water.
The bacteria and other microbes are treated water in two ways,
 anaerobic process
 aerobic process.
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Layout of Biological ETP:

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 Process sequence of Biological ETP:

Screening: Screening is the synonyms of filtration.

The filtration remove suspended solid from the waste water.
Separately, three screening chamber are used in screening unit.

Lifting tank: Lifting tank is connected to screening unit. It contains screened

water. It has three lifting pump which supply the waste water to storage tank .
lifting tank contains sensor which indicate the water level . If water is full in tank,
then lifting pump supply waste water to storage tank.

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Storage tank: Waste water is stored in storage tank. There is one storage
tank. The storage tank can contain up to 5000 cubic meter waste water.
Then, waste water goes to the neutralization chamber by
A under hole.

Neutralization chamber: Neutralization chamber helps to make the

water neutral . In waste water, Ph value is always more than 7. To make waste
water neutralize, sulfuric acid is given. . Ph represents concentration of
hydrogen ions in water.

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Distribution tank : After neutralization, waste water goes to
distribution tank by distribution pump . Distribution tank is under the
cooling tower. Antifoam is given to the distribution tank to
remove foam. Manually, Bacteria is feeding nutrient to proper living .

Oxidation tank: Waste water goes to the oxidation tank from distribution
tank. Treatment start in this tank, The bacteria and other microbes are eating
small organ carbon molecules and sludge are decomposed. The bacteria and
other microbes treated in aerobic process. Diffusers are providing air from
air blower.

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Feeding sedimentation channel: Treatment water goes to the
feeding sedimentation tank from oxidation tank. In, feeding sedimentation tank,
decolourant chemical has given to remove the black color from treatment water.
This decolourant chemical has given by dosing pump.

Clarifier tank: Then the water goes to the clarifiers tank from feeding sedimentation tank. This is a
special kind of filtration System. There are two thin tin sheets filteration.
Sludge are removed from water in this tank.

Post Aeration tank: Treatment water goes to the post aeration tank
from clarifiers tank by overflow.

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Sludge return tank: sludge goes to the sludge return tank from clarifiers tank.

Sludge thickener tank: When the sludge concentration more than 70%
then sludge goes to the sludge thickener tank from sludge return tank

Discharge of water : After clarification, treated water is discharged to

the river.
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Advantages of biological plant:

 It requires a low maintenance cost.

 Its mechanism is simple .
 It is simple theoretically as well as practically.
 It is the best treatment plant for any kinds of textile industries.

Disadvantages of biological ETP:

 Non-biodegradable chemicals can not be treated here.

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 The machine which are used in biological ETP

Blower: Blower gives oxygen to oxidation tank by

Diffuser. If air blower is stop for any reason bacteria will die in oxidization tank.

Polyelectrolyte machine: Polyelectrolyte machine helps to mix

polyelectrolyte in sludge thickener tank and filter press machine.

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Filter press machine: Filter press machine press the sludge
To remove the excess water from sludge. Then, sludge is remaining in filter
press machine.

Tests Performed at the ETP Lab:

1. Ph meter for Ph test.
2. TDS meter for TDS test.
3. Spectrometer for various type parameter test by kit.
4. Microscope for looking bacteria and other microbes etc.

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Maintenance of ETP
Air blower maintenance
 Check oil filter and clean.
 Check gear box oil seals for leaks.
 Clean gear box vent filter.

Filter press machine and Polyelectrolyte machine maintenance:

 Need to give grease on bearing.
 Need to check the motor condition is okay or not.

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Problem Finding, Analyzing and
Solution
During my internship period, Some technical problems were observed at AKH
Knitting and dyeing Ltd.
 Problem in Fiber Wheel
 Problem in Non-return valve
 Fire in Stenter machine
 Problem in bearing cage

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Problem in Fiber Wheel:
Analysis: In this case, problem occurs in stenter machine. Fabric was not set up
into pin properly by the fiber wheel. This problem occurs due to some reasons:
 Setup of fiber wheel
 Friction

Solution: In that case, fiber wheel can be replaced.

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Problem Non-return valve does not seal back flow

Analysis: The air is not passing properly from the air blower. Operator has given pressure of
air 5 psi, but it gave only 3 psi. So, they checked the non return valve. And the non return valve
has broken. Because of the
 Vibration
 High –temperature.

Solution: The broken non return valve should be replaced with a new Non- return valve.
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 Problem: Fire in stenter machine.
Analysis: In stenter machine, Hot chamber creates a lot of dust from fabric. In hot chamber
temperature is too high. Because of this heat, these dusts are burning inside of the hot chamber.

Solution: Stenter machine need to clean twice in a week.

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 Problem in Bearing :
Analysis: In this case, problem was found in stenter Machine. Sometimes the roller is not
rotating because of bearing. The bearing was damaged. This problem occurs due to some reasons.
They are given below:
 Vibration
 Excessive Speed

Solution: The bearing can be replaced.

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Conclusion:
 Industrial training is an essential part for engineering education because it
minimizes the gap between theoretical and practical knowledge.
Undoubtedly, this industrial training helped me to gain knowledge about
textile technology, production process, machineries, and industrial
management and made me comfortable with industrial life. Besides, it has
given me the first opportunity to work in industry.

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 Recommendation:
After observing the whole factory, I recommend

 In dyeing section, air temperature is always high. At present, there are

two exhaust fans in the dyeing section. They should install more or
better exhaust fans for proper air circulation.

 Most of the time the dyeing floor is watery; it should be cleaned and
dried frequently.

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