WELCOME

TO MY
PRESENTATION

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 A study on the operation of
machineries at Rim Dyeing Ltd.

Lutfur Rahman
ID: 14207101
Program: BSME

Department of Mechanical Engineering

IUBAT—International University of Business
Agriculture and Technology
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 Contents
 Introduction
 Objectives
 Company Profile
 Chain of Production Process at Rim
Dyeing Ltd
 Machine Details
 Problem Finding
 Analyzing and Solution
 Recommendations
 Conclusion
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 Introduction
Rim Dyeing Ltd. is a Textile Dyeing Industry.
Textile production is the process by which fabrics,
yarn, and thread both natural and synthetic are
made. It also comprises the production of objects
made with these materials. Both processes have
their own steps for production.

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 Objectives
 To gain basic understanding of operation of
different machineries, Trouble-shooting
procedures and the related aspects at Rim
dyeing Ltd.
 To have practical experience of job life.
 To gain knowledge about Production
Operation (Mechanical part).
 Primary test and check equipment’s
 Find out primary fault
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 Company Profile
Rim Dyeing Ltd. is committed to provide excellent
services to it’s clients. It is dedicated to focus on quality
in order to excel in its performance, since December 09,
2004. Now they have one dyeing factory and two
garment manufacturing units.

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Factory Basement Layout
 Location
Head Office:
Rim Industries Ltd.
20, Ahsan Ullah Road , Nawab Bari.
Islampur, Dhaka, Bangladesh
Mobile :01712128296
Mail: rimdyeing@gmail.com

Factory Location:
Rim Dyeing Ltd.
211-213, Bscic Industrial Estate
Tongi, Gazipur- 1712, Bangladesh
Mobile; 01715616581
Mail: nazrul.r7@gmail.com Figure: Factory Gate
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Company Products

Figure: Products
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Buyers

Figure: Buyers 10
Chain of Production Process

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 Machine Details
 Gas Singeing Section: Gas Singeing
Machine

 Mercerize Section: Mercerize Machine

 Dyeing Section: Dyeing Machine

 Finishing Section:
1. Dryer Machine
2. Stenter Machine
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 Gas Singeing Machine
 The fabric passes over a burning gas flame at
such a speed that only the fibers burn and the
main body of the fabric is not damaged by the
flame.
 Function of the Gas Singeing Machine:
 Smoothness and evenness of the fabric is
increased.
 Gas flame can be changed according to fabric
with.
 Both side of the fabric can be singeing

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 Continue
Main Parts:
 Brush
 Gas Burner
 Guide Roller
 De-sizing Tank
 Squeezing Roller

Figure: Gas Singeing Machine 14

 Continue

Schematic view of Gas Singeing Machine

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 Operation
 At first collect the raw material or fabric. This fabric
transfer to brush with the help of squeezing roller.
 At this time removing dust from the fabric. Then fabric
transfer to the gas burner.
 The fabric is moved very quickly, and only the fiber
ends are destroyed.
 As soon as the fabric leaves the singeing area, it enters
a water bath or de-sizing bath. It’s containing de-sizing
liquor. For de-sizing wetting agent, Enzyme, soda, salt
Acetic acid is required. Temperature is maintained
around 80-100’C.
 After de-sizing fabric is collect in rolled in batching in
uniform tension.
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 Mercerize Machine
 Mercerize machine is a process for increasing
absorbency, strength, and luster of the fabric by
physio-chemical treatment.
Function of Mercerize Machine
 Increased luster
 Increased tensile strength
 Increased apparent color depth after dyeing
 Improved dimensional stability

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 Mercerize Machine
Main parts:
 Fabric inlet
 Impregnation-
1(IMP)
 Impregnation-
2(IMP)
 Washing chamber
 Neutralizing
chamber
 Batching
Figure: Mercerize Machine 18
 Continue

Schematic view of Mercerize Machine

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 Operation
 First of all collect the fabric. Then this fabric transfer to
the first impregnation section using guide roller.
 In that time caustic process is happen, where is use
temperature is around 60’C.
 Then using squeezing roller fabric transfer to the second
impregnation section. That time same process will be
happen.
 After that using squeezing fabric transfer to the washing
chamber.
 Here fabric passed over some driven roller to make proper
hot wash. Here temperature is maintained is around 90’C.
 after washing fabric goes through neutralizing chamber.
 In that time remove the alkaline from the fabric.
 After neutralizing chamber fabric is collect in batching in
tension. Then the fabric goes to dyeing section.

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Dyeing Section

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 Dyeing
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 particular chemical material.
The temperature and time controlling are two key factors in dyeing.

Figure: Dyeing Section 22

Sequence of Operation of Fabric Dyeing

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 Main Parts of Dyeing Machine
 Power control
board
 Water line
 Steam line
 Air line
 Winch
 Dosing tank
 Mixing tank
 Pump
 Heat exchanger
 Reserve/PT tank

Figure: Dyeing Machine

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Different Types of Valves and Device

Butterfly valve Steam Trap

Air Regulator Solenoid Valve

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Finishing Section

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 Finishing
The final processing of the fabric to increase the natural
properties or attractiveness before the fabric is cut into
apparel or made into any article of textile is called finishing.

Figure: Finishing Products

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 Object of Finishing
 To enhance the suitability of the fabric for end
use.
 To improve appearance and sale appeal for
comport and utility.
To give desirable qualities to the fabric like-
Softness
Luster
Drape
Dimensional stability
Crease recovery
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Flow Chart of Finishing Process

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 Dryer Machine
 Dryer machine as a process to dry the fabrics.
We can define drying as a process where the
liquid portion of the solution is evaporated from
the fabrics.
Function of Dryer Machine:
 To dry the fabric
 To control the shrinkage
 To control the overfeed system

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 Continue
Main parts of
Dryer machine:

 Squeezing Roller
 Cylinder
 Steam
 Condensate

Figure: Dryer Machine

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 Continue

Schematic view of Dryer Machine

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 Operation
 After dyeing collect the fabric.
 Then fabric go to the cylinder using squeezing
roller.
 After that reduce the water from the fabric, that
time fabric totally dried with the help of cylinder.
 After dry fabric will be collect in batching or
trolley.

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 Stenter Machine
 Stenter machine is used for open form fabric.
After passing the open compactor, fabric center
into the steneter. Then stenter is to stretch the
fabric widthwise and to the recover the uniform
width.
Function of Stenter Machine
 GSM Control
 Width Control
 Shrinkage

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 Continue
Main parts of
Stenter machine:
 Wheel
 Chain Rail
 Nozzle
 Burner
 Blower
 Guide Roller

Figure: Stenter Machine

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 Continue

Schematic view of Stenter Machine

Operation:
 The fabric is entered into the guide roller. Guide roller guide the
fabrics and also weave of the fabric is gripped by the clips and pins are
also provided.
 There are 6 to 8 chambers provided on the machine each chamber
contains a burner and filters are provided to separate dust from air.
 The circulating fans blow air from the base to the upper side and
exhaust fans sucks all the hot air within the chambers.
 Attraction rollers are provided to stretch the warp fabric.

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Problem Finding, Analyzing
and Solution

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Problem Finding, Analyzing and Solution
As Gas Singeing, Mercerize, dyeing, Dryer, Stenter
machine components are always working under
high rotational forces, various problems may
happen. The most significant problems are:
 Problem in Bearing Cage
 Problem in shaft
 Problem in roller
 Problem in Fiber Wheel
 Problem in Dryer was not heated
 Problem in coupling and Bearing

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 1.Problem in Bearing Cage
Analysis: In this case
problem was found in
Gas singeing Machine.
Sometimes the bearing
cage was damaged. This
problem occurs due to
some reasons. They are
given below:
 Vibration
 Excessive load

Fig: Problem in Bearing Cage 39

 Continue
Solution: In this case bearing cage damage, the
bearing can be replaced.

It was the time to change the bearing of gas singeing machine. 40

 2.Problem in Roller shaft
Analysis: In mercerize
machine sometimes
the problem occurs due
to wear and bearing
failure. Sometimes due
to excessive rotation
the problem is created.
Shaft erosion can be:
 lubrication
 friction
 overload
Fig: Problem in Roller Shaft 41
 Continue
Solution: The roller
shaft can be
repaired by welding
and grinding.

During setup roller of mercerize machine.

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 3.Problem in Roller
Analysis: In this case
problem was occurs
in dryer machine.
Sometimes fabric
was not properly dry
by the roller. This
problem occurs due
to some reason:
 Roller rubber erosion

Fig: Problem in Roller 43

 Continue
Solution: In case
of roller damage,
so the roller can be
replaced.

Fig: Chance the Roller 44

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

Fig: Problem in Fiber wheel

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 Continue
Solution: Several times this problem occurs due
to friction of the fiber wheel. In that case, fiber
wheel can be replaced.

Fig: Chance the Fiber Wheel 46

 5.Problem in Dryer was not heated
Analysis: In this case
problem was occurs
in dryer machine. It
is use to dry many
different types of
fabrics. This problem
occurs due to some
reason:
 Hose pipe leakage

Fig: Problem in hose pipe leakage

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 Continue
Solution: In case of hose pipe leakage, in that
time hose pipe can be replaced.

It was the time to setup hose pipe of Dryer machine.

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 6.Problem in coupling and Bearing
Analysis: In this case
JT tank Machine
problem was found.
Sometimes the bearing
and coupling was
damaged. This
problem occurs due to
some reasons. They
are given below:
 Vibration
 Overheating
Fig: Problem in Coupling and Bearing
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 Continue
Solution: In that reason bearing and coupling
damage, the bearing and coupling can be replaced.

It was the time to setup coupling and bearing of JT tank machine. 50

 Recommendations
 The factory has some old manual machines
which consume more electricity this
consumption can be reduced by replacing the
latest automatic machine.
 The diameter of the hose pipe should be larger
than the existing one in order to ensure more
supply of steam.
 Installation of full automation will reduce the
production cost and save production time.

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 Conclusion
Industrial training is an important and essential part
of our education. It gives us an opportunity to
compare the theoretical knowledge with practical
facts which develop knowledge and skills of a
student. This industrial training also gives an
opportunity to enlarge the knowledge about
production planning, procurement system,
production process, operation of machineries. It
teaches a student to adjust with the practical life.
After all, I realized that industrial training increase
our practical knowledge and confident for future
life.

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THANKS TO ALL