Industrial attachment of APS group ltd

1 Industrial Attachment-2014 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF APS GROUP LTD. 2 Industrial Attachment-2014 Introduction Industrial Attachment is the first step to professional life of a student. Especially of technical side it’s an indispensable part of study a practically running processing technology of an industrial unit for a student. In our University, processing machines are not in continuous running condition. So it would only provide demonstration of mechanical features & processing technology of the material in accomplishment of the theory there of but not of the situational variables to achieve practical knowledge. Six weeks industrial attachment program in a dying mill was arranged for us this type of attachment program enabled us to avoid the gap between theory & its applicability the mill practice the incumbent was deeded to APS Group (Dyeing Unit). In the field of ever changing moderns fashion work. APS Group (Dyeing Unit). considers its prime mission to every new test. Which & demand of customers from around the World & all strains human culture DGL acts on the basis premise that fashion is an exploration in to the images people seek to convey about themselves & the way they live. We have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for our future carrier. 3 Industrial Attachment-2014 Table of Content Chapter Description Page no Chapter-1 Over View of the Factory 5-17 Chapter-2 Raw Materials 18-24 Chapter-3 Knitting section 25-41 Chapter-4 Laboratory section 42-46 Chapter-5 Batch section 47-53 Chapter-6 Dyeing Section 54-76 Chapter-7 Water Treatment Plant “WTP” 77-79 Chapter-8 Finishing Section 80-95 Chapter-9 Quality Control 96-105 Chapter-10 Description of ETP 106-108 Chapter-11 Garments 109-115 Chapter-12 Maintenance 116-118 Chapter-13 Store & Inventory control 119-121 Chapter-14 Social & Environmental information 122-127 4 Industrial Attachment-2014 CHAPTER: 1 “Over View of the Factory” 5 Industrial Attachment-2014 Address: Pubail, Gazipur, Sadar, Gazipur 6 Industrial Attachment-2014 AT A GLANCE APS Group (Dyeing Unit) 100% Export Oriented Composite Knitwear Factory Address: Pubail, Gazipur, Sadar, Gazipur Tel: +88-02-9815028, www.aps-group.org Head Office - Pubail, Gazipur, Sadar, Gazipur Tel: +88-02-9815028 Factory - Pubail, Gazipur, Sadar, Gazipur Nature of project - 100% Export Oriented Composite Knitwear Factory Bank - Bangladesh Shilpa Bank, Head Office, Dhaka. Management - 1. Md. Alfaz Managing Director/Chairman Contact Person - 1. Engr. Md. Rashedul Islam (Babu), General Manager (Fac.) Mobile: 01713454160  -2. Md. Rezaul Karim (Babu) Manager (Dyeing & Finishing) Mobile: 01718218497  3. Md. Bellal Uddin Manager (Knitting)  4. Md. Musa Kalim (Manager Finishing) 7 Industrial Attachment-2014 Composition of Factory The Enterprise have been organized in the following manner: APS Group (Dyeing Unit) Unit : Fabrics Knitting APS Group (Dyeing Unit) Unit : Fabrics Dyeing Year of Establishment : January, 2000 Location: Our Head office is located at a posh area called Uttara while the factory is located in an industrial area at Pubail, Gazipur which is only 2.2 Km. Production Capacity and Facilities : 1) Knitting Division : Area : 10,000 sft. Man Power : 46 Production Capacity : 6000 Kgs/day List of machinery : As below 8 Industrial Attachment-2014 a) Type of Machine Circular Knitting Machineries Sl.No. Dia Gauge Qty of feeder Brand/Origin Fabrics No of Machine 1 21" 20+24 63 Jiunn long/Taiwan Single Jersey 2 2 23" 69 3 3 25" 75 Single Jersey/Pique 3 4 28" 84 2 5 30" 90 2 6 36" 108 1 7 34" 18+24 68 Rib/Interlock 1 8 40" 18+24 80 1 Equipped With Lycra Attachment Total 15 b) Type of Machine Flat Knitting Machineries (Specially Collar & Cuffs) Sl.No. Length Gauge Colour Brand/Origin No of Machine 1 52" 14 6 Jy-Leh/Taiwan 2 2 68" 1 9 Industrial Attachment-2014 2) Dyeing Division : Area : 25,200 sft. Man Power : 195 Production Capacity : 10890 Kgs/day List of Machinery : As below a) Type of Machine : Dyeing Machineries Sl.No. Origin / Brand Description of Machine Capacity in KG No. Of Machine 1 AK / Taiwan AK brand high temperature & high pressure Dyeing machine ( Model 2007) 500 2 2 250 1 3 100 1 c) Type of Machine : Fabrics Inspection Machineries Sl.No. Model Origin Brand No of Machine 1 HCTIM Taiwan Hsing Cheng 1 10 Industrial Attachment-2014 4 50 1 5 600 2 6 800 2 7 Atmoispheric Dyeing Machine 30 1 8 25 1 9 15 1 10 FONGS/China Atmoispheric Dyeing Machine 1200 1 Total 5470 13 b) Type of Machine : Finishing Machineries Sl.No. Brand Origin Description of Machine No. Of Machine 1 Corino Italy Squeezer for Tubler Knitted Fabric 2 2 LK Taiwan 4- Chamber Tensionless Dryer 1 3 FAB-CON USA Computerized Compactor 1 4 Tube-Tex USA Computerized Compactor 1 5 Hsing Cheng Taiwan Over Turning Machine 1 c) Type of Machine : Laboratory Machineries The Factory is equipped with a most modern set up of brand new & latest Model Laboratory [...]... and quality Before production of knitted fabric, these factors are needed to consider Those are as follows- Type of Fabric or design of Fabric - Finished G.S.M - Yarn count - Types of yarn (combed or carded) - Diameter of the fabric - Stitch length - Color depth Industrial Attachment- 2014 26 Name & Picture of Knitting Machine in APS knitwear Textile Ltd Machine Name Number of machine Production shift(kg)... quality dyes like REMAZOL, REACTRON, REACTIVE, TERACIL etc During the time of using dyestuff they give importance upon the quality of dyes than the price of the dyes and chemicals Industrial Attachment- 2014 23 CHAPTER: 3 “KNITTING SECTION” Industrial Attachment- 2014 24 Machine Description of Knitting Section: M/C M/C M/C M/C No Of No Of M/C S/L Dia Gauge Model Feeder Needle Spec 1 30” Rib-18 XR2B/CE 60... Interlock Machine (Pailung) 05 per 1.5 Ton Industrial Attachment- 2014 27 Fig: PAI LUNG Knitting Machine Industrial Attachment- 2014 28 Fig: FUKAHARA Knitting Machine Industrial Attachment- 2014 29 Fig: Mayer & Cie knitting machine Industrial Attachment- 2014 30 Knitting Production and Raw Materials: Methods of increasing production: By the following methods the production of knitted fabric can be increased –... quality Before production of knitted fabric, these factors are needed to consider Those are as followsType of Fabric or design of Fabric Finished G.S.M Yarn count Types of yarn (combed or carded) Diameter of the fabric Stitch length Color depth Effect of stitch length on color depth: If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop... Similarly in case of light shade loop length should be relatively smaller Factors that should be change in case of fabric design on quality change: a) Cam setting b) Set of needle c) Size of loop shape Industrial Attachment- 2014 35 Faults & Remedies of knitting fabric: 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... m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time By using machine of higher gauge: The more the... Invatex PC 97 39 Invatex AC 117 40 Catalar BF 324 Dyes Rate per kg 01 Solazol Black sp GRI 300 02 Reactofix Red ME4BL 262 03 Cottofix Red ME4BL 262 04 Reactofix Orange ME2RL 294 05 Reactofix N.ME2GL 354 4 Dyes: Industrial Attachment- 2014 21 06 Reactive Yellow H4GL 500 07 Reactive Deep Black N 200 08 Cottofix Black B 141 09 Reactive Blue R(SP) 950 10 Remazol Red RR 1080 11 Remazol Yellow RR 746 12 Remazol... : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt, Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear& all kinds of knit garments & Knit fabrics Industrial Attachment- 2014 12 BASIC LAY-OUT OF THE FACTORY 3 4 2 1 Entry 5 9 6 10 11 7 12 13 8 1 Industrial Attachment- 2014 13 1 Security office 2 Mosque 3 Store 4 Knitting section 5 Finishing (Gr Floor)+ Knitting (2nd Floor)+ Garment section (3rd -7th Floor)... using machine of higher gauge production can be increased By imposing other developments:  Using creel-feeding system  Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage  Using yarn feed control device  Using auto lint removal Industrial Attachment- 2014 31 Production calculation: A Production/shift in kg at 100% efficiency:  B RPM  No of Feeder No of Needle... SL(mm) 3527.80  Yarn count Production/shift in meter: Course / min Course / cm RPM  No of Feeder  60  12  Efficiency  Course / cm  100  C Fabric width in meter: Total no of wales Wales / cm  100 Total no of Needles used in knitting  Wales / cm  100  Industrial Attachment- 2014 32 Process flow chart of knitting: Yarn in cone form ↓ Feeding the yarn cone in the creel ↓ Feeding the yarn in . 1 Industrial Attachment- 2014 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF APS GROUP LTD. 2 Industrial Attachment- 2014. Introduction Industrial Attachment is the first step to professional life of a student. Especially of technical side it’s an indispensable part of study a practically running processing technology of. 7 Industrial Attachment- 2014 Composition of Factory The Enterprise have been organized in the following manner: APS Group (Dyeing Unit) Unit : Fabrics Knitting APS Group (Dyeing