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This document provides information about an industrial attachment at Square Fashions Ltd., a textile factory in Bangladesh, completed by four students from Bangladesh University of Textiles. It includes details about Square Fashions such as its establishment, production capacity, departments, manpower organization, shift changes, knitting section layout and machines. It also summarizes the dyeing, finishing, quality control, utility and effluent treatment processes at the factory.
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- 1. BANLADESH UNIVERSITY OF TEXTILES 92, SHAHID TAJUDDIN AHMED SARANI TEJGAON INDUSTRIALAREA, DHAKA-1208 Welcome to our presentation On Industrial Attachment At From 19th May,2015 to 19th July 2015
- 2. SUPERVISING TEACHER MD. EMDAD SARKER Assistant Professor, Department of Fabric Engineering, Bangladesh University of Textiles SUBMITTED BY SAYEED IBNE REZA (2011-1-081) MD. FAKHRUL ISLAM (2011-1-086) YEASIN ARAFAT (2011-1-232) MONIKA JAHAN (2011-1-250)
- 3. Square Fashions Ltd. at a glance Factory Location Rokeyapur,Jamirdia,Habirbari,Valuka,My mensingh Corporate Office Mascot plaza,(11 𝑡ℎ −12 𝑡ℎ Floor ), Plot# 107/A, Sector# 7,Sonargaon janapath,Uttara Model Town,Dhaka- 1230,Bangladesh Year of establishment: 2001 Commencement of production: June ,2002 Target market : Export oriented readymade garment Industry Investment:Us $20 million Production Capacity : 12 tons of knit fabrics per day (fabric unit -1) Total Factory Area: 165000 sq.ft Production space : 135000 sq.ft
- 4. Department of Square Fashions Ltd. Production Pertaining Department: Fibre Dyeing department Yarn store department Yarn dyeing department Knitting department Physical and chemical lab Dyeing Finishing department Quality control department R & D (research & development) Supporting department: Finance & Accounting HRM Department Utility Department Security Department Administration Marketing & Merchandising
- 6. Section wise Manpower Distribution Section No of Worker Fabric Dyeing 75 Yarn Dyeing 30 Knitting 115 Finishing 60 Quality 75 Physical Lab 30 Chemical Lab 15 R&D 20 HR & Admin 25 Others 35 Total Worker & Stuff 750
- 7. Shift Change There are three shifts in this industry. So the shifts are changed at every 8 hours. General Shift: 8 a.m. to 5 p.m. Shift A (Day): 6 a.m. to 2 p.m. Shift B (Day): 2 p.m. to 10 p.m. Shift C (Night): 10 p.m. to 6 p.m. General Shift is provided only for General manager/ Assistant General Manager/ Sr. Manager /Sr. Executive
- 8. Knitting Section Number of machines Needle bed Machine Type No. of machine Circular Single jersey 20 Fleece 3 Engineering Stripe 14 S/J jacquard 4 Rib 7 S/J Semi jacquard 3 Interlock 4 Flat 22 Total 77
- 9. Layout plan of circular knitting section (fabric unit 1)
- 10. Relanit Technology Technology of using vertical sinker in circular knitting machine is called Relanit technology. It is a modern innovation of MAYER & Cie. Relanit Versions: Relanit 1.6R Relanit 1.6RE Relanit 2. 53SE Relanit 3.2 ii Relanit 4.0 Diameter of cylinder = Number of feeder / Relanit model
- 11. Relanit 4.0 (High speed machine) Higher number of feeder ,Special types needle & cam ,Vertical sinker Needle Cam Vertical Sinker
- 12. Feeder stripe Stripe effect is produced by using different color yarn in different feeder in an orderly manner according to repeat 10 Course Repeat of a feeder stripe design: Red = 5 course Green = 3 course Black =2 course Total = 10 course While producing this fabric in a 54 feeder machine, active feeder would be = 10×5 =50 The rest 4 feeder will be all miss cam. Yarn arrangment would be : Feeder (1-4)= miss Feeder(5-9) =Red Feeder(10-12)= Green Feeder(13-14)= Black Then, Feeder (15-19) = Red Feeder (20-22) = Green Feeder (23-24) = Black & so on.
- 13. Engineering stripe Stripe effect is produced by adding different colored yarn in each feeding position according to repeat with the help of “ Finger Mechanism”. 45 Course Repeat of a E-stripe Design Red =10 course Green = 5 course Red = 5 course White = 5 course Pink = 10 course White = 5 course Red = 5 course Color of yarn in the Finger Finger 1 = Red Finger 2 = Green Finger 3 = White Finger 4 = Pink The Programme will be : Finger 1 = (1-10) Finger 2 = (11-15) Finger 1 = (16-20) Finger 3 = (21-25) Finger 4 = (26-35) Finger 3 = (36-40) Finger 1 = (41-45)
- 14. Yarn Selection by Fingering Device Automatic Cam Arrangement System
- 15. Circular mechanical jacquard knitting machine Knitting Elements: 1.Peg box 2.Peg 3.Selector 4.Raising Cam 5.Cam box 6.Jack cam 7.Needle cam 8.Pin Cam 9.Sinker Cam 10.Jack 11.Needle 12.Pin 13.Sinker
- 16. Needle of Different Butt Position Needle Selector Knob Cam Box of Semi Jacquard Machine
- 17. Electrical Circular Jacquard Knitting Machine Knitting Elements: Electromagnetic needle selector. Spring Jack. Jack Cam Box and Jack cam. Needle Pin Sinker Special cam box for electrical circular jacquard.
- 18. Needle and Sinker of Electrical Jacquard knitting machine Cam system of Electrical Jacquard knitting machine Cylinder of Electrical Jacquard knitting machine
- 19. A flow process is given for designing a jacquard design. Open Gridm file Take a repeat for a design Draw the design Save the file Open the cone file Take a new file selecting the gridm file Edit the cone color arrangement Calculate the cone color arrangement Save the file in the same folder as the gridm file saved Open the gridm file Open the cone color arraangement file Invert the file Give the tuck if necessary Save the file as the same of cone color arrangment name Open the RAP Open the cone color arrangement file through it. Convert it For 2 ways or 3 ways technique. Edit the file Test the file Save the file as the same name as cone file. Sent this file to the machine computer through data cable.
- 20. Knitting Cost of Different Fabrics (approx.) FABRIC NAME COST PER KG (TK) Single Jersey 10-11 Single Jersey with Lycra 34 Single Lacoste 16-18 Double Lacoste 16 Single Pique 18 Double Pique 18 Rib (1x1) 18 Rib Feeder Stripe(1x1) 30 Design Rib 50 Lycra Rib(1x1) 40 2X2 rib 30-40 2X2 rib Lycra 40 Interlock 30 Feeder stripe 30 Auto stripper 80-100 Auto striper with Lycra 140 Fleece 20 Jacquard Design 250-300
- 21. List of Buyers: Puma Mustang G-Star Mexx H & M Next M & S Fire Trap S.Oliver Engelbert Strauss P & C Target Australia Pierre Cardin Malfini Gutteridge Kitaro Espirit Tom tailor
- 22. Types of Yarn Used Cotton Yarn(Card and Combed) Polyester Yarn CVC PC Melange Spandex (Lycra)
- 23. Pie chart of Yarn used in Square knit fabric Ltd. 17% 4% 26% 5% 11% 8% 8% 4% 4% 5% 3% 2% 3% Pie chart of various types of yarn with count used in knitted fabric at Square fashions Ltd. 20 D lycra 40 D lycra 34's 40 viscose 30's 28's 26's 30 CVC 60/2 mercerised 24's melange 20's slub 60's P/C others
- 24. Fibre Dyeing Fibre dyeing is done to produce Melange Yarn Fibre used : 1.Cotton 2.Polyester 3.Viscose 4.Rayon 5.Flax 6.Ramie Cake Preparation Scouring+Bleaching+Dyeing at same bath Hydro extraction (2 hours in 3 steps) Cake Opener Dryer (Feeding,wet losing,stream dryer) Bale pressing and preparation( 50-120 kg/bale)
- 25. Yarn Dyeing Yarn are processed in three Forms: 1. Package form (mercerised+non mercerised) 2. Hanks form (only mercerised yarn) 3. Sewing thread preparation(used 100% polyester,50/2 polyester,20/2 polyester,150D filament,120D rayon )
- 26. Process flow of yarn processing in package form Grey Yarn from spinning Making soft winding package Batching Dyeing Hydroextracting Radio frequency dryer Hard/Random winding package Delivery for knitting or weaving
- 27. Soft Winding Batching Hard/Radom Winding
- 28. Machine used in yarn dyeing Types of the machine Quantity Yarn dyeing machine (package form) 11 Yarn dyeing machine(hank form) 04 Mercerized machine(yarn mercerizing) 01 Soft package winding machine(no.of head-240) 02 Hard /random winding machine(no. of head-312) 03 Hydroextractor machine 01 Radio frequency dryer 01 Gas singeing machine for yarn (No. of head-96) 02 Soft winding package machine for sewing thread 02 Reconning machine 02 Sewing thread dyeing machine 15 Reeling machine 4
- 29. Batching Batching is the pre-plan of dyeing process. Machine used in batch section: 1. Back sewing machine: Laycra/single jersey fabric is turned into tube form. 2. Turning machine: It makes the face side into back & back side into face. 3. Padder machine: It is used to open out the fabric from roll form. 4. Balance : It is used to weigh the grey fabric.
- 30. Fabric Dyeing Machine used of different Brand: Sl. No. Brand Type No. Of machine Origin 1 Fongs Sample Dyeing 07 China 2 Fongs Dyeing 02 China 3 Sclavos Dyeing 09 Grece 4 Thies Dyeing 04 Germany
- 31. Finishing Types of finishing: 1. Chemical finishing 2. Mechanical finishing Machines used in finishing: Slitting machine Dewatering machine Stenter machine Open Compactor Tube compactor Dryer Special Finishing Machine: Sueding machine Brush Finish machine
- 32. Finishing Machine used in Square knit fabric Ltd. Machine Name No. Of Machine Dewatering machine 01 Slitting machine 02 Dryer 02 Stenter machine 04 Open tube compactor 02 Tube compactor 01 Sueding machine 01 Brush finish machine 01
- 33. Laboratory tests Determination of G.S.M Fabric width Shrinkage test Spirality test Brusting Test Piling test Color fastness to rubbing Color fastness to wash Color fastness to perspiration Color fastness to water Color fastness to light
- 34. Utility section
- 35. Source of Utilities Water- Own supply (Pump) Steam- Own supply (Boiler) Electricity- Generator and PDB Gas- Titas Gas transmission and Distribution Co. Ltd. Compressed air- Own supply (Air compressor) Different Machines of Utility Gas generator Boiler Compressor Air conditioning machine Chillier
- 36. Effluent Treatment Plant (ETP) Treated Water Storage and Equalization Tank Mixing Tank
- 37. In square Fashions Ltd. Biological process is applied in ETP plant. Capacity of their plant = 4200 m3/day (ETP-01+ETP-02)=(50+125)=175 m3/hr Biological plant 1. Bacteria (Bacilli,Cocei,Spirillum) 2. Yeast 3. Fungy 4. Alge Micro organism is the main raw material for Biological plant.
- 38. Caustic Recovery Plant (CRP) Square Fashions Ltd. Has a caustic recovery plant to Recycle fabric and yarn mercerization machine discharge wastage weak lye caustic of average 5 Be(32 gm/L).Here collecting of weak lye seperately from machines and pumped in CRP storage tank.CRP recover strong lye at 30 Be( 296.8 gm/L)
- 39. Thank You