2. PRESENTED BY
Name Exam. Roll Registration No.
Jorjis Ridwan 234 345
Sabbir Ahammed 213 275
S.M. Riadul Zannat 228 330
Al Shaharir Shakib 226 313
Mahmud Sharif Bhuiyan 225 312
3. CONTENTS
General Information
Factory Introduction
Raw Materials Description
Production Planning & Controlling
Pre-Treatment Section
Dyeing Section
Finishing Section
Quality Assurance Laboratory
4. General Information
Factory Name : BEXIMCO TEXTILE LIMITED
Location : BEXIMCO Industrial Park (Sarabo, Kashimpur, Gazipur)
Date of incorporation : 30 May, 1984
Commercial production : 1990
Business line : Manufacturing & Marketing of high Quality fabric.
Listing status : Public listed company
Number of Woven loom installed : 293
Number of spindled installed : 119,520
Number of Denim loom installed : 56
Number of circular knit machine installed : 30
Production Capacity : 28 Million LM
Number of employees : 5181
Website : www.beximco.org
5. Factory Introduction
BEXIMCO Textile Ltd. is one of the most modern composite mills in Bangladesh.
BEXIMCO Textile Ltd. has an installed capacity of 299 high-speed air-jet looms in
its weaving section and a high-tech dyeing and finishing section with a capacity of
100,000 yards of finished fabric per day. This company is located at the BEXIMCO
Industrial Park.
Duration of Internship: 1 June to 31 July,2022
8. Raw Materials Description
Weaving:
100% Cotton
CVC (60/40, 80/20,90/10,55/45)
PC (65/35,80/20)
PC with Lycra
Dyeing:
Gray Fabric
Dyes
Chemicals & Auxiliaries
9. Production Planning &
Controlling
Capacity planning
Time and Action (TNA)
Scheduling
PP meeting
Order allocation
Man, power and machine allocation
Execution of every task
Materials planning and in-house follow up
Delivery meet
10. Pretreatment Section:
Singeing:
Process for removing hairy/projecting fiber
Singeing-Desizing Chemicals/Materials:
Desizing Agent
Deaerating Agent
Wetting Agent
Sequestering Agent
Natural gas for burner, Steam, Compressed Air, Water.
11. Desizing
Process of removing sizing
materials.
Singeing & Desizing Rout:
Grey fabric report checking
Lay in
Fabric stitching
Chemical Preparing (PH check)
Optimum Temperature rise up
Padder Pressure Setting
Production Fabric Stitching with guiding fabric
Singeing & Desizing start with proper flame- intensity
Rotation
Figure: Singe-Desize Machine.
12. Scouring:
Process to remove impurities such as: oils, waxes, fats, vegetable
matter, dirt etc.
Chemicals
• H2O2 (50%)
• NaOH (400 Be)
• Stabilizer
• Detergent/ Wetting agent
• Sequestering agent
Chemical Composition (ml/kg )
(24-30)
(30-34)
(5-6)
(4-5)
(1-2)
13. Cold Bleach:
Process to remove dirt, dust, husk,
leaf from the fabric and transform
it into permanent white by
chemical treatment in cold
condition.
Cold Bleach Recipe:
H2O2 (50%) 45g/l
NaOH (400 Be) 30g/l
OKM 8g/l
WBL 8g/l
S.FR 1g/l
NBA 1g/l
S.P.S 2g/l
Figure: Bleaching Machine.
Singing-Cold bleach Rout:
Grey fabric report checking
Lay in
Fabric stitching
Chemical Preparing (PH check)
Padder Pressure Setting
Cold Bleach start with proper flame intensity
Rotation
14. Mercerization:
Process to increase the dye absorbency, strength and luster of the
fabric by chemical treatment.
Chemicals/Materials used Chemical Composition
Sodium Hydroxide (NaOH) 280 Be (Baume)
215 gm/l
Acetic acid (99%) 5% of total water
Wetting agent: If required 3 gm/l
4gm/l [for Canvas, CN 082]
Compressed air As required
Steam, Water As required
Figure: Mercerization Machine
15. Dyeing Section:
Dyeing: Application of dyes or pigments on textile materials such as
fibers, yarns and fabrics with goal of achieving color.
Solid Dyeing (PDB process): Process of applying dye to the mercerized
fabric.
Recipe:
Reactive dyes a-g/l
Reduction Inhibitor b-g/l
Anti-migrating Agent c-g/l
Urea d-g/l
Alkali e-g/l
Wetting agent f-g/l
Temperature 1500C -1700C
(All the chemicals are added according to fabric construction)
16. Pad Dry Bake or PDB Process:
Impregnate with dye and squeeze
of surplus liquor
Partial drying of fabrics in IR-
section
Complete drying of fabric in Hot
Flue
Recipe:
Reactive dyes
Reduction Inhibitor
Anti-migrating Agent
Wetting Agent
Process Flow Chart:
Dyes + Soda Ash + Urea + Thermosol M.P.
↓
Padding
↓
Drying (130℃, 2 min.)
↓
Curing (160℃, 1 min.)
↓
Cold Wash
↓
Hot Wash (75℃)
↓
Cold Wash
↓
Ironing
↓
Shade check
17. CPB Process:
Impregnate with dye and alkali squeeze
of surplus dyeing liquor
Store wet for 8-12 hours (Batching)
Wash-off
QC check
Carried out in 25-280C temp.
Recipe:
Reactive Dyes
Reduction Inhibitor
Urea
Alkali-1
Alkali -2
Process Flow Chart:
Dyeing
↓
Wrapping the fabric with polyethene
↓
Oven Drying (30 minutes)
↓
Hot Wash
↓
Cold Wash
↓
Ironing
↓
Shade check
18. One–Bath Solid Dyeing process:
Impregnate with dye and squeezing of surplus liquor
Partial drying of fabric in IR-section
Complete drying of fabric in hot flue
Fixations of dyes by means of relatively very high temp. with dry air.
Recipe:
Disperse dyes
Reactive dyes
Reduction Inhibitor
Anti-migrating agent
Urea
Dispersing agent
Alkali
19. Solid Dyeing with Vat
Dyes (Pad-Dry or PD
process):
Impregnate with dye and squeezing
of surplus liquor
Partial drying of fabric in IR-section
Complete drying of fabric in hot
flue
Recipe:
Vat Dyes
Dispersing Agent
Anti-migrating Agent
Dyeing with vat dyes
↓
Rinse with cold waste
↓
H₂O₂ treatment (60℃, 2 minutes)
↓
Hot Wash
↓
Neutralization with Acetic acid
↓
Ironing
↓
Shade check
Process Flow Chart:
20. Solid Dyeing with Pigments:
Impregnate with pigments and
Binder squeeze of surplus liquor
Partial drying of fabric in IR-
section
Complete drying of fabric in hot
flue
Fixation (Binding) of pigment by
means of relatively high
temperature with dry air
Recipe:
Pigments
Binders
Anti-migrating Agent
Washing Process:
Process to remove
impurities through
water treatment.
Washing Chemicals:
Water
Steam
Detergent/Soap
Compressed air
21. FINISHING SECTION:
Finishing: Process to provide required quality to the fabric.
Refinishing & Topping: Refinishing
and topping is a repetitive finishing
process to minimize the dyeing as per
the customer swatch.
Equipment: Monforts Stenter
Machine – I, II & III
Textile Finishing
Chemical
Finishing
Mechanical
Finishing
22. Heat Setting and Stretching:
Heat setting is a mechanical process to give dimensional stability and
shrinkage control.
Equipment: Monforts Stenter Machine
Materials/Chemicals used:
Sometimes wetting agents (e.g. Mixture of surface-active
compound) are used as chemical for the Heat Setting and Stretching
process
23. STENTERING:
A process for drying and heat
treating fabric after wet
processing.
Chemicals/Material for
Colored Fabric :
Softener
Dye Fixer (It is used according to
the color fastness)
pH adjusted with Acetic acid
Anti-foam, for 100% Cotton and
Twill Fabric (for deep shade)
Chemicals/Material for White
Fabric :
Cotton OBA (Optical
Brightening Agent)
Polyester Cotton OBA
Softener
Tinting Agent
Fig.: Stenter Machine
24. SANFORIZING:
A mechanical process for
shrinkage control.
Materials/Chemicals used:
No chemical is used for
Sanforizing machine.
Company name : Changzhou Hongda Technology
Model : LMA451B-240
Power : 380 V 3P
Frequency : 50 HZ
Capacity : 48 KVA
Fig.: Monforts Sanforizing machine.
25. EMERIZING:
A mechanical treatment of fabric in the emerizing machine for giving the
fabric a soft hairy appearance by protruding the fiber from the fabric
surface.
Materials/Chemicals
used :
Emery Sticks and Emery
paper and brush with
different grades are used
in this process. Chemicals
are not used directly on
the Emerizing Machine.
Figure: Emerzing Machine
26. CALENDARING:
A finishing process to achieve effects like smoothing effects, luster effects,
handle effects.
4 types of calendaring are done :
a. Chintz calendar (smoothing effect -
with paper roll and steel roll)
b. Ironing (Soft, smoothing and
glazing effect - with steel roll)
c. Calendaring for smooth surface
(Mating effect-with cotton)
d. Calendaring (Soft and Smoothing
effect-with cotton roll, paper roll and
steel roll)
Figure: The Ramisch Calendaring
Machine
27. Quality Assurance Laboratory
Wet Test:
Color fastness to Washing
Color fastness to
Perspiration
Color fastness to Sea water
Physical Test:
• Tear Strength Test
• Tensile Strength Test
• Seam Strength Test
• Abrasion Resistance Test
• Color fastness to Rubbing
Laboratory Tests
Purpose: To assure required quality.
28. Tear Strength Test:
Purpose: Determination of strength
against tear force of the fabric.
Apparatus: Elma Tear Machine
Sample size: Sample fabric size is of
10cm x 6.3cm
Figure: Elma Tear Machine
29. Tensile Strength Test:
Purpose: Determination of tensile strength of woven
fabric against tensile force.
Apparatus: Tensile strength tester
Sample size: Sample fabric size is of 10cm x 15cm
Figure: Tensile strength tester
Seam Strength Test: (EN ISO 13936-1)
Purpose: Determination of strength of sewed fabric
against tensile force. a
Apparatus: Tensile strength tester
Sample size: Fabrics are to be sewed by taking 12mm
distance from the edge.
30. Pilling Test:
Purpose: Determination of
pilling formed in the fabric.
Apparatus: Nu-Martindale
Machine.
Sample size: Sample fabric dia.
is of 38cm
Figure: Nu-Martindale Tester
Abrasion Resistance Test:
Purpose: Determination the abrasive
resistance of fabric.
Apparatus: Nu-Martindale Machine.
Sample size: Sample fabric dia. is of
15.2cm
31. Color Fastness to Rubbing:
Purpose: This test is done to determine the
color fastness of fabric against rubbing.
Apparatus: Crockmaster Machine,
Rubbing cloth, Gray scale
Sample size:
Specimen size:14cm x 5cm
Crocking cloth: 5cm x 5cm
Figure: Crockmaster Machine
32. Color Fastness to Washing:
Purpose: Determination of color fastness to domestic washing &
drying.
Apparatus: Gyro wash, Multifiber, Gray scale, Light source D-65
Sample size:
Dyed sample:10cm x 04cm
Multifiber: 10cm x 04cm
Recipe:
Detergent : 5gm/L
Sodium Carbonate : 2gm/L
Temperature x Time : 95℃ x 4 hours
No. of stainless-steel boll : 10
M:L : 1:50