Industrial attacthment of masco industries ltd.

INTERNY PAPER ON MASCO GROUP
1
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
MASCO INDUSTRIES LTD.

2
INTRODUCTION
Chapter: 1
INTRODUCTION

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Textile and garments sector is the biggest and fastest growing sector in
Bangladesh. It is also the highest foreign currency earning sector in Bangladesh.
Among this sector, Knit garment is growing very rapidly due to smaller investment
requirement, greater backward linkage facility & higher profit than woven
garments. That’s why export of knit garments is increasing steadily for last few
years and up to now.
Textile education can’t be completed without industrial training. Because this
industrial training minimizes the gap between theoretical and practical knowledge
and make us accustomed to industrial environment. I got an opportunity to
complete two-months long industrial training at MASCO INDUSTRIES
LIMITED, which is a 100% export-oriented composite Knit Dyeing Industry. It
has well planned & equipped fabric dyeing-finishing and garments units in
addition to facilitate knitting and knitwear manufacturing.
Introduction
By means of practical knowledge it’s possible to apply the theoretical knowledge
in the practical field. For any technical education, practical experience is almost
equal important in association with the theoretical knowledge.
The industrial attachment is the process, which builds understanding, skills and
attitude of the performer, which improves his knowledge in boosting productivity
and services. University education provides us vast theoretical knowledge as well
as more practical attachment, in despite of all these industrial attachment helps us
to be familiar with technical support of modern machinery, skill ness about various
processing stages.

4
It also provides me sufficient practical knowledge about production management,
work study, efficiency, industrial management, purchasing, utility and
maintenance of machinery and their operation techniques etc. the above mentioned
can not be achieved successfully by means of theoretical knowledge only. This is
why it should be accomplished with practical knowledge in which it is based on.
Industrial attachment makes us reliable to be accustomed with the industrial
atmosphere and improve courage and inspiration to take self responsibility.
I have prepared this report as required on completion of my attachment of my
attachment course in regarding guideline given by the university authority.

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Chapter: 2
INFORMATION ABUOT FACTORY

6
GENERAL INFORMATION ABOUT THE FACTORY:
Name of Company : MASCO INDUSTRIES LTD.
Factory : MASCO INDUSTRIES LTD.
297 Khortoil, Tongi,
Gazipur-1712.,Dhaka
Bangladesh.

7
LAYOUT FOR GOING TO THE MASCO GROUP FROM DHAKA:
Different Sections of MASCO Knit-Dyeing Composite Unit:
DHAKA-MAYMANSHING HIGHWAY
KAI
Alluminim
Co.Ltd.
MASCO
GROUP
MASCO
GROUP
SMP
Design
Pvt. Ltd.
Oishi
Fashion
Pvt.
Ltd.
Gajipur
a
Tongi
Board
Bazar
Dhaka
Viyellatex
Group
SOUTH
EAST
NORTH
WEST

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Different Sections
a) knitting Section:
 Knitting
 Inspection
b) Dyeing section:
 Batch section
 Dye house
 Dyeing lab.
 Quality control
 Finishing
c) Garments section:
 Merchandising
 Sample
 Cutting Section
 Sewing Section
 Finishing Section
d) Maintenance section:
 Electrical
 Mechanical
e) Store Section
f) Administration Section
g) Security Section
h) Marketing Section
i) Production Planning & Control
j) Human Resource & Development Section

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MASCO GROUP INFORMATION
Capacity:
KNITTING Production
Capacity
: 650 tons per months
No. of
Machines
: Circular 74, Auto Striper : 8, Flat bed : 20
Available Dia
: Single Jersy : 18”-48”,Rib : 30”-40”, Interlock
: 30”-38”
Gauges
Converter
: Single Jersy -16,20,24,28,32, Rib- 16,18,
Interlock-24.
Fabric Type:
: Single Jersey Rib, Interlock, lacoast, Polo
Pique,Drop needle, Fleece, Terry, stripe, Auto
stripe 100 of Designs in different gauges.
DYEING & FINISHING
Production Capacity : 650 tons per month
No. of Machine : Bulk Dyeing – 44, Sample Dyeing- 11
Machine Capacity : 20kg to 1500kg
Types of Machine : Atmospheric & High Temperature
.
Special Fabric Type : Viscose, Lycra-viscose, Modal, Bamboo, Polyester etc.
Special Fabric Type : Carbon/Moss/Sueding, Both side brush, Antibacterial,
Moisture Management Water/Soil repellent, Anti UV, Scotch
guard, Teflon finish etc
Finishing Facility: Both Open & Tubular Line

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Garments Unit
SAMPLE
UNIT
Total
Machines :
75
Sample
Capacity:
300 pcs /day (depending on
styling)
Dummy: Both for Children & Ladies
CAD UNIT
Software
Facility:
Garber, Euro Cad, Winda, Photo digitizer
Plotter: Garber, Winda, Morgan, Kama Tech
Pattern Maker
& Cutter:
Winda.
Spreader: 5 machine from Morgan.
SEWING
UNIT
Area: 5,56,300 Sft.
Man Power: 9,200
Production
Capacity:
3.5 Million pcs per month.
No. of
Machines:
3010
Sewing lines: 96 sewing lines
Cutting: Marker from CAD & Auto spreader facility.
Product Mix:
All Kinds of baby items. Men’s & Ladie’s Light
& medium wears.
Special
Machines:
Pneumatic Button attaching machine from
Prym.

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Special
Sewing m/c:
4 smoking machine, pneumatic button attaching
& Button pull test machine at sewing facility
Special
Facilities:
Quarantines area for metal free zone.
Finishing:
All garments pass through metal detector &
Finishing is done in quarantine zone.
LAUNDRY
UNIT
Number of
Machine:
4 washing m/c, 1 sample m/c,7 tumble dryer.
Washing
Capacity:
80,000pcs/day
Wash Facility:
Garments wash, Silicon wash , Enzyme wash,
Pigment
Dyeing. Acid wash, Enzyme Stone wash, Spray
wash etc.
Printing & Embroidery Ltd
Machine
Facility
Auto
Circular
Machine
: Pannon, Spain
Printing Unit Area : 139,322 square feet.
Man Power
: Worker – (Male- , Female-), Stuff – (Male- ,
Female - ).
Production
capacity
: 80,000 – 100,000 pcs/day (considering 3-4
color print),
Number of
Tables
: 77 regular, 17 glass of 8500 running feet with
3 sample tables
(200 running feet).

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Voltage/
Tension
: 220 || 50/60 Horse
Colors (Heads) : 6
Palate : 12
Dryers : 4
Capacity of
one Machine
: 300 pcs per hr (Two Colors)
Design
Section
Manpower
: Four employees act as designers in design
section
Capacity
: 1 color: 50 designs , 2 Color: 25 designs , 3
Color : 10 designs, 4 Color: 8 designs
Positive
section
Machine : Katana, China
Productivity : 100.000 square inch per day
Screen
preparation
Name of
Exposing
Machine
: Atma, Taiwan
Capacity : 180-200 pcs per day
Name of
Dryer
: Atma Auto Exposing Dryer
Capacity : 1000 pcs
Stretching
Machine
: Atma
Capacity : 180- 200 pcs of Frames

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Curing Name of
Machine
: Jet- Force, UK.
Type of
Machine
: High temperature.
Number of
Chamber
: 3
Type of Belts : Duel
Number of
Machines
: 2 pcs
Color kitchen Auto mixing
machine
: 3 Pcs
Digital
Balance
: 12 Pcs
Recipe
Maintenance
: By register
Printing
Technique
: Screen print (major), Heat transfer, Spray,
Stencil etc..
Lab Section: In Lab all types of styles are cleaned up with a view to checking
the printing color, rubbing fastness in order to ensure whether
colors clear away or not at five times daily.
Storage Storage Area belongs to 2400 square feet (3 floor).
Inventory
Facility
Masco Printing & Embroidery Ltd. Abounds with incoming
goods, storage and checking area.
Dyestuff &
Auxiliaries
CHT (Germany) – Pigment paste, Fixer, Binder, Flock paste,
Glitter paste,
Bezama (Switzerland) – Pigment color,

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Kukyoto (Japan)- Pigment Fixer,
Magna (UK) – Discharge ink,
Silkflex (Malaysia) Rubber,
Zhong Dic Color (China) Rubber,
Changzhu (China) Flock,
Asuluck (Spain) Pigment ready paste, Pearl,
Embroidery
Facility
Area : 10,500 square feet.
Manpower : Stuff – 34, Worker -96.
Production
Capacity
: 120 million stitches per day.
Design
Section
: Two dedicated designers.
Software : Wilcom ES45, DGML by Pules.
Embroidery
technique
: Regular stitch, 3D embroidery, Sequin, Boring.
Machine
Facility
Name of
Machines
: Tajima, Japan and SWF,Korea
Number of
Machines
: 12 ( 20 head of each)
Heads : 20
Colors : Maximum 9,
Name of
Appliqué
cutting
Machine
: Yueming Laser
Number of
Machines
Applique
cutting M/C
: 3

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Capacity : 10200- 10800 nm
Sequin source : Wonil (Korea).
Yarn source
: Regular yarn : Well Thread (Bangladesh), Innova Textile
(Bangladesh), Air plane (Korea),
Lurex : Marthon (Korea).
Embroidery
Category
: Regular stitch (run, satin, tatami), motif, Cross stitch, Chain,
Boarder do, Aplique (felt, twill, jersey), Sequin, boring.
Yarn category
: Regular shiny yarn, matt yarn, Acrylic, Thicker yarn, Filament,
Lurex, Multiclolor
Buyer:
Buyers Name Country
H&M Sweden
C&A Belgium
Tchibo Germany
Zare Spain
Pull & Bear Spain
Bon Prix Germany
Mayoral Spain
United colors of benetton Italy
Lemoir Japan
Target Australia
Kappahl Sweden
New Yorker Germany

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Production Capacity
• WEAVING : 36, 000, 00 LBS/YEAR
• DYEING : 37, 50,000 LBS/YEAR
• SEWING AND FINISHING : 38, 30,000 LBS/YEAR
CSRP: Run ETP to treat dyeing water before release to environment
Donate Blood transfusion Thalassaemia Hospital
Donated Kidney Dialysis Machine by Rotary Club Dhaka
North-West
Scholarship to meritorious students
A Local school runs by Masco group Welfare Trust
Projected 80 bedded general Hospital
Carbon Footprint Project by BASF
Reuse of Generator exhaust to run chiller & Boiler
Preserve Rain water
Free Eye Camp & health Campaigns for local community
Take part on others social & national activates, disaster etc.

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Name Function Address
Masco Center Corporate Office
Masco Center
House -06, Road -01, Sector -03
Jashimuddin Avenue, Uttara
Dhaka-1230, Bangladesh
Phone: +88 02 8918082, 8914130
Fax: +88 02 8923126
Masco Industries Ltd.
Composite Knit
Garments
221-223, Shataish Road, Gazipura,
Tongi, Gazipur - 1712, Bangladesh.
Phone: +88 02 9813362-63, 9815041-42
Fax: +88 02 9810790
Mascotex Limited
Garments
Manufacturing
31-32 Mannan Mension, Shataish, Tongi,
Gazipur-1712.
Masco Cottons Limited
Garments
Manufacturing
44, Redwan Complex, Gazipura, Tongi,
Gazipur-1712, Bangladesh.
Tasniah Fabrics Limited
Garments
Manufacturing
Nayapara, Kashempur, Gazipur.
MPL Wear Limited
Garments
Manufacturing
44, Redwan Complex, Gazipura, Tongi,
Gazipur-1712, Bangladesh.
Concept Knitting
Limited
Composite Knit
Garments
Tilargati, Sataish Bazar, Tongi, Gazipur-
1712.
Masco Printing &
Embroidery Ltd
Printing & Embroidery
15/4 M. I. Khan Bhaban, Shataish
Maddhapara, Tongi, Gazipur-1712.
Masco Exports Limited
Terry Towels
manufacturring
Baghata, Palbari, Norshindi.
HR (Human Resources)

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Group HR
Support
Service
Compliance C&B and
ES
T&D ER & TM
BU HR, Garments,
BU HR, Fabrics,
GDL & FPPL,

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Chapter: 3
RAW MATERIALS

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Raw material is a unique substance in any production oriented textile
industry. It plays a vital role in continuous production and for high quality fabric.
Types of raw material:
1. Yarn
2. Fabric
3. Dye stuff
4. Chemical and auxiliaries
Name and source:
Yarn:
The raw material (cotton yarn) used in Knitting are the product of another
spinning Mill. They produce carded and also combed yarn according to their buyer
requirement. The yarn count range vary for carded yarn from(34/1) to (7/1) Ne.
The yarn count range vary for combed yarn from(40/1) to (20/1) Ne.
Mellange:
Mellange is produced by blending different amount of top dyed fibre with grey
fibre. Different types of mellange used in knitting are:
Mellange
White/Ecru mellange Grey mellange Anthra mellange
(dyed fibre 0.2-5%) (dyed fibre 5-15%) (dyed fibre 15-30%)
Sources of mellange:
 Patartoli
 Prime
 Shohag pur
 Thermax
Sources of polyester:
 Kader Synthetic.
 China.
 Count: 75den, 100den, 150den.
Raw Materials

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Sources of Lycra:
* Brand : Roica
Country : Taiwan.
* Brand : Texlon
Country : Korea.
*Brand : Acelen
Country: China
*Brand : Creora
Country: Japan
*Brand : Lioli (In Masco used mostly)
Country: China
 Count: 20 den, 40 den, 70 den.
Price list of different types of yarn:
Cotton:
Yarn Count Combed Yarn Carded Yarn
40/1 3.65 $/Kg 2.65-2.7 $/Kg
34/1 3.00 $/Kg 2.5-2.6 $/Kg
32/1 2.90 $/Kg 2.30 $/Kg
30/1 2.70 $/Kg 2.30 $/Kg
28/1 2.70 $/Kg 2.25 $/Kg
26/1 2.65 $/kg 2.25 $/Kg
24/1 2.60 $/Kg 2.25 $/Kg
22/1 2.55 $/Kg 2.20 $/Kg
20/1 2.50 $/Kg 2.15-2.2 $/Kg
Polyester Yarn:
Kader Synthetic - 2.40 $/Kg
China - 1.60 $/Kg
Lycra Yarn:
20 den - 12.70 $/Kg
40 den - 8.40 $/Kg
70 den - 7.50

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Chapter: 4
KNITTING SECTION

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Organogram of Knitting Section (Consider-68 m/c):
DGM / AGM
Manager /Asst. Manager (Production & Plan)(02) Manager/
(Technical)
Asst. Manager(01)
Sr. Executive (Production, Plan & Sample)(02)
Prduction officer (01)
Executive / Jr. Executive (Prod. & Sample)(05)
Asst. Feeder(04)
Sr. Supervisor/Supervisor(06) Sample Supervisor(02)
Needle Man(03)
Sr. Operator/Operator(135) Sample Asst.(05)
Servicing Man(06)
Asst. Operator(33)
Servicing Helper(06)
Production Helper(21)
Manager / Asst. Manager (Store)(01)
Sr. Executive / Executive (02)
Jr. Executive (Yarn)(02) Jr. Executive (Grey Fabric)(03)
Store Asst.(Yarn)(03) Store Asst.(Grey Fabric)(07)
Loader (Yarn)(26) Batch Helper/Loader (35)
KNITTING SECTION
S

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Machine List of Knitting Section in Masco Group :
Machine name Machine Quantity
Circular Knitting(Single jersey) m/c 38
Circular Knitting(Rib) m/c 05
Circular Knitting(Interlock) m/c 05
Engineering Stripe m/c 05
V-bed Knitting m/c 18
Grey Fabric Inspection m/c 03
Specification of Circular Knitting Machine:
Machine no-01
M/c type: Single jersey
Model: KM-3SF
Brand name: Pai Lung
Origin: Taiwan
Cylinder Dia: 30
Gauge: 24G
Cylinder: 1
Needle: 2256
Feeder: 90F
Safety rpm: 25
Date of manufacturing: 2009,9
Machine no-03
Model: KM-3WV4T
Brand name: Keum Yong
Origin: Korea
Cylinder Dia: 30
Gauge: 24G
Cylinder: 1
Needle: 2256
Feeder: 90F
Safety rpm: 28
Machine no-05
Machine no-02
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 26
Gauge: 24G
Cylinder: 1
Needle: 1968
Feeder: 78F
Safety rpm: 28
Machine no-04
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 30
Gauge: 24G
Cylinder: 1
Needle: 2256
Feeder: 90F
Safety rpm: 28
Machine no-06
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 26

26
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 32
Gauge: 24G
Cylinder: 1
Needle: 2400
Feeder: 96F
Safety rpm: 28
Machine no-07
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 26
Gauge: 24G
Cylinder: 1
Needle: 1968
Feeder: 78F
Safety rpm: 28
Machine no-09
Model: : KRB-2TIV
Origin: Korea
Cylinder Dia: 36
Gauge: 24G
Cylinder: 1
Needle: 2712
Feeder: 72F
Safety rpm: 28
Machine no-08
M/c type: Interlock
Model: KRB-2TIV
Origin: Korea
Cylinder Dia: 38
Gauge: 24G
Cylinder: 1
Needle: 2856
Feeder: 73F
Safety rpm: 28
Machine no-10
Model: : KM-3SF
Origin: Korea
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2568
Feeder: 102F
Safety rpm: 28

27
Machine no-11
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2568
Feeder: 72F
Safety rpm: 28
Machine no-13
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 36
Gauge: 24G
Cylinder: 1
Needle: 2712
Feeder: 108F
Safety rpm: 28
Machine no-15
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 38
Gauge: 24G
Cylinder: 1
Needle: 2856
Feeder: 114F
Safety rpm: 28
Machine no-12
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 36
Gauge: 24G
Cylinder: 1
Needle: 2712
Feeder: 144F
Safety rpm: 28
Machine no-14
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 36
Gauge: 24G
Cylinder: 1
Needle: 2712
Feeder: 144F
Safety rpm: 28
Machine no-16
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 38
Gauge: 24G
Cylinder: 1
Needle: 2856
Feeder: 114F
Safety rpm: 28
Machine no-18
Model: KM-3WV4T
Origin: Korea

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Machine no-17
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 40
Gauge: 24G
Cylinder: 1
Needle: 3000
Feeder: 160F
Safety rpm: 28
Machine no-19
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 44
Gauge: 24G
Cylinder: 1
Needle: 3312
Feeder: 132F
Safety rpm: 28
Machine no-21
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 44
Gauge: 24G
Cylinder: 1
Needle: 3312
Feeder: 132F
Safety rpm: 28
Machine no-20
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 46
Gauge: 24G
Cylinder: 1
Needle: 3456
Feeder: 138F
Safety rpm: 28
Machine no-22
Model: KRB-2TIV
Origin: Korea
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2568
Feeder: 68F
Safety rpm: 28
Machine no-24
Model: KM-3WV4T
Origin: Korea

29
Machine no-23
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2568
Feeder: 102F
Safety rpm: 28
Machine no-25
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2568
Feeder: 96F
Safety rpm: 28
Machine no-27
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 28
Gauge: 24G
Cylinder: 1
Needle: 2111
Feeder: 84F
Net wt: 2310kg
Safety rpm: 37
Date of manufacturing: 2006-11
Machine no-26
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 28
Gauge: 24G
Cylinder: 1
Needle: 2111
Feeder: 84F
Net wt: 2310kg
Safety rpm: 37
Machine no-28
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 25
Gauge: 24G
Cylinder: 1
Needle: 1872
Feeder: 74F
Net wt: 2310kg
Safety rpm: 42
Date of manufacturing: 2007.03
Machine no-30
Model: PL/XSB3/C
Origin: Taiwan

30
Machine no-29
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 23
Gauge: 24G
Cylinder: 1
Needle: 1728
Feeder: 68F
Net wt: 1800kg
Safety rpm: 40
Machine no-31
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 19
Gauge: 24G
Cylinder: 1
Needle: 1428
Feeder: 56F
Net wt: 1550kg
Safety rpm: 55
Machine no-33
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 33
Gauge: 24G
Cylinder: 1
Needle: 2256
Feeder: 90F
Net wt: 2310kg
Safety rpm: 37
Machine no-32
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 19
Gauge: 24G
Cylinder: 1
Needle: 1428
Feeder: 56F
Net wt: 1550kg
Safety rpm: 55
Machine no-34
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2544
Feeder: 102F
Net wt: 2450kg
Safety rpm: 30

31
Machine no-35
Model: PL/XSB3/C
Origin: Taiwan
Cylinder Dia: 36
Gauge: 24G
Cylinder: 1
Needle: 2712
Feeder: 108F
Net wt: 2850kg
Safety rpm: 29
Machine no-36
TYPE MASCHINE-NR BAUJAHR
OV3, 20 51557 2001
NENNDURCHMESSR TEILANG FEINEIT MODELAR ZAHL
762MM 30 INCH 106M 24E 2×2268
Machine no-37
OV3, 20 51556 2001
762MM 30 INCH 106M 24E 2×2268
Machine no-38
FV2,0 51554 2001
672MM 30 INCH 1.59M 16E 2×1512
Machine no-39
FV2,0 51555 2001
864MM 34 INCH 1.59M 16E 2×1704
Machine no-40 Machine no-41
Model: PL-XR2B/C
Origin: Taiwan
Cylinder Dia: 36

32
Model: PL-XRA/C
Origin: Taiwan
Cylinder Dia: 40
Gauge: 18G
Cylinder: 1
Needle: 2256
Feeder: 40F
Net wt: 3200kg
Safety rpm: 22
Machine no-42
Model: PL-XR2B/C
Origin: Taiwan
Cylinder Dia: 34
Gauge: 18G
Cylinder: 1
Needle: 1920
Feeder: 60F
Net wt: 2450kg
Safety rpm: 25
Machine no-44
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 34
Gauge: 24G
Cylinder: 1
Needle: 2568
Feeder: 102F
Safety rpm: 28
Machine no-45
Machine no-43
Model: KM-3WV4T
Origin: Korea
Cylinder Dia: 36
Gauge: 24G
Cylinder: 1
Needle: 2712
Feeder: 108F
Safety rpm: 28
Machine no-41
Model: PL-XR2B/C
Origin: Taiwan
Cylinder Dia: 36
Gauge: 18G
Cylinder: 1
Needle: 2040
Feeder: 72F
Net wt: 2450kg
Safety rpm: 25

33
MV4-3,2 52580 2001
610MM 24 INCH 1,06M 24E 1800
Machine no-46
MV4-3,2 52581 2001
559MM 22 INCH 1,06M 24E 1656
Machine no-47
MV4-3,2 52579 2001
508MM 20 INCH 1,06M 24E 1512
Machine no-48
MV4-3,2 52578 2001
457MM 18 INCH 1,06M 24E 1368
Machine no-49
M/c type: Auto Striper(S/j)
Model: PL-XSC/6
Origin: Taiwan
Cylinder Dia: 30
Gauge: 24G
Needle: 2256
Feeder: 42F
Net wt: 2650kg
Safety rpm: 22
Machine no-50
Model: PL-XSC/6
Origin: Taiwan
Cylinder Dia: 32
Gauge: 24G
Needle: 2400
Feeder: 44F
Net wt: 2850kg
Safety rpm: 20
Machine no-52
Model: PL-XSC/6
Origin: Taiwan

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Machine no-51
Model: PL-XSC/6
Origin: Taiwan
Cylinder Dia: 31
Gauge: 24G
Needle: 2544
Feeder: 18F
Net wt: 2850kg
Safety rpm: 20
Machine no-53
Model: PL-XSC/6
Origin: Taiwan
Cylinder Dia: 30
Gauge: 24G
Needle: 2256
Feeder: 42F × 6
Net wt: 2650kg
Safety rpm: 23
Specification of V-Bed Knitting Machine :
No. of V-Bed Knitting m/c: 18
Machine no: 01
M/c type: Rib (collar)
Model: M-100
Gauge: 14 G
Manufacturing no: 7695
Date : 6.2001
Machine no: 02
Model: M-100
Gauge: 14 G
Date :6.2001
Machine no: 04
Model: M-100
Gauge: 14 G
Date : 6.2001

35
Machine no: 03
Model: M-100
Gauge: 14 G
Date :6.2001
Machine no: 05
Model: M-100
Gauge: 14 G
Date : 6.2001
Machine no: 07
Model: M-100
Gauge: 14 G
Date : 6.2001
Machine no: 09
Model: M-100
Gauge: 14 G
Date : 1.2002
Machine no: 11
Model: M-100
Gauge: 14 G
Date : 1.2002
Machine no: 13
Machine no: 06
Model: M-100
Gauge: 14 G
Date : 1.2002
Machine no: 08
Model: M-100
Gauge: 14 G
Date : 1.2002
Machine no: 10
Model: M-100
Gauge: 14 G
Date : 1.2002
Machine no: 12
Model: M-100
Gauge: 14 G
Date : 1.2002

36
AROUND STAR INTERNATIONAL CO. LTD
S/N: 37045
Date: 2007 #7#31
Model: AS-318, 14G , 40“
Power: AC 220V,-Hz, 1Ơ
Machine no: 14
S/N: 37046
Date: 2007 #7#31
Model: AS-318, 14G , 40“
Power:Ơ: AC 220V,-Hz, 1Ơ
Machine no: 15
S/N: 37048
Date: 2007 #7#31
Model: AS-318, 14G , 40“
Machine no: 16
S/N: 37047
Date: 2007 #7#31
Model: AS-318, 14G , 40“
Machine no: 17
KAVO HENG CO.LTD
Model: KH-313J, 14G
S/N: 412455
Date: 2006 12
Power: 220V, 50Hz 1 Ơ
Made in TAIWAN
Machine no: 18
KAVO HENG CO.LTD
Model: KH-313J, 14G
S/N: 412454
Date: 2006 12
Power: 220V, 50Hz 1 Ơ
Made in TAIWAN

37
Pictures of Knitting Machine of MASCO GROUP:
DIFFERENT PARTS OF KNITTING MACHINE
Single Jersey Circular Knitting m/c
V-Bed Knitting m/c

38
Creel: Creel is used to place the cone.
Feeder: Feeder is used to feed the yarn.
Tensioning device: Tensioning device is used to give proper tension to the yarn.
VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch
length.
Guide: Guide is used to guide the yarn.
Sensor: Sensor is used to seen & the machine stops when any problem occurs.
Spreader: Spreader is used to spread the knitted fabric before take up roller.
Take up roller: Take up roller is used to take up the fabric
Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting
Machine to feed the yarn at specific finger.
Rethom: These devise are used in Electrical Auto Striper Knitting machine
PROCESS FLOW CHART OF KNITTING:
Yarn in cone form
Feeding the yarn cone in the creel
Feeding the yarn in the feeder via trip-tape positive feeding arrangement and
Tension device.
Knitting
Withdraw the rolled fabric and weighting
Inspection
Numbering

39
RAW MATERIALS USE FOR KNITTING:
Type of yarn Count
Cotton Yarn
16s
,20s
, 22s
, 24s
, 26S
, 28S
, 30S
, 34S
,
40S
Polyester Yarn 75D, 100D,150D
Spandex yarn 20D,40D,70D
Grey Mellange (C-90% V-10%) 20S
,22S
,24S
, 26S
,30S
,34S
PC (65%Polyester & 35% cotton) 24S
, 26S
, 28S
, 30S
CVC 24S
, 26S
, 28S
, 30S
CONSIDERABLE POINTS TO PRODUCE KNITTED FABRICS
When a buyer orders for fabric then they mention some points related
to production and quality. Before production of knitted fabric, these factors are
needed to consider. Those are as follows-
 Finished G.S.M.
 Type of Fabric or design of Fabric.
 Yarn count
 Types of yarn (combed or carded)
 Diameter of the fabric.
 Stitch length
 Color depth.

40
Fabric Type GSM Yarn Count Color Stitch Length M/c dia x gauge Finished Width
Plain 115 40/1 CB Black 2.54 30 x 28 33" Tube
Single 135 30/1 CD Anthracite 2.68 36 x 24 72" Open
Jersey 150 28/1 CB Black 2.75 36 x 24 74" Open
160 26/1 CD Ribbon red 2.7 30 x 24 62" Open
Lycra H.F.L-190 32/1+20DL Wash 2.85 30 x 28 64" Open
Single F.F.L-250 30/1CB+40DL Black 2.98 30 x 28 64" Open
Jersey 190 32/1+20DL Wash 2.85 30 x 28 64" Open
160/65 32/1CD Blue 2.7 30 x 24 43" Tube
210/20 22/1CD White 2.72 28 x 24 76" Open
Single 210/20 22/1CD White 2.75 25 x 24 35.5" Tube
Lacost 220 22/1CD White 2.75 24 x 24 66" Open
220 22/1CD White 2.75 25 x 24 66" Open
215/20 24/1CB Light 2.64 32 x 24 46" Tube
Lycra S/Lacost 210 28/1+40DL Average 2.85 26 x 24 66" Open
160/65 30/1CD White 2.65 30 x 24 43" Tube
Double 160/65 30/1CD White 2.65 28 x 24 41" Tube
Lacost 160/65 32/1CD Blue 2.58 30 x 24 43" Tube
160/65 32/1CD White 2.52 30 x 24 43" Tube
175 34/1 CB Light 2.54 40 x 18 37" Tube
200 30/1 CB Light Violet 2.52 38 x 18 74" Open
200 30/1 CB Medium 2.64 38 x 18 37" Tube
1x1 Rib 200 30/1 CB Light 2.54 38 x 18 68" Open
200 32/1 CB Black 2.54 38 x 20 41" Tube
200 28/1 CB White 2.58 38 x 18 74" Open
220 28/1 CB Red/Green 2.52 36 x 18 68" Open
1x1 Lycra 280 28/1CB+70DL Average 2.85 34 x 18 32" Tube
Rib 380 34/2CB+70DL Average 3.1 36 x 16 34" Tube
2x2 Rib 300 24/1 CB Average 3.3 40 x 18 24" Tube
380 20/1 CB Average 3.42 40 x 18 24" Tube
2x2 Lycra Rib 340 24/1CB+70DL Average 3.45 36 x 18 22" Tube
Pique 220 20/1CD Average 2.78 26 x 24 37" Tube
Fleece 260 30/1CD+75DP+26/2CB Medium P-4,B-3,L-1.5 30 x 20 68" Open
280 34/1GM+75DP+20/2CB Anthalatic Grey P-3.5,B-3.25,L-1.6 30 x 20 68" Open
B/B 270 32/1CD+12/1CD Dark P-4.3,B-3.3,L-1.6 30 x 20 74" Open
B/B 300 32/1CD+12/1CD Dark P-4.1,B-3.3,L-1.6 30 x 20 74" Open
Lycra Fleece 260 30/1CD+70DP+26/1CB+20DL Medium P-4,B-3.1,L-1.5 30 x 20 68" Open
260 30/1CD+75DP+26/1CB+20DL Dark P-4,B-3,L-1.5 30 x 20 64" Open
Engineering 165 26/1Dyed Wash 2.75 30 x 24 64" Open
Stripe(S/j) 190 Wash 3 36 x 24 76" Open
200 Wash 2.85 30 x 24 64" Open

41
END PRODUCTS OF CIRCULAR KNITTING MACHINE:
Single Jersey M/C:
a) S/J Plain
b) Single lacoste
c) Double lacoste
d) Single pique
e) Double pique
f) Terry
Rib M/C:
a) 1*1 Rib fabric
b) 2*2 Rib fabric
END PRODUCTS OF FLAT BED KNITTING MACHINE:
a) Collar
b) Cuff
c) Emboss
PRODUCTION CALCULATION:
A. Production/shift in kg at 100% efficiency
countYarn
mmSLNeedleofNoFeederofNoRPM



80.3527
)(..
B. Production/shift in meter
100/
1260.
/
.min/




cmCourse
EfficiencyFeederofNoRPM
cmCourse
Course
C. Fabric width in meter:
100/
.
100/
.




cmWales
knittinginusedNeedlesofnoTotal
cmWales
walesofnoTotal

42
PRODUCTION PARAMETER:
1. Machine Diameter
2. Machine rpm (revolution per minute)
3. No. of feeds or feeders in use
4. Machine Gauge
5. Count of yarn
6. Required time (M/C running time)
7. Machine running efficiency
SAMPLE OF VARIOUS TYPE OF KNITTED FABRIC:
Fabric Type Sample
Single jersey
Lycra Single jersey
Single Lacost
Double Lacost

43
Fleece
Grey Mellange
(1*1) Rib
(2*2) Rib
Lycra Rib
Stripe Single jersey

44
FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:
1. Hole Mark
Causes:
 Holes are the results of yarn breakage or yarn cracks.
 During loop formation the yarn breaks in the rejoin of the needle hook.
 If the yarn count is not correct on regarding structure, gauge, course and
density.
 Badly knot or splicing.
 Yarn feeder badly set.
Remedies:
 Yarn strength must be sufficient to withstand the stretch as well as uniform.
 Use proper count of yarn.
 Correctly set of yarn feeder.
 Knot should be given properly.
2. Needle Mark
Causes:
 When a needle breaks down then needle mark comes along the fabrics.
 If a needle or needle hook is slightly bends then needle mark comes on the
fabrics.
Remedies:
 Needle should be straight as well as from broken latch.
3. Sinker Mark
Causes:
 When sinker corrode due to abrasion then some times can not hold a new
loop as a result sinker mark comes.
 If sinker head bend then sinker mark comes.
Remedies:
 Sinker should be changed.
4. Star
Causes:
 Yarn tension variation during production.
 Buckling of the needle latch.
 Low G.S.M fabric production.
Remedies:

45
 Maintain same Yarn tension during production.
 Use good conditioned needles.
5. Drop Stitches
Causes:
 Defective needle.
 If yarn is not properly fed during loop formation i.e. not properly laid on to
the needle hook.
 Take-down mechanism too loose.
 Insufficient yarn tension.
 Badly set yarn feeder.
Remedies:
 Needle should be straight & well.
 Proper feeding of yarn during loop formation.
 Correct take up of the fabric & correct fabric tension.
 Yarn tension should be properly.
6. Oil stain
Causes:
 When oil lick through the needle trick then it pass on the fabrics and make a
line.
Remedies:
 Ensure that oil does not pass on the fabrics.
 Well maintenance as well as proper oiling.
7. Rust stain
Causes:
 If any rust on the machine parts.
Remedies:
 If any rust on the machine parts then clean it.
 Proper maintenance as well as proper oiling.
8. Pin hole
Causes:
 Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies:
 Change the needle

46
9. Grease stain
Causes:
 Improper greasing
 Excess greasing
Remedies:
 Proper greasing as well as proper maintenance
10. Cloth fall- out
Causes:
 Cloth fall- out can occur after a drop stitch especially when an empty needle
with an empty needle with closed latch runs into the yarn feeder and remove
the yarn out of the hook of the following needles.
Remedies:
 Make sure all the latches of needle are closed with feeding yarn after a drop
stitch.
11. Barre:
A fault in weft knitted fabric appearing as light or dark course wise (width
wise) Stripe.
Causes:
 This fault comes from yarn fault.
 If different micro near value of fiber content in yarn.
 Different lusture, dye affinity of fiber content in yarn.
 During spinning different similar classes of fiber is mixed specially in
carded yarn & these fibers have similar characteristics.
 In draw fame different similar classes sliver is mixed and make one sliver.
Remedies:
 We can use this fabric in white color.
12. Fly dust:
Causes:
 In knitting section too much lint is flying to and fro that are created from
yarn due to low twist as well as yarn friction. This lint may adhere or
attaches to the fabric surface tightly during knit fabric production.

47
Remedies:
 Blowing air for cleaning and different parts after a certain period of time.
 By cleaning the floor continuously.
 By using ducting system for cleaning too much lint in the floor.
 Over all ensure that lint does not attach to the fabric.
13. Yarn contamination
Causes:
 If yarn contains foreign fiber then it remains in the fabric even after
finishing,
 If lot, count mixing occurs.
Remedies:
 By avoiding lot, count mixing.
 Fault less spinning.
14. Yarn Faults:
 Neps.
 Slubs.
 Yarn count variations.
 Thick/Thin place in yarn.
 Hairiness.

48
DIFFERENT TYPES OF KNITTING FAULTS:
Fault Name Sample
Hole
Pin Hole
Slab
Yarn contamination
Barre mark

49
Drop Stitch
Lycra Out
Dust Sport
Needle mark
Fly

50
Chapter: 5
LABORATORY

51
LABORATORY MACHINERIES WITH ITS SPECIFICATION:
Test Name : Colourfastness to Washing, Dry cleaning.
Name of the m/c : Rota Wash
Origin : U.K
No.of m/c : 02
Test Method :ISO105-C06, ISO105-D02
Test Name : Dimensional Stability, Spirality, Appearance after washing.
Name of the m/c : Eltrolux wascator.
Origin : U.K
No.of m/c : 01
Test Method : ISO 6330, ISO 26330
Test Name : Shrinkage Test.
Name of the m/c : Eltrolux
Origin : U.K
No.of m/c : 01
Test Method :
Test Name : Colour Fastness to Wash Test.
Name of the m/c : Gyro wash
Origin : U.K
No.of m/c : 02
Test Method : ISO 105-C06
Lab Dip m/c:
No.of m/c: 02
M/C NO- 01
Brand name : Ahiba Nuance Lab Dip Dyeing m/c
Origin : U.S.A
M/C NO- 02
Brad name : Ahiba Nuance Lab Dip Dyeing m/c
Origin : U.S.A
LABORATORY

52
Colour Matching Cabinet (Light box):
No. of Light Box: 02
Light Box no: 01
Brand : Spectralight-111
Origin : U.S.A
Light Source:
 Day Light (D-65)
 Cool White
 Horizon
 UV
 TL-84
 A (F11-10 degree)
Light Box no: 02
Brand : Verivide
Origin : U.K
Light Source:
 Day Light (D-65)
 UV
 TL-84
 A (F11-10 degree)

53
Lab Dip Procedure:
Available Stock Solutions:
 Red – 0.1%, 0.5%, 1.0%, 2.0% (very common)
 Yellow – 0.1%, 0.5%, 1.0%, 2.0% (very common)
 Blue - 0.1%, 0.5%, 1.0%, 2.0% (very common).
Ref. recipe
Stock solution preparation
Pipe ting
Sample measuring
Take Dye Solution, Sample, and Salt in
the jar and set to the dyeing machine
Raise temp up to 600
C and run for 20 min
Add Soda as recommended in the recipe
Then run for further 60 min at the same temp
Unload and wash in cold water
Hot wash for 5 min at 900
C with PS- 60
Wash in cold water
Squeeze and Dry

54
Preparation:
- To prepare 0.1% Stock solution, it is necessary to mix 0.1 g dye and 100
cc water.
- To prepare 0.5% Stock solution, 0.5 g dye stuff is mixed with 100 cc
water.
- To prepare 1.0% & 2.0% Stock solution similar procedure is followed.
- To prepare 10% Stock solution of Soda ash, 10 g Soda is mixed with
100 cc water.
Depth of shade:
Masco Industries Ltd. produces 0.5% to 5% shade for the goods.
Calculation:
Usually following calculations are followed -
Recipe % * Sample Weight
** Dye Solution = (cc).
Stock solution %
Recipe % * Liquor)
** Salt = (gram per liter, gpl).
1000
Recipe % * 100 * Liquor)
** Soda Solution = (cc).
(1000 * Stock solution %)

55
SAMPLE CALCULATION FOR 0.5% SHADE
 Sample wt. = 5 mg
 Material liquor ratio = 1: 10
 Total liquor (5  10) = 50 cc
5  0.5%
 Dye solution required = ------------------- = 2.5 cc
1 %
50  25
 Salt solution required = ------------------- = 6.25 cc
20  10
50  10
 Soda ash solution required = ------------------- = 2.5 cc
20  10
 Water required {50 - (2.5 + 6.25 + 2.5)} = 38.75 cc
Working Procedure
All ingredients had been taken according to the recipe into the pot of sample
dyeing machine. At a room temp the material had run then after 10 mins started to
rise the temperature at 1°C/ min. to get 60°C temperature. For performing the
required dyeing temperature it took 30 mins. The material had dyed at 60°C for 45
mins. then the temperature was reduced at room temperature within in 10 mins.
The fabric washed in cold water & then the material was washed in 1 gm/l soap
solution (liquor ratio 1:20) at 90°C temperature for 15 mins. Then after rapidly
cold washing the material was dried & preserved.

56
Process Sequence:
Pretreatment
Enzyme (Antipilling)
Dyeing
Soaping
Softening
Quality Management System
The Quality Assurance Department is assigned to maintain consistently uniform
quality of the material in process and various stages of its manufacturing.
Objects of quality control:
 Research.
 Selection of raw materials.
 Process control.
 Process development.
 Product testing.
 Specification test
Quality management system in viyellatex:
QA
On-Line Off-Line

57
Online Quality control:
There are two types of online quality control. These are as follows: -
 Raw material control:
Raw material control means control the quality of raw materials (e.g.- Quality of
Grey fabric, Dyes, Chemicals and Auxiliary)
 Process control:
Process control means the selection of right process and controlling of some
parameters. Such as PH
, Water hardness, water volume, Temperature, Reel Speed,
Pump pressure, etc.
Online Tests:
o Dyed fabric.
o Shade check.
o Wash fastness.
o Water fastness.
o Crocking fastness.
Laboratory:
Laboratory is the heart of dyeing Industry. An efficient laboratory can increase the
efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before
bulk production a sample is sent to buyer for approval. Laboratory supplies the
recipe to the floor.
Purpose of Laboratory:
o Get color approval from buyer.
o Recipe supply to the floor.
o Shade correction.
o Minimize the deviation between bulk and laboratory.
Laboratory line:
 Standard sample:

58
At first recipe % of standard sample is measured by CCM (computer color
matching) system.
 Laboratory Trial:
Then by taking those recipe laboratory officers produce laboratory trial and
match with standard according to buyer requirement.
 Approved Sample:
Then sample swatch, which is matched with the standard, is send to buyer for
approval.
Off-Line Tests:
Off-Line tests for finished fabrics are divided into two groups. These are as
follows:
o Physical tests
o Chemical tests
Physical Tests:
o GSM of Fabric.
o Abrasion resistance / Pilling.
o Dimensional stability test.
o Spirality test.
o Color fastness to rubbing test (Dry / Wet).
o Bursting strength test (For Knitted fabric).
o Tensile Strength test (For Woven fabric).
Chemical Tests:
o Color Fastness to washing.
o Color Fastness to light.
o Color Fastness to heat.
o Color Fastness to actual laundering
o Color Fastness to Chlorinated water.

59
o Color Fastness to water spotting.
o Color Fastness to perspiration.
o Color Fastness to Seawater.
o Flammability test.
o Fibre analysis.
o PH
test.
o Spray test (water repellency).
o Phenolic yellowing.
Quality standard:
Here in the factory they are following ISO standards for their testing purpose.
But testing standard depends on buyer requirements.
SOME TEST PROCEDURE
Color fastness to rubbing (wet & dry):
Procedure:
At first take a sample of size (14 × 5) cm at Wales & Course wise. Put the
crocking cloth on to the finger & stag by finger clip & run 10 times in 10 seconds
manually & assess the crocking cloth with gray scale.
Place the crocking cloth on the water, it will sucked some water and then squeeze
the crocking cloth. Then place the wet rubbing cloth on to the finger and stag with
finger clip and run 10 times in 10 seconds manually. Then assess the crocking
cloth by gray scale for wet rubbing. Wet and dry rubbing are checked according to
buyer’s requirement.
Color fastness to washing. (ISO/05-CO6):
Procedure:
1. Size of specimen: Cut sample & multifibre at (10 × 2)cm then stitch.
2. Detergent: 4g/l ECE detergent (WOB) + 1g/l sodium per borate put in
distilled water & cooled at 20°C & measured PH
(where necessary).
3. Run the program in the following way: -

60
Test no. Temp°C Liq.volume ml Time min. Steel balls Adjust pH
C2S 60°C 50 30 25 10.5±1
4. Rinse the sample twice with cold water.
5. Dry at 60°C by hanging or by flat iron pressing but temperature should not
less more than 150°C.
Pilling test:
Procedure:
Cut the fabric 12.5 x 12.5cm & balance mark should be 10cm by using
template. Then sewn the fabric so that it can be firmly fit in the tube a moulded
polyurethane tubes. Then four tubes are placed in a box & start 60±2 rev/min
for 5 hrs or according to buyer requirement. Here mainly used 3hrs(1100 cycle).
Then assess the pilling by putting tested specimen on the viewing cabinet &
compare with standard photographs.
Shrinkage & Spirality test:
Buyer’s requirements:
Template size: 50cm & 50cm, 35cm &35cm (use after quick wash).
Shrinkage: length wise--- 5%
Width wise----5%
Spirality: Left -------- 5%
Right -------- 5%
Procedure:
At first take two ply of fabric & put the template (50cm) on to the fabric. The
template has 4 holes. Both length & width wise the template holes can measure
35cm at 3 places. Then we mark the 4 holes by permanent marker & also at the
edges of the template.
Then sewn the fabric & it is given to the washing m/c for run at 60°C for
60minutes with water. After that dry the sample & then measure the fabric
Spin speed --- 500rpm
Drum speed--500rpm

61
Calculation:
 Shrinkage Test:
Lengthwise:
After wash – Before wash
= ----------------------------------×100
Before wash
Width wise:
After wash – Before wash
= ----------------------------------×100
Before wash
 Spirality test:
=
M)&HforthLength(wid
2
sideRightsideLeft 
× 100 %
Color fastness to water (ISO 105 EO1):
1. Sample size: Cut the specimen & multi-fiber at 10×4cm & sewn together.
2. Solution: Wet in distilled water at room temperature.
3. Place it in acrylic resin plates & put the weight on to the plates.
4. Keep it in oven & keep the temperature at 37± 2°C for 4hrs.
5. Open the specimen & dry it in the air hot exceeding 60°C.
6. Assess the staining & shade change with gray scale.
Color fastness to perspiration Alkaline & Acid solution (Method: ISO 105
E04):
1) Procedure:
Cut the specimen & multifibre at 10×4cm & sewn together.
2) Prepare solution:
Start to prepare 0.1 mol/l Hyroxide (Naoh) by solving 4.0g Naoh in 1 litre distilled
water.

62
Alkaline Solution:
 0.5g/l of 1-histadine mono hydrochloride monohydrate
 5g/l of sodium chloride
 2.5 g disodium hydrogen ortho phosphate.
This solution is brought to pH -8 with 0.1 mole/l caustic solution.
Acid solution:
 0.5 g/l of 1-histadine monohydrochloride monohydrate
 5g/l of sodium chloride.
 2.2 g/l of sodium dihydrogen orthophosphate dehydrate.
This solution is brought to pH-5.5 with 0.1 mole/l caustic solution.
3) M: L = 1: 50
4) Wet the specimen in flat dish containing acid & alkaline solution & keep for
30min. Then take the specimen & squeeze the excess solution by two glass rods.
5) Put the specimen in to the acrylic resin plates & put wt. on the plates.
6) Keep it in the woven at 37°C ± 2°C for 4hrs.
7) Open the specimen 6 multi fibre & dry separately in the air temperature not
exceeding 60°C.
8) Access the staining & shade change with grey scale.
PH
Test:
Procedure:
Take 2gm sample fabrics and cut into small pieces. Then put it conical flax with
100cc water (M: L -1:50). Then shake it 15 min, then place it in a shaker m/c for 1
hour. Then check PH
by PH
meter.
GSM TEST:
Procedure:
GSM is the most important factor. There is a GSM cutter. The sample cut
by the GSM cutter is weighted in the electronic balance. The reading (in gm) from
the balance is multiplied by 100 to get the value of GSM.

63
SCOPE OF QUALITY CONTROL,QUALITY ASSURANCE ANDTESTING
The scope of quality control, quality assurance and testing are good. It has very
well -----
o Testing Laboratory.
o Machine auditing system.
o A good training system.
o Excellent analytical backup.
o Technical expertise.
RESPOSIBILITY OF OFF-LINE QUALITY CONTROL:
To check the following things:
 Inspection of fabric in the inspection M/C under 4-point system.
 Yarn count and lot no.
 Buyer.
 Design.
 Stitch length of grey fabric.
 Shade of grey fabric with in one order.
RESPOSIBILITY OF ON LINE QUALITY CONTROL:
To check the following things:
 M/C Dia/Gauge
 Buyer
 Design
 Grey fabric GSN & Stitch Length
 Yarn count & Lot no
 Yarn whether approved or not by Q.C. Department
 Finished dia & grey dia.
 Fabric quality checking under 4-point system.
RESPONSIBILITY OF IN CHARGE OF QUALITY CONTROL:

64
 Making report.
 Supervise the grey Q.C.
 Check machine is running according to program or not
 Check program can meet the requirement. Which is mentioned in the
order sheet or not.
 Check yarn is approved by Q.C. or not.
RESPONSIBILITY OF THE FINISHING Q.C.:
Finishing Q.C. (shade):
 After unloading from dyeing cut small piece, check shade with
std/approved lab dip/production sample & previous production batch (if
any).
 Then instruction to finishing for finish by mentioning specific temperature
in dryer.
 After finish again cut sample & check same way like before at dry state.
 Keep the record of every lot after dry & after finished state.
 If any batch is not OK at any stage then make the re-process card for
dyeing.
 If any batch is closer to standard but not exactly pass with standard, then
make trial for that batch in finishing to make it OK.
 Maintain the resister of all batches.
 Check the shade of Body to Rib, Body to Collar & Cuff.
In charge:
(1) Supervise the trainee Q.C. & Q.C.
(2) Make report every day.
(3) Cross check whatever shade already checked by Q.C.
Q.C. (Finishing):
 Make the R2R continuity of each dye lot by cutting small piece from each
roll of dye lot.
 Inspect 30-40 % of each dye lot under 4-point inspection system & report
accordingly.

65
 If found any problem then re-inspect 100% of that dye lot and make report
& re-process card (if re-process able) for dyeing. If it is knitting faults then
immediately inform to officer asking decision.
 Check the evenness of a dye lot by checking R2R continuity.
 Check the shade of body to rib, body to collar & cuff.
In charge:
 Monitor the all Q.C.’S (finishing) work including shade Q.C.
 Take decision when asking advise from his subordinate.
 Make daily problematic batch report.
 Make daily production report.
 Maintain resister khata.
 Make daily batch re-process job card.
RESPOSIBILITY OF QUALITY ASSURANCE MANAGER:
(1) Responsible for all quality matter of fabric.
(2) Yarn selection.
(3) Monitoring product development.
(4) Organize Laboratory.
(5) Control grey and finished fabric inspection under 4- point inspection
system.
(6) Documentation after shade check of every lot.
Remarks:
They have a well-equipped Testing laboratory called Textile Testing Services
limited for all kinds of Textile Testing. The laboratory of viyellatex is approved by
world renowned buyer Marks & Spenser and also Puma. Now they are just testing
their internal tests but they are trying to develop their laboratory. So that external
author can send their textile material for testing by suitable testing fees.

66
Chapter: 6
BATCH SECTION

67
Batching is the process to get ready the fabrics which should be dyed and
processed for a particular lot of a particular order.
Function or Purpose of Batch Section:
- To receive the grey fabric roll from knitting section or other source.
- Turn the grey fabric if require.
- To prepare the batch of fabric for dyeing according to the following
criteria –
 Order sheet (Received from buyer)
 Dyeing shade (color or white, light or dark)
 M/C capacity
 M/C available
 Type of fabrics(100% cotton, PE, PC, CVC)
 Emergency
- To send the grey fabric to the dyeing floor with batch card.
- To keep records for every previous dyeing.
Proper batching criteria:
- To use maximum capacity of existing dyeing m/c.
- To minimize the washing time or preparation time & m/c stoppage time.
- To keep the no. of batch as less as possible for same shade.
- To use a particular m/c for dyeing same shade.
Batch management:
Primarily batching is done by dyeing manager taking the above
criteria under consideration. Batch section in charge receives this primary batch
plan from dyeing manager. Some time planning is adjusted according to m/c
condition or emergency.
BATCH
SECTION

68
Machines in batch section
M/c quantity: 01
M/c Specification:
Machine Name : Air turning m/c
M/c No : 01
Brand Name : Taida
Origin : China
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company :Shandong Taida Dyeing & Finishing
Machinery Co.Ltd
M/c quantity: 01
M/c Specification:
Machine Name : Air turning m/c
M/c No : 02
Brand Name : Taida
Origin : China
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company :Shandong Taida Dyeing & Finishing
Machinery Co.Ltd.

69
Organogram of Dyeing Section:
C.E.O (Fabric)
G.M / D.G.M / A.G.M (01)
Manager (01)
Assistant Manager (02)
Senior Executive (03)
Executive (03)
Production Officer (03)
Senior Supervisor
Supervisor / Jr. Supervisor
Production Operator
Production Helper
Dyeing Section

70
Responsibility of production officer:
 Overall supervision of dyeing & finishing.
 Dyes & chemicals requisition issue & check.
 Program making, sample checking color measurement.
 Control the supervisor’s operators & helpers of machines.
 To give dye-line or the program slip according to daily production plan, batch
preparation & PH
check.
 To rectify the finished fabric which rejected from quality control department
 To check daily production report.
 To study dye & chemicals nature delivery by the manufacture & applied them
correctly to the production to get best product
Job Description:
Title: Production officer.
Dept: Dyeing
Report to: Senior production officer.
Job summary: To plan execute & follow up the production activities
& control the quality production with related activities.
Title: Senior production officer.
Dept: Dyeing.
Report to: Dyeing manager.
Job summary: To plan execute & follow up the production activities
& control the quality production with related activities
Dyeing Machine
Sample
No. of High temperature sample dyeing machine = 08 pcs
Total machine capacity of sample m/c = 260 kgs
Total production capacity of sample m/c = 200 kgs
Production
No. of High temperature dyeing machine = 05 pcs
Total Machine capacity on dyeing floor = 10,250 kgs
Total Production capacity on dyeing floor = 16 metric tons/day

71
Dyeing Machine Specification:
Machine no-01
Brand name : Thies (High temperature machine).
Origin : Germany
Capacity : 750 kg
Model : 41342
Number of nozzle : Three (03)
Max. working Temperature : 100°C
Max. Liquor Capacity : 12190 liter
Working Pressure : 0.35 Mpa
Test pressure : 0.55 Mpa
Year of Construction : 2002
Machine no. -02
Origin : Germany
Capacity : 500 kg
Model : 43891
Number of nozzle : Two (02)
Machine no-03
Origin : Germany
Capacity : 250 kg
Model : 43879
Number of nozzle : One (01)

72
Machine no-04
Brand name : Dilmenlor (High temperature machine).
Origin : Turky
Capacity : 600 kg
Model : 41346
Number of nozzle : Four (04)
Machine no-05
Brand name : Dilmenlor (High temperature machine).
Origin : Turkey
Capacity : 900 kg
Model : 41350
Number of nozzle : Six (06)
Machine no-06
Brand name : AC (Normal temperature machine).
Origin : Chaina
Capacity : 200 kg
Model : 41354

73
Machine no-07
Origin : Chaina
Capacity : 600 kg
Model : SHI 0515416/25
Design Pressure : 380 Kpa
Hydraulic Test pressure : 585 Kpa
Safety Valve Set : 380 Kpa
Manufacturer : Fongs National Engineering (SHENZHEN)
Company Ltd.
Machine no-08
Origin : Chaina
Capacity : 600 kg
Model : SHI 0515416/25
Company Ltd.
Machine no-09
Origin : Chaina
Capacity : 600 kg
Model : SHI 0515416/25
Company Ltd.

74
Machine no-10
Origin : Chaina
Capacity : 400 kg
Model : SHI 0515416/23
Number of nozzle : Two (02)
Company Ltd.
Machine no-11
Origin : Chaina
Capacity : 200 kg
Model : SHI 0515416/19
Company Ltd.
Machine no-12
Origin : Chaina
Capacity : 1200 kg
Model : SHI 0515416/03
Company Ltd

75
Machine no-13
Origin : Chaina
Capacity : 800 kg
Model : SHI 0515416/27
Company Ltd.
Machine no-14
Origin : Chaina
Capacity : 200 kg
Model : SHI 0515416/22
Company Ltd.
.
Machine no-15
Origin : Chaina
Capacity : 200 kg
Model : SHI 0515416/29
Company Ltd.

76
Machine no-16
Brand name : Santex (Normal temperature machine).
Origin : Chaina
Capacity : 1500 kg
Model : SHI 0515416/29
Company Ltd.
Machine no-16
Brand name : Santex (Normal temperature machine).
Origin : Chaina
Capacity : 1500 kg
Model : SHI 0515416/29
Company Ltd.

77
Specification Of Sample Dyeing Machine:
Machine no-01
Brand name : Thies (High temperature machine)
Origin : Germany
Capacity : 50 kg
Nozzle Pressure : 700 Kpa
Kier Pressure : 700 Kpa
Machine no-02
Brand name : Tecninox (High temperature machine)
Origin : Portugal
Capacity : 25 kg
Max. Variable Temperature : 98°C
Max. Operating Pressure : 400 Kpa
Machine no-03
Brand name : Suntex (Normal temperature machine)
Origin : China
Capacity : 15 kg
Manufacturer : wuxinda dyeing machine factory.
SAMPLE SECTION

78
Machine no-04
Origin : China
Capacity : 30 kg
Machine no-05
Origin : China
Capacity : 15 kg
Machine no-06
Origin : China
Capacity : 15 kg

79
Chapter: 7
RAW MATERIALS

80
Raw materials for dyeing:
Raw materials used in the dyeing section are:
1. Grey fabrics
2. Dyes
3. Chemical.
Grey fabrics:
Following types of gray fabrics are dyed:
 Single jersey
 Single jersey with lycra
 Polo pique
 Back Pique
 Single lacoste
 Double Lacoste
 Fleece
 Rib
 Rib with lycra
 1Χ1 rib
 2Χ2 rib
 Different types of collar & cuff.
Raw Materials

81
Different Types of Dyes Used In Masco Group With There Brand Name:
REACTIVE DYES:
BRAND
NAME
COUNTRY
NAME NAME OF DYE STUFF
DY-STAR GERMANY
Remazol Golden Yellow RGB
Remazol Deep Black RGB
Remazol Deep Black GWF Gran
Remazol Red RGB Gran
Remazol Turquoise Blue G133%
Remazol Brilliant Blue R Spec
Remazol Brilliant Blue BB 133% Gran
Remazol Ultra Carmine RGB
Remazol Ultra Carmine RGB GR
Levafix Rubine CA Gran
Levafix Red CA Gran
Levafix Olive CA Gran
Levafix Fast Red CA Gran
Levafix Brillant Red E-4BA Gran
Dianix Navy CC
Dianix Turquoise S-BG
IMPOCOLOR GERMANY
Imcozin Blue E-NR
Imcozin Blue V-CR 150%
Imcozin Brilliant Red V-F3B
Imcozin Brilliant Yellow V-4GL
Imcozin Yellow E-3R 150%
BENZEMA SWITZER LAND
Bezaktive Blue S-GLD 150
Bezaktive Yellow S-3R 150
Bezaktive Red S-3B 150
CLARIANT SWITZER LAND Drimarene Yellow K-4G Cdg
HUNTSMAN SWITZER LAND
Terasil Red W-4BS
Terasil Nevy W-RS
Novacron Red FN-R-01
Novacron Yellow F-4G
JIHUA CHINA
Starfix Black B 150%
Starfix Red EP 150%
SUMIFIX JAPAN
Sumifix Supra Blue E-XF
Sumifix Supra Yellow E-XF
SUN COLOR KOREA Sunfix Navy Blue MF-D

82
DISPERSE DYES:
BRAND
NAME
COUNTRY
NAME NAME OF DYE STUFF
HUNTSMAN SWITZER LAND Terasil Golden Yellow W -3R
Different Types of Chemicals Used In Masco Group With Their Brand
Name:
CHEMICAL NAME BRAND NAME COUNTRY NAME
Wetting agent Huntsman Switzerland
Levelling agent Huntsman Switzerland
Sequestering Agent Eurodye Belgium
Anti foaming agent Huntsman Thailand
Anti creasing agent Huntsman Thailand
softener Croda India
Fixing Agent Huntsman Switzerland
Per Oxide Stabilizer
Kapazon H-53
ThailandClarite CBB
Stagen-B
Caustic Caustic China
Soda Ash Soda Ash Chaina
H2O2 H2O2 Chaina+Korea
Optical Brightener
Agent
Syno White 4Bk
Syno White 2Bk
Korea
H2O2 Killer Huntsman Thailand
Acitic Acid Jubiilant India
Enzyme
Huntsman Switzerland
Biocid -EL Srilanka
Electrolyte / Salt
Sodium Sulphate
Anhydrose India
Glubar Salt
Detergent Huntsman Switzerland
Soaping Agent
Croda India
Optavon-NW
China
Bergal-500

83
Flow Chart For Dyeing:
Grey fabric receive from knitting section
Batching
Select m/c no
Fabric loading
Select production program
Pre treatment
Select recipe for dyeing
Recipe confirm by D.M / S.P.O
Dyeing
Post treatment
Unload
RECIPE FOR PRETREATMENT PROCESS OF DYEING:
Recipe for scouring and bleaching :( For cotton)
Detergent (CRA) = 0.4 gm/l
Stabilizer (Clarite CBB) = 0.05 gm/l
Anti foaming agent (Albaflow FFC) = 0.05gm/l
Caustic = 0.2 gm/l
Hydrogen per oxide (H2O2) =2.5 gm/l
 60 min at 98˚C with PH = 11

84
Process Flow Chart of SCOURING/ BLEACHING:
Machine filling with water
Chemical Dozing at 50 0
C
Run time 10 min.
NaOH Dozing
Heating at 60 0
C
H2O2 dozing
Heating at 70 0
C
Run time 20 min.
Cooling at 95 0
C
Rinse at 80 0
C
H2O2 - Killer Dozing
Run time 10 min
Run time 10min.
Cooling for 55 0
C
Sample Check
Check H2O2

85
Acid wash 3 min
Drain
Process Scheme:
Process
Rinse
Peroxide
700
C 20′ Check Peroxide
7′
950
C
Chemicals 20′
15′ 10′ 800
C
Caustic (600
C) 10′
3′ Peroxide Killer
6′ 500
C 4′ 550
C
′
12′
Acetic Acid
Time in min
Recipe for enzyme treatment: :( For cotton)
Unizyme Cat = 0.06 gm/L
Acid (acetic acid) = 0.50 gm/L
NSB = 0.50 gm/L
Unizyme – 800L = 0.30 gm/L
 60 min at 55˚C with PH = 5.5
Recipe for hot (cotton black):
 10 min at 80˚C
Temperaturein0
C
Fig: Pretreatment Process

86
Process Flow Chart of ENZYME:
Machine filling with water
Acetic acid dozing
Run for 4 min. at 48 0
C
Heating at 55 0
C
Dozing enzyme
Run time 45 min.
Drain
Process
Rinse
Enzyme dosing
Acid
550
C
480
C 45 min
400
C 5 min 4 min
Rinse
Time in min
Temperaturein0
C
PH
Check

87
Fig:Enzyme Process
Recipe For Cotton Dyeing (Light Shade):
Colour: M:L -1:10
Recipe for Scouring & Bleaching:
Detergent (CRA) : 0.40 gm/l
Stabilizer (Clarite CBB) : 0.30 gm/l
Anti foaming agent (Albaflow FFC) : 0.05gm/l 980
C X 1 hr
Hydrogen per oxide (H2O2) : 3.50 gm/l
Caustic : 1.8 gm/l
Recipe Enzyme Treatment:
Unizyme Cat : 0.06 g/l
Acetic Acid : 0.50 g/l 550
C X 1hr
Matexil NSB :0.50 g/l
Unizyme – 800L : 0.80 g/l
Recipe for Levelling:
Albatex DBC (Leveling Agent) : 1.00 g/l
Albaflow FFC (Anti-foaming agent) : 0.05 g/l 400
C X10 min
Dyes
Remazol yellow RR : 0.074 % (owf)
Supra Red 2BS : 0.58 %(owf) 400
C X 30
min
Linear dosing
Salts and Alkali
Glauber salt (Na2SO4) : 30.0 g/l 400
C X 15
min
Inject
First Soda ash ( Na2CO3 ) : 0.50 g/l 400
C X 25
min
Progressive dosing
Soda ash ( Na2CO3 ) : 13.50 g/l 400
C X 30
min
Progressive dosing
Recipe for Neutralization:

88
C X20 min
Recipe for Hot Wash:
Meteril ADW : 0.5 g/l 900
C X 10 min
Recipe for Fixing:
Albafix FRD : 0.25 g/l 400
C X 30 min
Acetic Acid : 1.00 g/l
Recipe for Softening:
Sapamine CWS : 20.0 g/l 400
C X 30 min
Process Flow Chart For Cotton Dyeing (Light Shade With Cold Brand
Reactive Dyes):
Water Loading
Fabric Loading
First Chemicals Inject
(500
C X 5min)
Caustic dosing
(600
C X 5min)
H2O2 dosing
(700
C X 5min)
(980
C,1hr)
Rinsing( Hot wash)
(900
C X 10 min)
Rinsing (Cold wash)
(600
C X 5 min)
Water Loading
Acetic Acid
pH Check (4.0~4.5)
Enzyme Chemical
(550
C X 60min)
800
C X 10min
Drain

89
Water loading
(400
C,PH check= 6.5-7)
Leveling Chemicals
(400
C X 10 min)
Adding Dyes
(400
C X 25min, Linear dosing)
Running
(400
C X 10 min)
Adding Salt
(400
C X 15 min, progressive dosing)
Running
(400
C X 30 min)
Adding First Soda
(400
C X 25min,progressive dosing)
Running
(400
C X 5min)
Adding Second Soda
(400
C X 30 min,progressive dosing)
Running
(400
C X 5min)
Sample Cutting
(After 20 min)
Shade Match
(Not ok) (Ok)
Bath Drain
Water loading
Neutralization (Acetic Acid)
(500
C X 20 min)
Drain
Hot Wash
(700
C, 15 min)
Aquachoron
(900
C X 10 min)
Sample Cutting
Shade Match
Drain
Rinsing
Water loading

90
(Acetic acid,PH Check=5-5.5)
Fixing Chemical
(400
C X 15 min)
Drain
Water Loading
(Acetic acid,PH Check=5)
Apply Softener
(400
C X15 min)
Fabric unload

91
DYEINGCURVEFORLIGHT/MEDIUMSHADE
CheckpH
ColordosingSaltdissolvingSodadosing
CheckpH
CheckpH
Runtime10′
Runtime10′Runtime30′
Samplecheck
Incaseofs/jlowgsmfabricanti-creasingagentshavetouseinscouring&withR-hot.
Incaseofs/jlowgsmfabricheatingandcoolingduringscouring&R-hothavedowithgradient.
Heating-2.5°C/min.
Colling-1.5°C/min
Itis40°Cisothermaldyeing.
Progressivedosing
45minutes
15minutes
Lineardosing
30minutes
Levelingagent
4.5
Runtime20′
Bath
drop

92
Recipe For Cotton Dyeing (Dark Shade With Hot Brand Reactive Dyes):(With
Enzyme Treatment)
Colour: Black M:L -1:8
C X 1 hr
Caustic : 2.00 gm/l
C X 1hr
C X10 min
Dyes
Synozl Red HB : 1.2528 % (owf)
Synozl Yellow HB : 1.3546 %(owf) 600
C X 30
min
Linear dosing
Salts and Alkali
Industrial salt (Na2SO4) : 60.0 g/l 600
C X 15
min
Inject
C X 20
min
Progressive dosing
Soda ash ( Na2CO3 ) : 19.50 g/l 600
C X 25
min
Progressive dosing
Levelin
40°C

93
C X20 min
C X10
min
Recipe for Fixing:
C X 10 min
C X 5 min
Process Flow Chart For Cotton Dyeing (Dark Shade With Hot Brand
Reactive Dyes)
Water Loading
Fabric Loading
(500
C X 5min)
Caustic dosing
(600
C X 5min)
H2O2 dosing
(700
C X 5min)
(980
C,1hr)
Rinsing( Hot wash)
(900
C X 10 min)
Rinsing (Cold wash)
(600
C X 5 min)
Water Loading
Acetic Acid
pH Check (4.0~4.5)
Enzyme Chemical
(550
C X 60min)
800
C X 10min
Drain
Water loading

94
(600
C,PH check= 6.4-6.8)
Leveling Chemicals
(600
C X 10 min)
Adding Salt
(600
Running
(600
C X 10 min)
Adding Dyes
(600
Running
(600
C X 30 min)
Adding First Soda
(600
Running
(600
C X 5min)
Adding Second Soda
(600
Running
(600
C X 60min)
Sample Cutting
(After 20 min)
Shade Match
(Not ok) (Ok)
Bath Drain
Water loading
(500
C X 20 min)
Drain
Hot Wash
(700
C, 15 min)
Aquachoron
(900
C X 10 min)
Sample Cutting
Shade Match
Drain
Rinsing
Water loading
Fixing Chemical

95
(400
C X 15 min)
Drain
Water Loading
Apply Softener
(400
C X15 min)
Fabric unload
(Enzyme is done according to the buyer’s requirement)

96
DYEINGCURVEFORDARKSHADE
CheckpH
Samplecheck
Incaseofs/jlowgsmfabricheatingandcoolingduringscouring&R-hothavetodowithgradient.
Itis60°Cisothermaldyeing.
Incaseofdarkshade,saltdosinghavetogivebeforecolordosing.

CheckpH
Levelin
SaltdissolvingColordosingSodadosing
CheckpH
CheckpH
Runtime10′Runtime15′
Runtime30′
Progressivedosing
45minutes10minutes
Lineardosing
30minutes
Levelingagent
Bath
drop
4.5
Runtime10′

97
Recipe For Cotton Dyeing (Turquish Shade With Hot Brand Reactive
Dyes):(With Enzyme Treatment)
Colour: Black M:L -1:8
C X 1 hr
Caustic : 2.00 gm/l
C X 1hr
C X10 min
Dyes
Nova Red-TS-3B : 0.01045 % (owf)
Nova Yell-TS-3R : 0.00154 %(owf) 800
C X 30
min
Nova Blue-TS-3G :0.00019% (owf)
Linear dosing
Salts and Alkali
C X 15
min
Inject
C X 10
min
Progressive dosing
Soda ash ( Na2CO3 ) : 19.50 g/l 600
C X 25
min
Progressive dosing
60°C

98
C X20 min
C X10
min
Recipe for Fixing:
C X 10 min
C X 5 min
Process Flow Chart For Cotton Dyeing (Turquish Shade With Cold Brand
Reactive Dyes):
Water Loading
Fabric Loading
(500
C X 5min)
Caustic dosing
(600
C X 5min)
H2O2 dosing
(700
C X 5min)
(980
C,1hr)
Rinsing( Hot wash)
(900
C X 10 min)
Rinsing (Cold wash)
(600
C X 5 min)
Water Loading
Acetic Acid
pH Check (4.0~4.5)
Enzyme Chemical
(550
C X 60min)
800
C X 10min
Drain
Water loading
(400
C,PH check= 6.5-7)

99
Leveling Chemicals
(600
C X 10 min)
Adding Dyes
(800
Running
(800
C X 10 min)
Adding Salt
(800
Running
(800
C X 30 min)
Migration
(900
C X 30 min)
Cooling
(600
C X 10 min)
Adding First Soda
(600
C X 20min,progressive dosing)
Running
(600
C X 10min)
Adding Second Soda
(600
Running
(600
C X 10min)
Color Steam
(650
C X 30min)
Color Steam
(850
C X 10min)
Sample Cutting
(After 20 min)
Shade Match
(Not ok) (Ok)
Bath Drain
Water loading
(500
C X 20 min)
Drain
Hot Wash
(700
C, 15 min)
Aquachoron
(900
C X 10 min)
Sample Cutting
Shade Match

100
Drain
Rinsing
Water loading
Fixing Chemical
(400
C X 15 min)
Drain
Water Loading
Apply Softener
(400
C X15 min)
Fabric unload

101
DYEINGCURVEFORTURQUOISESHADE
CheckpH
Checksample
CheckpH
CheckpH
Runtime10′
Runtime30′
Progressivedosing
50minute15minutes
Lineardosing
30minutes
Levelingagent
Iiis80°Cisothermaldyeing.
Turquoisecolorshouldmixedseparatelywithlevelingagentandfilteredtwice.
Saltdissolving
Colordosing
Sodadosing
Runtime10′
90°C
Runtime
30′
Runtime20′
60°C

102
Recipe For Dyeing of P/C Blend Fabric(65/35):
Polyester Part
Recipe For Polyester Dyeing:
Colour: Organic M: L - 1:10
C X 1 hr
Caustic : 2.00 gm/l
C X 1hr
Matexil NSB : 0.50 g/l
Recipe for Leveling:
Univadin Top (Leveling Agent) : 1.00 g/l
C X10 min
Dyes
Terasil Navy - WRS : 1.2528 % (owf)
Terasil Red – FBN : 1.3546 %(owf) 600
C X 30 min
Terasil G – yellow W3R
Linear dosing
Recipe for Reduction Clearing:
Hydrose : 2.0 g/l 800
C X 30 min
X 30 min
Caustic Soda (Alkali) : 1.0 g/l
Acetic acid : 1.0 g/l .0 600
C X10 min
X10 min
Levelin
6.6
80°C

103
Cotton Part
Recipe For Cotton Dyeing:
Colour: Organic M:L -1:10
C X10 min
Dyes
Synozl Red HB : 1.2528 % (owf)
Synozl Yellow HB : 1.3546 %(owf) 600
C X 30
min
Linear dosing
Salts and Alkali
C X 15
min
Inject
C X 20
min
Progressive dosing
Soda ash ( Na2CO3 ) : 19.50 g/l 600
C X 25
min
Progressive dosing
C X20 min
C X10
min
C X 5 min
Acetic Acid

104
Process Flow Chart of P/C Blend Fabric(65/35):
Polyester Part
Water Loading
Fabric Loading
(500
C X 5min)
Caustic dosing
(600
C X 5min)
H2O2 dosing
(700
C X 5min)
(980
C,1hr)
Rinsing( Hot wash)
(900
C X 10 min)
Rinsing (Cold wash)
(600
C X 5 min)
Water Loading
Acetic Acid
pH Check (4.0~4.5)
Enzyme Chemical
(550
C X 60min)
Normal hot
(800
C X 10min)
Drain
Water loading
(600
C,PH check= 4.5)
Leveling Chemicals
(600
C X 10 min)
Color dosing (Until Water Clean)
(1350
C X 1hr)
Cooling
(780
C)
Reduction Clearing
(800
C X 30min)
Neutralisation
(600
C X 15min)

105
Then Proceed For Cotton Part
Cotton Part
After the Process of Polyester Part
pH Check
(6.5~ 6.8)
Leveling Chemicals
(600
C X 10 min)
Adding Salt
(600
Running
(600
C X 10 min)
Adding Dyes
(600
Running
(600
C X 30 min)
Adding First Soda
(600
Running
(600
C X 5min)
Adding Second Soda
(600
Running
(600
C X 60min)
Sample Cutting
(After 20 min)
Shade Match
(Not ok) (Ok)
Bath Drain
Water loading
(500
C X 20 min)
Drain
Hot Wash
(700
C, 15 min)
Aquachoron
(900
C X 10 min)
Sample Cutting
Shade Match
Drain

106
Rinsing
Water loading
Fixing Chemical
(400
C X 15 min)
Drain
Water Loading
Apply Softener
(400
C X15 min)
Fabric unload

107
DYEINGCURVEFORBLENDDYEING
Colling-1.5°C/min.
Incaseof80°Cdyeingmigrationwillbeat90°Candrun20minutes
15minutes
Lineardosing
35minutes
Colordosing
CheckpHCheckpH
Saltdissolving
Levelingagent
Progressivedosing
45minute
Samplecheck
Levelin
Sodadosing
Runtime20′
135°C
90°C
2°C
80°C
1hr
30′
Bath
drop
Levelingagent
Levelin
40°CRuntime10′Runtime10′
Runtime30′
60°C
Bath
drop

108
Recipe For Cotton Dyeing (White colour):
Colour: White M:L -1:8
C X 1 hr
Caustic : 2.00 gm/l
Recipe for Dyeing:
Optical Brightener
Syno White 4BK : 0.8% (owf) 600
C (Apply
with Scouring
C X20 min
C X10
min
C X 5 min
Process Flow Chart For Cotton Dyeing (White colour):
(Without Enzyme treatment )
Water Loading
Fabric Loading
(500
C X 5min)
Caustic dosing
(600
C X 5min)
H2O2 dosing
(700
C X 5min)
Brightener
(800
C X 5min)

109
(980
C,1hr)
Cooling
(800
C X 10 min)
Drain
Rinsing (Cold wash)
Water Loading
Sample Cutting
(After 30 min)
Shade Match
Acetic Acid
pH Check (5.0)
Apply Softener
(400
C X15 min)
Fabric unload
(Enzyme is done according to the buyer’s requirement)
H2O2
Chemicals
Caustic 60′
5′ Drain
5′ 5′ 700
C
5′
600
C
Time in min
Temperaturein0
C
Fig: White Dyeing Process
800
C
980
C

110
Process Flow Chart For Topping of Cotton (Using Cold Brand Reactive
Dyes):
Water Loading
Fabric Loading
Neutralization
(700
C X 12 min)
Rinsing
(600
C X 10 min)
PH
Check (6.5~7)
Leveling Chemicals
(600
C X 10 min)
Adding Salt
(600
C X 10 min-dosing)
Running
(600
C X 10 min)
Adding Dyes
(600
C X 25min-dosing)
Running
(600
C X15 min)
Adding Soda
(600
C X 30 min-dosing)
Running
(60 min)
Sample Cutting
(After 20 min)
Shade Match
(Ok)
Rinsing
(600
C X 15 min)
Neutralization
(600
C X 15 min)
Rinsing (600
C X 15 min)
Hot Wash
(800
C X 25min)
Rinsing (600
C X 20 min)
(After 30 min)
Sample Cutting
Shade Match
(Ok)

111
Cooling
(Up to 400
C; at 2.0 Gradients)
Apply Softener
(400
C, 15 min)
Fabric unload
Recipe ForWashing of Gray mélange(10% Viscose -90% cotton):
Colour: Gray mélange M:L -1:8
C X 1 hr
Caustic : 2.00 gm/l
C X20 min
C X 5 min
Process Flow Chart For Washing of Gray mélange:
Water Loading
Fabric Loading
(Add At 600
C) Scouring Chemical (washing)
(600
C X 5 min)
(980
C X 40min)
Rinsing
(700
C, 15min)
Neutralization
(600
C, 10 min)
Rinsing
(600
C, 10 min)
Apply Softener
(400
C, 15 min)
Fabric unload

112
Some dyed fabric with recipe:
Description Sample Presentation
Color Type: Dark
Color: Black.
Dyeing Polyester part
T Vell W 3R – 0.24000%
T Red W4BS – 0.2400%
T Black BFE – 3.00%
Reduction cleaning
Hydrose-2 g/l
Caustic- 2 g/l
Dyeing Cotton part
S VELL MF3RD-0.7282%
S RED MF3BD- 0.3542%
RS BLACK WM- 5.6416%
Salt – 90 g/l
Soda – 5 g/l
Caustic-1.75 g/l
Nature of fabric: CVC Fleece
GSM: 280
M:L-1:6
Color: White.
BAM (OBA) – 0.90%
Caustic-2.5 g/l
H2O2 -10 g/l
Nature of fabric: S/J+(1*1)
GSM: 160
M:L-1:7
Color Type: Dark
Color: LT-NAVY
R.G. Yellow RGB – 0.2068%
R. UL. Car RGB – 0.3520%
R. Blue R.R – 1.800%]
Salt – 60 g/l
Soda – 18 g/l
Nature of fabric: Fleece
GSM: 260
M:L-1:6

113
Color Type: Dark
Color: Mountain Lake
R. Yellow RR – 0.1540%
R. TURQG – 2.0370%
R. BLUE RR-2.6400%
Salt – 80 g/l
Soda- 20 g/l
Nature of fabric: S/J
GSM: 160
M:L-1:7
Color Type: Medium.
Color: Reef Blue.
M. BR. Yellow V-4GL – 0.0126%
M. BR. Turk VG – 1.84%
Salt – 60 g/l
Soda – 16 g/l
Nature of fabric:100% Cotton S/J.
GSM: 160
M:L-1:7
Color Type: Dark
Color: Black Newyork 1102B.
R. G. Yellow RGB – 0.4959%
R. UT. Car RGB – 0.131%
R. Deep Black RGB – 6.84%
Salt – 90 g/l,
Soda – 5 g/l
Nature of fabric:100% Cotton Fleece
GSM: 260
M:L-1:7

114
Pictures of Dyeing Machine & its Parts of Masco Group:
7.3 DIFFERENT TYPES OF KNIT DUEING MACHINES
Fig: Jet dyeing machine (Fongs) Fig: Jet dyeing machine (NPL)
Fig: High temperature dyeing machine (SCLAVOS)

115
Heat Exchanger
Dyed Fabric Unloading From Fong’s Dyeing
m/c
UnDyed Grey Mellange
Fabric Loading To Thies m/c

116
Filter of Heat
Exchanger
Chemical Tank

117
Common dyeing faults with their remedies
1. Uneven dyeing:
Causes:
- Uneven pretreatment (uneven scouring & bleaching).
- Improper color dosing.
- Using dyes of high fixation property.
- Uneven heat-setting in case of synthetic fibers.
- Lack of control on dyeing m/c
Remedies:
- By ensuring even pretreatment.
- By ensuring even heat-setting in case of synthetic fibers.
- Proper dosing of dyes and chemicals.
- Proper controlling of dyeing m/c
2. Batch to Batch Shade variation:
Causes:
- Fluctuation of Temperature.
- Improper dosing time of dyes & chemicals.
- Batch to batch weight variation of dyes and chemicals.
- Dyes lot variation.
- Improper reel speed, pump speed, liquor ratio.
- Improper pretreatment.
Remedies:
- Use standard dyes and chemicals.
- Maintain the same liquor ratio.
- Follow the standard pretreatment procedure.
- Maintain the same dyeing cycle.
- Identical dyeing procedure should be followed for the same depth of the
Shade.
- Make sure that the operators add the right bulk chemicals at the same time
and temperature in the process.
- The pH, hardness and sodium carbonate content of supply water should
check daily.
2. Patchy dyeing effect:
Causes:
- Entanglement of fabric.
- Faulty injection of alkali.
- Improper addition of color.
- Due to hardness of water.
- Due to improper salt addition.

118
- Dye migration during intermediate dyeing.
- Uneven heat in the machine, etc
Remedies:
- By ensuring proper pretreatment.
- Proper dosing of dyes and chemicals.
- Heat should be same throughout the dye liquor.
- Proper salt addition.
4. Roll to roll variation or Meter to Meter variation:
Causes:
- Poor migration property of dyes.
- Improper dyes solubility.
- Hardness of water.
- Faulty m/c speed, etc
Remedies:
- Use standard dyes and chemicals.
- Proper m/c speed.
- Use of soft water
5. Crease mark:
Causes:
- Poor opening of the fabric rope
- Shock cooling of synthetic material
- If pump pressure & reel speed is not equal
- Due to high speed m/c running
Remedies:
- maintaining proper reel sped & pump speed.
- Lower rate rising and cooling the temperature
- Reducing the m/c load
- Higher liquor ratio
6. Dye spot:
Causes:
- Improper Dissolving of dye particle in bath.
- Improper Dissolving of caustic soda particle in bath.
Remedies:
- By proper dissolving of dyes & chemicals
- By passing the dissolved dyestuff through a fine stainless steel mesh
strainer, so that the large un-dissolved particles are removed

119
7. Wrinkle mark:
Causes:
- Poor opening of the fabric rope
- Shock cooling of synthetic material
- High temperature entanglement of the fabric
Remedies:
- Maintaining proper reel sped & pump speed.
- Lower rate rising and cooling the temperature
- Higher liquor ratio
8. Softener Mark:
Causes:
- Improper mixing of the Softener.
- Improper running time of the fabric during application of softener.
- Entanglement of the fabric during application of softener
Remedies:
- Maintaining proper reel sped & pump speed.
- Proper Mixing of the softener before addition.
- Prevent the entanglement of the fabric during application of softener

120
Chapter: 8
FINISHING SECTION

121
Organogram of Finishing Section:
Executive Director (E.D)
Manager / Asst.Manager
Sr. Principle officer (P.O)
Finished Fabric Finished Collar / Cuff
Sr. Supervisor / Supervisor /
On line System Off line system Jr. Supervisor
Sr. Supervisor / Supervisor Sr. Supervisor / Supervisor Quality Controller
/ Jr. Supervisor / Jr. Supervisor
Asst. Quality Controller
Quality Controller Quality Controller
Asst. Quality Controller Asst. Quality Controller
FINISHING
SECTION

122
Flow chart for knit fabric finishing Process:
Dyed fabrics from the dyeing section
Send one roll check (check roll)
Check roll ok Check roll not
ok
Process running Process stop
Roll correction
Tube fabric Open fabric
Dewatering Slitting
Dryer Stenter/Dryer(santex)
Turning Compactors
Soft setting Inspection
Compacting Packing
Inspection Delivery
Packing
Delivery
Machine List of Finishing Section:
Raising/Sueding
Stenter/Dryer(santex
)

123
Machine Name Machine Quantity
Slitting m/c 02
Dewatering m/c 02
Dryer 02
Stenter 02
Open Compactor 01
Tube Compactor 01
Single Drum Raising m/c 01
Double Drum Raising m/c 01
Sueding m/c 01
Slitting Machine
Machine specification:
Slitting m/c:-01
Brand name-Bainco (Linea Taglierina)
Origin: Italy
Serial no: M04529-021538
Construction Year: 2005
Maximum Speed: 9m/min.
Capacity: 10Ton.
Slitting m/c:-02
Brand name- Inox
Origin: China
M/C No: P00907019
Model: D-S-01
Capacity:10Ton
Campany: Inox Machinery com. Ltd.
Slitting:
Slitting is a process that is applied for cutting the tubular fabric through the
intended break Wales line on lengthwise direction prior to stenter processing.
Machine parts:

124
1. Rotary blade: To cut the fabric through break Wales line.
2. Ring: To help cutting.
3. Guide Roller: To guide the fabric to plaiting.
4. Plaiting: To plait the fabric.
5. Sensor: Sense for cutting through break Wales line.
Working principle:
The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder.
After dyeing completed and falling of water from fabric the fabric is fed in slitting
m/c. So it is necessary to remove some water initially for the case of further
processing in this m/c. The initial squeezer does this work. The de-twisting unit
removes twists that may present in tubular rope form fabric. This unit has 3 de-
twisting rollers, one rotation drum and 2 feeler rollers with sensors. By these
rollers it detects twist in fabric and removes by rotating rope fabric in opposite
direction. Before slitting there is a blower which blows air to open the tubular
fabric & makes it easy to pass over cigger. The cigger can be extended in
circumference and opens the tubular fabric in full circumference. Slitting is done
by using open mark detecting golden eye by around knife. Then the fabric passes
through the padder where washing or chemical treatment is done. Squeezer is used
to remove 60-70% of water. After removing water width is controlled by stretcher
and fabric is delivered by folding device.
Operational parameter:
-Set the padder pressure as required (3-7bar)
-Set the speed as much as possible (30-80m/min).
Function of the Machine:
 Used to remove excess water after pretreatment and dyeing.
 To slit the tube fabric by the knife for opening of the fabric and
ready for stentering.
 Delivered fabric in crease free state.

125
 Before squeezing balloon is formed with the help of compressed air
passing by a nozzle or air sprayer.
 It can control the diameter of fabric and GSM and shrinkage by over
feeding mechanism.
Detwister Rotary Knife Cutter
Slitting m/c

126
DEWATERING
Machine specification:
No of Dewatering m/c : 02
Function:
 Reduce water content.
 Apply chemicals.
 Apply over feed to give some compaction.
 Open the fabric from the rope form.
 Width wise stretch the fabric.
 Plait the fabric.
Operational parameter
 Speed: As much as possible (40-60 m/min). Higher the GSM lower the
speed.
 Over feed: As required. Higher the GSM higher the over feed.
 Padder pressure: 3-7 bar as required. Higher the GSM lower the padder
pressure.
 Width: Fabric width is adjusted as per required width.
N.B: Santex contains two bath. One for padder bath and another for softener bath
where softener given 1 g/l. The softener bath capacity is 80 liters.
Machine no: 01
Machine name: Dewatering
Brand name:Tube Tex 4-roll pad
M-C No: 13-M-9692
Model: Delta plus 4-60
Capacity:8Ton
Origin:U.S.A
Company: Tubular Textile com.LLC.

127
Working principle of Dewatering:
After completing the dyeing process from the dyeing m/c then the fabrics are
ready for de-watering. In de-watering m/c tubular fabrics are mainly processed.
There is a magnetic sensor which scene the twist of the fabric and its direction and
turn the fabric in opposite direction to remove twist automatically. Here
dewatering is performed De-watering is the process to remove the water from the
fabric completely by squeezing and it is done by the padder. A suitable expander is
used before the fabric is passed through the nip of the padders, which expands the
fabric flat wise and adjust the width. The expander width is adjusted as S/J- 20%,
PK-25%, Int.-35%, Lacoste-40% wider than the required width. There is a pair of
rubber coated padder, where water is removed from fabric when passed through
the nip of it.
Normally squeezer contain single or double padders where,
- One for removing water and
- Other for applying finishing chemicals such as softener.
But this finishing is done only for the tubular fabric. Open width knitted fabrics are
applied finishing treatment later in stenter.
Here present the compressor which given compress air to form ballooning before
passing through the padder. This balloon remove crease mark but not form the
maximum balloon otherwise shrinkage increase
DRYER
Dryer- (multifunctional)
Band name:- Santex
Origin: – China
M/C Type-Santashrink progress.
Year of construction- 2008
Chamber: -4
Com.no: 6960/2600(mm)
Elect-Voltage:3×400/50(Volt/Hz)
Connected Load: 193/435(KW/A)
Function of Suntex dryer m/c:
To dry the fabric.
To control the hand Feel
To control the Twist
To control the shrinkage +Dia+Gsm
Main parts of the machine:
Heating chamber.
Blower.

128
Synthetic blanket as aconveyor.
Folder.
Exhaust fan.
Heating arrangement:
Heating chamber: 4
No of burner: 4
Controlling points of dryer:
Overfeed
Temperature
Padder pressure
Speed
Checking points of Dryer:
Shade check
Width check
Fabric faults (color spot, uneven, hole, Dia,mark, ec).
OPERATING PARAMETERS
 Temperature:-Set the temperature between 1300
c -1500
c for white and
1500
c -1700
c for color fabric. If GSM increase than the temperature is
increase Or, if moisture content increase than temperature is also increase.
 Set the over feed up to 25~50% or as required to get finish G.S.M.
 Set the speed as much as possible (6~20m/min). GSM speed

129
PARAMETERS USED FOR DIFFERENT CONSTRUCTED FABRIC
For cotton fabric:
Fabric
Type
Overfeed
%
Temperature0
C Speed (m/min) Folder
Speed
(m/min)
Vibration
Color
White
Color
High
G.S.M
Low
G.S.M
Single
Jersey
30 % to-
40%
150-
1600
C
130-
1500
C
15-20 20-25 2~3
As
Required
Single
Lacoste
30 % to-
35% 160-
1650
C
130-
1500
C 15-20 20-25 2~3
As
Required
Polo
Pique
30 % to-
40%
155-
1600
C
130-
1500
C
15-20 20-25 2~3
As
Required
Interlock
30 % to-
40%
165-
1700
C
130-
1500
C
14-18 22-24 2~3
As
Required
Grey
Mélange
30%-
40%
155-
1600
C
130-
1500
C
10-18 20-22 3~4
As
Required
N.B:  If fabric is more Redder than the standard one, then reduce the
temperature.
 If fabric is more Yellower than the standard one, then increase the
temperature.

130
 If fabric is more Bluer than the standard one, then increase the
temperature.
STENTER
Machine specification :
No. of Stenter : 02
Stenter m/c no :- 01
Brand name : - Sun-Super
origin : -South Korea
Manufacturing date-: 2005
MFG No:4988
Width Range : -2400mm/94.48inch.
Maximum Speed: - 100m/min
Capacity : 10 Ton
Chamber : - 8
Company: Ilsung Machinery Com.LTD.
Stenter m/c no :– 2
Brand name : platinum
origin : South Korea
Width Range:2400mm/94.48inch
Manufacturing Year : 2010
Maximum Speed: 8-120m/min
Chamber : 4
Capacity :8 ton
Ratiomatic Burner for Fuel Combustion:
Origin - Germrny
Year-11/2003
Capacity-200 kw
Voltage-230/400 v
Frequency-50/60Hz
Fuel- Natural gas
Pressure- 50 m bar

131
Important parts of stenter
-Burner (12)
- Exhaust air fan (16)
-Over feed roller.
- Suction fan (12)
-Nozzle
-Chain arrangement.
S-tank
1 2 3 4 5 6 C-c
U-F
L-F
Fig: Flow path of Stenter (BRUCKNER)
S
(1-6) = Heating chamber. S-tank = Softener tank
U-F = Upper feeder roller L-F = Lower feeder roller.
C-c = Cooling chamber. = Direction of fabric path.
S = Squeezer roller

132
FUNCTION OF STENTER:
- Drying
- Shrinkage control.
- Heat setting.
- Width control Finishing chemical application.
- Loop control.
- Moisture control.
- Spirility control.
12.4 DIFFERENT SECTIONS OF STENTER MACHINE
A. Padder Section
In the padder section the fabric is treated with chemicals specially with softener
and acid in two tanks.
B. Weft Straighter
The main function of Weft Straightner is to control the bowing & Skewnesss of the
fabric.
C. Width Setting Chamber:
This Chamber control the width of the fabric by clip of pin.
D. Heatting Chamber:
This chamber controls the shrinkage and the G.S.M of fabric.
Temperature Range: Cotton-- 1500
C~1700
C.
Polyester-- 1650
C~1850
C.
With Lycra -- 1750
C~1900
C.
E. Cooling Chamber:
This chamber cooled the hot fabric before reach to delivery zone.

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