Industrial attachment of micro fibre ltd

INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
MICRO FIBRE LTD

ACKNOWLEDGEMENT
At first my gratefulness goes to Almighty Allah for giving me strength and ability to
complete the industrial training and this report. You have made my life more bountiful. May
your name be exalted, honored and glorified.
Now I wish to take this excellent opportunity to thank a lot of people who have assisted
and inspired me, Prof. Syed Fakhrul Hassan my supervisor, to whom I am extremely indebted
for his tremendous support and guidance throughout my training period. Working with him I
have not only earned valuable knowledge but also was inspired by him innovativeness which
helped enriches my experience to a greater extent. His ideas and way of working was truly
remarkable.
I would like to thank the management of the MICRO FIBRE LTD. for giving me the
opportunity to complete the industrial training successfully and also for their valuable
suggestion. My deepest gratitude goes to Executive Director Mr. Amirul Haque, General
Manager Mr. Mizanur Rahaman Patwoary, Assistant general manager Mr. Solaiman Hossain,
MICRO FIBRE LTD. for their permission to conduct my industrial training without which it
would be impossible. Their generous support is greatly appreciated. I would also like to thank
specially our senior brothers and sisters working there efficiently as textile engineer. I am greatly
indebted to them. I also want to thank executives, senior executives and other official’s employee
of MICRO FIBRE LTD. for helping me to complete industrial training successfully. My
gratitude also goes to all the employees of MICRO FIBRE LTD. for their sincere co-operation,
support and valuable advices.
Finally my heartfelt thanks goes to my training mates for their indescribable co-operation
& sincerity.

Introduction:
Final course industrial training is one of the most essential parts of engineering &
technical education. This industrial training is included in our syllabus to acquaint us with the
practical implementation of the technology studied within the industrial environment. Though it is
very helpful & lays the milestone for starting the carrier for fresh Textile graduates.
Fabric manufacturing and Wet processing technology which occupies a vast field in
modern Textile technology is undergoing many stages of processing. Many problems are generally
being encountered during each operation stage starting from yarn to fabric and fabric desizing to
finishing stage. Finally from mill training, we learn practical Knowledge about on fabric
manufacturing and wet processing under industrial environment. We think it will be helpful in our
future carrier.
Vision:
To establish as a one stop source for the Global knit Apparel market and to satisfy
and meet customers expectation by developing and providing products and services on time,
which offer value in terms of Quality, Price, Safety and Environmental impact.
Assuring complete compliance with the international quality standards and also
providing the employees internationally acceptable working condition and standards. To
promote the development and to use human talent and equal opportunity of employment.
Mission:
Micro fibre realizes the need to take out a competitive segment in the changing global
market of today through technological excellence and human expertise. Micro fibre is committed to
transpose its local success to the world scene.

Industrial Attachment Report 2011
S
Chashara
Location Of The
MICRO FIBRE GROUP
Shibo Market
E
Micro
W
N
Ramarvag
Narayanganj
Fatullah
Fibre
Fatullah
Stadium
Fatullah
Rail
Sign Tikatol
Chittagong
Board
ZatraBari
Kamolapur
railstation Gulistan

Contents
CHAPTER-01..............................................................................................................1
PROJECT DESCRIPTION .......................................................................................1
Name of the project........................................................................................................................................................... 1
Sister organizations........................................................................................................................................................... 1
Type of the mill ................................................................................................................................................................. 1
Year of establishment........................................................................................................................................................ 1
Registered Office............................................................................................................................................................... 1
Factory Address ................................................................................................................................................................ 1
Communication................................................................................................................................................................. 1
Sponsors ............................................................................................................................................................................ 1
Capacity............................................................................................................................................................................. 2
Project cost ........................................................................................................................................................................ 2
Project area ....................................................................................................................................................................... 2
History of project development: ....................................................................................................................................... 2

Different departments:...................................................................................................................................................... 3
Product mix:...................................................................................................................................................................... 3
LAYOUT DESIGN ........................................................................................................................................................... 4
Layout plan of printing section:....................................................................................................................................... 5
Remark:............................................................................................................................................................................. 6
Physical Infrastructure: ................................................................................................................................................... 7
CHAPTER -2...............................................................................................................8
MANPOWER MANAGEMENT...............................................................................8
Organ gram of man-power administration...................................................................................................................... 8
Management system: ........................................................................................................................................................ 8
Shift change:..................................................................................................................................................................... 9
Total Section Wise Man power Management system: .................................................................................................... 9
Responsibilities of S.P.O/P.O:........................................................................................................................................ 10
Job description of S.P.O/P.O................................................................................................................................ 10
Remarks........................................................................................................................................................................... 10
CHAPTER-3..............................................................................................................11
MACHINE DESCRIPTION....................................................................................11

List of Single Jersey Circular knitting Machineries :................................................................................................... 11
List of Single Jersey Circular knitting Machineries :................................................................................................... 12
List of Double Jersey Circular knitting Machineries :................................................................................................. 13
List of Auto Stripe Circular knitting Machineries :...................................................................................................... 14
List of Flat Bed knitting Machineries : ......................................................................................................................... 14
List of Cloth Inspection Machineries :.......................................................................................................................... 15
Machine Picture.............................................................................................................................................................. 16
Lay-out Plan of knitting Machineries : ......................................................................................................................... 18
Remarks : ........................................................................................................................................................................ 20
CHAPTER -04...........................................................................................................22
RAW MATERIALS..................................................................................................22
Types of Raw Materials:................................................................................................................................................. 22
Yarn: ............................................................................................................................................................................22
Grey Fabrics:.............................................................................................................................................................23
Chemicals:
..................................................................................................................................................................24
Commonly used dyes in fabric dyeing section in Micro fibre Ltd................................................................24

Chemicals & their function:........................................................................................................................................... 26
Chemicals used in Dyeing and their function: ...................................................................................................26
Printing chemicals function: ..................................................................................................................................28
Urea ..............................................................................................................................................................................28
Resist salt......................................................................................................................................................................28
Na .................................................................................................................................................................................28
Thickener......................................................................................................................................................................28
Price: ...........................................................................................................................................................................29
Annual requirement: ................................................................................................................................................29
Remarks: ......................................................................................................................................................................... 29
Chapter-05 .................................................................................................................30
Production planning, sequence & operation ..........................................................30
Introduction and Basic Procedure of Planning and Control:................................................................................. 30
Recommendable points of a buyer:................................................................................................................................ 30
Production Planning: ..................................................................................................................................................... 31
Knitting section ............................................................................................................................................................... 32

Production parameters: ..........................................................................................................................................32
Points that should consider in case of G.S.M. changing:................................................................................32
Production flow chart:.................................................................................................................................................... 33
Description of production process: ................................................................................................................................ 33
GSM:............................................................................................................................................................................34
Fabric width: .............................................................................................................................................................34
RPM:.............................................................................................................................................................................34
Loop length: ...............................................................................................................................................................34
No. of feeder or no. of cone: ................................................................................................................................34
Gauge:..........................................................................................................................................................................35
Production calculation:............................................................................................................................................35
Following Counts are used to achieve the mentioned G.S.M: ..................................................................................... 38
Relation between yarn count, fabric type, stitch length and finished GSM: ............................................................... 39
Fabric Dyeing Section:................................................................................................................................................... 44
Production flow chart for fabric:........................................................................................................................44

Process sequence:
....................................................................................................................................................45
Pretreatment: ...........................................................................................................................................................45
Scouring-Bleaching:....................................................................................................................................................... 46
Pretreatment program: (scouring ,bleaching and enzyme)
............................................................................46
Bio-Scouring:.................................................................................................................................................................. 48
Enzyme Treatment: .................................................................................................................................................48
Dyeing: ............................................................................................................................................................................ 50
Dying program for ME dyes:
.................................................................................................................................50
Dyeing program for HE Dyes: ...............................................................................................................................51
Dying program for W Dyes:...................................................................................................................................52
Dying program for Turquise Dyes:.......................................................................................................................53
Dying program for KHW Dyes: .............................................................................................................................54
Dyeing program for HF dyes:................................................................................................................................55
Dyeing program for WHITE color (Without enzyme):...................................................................................56
Dyeing program for WHITE color (With enzyme):.........................................................................................57

Dyeing program for Disperse Dyes: ....................................................................................................................58
Re-dyeing Process:...................................................................................................................................................59
Stripping process:....................................................................................................................................................60
After Treatment Of All Program:.......................................................................................................................61
After dyeing for neutralization:..........................................................................................................................62
For fixing: ..................................................................................................................................................................62
Softener solution(10% solution):..........................................................................................................................62
Necessary calculations used in textile dyeing processes:.............................................................................................. 63
Molarity ......................................................................................................................................................................63
Normality ...................................................................................................................................................................63
Stock solution preparation ....................................................................................................................................63
Dyeing calculation.....................................................................................................................................................63
Common textile auxlliaries used in dyeing: .................................................................................................................. 64
Acid..............................................................................................................................................................................64
Alkalis..........................................................................................................................................................................64

Buffer .........................................................................................................................................................................64
Oxidizing agent.........................................................................................................................................................64
Reducing agent..........................................................................................................................................................64
Surfactants ...............................................................................................................................................................65
Wetting agent...........................................................................................................................................................65
Detergent...................................................................................................................................................................65
Lubricant ....................................................................................................................................................................65
Anti-foaming agent..................................................................................................................................................65
Anti-creasing agent .................................................................................................................................................65
Anti-pilling agent......................................................................................................................................................65
Leveling agent ...........................................................................................................................................................65
Dispersing agent.......................................................................................................................................................65
Retarding agent........................................................................................................................................................65
Carrier ........................................................................................................................................................................66
Chemical formula of common chemicals used in textile dyeing:...................................................................66

Problems Encountered In Dyeing: ............................................................................................................................... 66
Uneven Dyeing...........................................................................................................................................................66
Uneven Shade in Rope to Rope..............................................................................................................................67
Off Shade..................................................................................................................................................................67
Dye Spots...................................................................................................................................................................67
Batch to Batch Shade Variation...........................................................................................................................67
Crease Mark ..............................................................................................................................................................67
Running Marks...........................................................................................................................................................67
Intensive Foaming ....................................................................................................................................................68
Patchy Dyeing............................................................................................................................................................68
Miscellaneous Problems ..........................................................................................................................................68
Remarks: ......................................................................................................................................................................... 68
Printing............................................................................................................................................................................ 68
Sample Preparation ........................................................................................................................................................ 69
Bulk Production:............................................................................................................................................................. 70

Available Printing Style in Micro Fibre LTD................................................................................................................ 70
Types of Printing in Micro Fibre Group:...................................................................................................................... 70
Reactive printing:.....................................................................................................................................................70
Discharge printing: ..................................................................................................................................................71
Pigment printing: ......................................................................................................................................................71
Recipe of Pigment paste:........................................................................................................................................71
Recipe of Discharge paste:....................................................................................................................................71
Recipe of reactive Paste:.......................................................................................................................................71
Pollutants during printing process:
......................................................................................................................72
Finishing section............................................................................................................................................................. 72
Objective of finishing:............................................................................................................................................72
Types of finishing:...................................................................................................................................................73
Flow chart of final process (knit fabric) ...........................................................................................................74
The machines that are used in open line that are given bellow: ..................................................................74
The machines that are used in tube line that are given bellow: ..................................................................75

Machine Specification: ...........................................................................................................................................75
Squeezer Machine:...................................................................................................................................................78
Hydro-extractor m/c..............................................................................................................................................78
Dryer m/c :..............................................................................................................................................................78
High Production Dryer:...........................................................................................................................................78
Utility:.............................................................................................................................................................................. 79
Calendar M/C: ...........................................................................................................................................................80
Width Compactor.....................................................................................................................................................80
Stentering Machine......................................................................................................................................................... 84
Purpose of the m/c:.................................................................................................................................................84
Main parts of the machine:....................................................................................................................................85
Procedure for Heat set for Lycra s/j fabric: ..................................................................................................87
Factor Consideration:..............................................................................................................................................88
CHAPTER-6..............................................................................................................90
Quality Assurance System........................................................................................90

Quality assurance:.......................................................................................................................................................... 90
Object of quality control:................................................................................................................................................ 90
Scope of quality control:................................................................................................................................................. 91
Quality Control Flow Chart:.......................................................................................................................................... 91
Quality Management system:......................................................................................................................................... 92
Online QC ...................................................................................................................................................................92
Off Line Test:...........................................................................................................................................................93
WORKING PROCEDURE FOR LAB........................................................................................................................... 94
List of Dyeing and Qc Laboratory Machinaries............................................................................................................ 95
Quality Standard:.......................................................................................................................................................... 100
Fabric Inspection:..................................................................................................................................................100
Grey Fabric Inspection.........................................................................................................................................100
Finished Fabric Inspection:................................................................................................................................. 101
Procedure of the Different Laboratory Tests: ............................................................................................................. 103
Color Fastness to Wash Test: ............................................................................................................................103
Required instrument:.............................................................................................................................................104

Procedure :...............................................................................................................................................................104
Evaluation:................................................................................................................................................................104
Washing fastness for solid dyeing is checked normally 3 times e.g. ........................................................104
Color the Fastness to Rubbing (Dry & Wet) Test: ........................................................................................104
Procedure:................................................................................................................................................................105
Evaluation:................................................................................................................................................................105
Color Fastness to cool Water:............................................................................................................................105
Testing Solution: ....................................................................................................................................................105
Color Fastness to hot Water: .............................................................................................................................106
Testing Solution: ....................................................................................................................................................106
Color Fastness to Perspiration Test: ................................................................................................................107
Color fastness to light:.........................................................................................................................................108
Accepted Quality standard: .......................................................................................................................................... 108
Measuring the Dimensional Stability (Shrinkage & Spirality):...................................................................108
Spirality test calculation: .................................................................................................................................... 110

pH of a Dyed Fabric Test .....................................................................................................................................111
Quality Standard:.......................................................................................................................................................... 112
SHORTLY DESCRIBED ABOUT OEKO-TEX STD100:................................................................................. 112
Remarks: ....................................................................................................................................................................... 113
CHAPTER-07..........................................................................................................114
MAINTENANCE ....................................................................................................114
Maintenance of machinery: ......................................................................................................................................... 114
Break down Maintenance:..................................................................................................................................... 114
Routine Maintenance:............................................................................................................................................ 114
Manpower Set-Up For Maintenance:.......................................................................................................................... 115
Maintenance procedure:............................................................................................................................................... 115
Maintenance work to the different machines:............................................................................................................. 116
Boiler Maintenance Schedule:............................................................................................................................. 116
Dyeing m/c maintenance Schedule .................................................................................................................... 117
Compacting m/c maintenance:............................................................................................................................. 118
Maintenance tools/equipments & their functions:...................................................................................................... 119

Remarks: ....................................................................................................................................................................... 120
CHAPTER-08..........................................................................................................121
UTILITY SERVICE...............................................................................................121
Available Utility Facilities:........................................................................................................................................... 121
Electricity:............................................................................................................................................................... 121
Gas:................................................................................................................................................................................ 122
Water:............................................................................................................................................................................ 122
Boiler:............................................................................................................................................................................ 122
Compressor: .................................................................................................................................................................. 123
Source of Utility:........................................................................................................................................................... 124
Utility cost: .............................................................................................................................................................124
Remark:......................................................................................................................................................................... 125
Water treatment plant................................................................................................................................................... 125
Process Flow chart.................................................................................................................................................125
Effluent Treatment Plant (ETP) .................................................................................................................................. 126
Flow chart for ETP: ...............................................................................................................................................127

Effluent analyzing report: ...................................................................................................................................128
Ref:............................................................................................................................................................................128
USPEA(United States Environment Protection Agency) .............................................................................128
Product Quality Checked: ....................................................................................................................................128
Chemicals Used in ETP:.........................................................................................................................................129
CHAPTER-09..........................................................................................................130
STORE & INVENTORY CONTROL..................................................................130
Inventory system for raw material:.............................................................................................................................. 130
Grey fabrics store:................................................................................................................................................130
Dyes & chemicals store: .......................................................................................................................................130
Spares:......................................................................................................................................................................130
Finished goods: ....................................................................................................................................................... 131
Remarks: ....................................................................................................................................................................... 131
CHAPTER-10..........................................................................................................132
COST ANALYSIS...................................................................................................132
Price of the product: ..................................................................................................................................................... 132

Remarks: ....................................................................................................................................................................... 132
CHAPTER-11..........................................................................................................133
MARKETING ACTIVITIES.................................................................................133
Consumers of Product:................................................................................................................................................. 133
Name of buyer:.............................................................................................................................................................. 133
Product Label:............................................................................................................................................................... 133
Package Size & Label:.................................................................................................................................................. 134
Local Market:................................................................................................................................................................ 134
Importing countries:..................................................................................................................................................... 134
Manpower of marketing:.............................................................................................................................................. 134
Marketing strategy:....................................................................................................................................................... 135
Duties and responsibilities of marketing officer:........................................................................................................ 135
Remarks: ....................................................................................................................................................................... 135
CHAPTER -12.........................................................................................................136
CONCLUSION........................................................................................................136

1 | P a g e
CHAPTER-01
PROJECT DESCRIPTION
Name of the project
Sister organizations
Type of the mill
Year of establishment
Registered Office
Factory Address
Communication
Sponsors
MICRO FIBRE GROUP
A-One polar Ltd,
Liberty Knitwear Ltd,
Midland Knitwear Ltd,
Orient Chem.-Tex Ltd.
100% export oriented knit composite textile mill.
1998
331, Tongi Dioversion Road, Moghbazar, Dhaka – 1217,
Bangladesh
Ramarbagh, Kutubpur, Fatullah, Narayangonj,
Bangladesh
0189-214648, 0173-034617 (E.D)
0171-3001607 (D.G.M-Production),
0173- 011112 (Merchandising Manager)
The project is easily accessible by road. The route has
been clarified in the location map presented in the
previous page.
The mill is sponsored by M.S. Zaman.

2 | P a g e
Capacity
Project cost
Project area
Gray knit fabric production 8000 Kg/day
(approximately)
Dyed knitted fabric 22-24 ton/day (approximately)
Cost of the project is approximately in Taka
250,00,00,000
7.00 acres
History of project development:
It is a moment of rejoice to introduce Micro Fiber Group (MFG) to its clients
and patrons. MFG believes whatever it has achieved; its credits should be directed toward its
clients.
Micro fibre group started their Textile business in 1998 by starting construction of the building
for project setup. At 1st
they set up Garments project. In 1999 they went to production of fabric
and dyeing with a dryer of 400 kg & 6 ton capacity boiler. As an ambition to expand the business
they setup knitting section in 2000 & to fill the demand of knitting they setup as well as stenter,
calendar, dewatering m/c, dryer for finishing. With the passage of time different type of m/c
were brought to the mill to improve the quality & production. The mill is well oriented for knit
composite project.
Therefore, when many struggle to survive in post-MFA world; its business in fact enjoying a
healthy growth.
Moreover, having endless efforts to ensure internationally accepted employment practice, its
clients recognize us as a partner to protect their value system and images among final consumers.

3 | P a g e
Different departments:
i. Knitting section
ii. Dyeing section:
Circular
Flat
Knit dyeing
iii. Garments section
iv. Costing & Finance
v. Logistics
vi. Maintenance
vii. Planning section
viii. QC section
Product mix:
Types of raw materials processed here are-
i. cotton- 100% combed or carded
ii. polyester-cotton blend (p/c or t/c), (65%pet+35% cotton)
iii. CVC (60% cotton+40% polyester)
iv. grey melange (85% cotton+15% viscose)
v. Ecru melange (98% cotton+2% viscose or 99% cotton+1% viscose)

S
E W
LAYOUT DESIGN
N
ETP
Midland Knitting
&
Garments
M
idl
a
n
Maintenanc
e
Department
Midland
Finishing
Laborator
y
Office Liberty
Garments
Midland
finishing
Midland
Dyeing
Micro
Dyeing
Micro
Finishing
Office
Office
Utilities
Cantee
n
Store
Entrance
Midland
Dyeing
Office
Midland
Printing
Room
Utilities
Room Dyes &
Chemicals
Car parking
Health
facilities
Room
Prayer
Security
Room
Office
4 | P a

55 | P a g e
Layout plan of printing section:
In the printing section of Micro fibre ltd there are 2 floors. In ground floor there are 3
Allover printing m/c and
Store
Keeper
E
MKT
Office
AGM
Office
Store
W
N S
C
E
C
Sample
Table
Ink
Jet m/c
1
1. Computer
2. Expose m/c
3. Retouching
table
2
C. Computer
E. Entrance
T. Toilet
3
T
Fig: 2nd
Floor of printing section

66 | P a g e
N
E Screen washing
zone
W
S
Allover
Printin
g
m/c # 3
Allover
Printin
g
m/c # 2
Allover
Printin
g
E
m/c # 1
E
Fig: Production Floor Printing Section
Remark:
Micro Fiber Group is a well established knit composite
industry. The industry stands on industrial area of Ramarbagh, Narayangonj. It is a
Group of Companies, . It is going to prove its own standard of product quality in
world market as they know that their reputation depends on quality. It is a profitable
project and contributes the economy of our country.

77 | P a g e
Physical Infrastructure:
MICRO FIBRE
GROUP
Knittin
g
Dyeing Garment Admin Maintena
nce
Knit
(admin)
Knit
(prod)
Cost &
finance
Accounts
Knit
dyeing
Prod
QC
Gmt(Ad
min)
Gmt
(Prod)
Electric
Dept
Mechanica
l Dept
Utility Clea
ning

88 | P a g e
CHAPTER -2
MANPOWER MANAGEMENT
Organ gram of man-power administration
MANAGING DIRECTOR
EXECUTIVE DIRECTOR
GENERAL MANAGER ASST.
GENERAL MANAGER
ASSISTANT PRODUCTION MANAGER MANAGER (LAB & QC)
SENIOR PRODUCTION OFFICER OFFICER
PRODUCTION OFFICER SENIOR OFFICER
ASSISTANT PRODUCTION OFFICER SENIOR LAB
ASSISTANT
SENIOR SUPERVISOR LAB ASSISTANT
SUPERVISOR LAB BOY
ASSISTANT SUPERVISOR
SENIOR OPERATOR
OPERATOR
ASSISTANT OPERATOR
HELPER
Management system:

99 | P a g e
In Micro Fiber Group the management system is regular. employees are
well skilled and are graduate in their respective profession.
Shift change:
The industry has two shift .Duration of every shift is 12 hours. Workers get
one hour break time. Shift change depends on the work order and production. There is
a supervisor in every shift who takes the working activities & understands his
responsibilities from previous supervisor during shift change.
Total Section Wise Man power Management system:
Micro Fibre Group has sufficient number of skilled manpower working in different
sections. A picture of manpower distribution with total manpower is given below:
DEPARTMENT MANPOWER
Knitting 445
Dyeing 560
Printing 138
Finishing 315
Garments 3587
Maintenance 40
Administration 23
Utility 20
Security 28
Total 5136

1010 | P a
g e
Responsibilities of S.P.O/P.O:
The main job as well as main responsibility of a s.p.o is to control process.
The responsibility of a s.p.o/p.o is to complete a batch in required time. Any fault or
disturbance happens in a batch, the blame goes to s.p.o/p.o. The p.o should try to
minimize overhead expenditures and also try to make a batch more profitable. In a
word he is in charge of the floor & his responsibility is to keep moving the production
smoothly.
Job description of S.P.O/P.O
stes to
1. To give program slip according to daily production plan.
2. To follow up production process from raw materials to finished goods.
3. To match shade in connection with fabric quality according to buyer
requirements.
4. To find out fabric faults as early as possible (before finishing), & take
recover it.
5. To rectify the finished fabric rejected from quality control department.
6. To coordinate with unit technical manager for achieving the target
production.
7. To motivate supervisors and workers for achieving maximum production
with
them
minimum faults.
8. To check the daily production report.
9. To study dye & chemicals nature delivery by the manufacturer & apply
Correctly to the production to get best product.
Remarks
The manpower management system in Micro Fiber Group is well
arranged. There are good number of textile engineers in the industry. but they are not
adequate enough to undertake the huge production of the industry. Some more are
expected to be enrolled there in the shortest possible time to meet up the growing
need. The efficiency of the worker should be increased for more quality production.

1111 | P a
g e
CHAPTER-3
MACHINE DESCRIPTION
List of Single Jersey Circular knitting Machineries :
Serial
No
Machine Brand
Name
M/C
Type
M/C
Dia
M/C
Gauge
M/C
Feeder
Origin
01 Jiunn Long S/J 22 24 66 F Taiwan

1212 | P a
g e
List of Single Jersey Circular knitting Machineries :
Serial
No
Machine Brand
Name
M/C
Type
M/C
Dia
M/C
Gauge
M/C
Feeder
Origin

1313 | P a
g e
46 Fukuhama S/J 30 24 90 F Taiwan
47 Fukuhama S/J 31 22 72 F Taiwan
List of Double Jersey Circular knitting Machineries :
Seri
al
No
Machine Brand
Name
Fabric
type
M/C
Type
M/C
Dia
M/C
Gaug
e
M/C
Feeder
Origin
01 Falmac Interloc
k
D/J 24 16 38 F Singap
ore
02 Falmac Rib D/J 34 16 54 F Singap
ore
ore
ore
05 Hubter Rib D/J 38 18 80 F Taiwan
09 Fukahama Interloc
k
D/J 36 18 72 F Taiwan
k
11 Fukahama Rib D/J 36 18 72 F Taiwan
k

1414 | P a
g e
List of Auto Stripe Circular knitting Machineries :
Serial
No
Machine Brand
Name
M/C
Type
M/C
Dia
M/C
Gauge
M/C
Feeder
Origin
01 Fukuhara S/J 30 24 48 Japan
05 Fukuhara Rib/
Interlock
36 18 48 Japan
List of Flat Bed knitting Machineries :
Seri
al
No
Machine
Name
M/C Type M/C
Bed
Length
M/C
Gauge
M/C
Cares
Origi
n
01 Around
Star
Computerized Flat Bed
M/C
40 14 Single
Cares
Taiwa
n
02 Around
Star
M/C
40 14 Single
Cares
Taiwa
n
03 Around
Star
M/C
40 14 Single
Cares
Taiwa
n
04 Around
Star
M/C
40 14 Single
Cares
Taiwa
n
05 Around
Star
M/C
40 14 Single
Cares
Taiwa
n
06 Around
Star
M/C
40 14 Single
Cares
Taiwa
n
07 Around
Star
M/C
86 14 Single
Cares
Taiwa
n
08 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
09 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
10 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
11 Around
Star
M/C
68 14 Double
Cares
Taiwa
n

1515 | P a
g e
12 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
13 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
14 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
15 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
16 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
17 Around
Star
M/C
68 14 Double
Cares
Taiwa
n
List of Cloth Inspection Machineries :
Serial
No
Machine Name Nos Brand Origin
01 Grey Fabric Inspection Machine 02 Sets UZU® Thailand

1616 | P a
g e
Machine Picture
SINGLE JERSEY CIRCULER KNITTING MACHINE
JIUNN LONG MACHINE CO. LTD.
TAIWAN.
Specification:
Model: JLS Cyl. Dia: 30"
Feeders: 90 F Gauge: 24 G
Needles: 2256 T
JIUNN LONG MACHINE CO. LTD.
TAIWAN.
Specification:
Model: JLS Cyl. Dia: 30"
Needles: 2256 T
FUKAHAMA MACHINERY CO. LTD.
YUANHSIEN, TAIWAN.
Specification:
Model: SH-JFA3 Cyl. Dia: 34"
Mfg. Date: Sep. 2010

1717 | P a
g e
FUKUHARA STRIPER MACHING
PRECISION FUKUHARA WORKS,LTD.
JAPAN.
Specification:
Gauge: 20/24 Feeders: 192 F
Size: 34"
Mfg. Date: March.2007
COMPUTERIZED FLAT KNITTING
MACHINE
AROUND STAR INTERNATIONAL CO. LTD.
TAIWAN.
Specification:
Bed Length: 40"
Gauge: 14 G
UZU® FABRIC INSPECTION MACHINE
AATPR INDUSTRY CO. LTD.
THAILAND.
Mfg. Date: April-2007

1818 | P a
g e
F
Lay-out Plan of knitting Machineries :
K
S
E W
D
N
H
I
A
M
C
B
J
E
G
L

1919 | P a
g e
A = Office of A.G.M (Knitting)
B = Office of Production Officer
C = Cloth inspection machine
D = Re-conning machine
E = Supervisor office & Knit Admin
F = Flat bed knitting section
G = Spare Cylinder room
H = Stair
I = Lift
J = Store of Spare parts & equipments
K = Fitter / Staff office
L = Toilet
M = Auto stripe Machine Section
= Circular Knitting Machine (Single & Double Jersey)
= Eyes marking or Floor marking
Total Floor space of the knitting floor = 20,338.93 Sq.ft (approximately)
Space of A.G.M. Office = 172.85
Sq.ft
Space of P.O Office = 175
Sq.ft
Space of Knit admin office = 96.15
Sq.ft
Staff office space = 175
Sq.ft
Stair space = 472.5
Sq.ft
Lift space = 157.5
Sq.ft
Space of Re-conning M/c = 52.5
Sq.ft
Cloth inspection M/c = 78.72 Sq.ft ×2 = 157.44
Sq.ft

2020 | P a
g e
Space of equipments office = 228
Sq.ft
Space of Spare Cylinder room = 383.8
Sq.ft
Space of Toilet = 547.1
Sq.ft
Space of Flat Bed Knitting Section = 1372.61
Sq.ft
Space of Auto Stripe Knitting M/c Section = 1478.73
Sq.ft
Total space used for different section = 5512.74
Sq.ft
Now ,Rest of the free space for circular knitting machine according with floor
marking,
= Total Floor space of the knitting floor - Total space used for different section
= (20,338.93 - 5512.74) Sq.ft
=14862.19 Sq.ft
In Micro Fibre Group the total number of knitting machine is 83 ( where Single
jersey circular knitting machine is 47, Double jersey circular knitting machine is 14,
Auto Stripe circular knitting machine is 5, And Flat Bed knitting machine is 17, total
83). But there has another knitting floor where other knitting machines are positioned.
The space of 14862.19 Sq.ft for Circular knitting machines which are assembles in
previous page.And in this lay out plan 40 No’s of Circular knitting machine are
situated.
One circular knitting machine with creel stand which required 262.44 sq.ft So, the
number of 40 knitting machines required space is, = 262.44 sq.ft × 40 = 10497.6 Sq.ft
The totally free space is = 14862.19 Sq.ft - 10497.6 Sq.ft = 4364.59 Sq. ft
Remarks :
The Lay out plan of the machineries is well Micro Fiber Ltd. arranged.
There are good number of textile machineries in the industry. They are adequate

2121 | P a
g e
enough to take the huge production of the industry. The efficiency of the worker
should be increased for more quality production.

2222 | P a
g e
CHAPTER -04
RAW MATERIALS
Micro Fiber Ltd. is a knit composite industry. In the industry raw materials
for different section is different. As for example knitting uses yarn as raw material,
Fabric processing department uses the knit fabrics, dyes and chemicals.
Types of Raw Materials:
Different type of raw materials are found like
1. Yarn
2. Grey Fabric
3. Dyes
4. Chemicals
Order is usually obtain in the form of making complete garments grey fabric or yarn
dyeing that is main raw material is fabric & yarn. Fabric is made in its own knitting
section from different types of yarn according to requirement, but sometimes buyer
may supplies this.
18/1,
150/D.
Yarn:
Following types of yarns are used to knit fabrics:
1. Cotton — 30 s/1, 80/2, 20/1, 60/2,34s/l, 26/1, 20/1,
24/1 (Carded or combed.)
2. Filament —20/D, 24/D, 30/D, 40/D,75/D, 100/D,
3. Polyester spun — 50/2 Ne, 20/2 Ne.
4. T/C —+30/1, T/C.
5. Viscose —26/1.
6. CVC (varying proportion)
The count mentioned above was found during mill training.
Sources:
Yarn is collected from the fo1lowing sources:

2323 | P a
g e
1. Shohagpur spinning mills
2. Delta spinning
3. Israk spinning mills
4. Delsy spinning mills
5. Techno spinning mills
6. Jamuna spinning mills
7. Malek spinning mills
8. Kader spinning mills
Price:
Not provided.
Grey Fabrics:
Following types of grey fabrics are dyed:
1.Single jersey:
- Single and double lacoste
- Polo pique
- Terry fleece
- Engineering stripe
2. Single jersey with Lycra
3. Double jersey:
- Rib
- Interlock
4. Double jersey with Lycra
5. Flat bed :
-Single Collar and Cuff
-Design Collar and cuff
Sources:
The required grey fabric is produce in the industry. The required fabrics are
supplied from Micro Fiber Ltd.
Price:
Price of grey fabrics depends upon the price of yarn and the
making charge of the fabric. For example, in case of 30’s spun cotton yarn, the price
of yarn is $3/kg and for single jersey fabric the knitting charge is $0.18. So the price
of single jersey fabric is $3.18/kg.

2424 | P a
g e
Chemicals:
CHEMICAL
NAME
TRADE NAME CHEMICAL
NAME
TRADE NAME
Optical
brightening
Bluton –BVB Anticreasing agent ACN
Wetting agent SCF Leveling agent CL-225
Fixing agent SR Softener FS
Peroxide killer OEM Antifoaming agent SF
Leveling agent RLF-349 Anticreasing agent CBA
Sequestering agent SQ-117 Antifixing agent TPA
Softener WCS Softener EAS
Sequestering agent 2UD Soap AW-501
Alkali RH Sequestering agent SQ-114
Acetic acid G.acid Brightening agent SQS
Silicon PE-40 Wetting agent MC
Optical
brightening
ER330 Enzyme MKL
Flame retardant WRN Optical
brightening
BBU
Dust remover Flock BM Sequestering agent InSA
Fixing agent SR Optical
brightening
BUBZAM
Commonly used dyes in fabric dyeing section in Micro fibre Ltd
For light color: RR dyes

2525 | P a
g e
i. Yellow RR
ii. Red RR
iii. Blue RR
If color shade% not matching under three different light source (D-65, TL-83,A), then
below dyestuffs are used:
DRI dyes:
i. DRI yellow HFR
ii. DRI Red HF3B
iii. DRI Blue HFRL
For medium shade: ME dyes (Navy blue, olive etc
i. G.yellow SP-3R
ii. RED SP3B
iii. N.BLUE ME2G
iv. BLUE RSPL
v. BLACK B
vi. BLUE BBNEW and so on.
RED:
i. W-dyes
ii. Orange W-3R
iii. Red KHW
iv. DK Blue WR
v. Yellow KHW
Black:
i. Super black G
ii. Black WNN

2626 | P a
g e
Turqious :
i. Yellow 4GL
ii. Blue BBNEW /N.Blue 2GL
iii. Blue G
Chemicals & their function:
Chemicals used in Dyeing and their function:
♦ Acid - The chemical compounds that dissolve in water and provide H+(proton). It
changes the color of litmas paper from blue to red. Strong acids - completely
ionized in water; For example: HClO4, Hl, HBr, HCl, HNOs, H2SO4, H3PO4.Weak
acids - partial ionized in water; For example: HF, H2S, HCN, HC2H3O2 and most
organic acids.
♦ Alkalis - The chemicaL compound that dissolve in water and provide 0H-
. It
changes the color of litmas paper from red to blue. Strong alkalis - completely
ionized in water; For example: NaOH, KOH, LiOH, Mg(OH)2 most metallic
hydroxides Weak alkalis - partial ionized in water; For example: NH4OH and
most organic alkalis
♦ Buffer - lt is a saturated solution of acid-salt or alkali-salt mixture. lt resists the
change of pH on addition of acid or alkali. Usually it is used to control the any
bath solution. Buffer solutions are solutions containing mixtures of a weak acid or
base and a salt of that acid or base. For exampre, the mixture of acetic acid and
sodium acetate, which dissociates as:
CH3COOH CH3COO -
+ H+
CH3COONa CHs COO -
+ Na+
♦ Oxidizing agent - The chemical compound which provide oxygen during
chemical reaction and converting to oxide, They gain electrons in a redox
chemical reaction, for example, O3, H2O2, Ca0Cl2.
♦ Reducing agent - The chemical compound which losses electron during chemical
reaction. lt reduces other substances chemically, especially by donating an
electron or electrons, for example, Hydrose (Na2S2O4), Rongalite C.
♦ Surfactants - Surfactants or surface-active agents act in solid-liquid, solid-gas, or
liquid-gas interfaces and reduces the interfacial tension. ln textile wet processing it
works in between solid-liquid interface and reduce the surface tension of liquid. lt
has a versatile application in textile industries especially in textile coloration, for
example, Wetting agent, Detergent, Lubricant, Foaming agent, Anti-foaming
agent, Leveling agent, Dispersing agent.

2727 | P a
g e
♦ Wetting agent - lt accelerates the wetability of material in solution; thus helps to
easy penetration of chemicals into substrate. Usually it is used in scouring,
bleaching and dyeing processes. lt is available in market in form of clear or
yellowish liquid.
♦ Detergent - Detergents are one kind of surface active agents but the reverse is not
always true. The surfactants which have detergency power and the number of
carbon in aliphatic chain are not less than 9. Usually it is used in textile to clean
the materials by removing undesirable substances. These products are either soaps
or synthetic detergents.
♦
♦ Lubricant - The chemical compounds use to prevent contact between solid
surfaces in relative motion in order to reduce friction, wear, overheating, and
rusting. They are very good coolants, provide the appropriate range of viscosities,
and are thermally stable.
♦ Anti-foaming agent - Anti-foaming agents are another type of surfactants which
are able to prevent or reduce foam. Usually, anti-foaming agents are used in
dyeing bath and in printing paste to hinder foam generation. Excess foam
generation can create adverse effect in processing and product.
♦ Anti-creasing agent - Usually used in dyebath or in finishing stage to prevent
creasing of fabric or garments.
♦ Anti-pilling agent - Some man-made and blended fibre fabrics can easily form
pills in their surface. Thus it reduces the aesthetic value of the fabric or garment.
Anti-pilling agents are used to prevent such kind of pills formation during wearing
of cloth.
♦ Leveling agent - Leveling agent is used in textile coloration process to achieve
uniform dyeing over the whole substrate by controlling the rate of dyeing.
Generally it is a non-ionic surfactants type compound either fibre substantive or
dye substantive. lt is available in market in liquid form.
♦ Dispersing agent - usually it is used in disperse and vat dyeing process helps to
distribute the dye molecules in dye bath. it is also help to penetrate the dye
molecules into the substrate. lt is available in market in powder form.
♦ Retarding agent - The chemical compound that are able to retard or control the
dye uptake inside of the fibre .Using retarders is very common in acrylic dyeing
♦ with cationic dyes.
♦ Carrier - Carriers are relatively small organic substances that usually have
affinity for polyester. lt acts as a catalyst to accelerate the dye penetration into the
fibe in disperse dyeing process.

2828 | P a
g e
♦ Chemical formula of common chemicals used in textile dyeing:
Water – H2O
Hydrochloric acid - HCI
Sulfuric acid –H2SO4
Phosphoric acid – H3PO4
Sodium chloride (common salt) - NaCl
Sodium carbonate – Na2CO3
Sodium sulfate (glauber salt) – Na2SO4
Sodium bicarbonate – NaHCO3
Sodium hydroxide - NaOH
Potassium hydroxide - KOH
Sulfur dioxide – SO2
Tri sodium Phosphate – Na3PO4
Benzene – C6H6
Acetic acid - CH3COOH
Oxalic acid - (COOH)2
Cellulose – C6H10O5
Starch - C6H10O5
Hydros (sodium hydrosulfite) – Na2S2O4
Bleaching powder- Ca(OCl)Cl
Printing chemicals function:
The functions of chemical used in printing process are given below
Urea: Hydroscoping agent, by using urea the steaming is finished within 5 to
10hours.
Resist salt: NaCl is penetrated by heating but resist salt is penetrated into
fabric without heating.
Na2CO3: Fixing the dyes molecules properly.
Thickener: Thickener helps the past or chemical to be not sprayed on the
fabric or not to be bleeding.
Increased paste viscosity.
Reduce screen pore radius.

2929 | P a
g e
Price:
Price of dyes & chemicals depend on the quality, type availability &
requirement. For high quality product, better dye & chemical should be used though
cost is high.
Annual requirement:
Annual requirement of dyes & chemical depend on the order of production but for
various reasons such as improper weighting, carelessness of operators, hydrolysis of
dyes, uneven process control, wrong recipe formulation, incorrect batching, improper
storage facilities & for different unwanted expenditure increases dyes & chemicals
requirement.
Remarks:
For smooth running of a factory uninterrupted supply of raw materials is very
essential. As far as we saw the raw material control of MFG is good.

3030 | P a
g e
Chapter-05
Production planning, sequence & operation
Introduction and Basic Procedure of Planning and
Control:
A planned work brings success. Without planning nothing is completed within the
required time. So planning has its own importance which is intolerable. "Planning"
gives a scheduled task and 'control' completes it successfully. But production planning
and control is not an easy task. So Micro Fibre Group has a high-performance
department called "Production Planning & Control". Its Basic working procedure is as
follows –
1. Taking orders from marketing division.
2. Analyzing the orders.
3. Planning for knitting the fabric.
4. Planning for dyeing the fabric.
5. Planning for finishing the fabric.
It is only a basic procedure. It may change according to the type of order.
Sometimes, order is places only for finishing the material or only for dyeing the white
goods. Then some steps are omitted for planning procedure.
Recommendable points of a buyer:
I. Diameter of the fabric
II. Design of the fabric
III. GSM of the fabric
IV. Total wt. of the fabric
V. Yarn count
VI. Types of yarn
VII. Color of the fabric
VIII. Finishing of fabric.
IX. Handling & fastness property.

3131 | P a
g e
Production Planning:
Marketing
Lab dip
Lab dip approval
Sample production
Sample approval & Order for bulk production
Knitting
Sample production according to buyer recommendation
Bulk knitting production
Batching Pre-
treatment
Dyeing
Finishing
Packing
Garment section
Ready for delivery

3232 | P a
g e
Knitting section
Production parameters:
Yarn processing:
Package Winding/ Re- conning
Package density,
Knitting:
Stitch length
GSM
Dia
Gauge
Count
Fabric dyeing:
pH,
Temp
M:L,
Time,
Finishing:
Overfeed,
Underfeed,
Stretch,
Temp,
Padding pressure.
Speed,
Dwell time
Points that should consider in case of G.S.M. changing:
i) VDQ (Variable Dia. Quality Control) pulley diameter.
ii) Yarn count.
iii) M/C gauge.
iv) Cam position
v) Take up motion

3333 | P a
g e
Production flow chart:
Work order received
Design development
Requisition of raw material (yarn)
Yarn collect by cone package from spinning
Setup yarn on creel and Yarn passage through different tentioner and positive feeder
Machine parameter setup (Adjust stitch length and GSM by VDQ pulley)
Produce ½ meter fabric and inspection
Knitting the fabrics and without any fault / If fault correct it
Cut the roll of fabric from the machine and Marking the roll
Grey fabric inspection and grading according to Quality Control
Fabric delivery or Transferred the fabric to grey store
Description of production process:
Micro Fiber Ltd. Is capable of producing stripes of any width and enormous
color. The engineering stripes machines are used for producing such fabrics. Except
this feeder stripes are also produced. Single jersey fabrics and its derivatives like
lacost, polo pique, terry fleece etc. are also produced. Rib and interlock fabrics and its
derivatives such as 2x2, 3x3 etc. are also produced. Different fabrics can be produced
by jacquard m/c by varying the tucking lengths and looping sequence.
Collar and cuffs of any designs are produced here in the flat bed m/cs. The jacquard
design can be computerized and transferred to the knitting m/c by floppy disks. The
yarn that used in the body fabric is also used in producing collar and cuff.

3434 | P a
g e
GSM:
It is the critical parameter that is checked and controlled at different staged of
processing the fabric after knitting to finishing. Fabric GSM can be controlled by the
following ways:
By varying the loop length by VDQ pulley.
By varying the no. of loops by needle gauge setting.
By using different count of yarn.
The yarn count, in all cases, has prescribed by the buyers. So m/c setting is the
only way to control the grey GSM. The final GSM in the finished fabric depend on
the finishing treatments and parameters of finishing machineries.
m/c.
Fabric width:
Fabric width can be controlled by changing cylinder diameter or by changing
RPM:
M/c rpm is adjusted with the lead time for production. When lead time is very
short then rpm may increase at a certain level for definite count and strength of yarn.
So it also depends on the yarn parameter and also with structure to be produced.
Loop length:
Loop length determines the fabric GSM. It can be controlled by changing the dia
of VDQ pulley In Mayer & CIE m/c , it can be controlled digitally.
No. of feeder or no. of cone:
It depends on the urgency of production, available cone packages, color to be knit
and structure of the fabric.

3535 | P a
g e
Gauge:
Needle gauge determines the no. of loops in a course which determines the GSM
of fabric.
Production calculation:
1. Production = no. of needle x no of feeder x RPM x stitch length/ yarn count
Production per shift in KG at 100% efficiency
RPM x no of feeder x no of needle x stitch length(mm) x 60 x 12
=
10 x 2.54 x 36 x 840 x 2.2046 x yarn count
2. Stitch length =
Ks X 590.5
Count (Ne) x GSM
Where,
Ks = knitting constant
Count = linear density of yarn
GSM = gm per square meter
Another formulae is
Stitch length = (Tex × Ks) / GSM
Ks is a constant. Its value is different for different fabric structure and fabric type. Ks
is calculated and estimated as below:
Ks = (GSM x Stitch length) / Tex

3636 | P a
g e
Fabric type Color Value of Ks
Single jersey Average 19.55
Single lacoste Average 22.4
Double lacoste Average 22.75
Polo pique Average 25
Plain interlock Average 39.3
1 X 1 rib Light 24.5
1 X 1 rib Average 26.5
3. Production/shift in meter:
=
Course/ min.
Course/ cm
=
RPM × No.of Feeder× 60×12× Efficiency
Course/ cm×100
4. Fabric width in meter:
=
Total no.of wales
Wales / cm ×100
=
Total no.of Needles knitting
Wales / cm ×100

Fabric
type
Yarn
count
Stitch
length
color D X G Finished
dia
Finished
GSM
Plain s/j 18s/1 2.94 white 26X24 30 inch 220-230
20s/1 2.98 white 30X24 33.5 inch 200-210
24 s/1 2.68 white 30X24 32 inch 175-185
26s/1 2.66 white 30X24 31 inch 160-170
28s/1 2.70 avg 26X24 25 inch 150-160
30s/1 2.68 avg 30X24 30 inch 130-140
34s/1 2.40 avg 26X24 24 inch 125-135
40s/1 2.44 avg 24X24 20 inch 100-110
1x1 Rib 26s/1 2.50 avg 40X18 41 inch 240
24s/1 2.75 avg 30X18 64 inch 235
26s/1 2.45 avg 40X18 40inch 245
26s/1 2.55 avg 40X18 47inch 235
26s/1 2.65 avg 32X18 32inch 230
36s/1 2.65 avg 32X18 33inch 170
24s/1 2.95 avg 34X18 32inch 220
24s/1 2.90 avg 40X18 38inch 225
28s/1 2.40 avg 30X24 38.5inch 232
2X1 L Rib 34s/1 2.60 avg 40X18 23inch 190
34s/1 2.70 avg 32X18 20inch 185
40s/1 2.76 avg 30X20 35”T 160
28s/1 2.87 avg 34X18 32”T 260
26s/1 3.25 avg 34X18 31”T 205
24s/1 3.50 avg 34X18 31.5”T 285
20s/1 3.25 avg 34X20 55”(op) 260
2X2 L/Rib 20/1+40D 3.10 avg 30X18 18”T 390
24/1+40D 2.90 avg 30X18 18”T 320
30/1+70D 2.90 avg 30X18 18”T 320
30/1+40D 2.98 avg 26X18 18”T 240
30/1+40D 2.80 avg 26X18 18”T 240
Single
lacost
18s/1 3.00 avg 30X24 46 inch 245-255
24s/1 2.64 avg 30X24 40 inch 210-215
26s/1 2.60 avg 30X24 36inch 200-210
30s/1 2.50 avg 30X24 33inch 180-190
37 | P a g e

3838 | P a
g e
For S/J without'Lycra
Fabric G.S.M Yarn Count
110-120 40 -36s
120-130 36s-32s
130-140 32s-28s
140-150 28s
150-160 26s
170-210 24s
For Rib without Lycra:
180-190 36s-32s
190-200 30s
200-210 28s
210-220 26s
220-250 24s
250-300 24s
Following Counts are used to achieve the mentioned G.S.M:
For S/J with Lycra
180-190 34s
190-210 32s
210-220 30s
220-240 28s
240-250 26s
For interlock without Lycra
200-220 34s
220-230 32s
230-250 30s
250-300 26s
For Lacoste without Lycra
180-190 30s
190-210 28s
210-230 26s
230-250 26s

3939 | P a
g e
Relation between yarn count, fabric type, stitch length and
finished GSM:
By the following three tables, we can summarize the above data:
For Single jersey-
FINISHED GSM COUNT FINISHED DIA
140 30/1 Machine dia=Finished dia
160 26/1 Machine dia+1=Finished
dia
dia
dia
dia
For 1X1 Rib
Finished gsm Count Gauge Finished dia
150-200 30/1 18 Machine dia
210-220 28/1 18 Machine dia
220-230 26/1 18 Machine dia+1
240-250 24/1 18 Machine dia+1/2
280-300 20/1 18 Machine dia+2/3
For Plain Interlock-
Finished gsm Count Gauge Finished dia
200 40/1 24 Machine dia
180 40/1 24 Machine dia+1
220-230 34/1 24 Machine dia+2

4040 | P a
g e
× × × ×
× • × •
× × × ×
• × • ×
× × × ×
240-250 30/1 24 Machine dia+2/3
If the fabric is to be Enzyme washed, the stitch length should be kept (10%) less than
the normal range. Because, enzyme wash reduces the total weight of the fabric by
removing the floating fibre and hairy fibre.
For light color, the finished GSM varies near about 15-20% from grey GSM
For average color, the finished GSM varies 20-25%
For dark color, grey GSM is kept less (i.e. the stitch-length is large) because take up%
of dark color is more and the weight of dyed fabric will be increased.
If the GSM varies 25-30%, it is not only necessary to control the VDQ pulley dia but
also yarn tension & take up roller.
Grey fabric introducing:
Factors that should be considered for changing of fabric design on:
i) Cam arrangement changing.
ii) Needle butt setting & needle dropping.
iii) Using of different colors in selected feeder.
iv) Using of jacquard mechanism.
v) Size of the loop shape
Stitch Notation, Cam Arrangement & Needle Repeat Of Some Knitted Fabric:
FABRIC NAME: SINGLE LACOST
Stitch Notation:
× = Knit stitch
• = Tuck stitch
K = Knit cam
T = Tuck cam
1 = 1 Butt Needle
2 = 2 Butt Needle
3 = 3 Butt Needle
Fig. Looping diagram

4141 | P a
g e
1
2
1
2
3
× × × ×
× • × •
× • × •
× × × ×
• × • ×
• × • ×
1
2
Cam arrangement & Needle arrangement:
i) Using two track cams:
▲ ▲ ▲ T ▲
▲ T ▲ ▲ ▲
ii) Using three truck cams:
▲ ▲ ▲ T ▲
▲ T ▲ ▲ ▲
▲ ▲ ▲ T ▲
FABRIC NAME: DOUBLE LACOST
Stitch Notation:
× = Knit stitch
• = Tuck stitch
K = Knit cam
T = Tuck cam
1 = 1 Butt Needle
2 = 2 Butt Needle
3 = 3 Butt Needle
▲ ▲ ▲ ▲ T T
▲ T T ▲ ▲ ▲

4242 | P a
g e
1
2
3
× × × ×
× × × ×
× × × ×
× × × ×
× × × ×
1
2
ii) Using three truck cams:
▲ ▲ ▲ ▲ T T
▲ T T ▲ ▲ ▲
▲ ▲ ▲ ▲ T T
Fig.- Cam arrangement Fig.- Needle arrangement
FABRIC NAME: SINGLE JERSEY
Stitch Notation:
× = Knit stitch
K = Knit cam
1 = 1 Butt Needle
2 = 2 Butt Needle
3 = 3 Butt Needle
▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲
Fig.- Cam arrangement
Fabric inspection :
Two ways of grey fabric inspection used to done by-
a) Auto turning fabric inspection m/c.
b) Varivide colour assessment cabinet –2
D-65, TL-84, TL-83, Florescent, UV.

4343 | P a
g e
♦ Grey fabric faults :
Following faults are found in the grey fabric:
Problem Reason Remedy
1. Hole Broken needle head Change the needle
2. Missing yarn Missing of one end of double
yarn
Careful observation and instant
stop when fault found
3. Needle line Bent needle latch Replace the needle
4. Thick & thin
yarn
Yarn fault Replace the yarn cone to a
more uniform yarn cone
5. Slubs Yarn fault Replace the yarn cone to a
more uniform yarn cone
6. Drop needle Needle fail to receive the yarn
while knitting, needle missing
Reset the needle
7. Barrie
mark/patta
Irregular tension of take down
roller
Adjust the take down tension or
synchronize the take down
speed with knitting
8. Pin hole Due to missing stiches or loop Concentrate on needle and
latch
9. Oil line Improper lubrication Proper lubrication
10. Fly contact Fly coming fro the adjacent m/c Separate one m/c from others
11. Oil stain Dirty m/c and improper handling
of fabric
Proper lubrication and clean
m/c

4444 | P a
g e
Fabric Dyeing Section:
Production flow chart for fabric:
Grey fabric inspection
Batching
Pretreatment
Dyeing
Dewatering
Dewatering (Tube form) Dewatering(Open form)
Tension less dryer Slitting
Calendaring Stentering
Compacting Inspection
Inspection Packing
Packing Delivery
Delivery

4545 | P a
g e
Process sequence:
For Cotton Dyeing:
Pretreatment
Enzyme (anti pilling)
Dyeing
Soaping
Softening
Pretreatment:
Two types of pretreatment are done in Micro Fibre Ltd.
1. Scouring-Bleaching
2. Bio-Scouring (Bio polishing/ Enzyme treatment)

4646 | P a
g e
Scouring-Bleaching:
Pretreatment program: (scouring ,bleaching and enzyme)
Fill water
Fabric load
Light color: M:L=1:10
SCF (0.25g/l)+2UD (0.25g/l)
ACN+CBA (0.25+0.25g/l) ( Dosing 10mins)
Temp=60o
c and run=20min
Drain
Fill water
SCF+InSA(0.65+0.65g/l) +ACN+CBA (1.25+1.25g/l) (Dosing 10mins at room temp)
Caustic Dosing at 40o
c (1.8g/l)
Temp 70o
c
Peroxide +stab (1.75+0.22g/l)
Temp=98o
c and Run=50-60mins
Cooling at 80o
c
Drain
Fill water
Drain
Raise temp. 80o
c and run 10 mins
OEM ( 0.3 g/l) dosing 20 minutes
Green acid( 0.5 g/l)
Hot wash (95o
c X 10mins)
Fill water

4747 | P a
g e
Medium/deep color: M:L=1:8
Fill water
Fabric load
SCF (0.17g/l)
ACN+CBA (0.425+0.425g/l) ( Dosing 10mins)
Temp=60o
c and run=20min
Drain
Fill water
SCF+InSA(0.552+0.637g/l) +ACN+CBA (0.637+0.637g/l) (Dosing 10mins at room
temp)
Caustic Dosing at 40
o
c (1.70g/l)
Temp 70o
c
Peroxide +stab (1.70+0.212g/l)
Temp=98o
c and Run=50-60mins
Cooling at 80o
c
Drain
Fill water
Hot wash (95o
c X 10mins)
Fill water
Drain
Raise temp. 80o
c and run 10 mins
G. acid(0.697g/l) OEM ( 0.3 g/l) dosing 20 minutes

4848 | P a
g e
Bio-Scouring:
Process description of Bio-Scouring is same as normal pretreatment process. But
in Bio-Scouring process, we use only one auxiliary (MA-stab XLC), where in normal
pretreatment process ,we use more than one auxiliary.
Enzyme Treatment:
Process Description of ENZYME TREATMENT:
Light color: M:L=1:10 Or, Medium/deep color: M:L=1:8
Water fill
Green acid (0.4g/l)(Check PH
)
MKL (0.3% owf)
Temp 55o
c and Run 60mins
Drain
Ready for dyeing

4949 | P a
g e
Chemica
10
Enzyme
60
Tem
Time
Fig: Enzyme Treatment

5050 | P a
g e
Dyeing:
Normaly for knit dyeing, there are many kinds of dyeing procedure such as Iso
thermal process, Critical migration process, Exhaust method etc. In Micro Fibre they
use Exhaust method for knit dyeing.
Dying program for ME dyes:
M:L=1:8
Leveling Agents: SQ-117 =1.275 g/l CL-
225 =1.275 g/l
CAN+CBA =0.85+0.85 g/l
pH =6.2-6.8
Run-10΄
Dyes-25΄(30% Dosing rate)
Run-30΄
Salt -15΄(20% Dosing rate)
Run-20΄
Soda-25΄(20% Dosing rate)
Run-20΄
Temp=60°C(2°C/min)
Then temp=70°C(2°C/min) if required
Run-20΄
Sample check

5151 | P a
g e
Dyeing program for HE Dyes:
Leveling
Run-5΄
Temp- 60°C
Dyes-25΄ (30% Dosing Rate)
Run-20΄
Salt-20΄ (40% Dosing Rate)
Run-15΄
Temp=90o
C
Cooling at 40°C
Soda-30΄ (40% Dosing Rate)
Run-30΄
Temp- 80°-87°C (2C/min)
RUN=2Omin
Sample check

5252 | P a
g e
Dying program for W Dyes:
Leveling
Run-10΄
Temp = 60°C
Dyes-15΄ (50% Dosing rate)
Run-10΄
Salt-15΄ (40% Dosing rate)
Run-10΄
Temp-67°C (1C/min)
Run-35΄
Cooling at 60°C (1C/min)
Soda-30΄ (50% Dosing rate)
Run-20΄
Sample Check
In need increase temp up to 65°C-67°C

5353 | P a
g e
Dying program for Turquise Dyes:
Leveling (5min Dosing time)
Run-10΄
Temp-60°C
Run-20΄
G.Salt-20΄ (20% Dosing rate)
Run-15΄
Temp-90°C (1C/min)
Run-45΄
Cooling at 40°C
Run-45΄
Temp-80°C (2C/min)
Run-20΄
Sample Check

5454 | P a
g e
Dying program for KHW Dyes:
Leveling (dosing 5min)
Run-10΄
Temp-60°C
Run-25΄
Common Salt-20΄ (40% Dosing rate)
Run-20΄
Temp-67°C
Run-30΄
Cooling at 40-45°C
Run-5΄
Caustic solution 20’ (dosing rate 20%)
Run=20min
Temp-60°C (2C/min)
Run=20min
Sample Check

5555 | P a
g e
Leveling Agents: SQ-117 =0.85g/l
CL-225 =0.85 g/l
ACN+CBA =0.85+0.85 g/l
Dyeing program for HF dyes:
L.R=1:8
pH=6.2-6.8
Run-10΄
TEMP=40O
c
Dyes-25΄(30% Dosing rate)
Run-30΄
TEMP=60O
c(1O
c/min)
Salt -20΄(40% Dosing rate)
Run-30΄
Soda-30΄(40% Dosing rate)
Run-20΄
Sample check

5656 | P a
g e
Dyeing program for WHITE color (Without enzyme):
SCF+InSA
ACN+CBA
Dosing time 10min
Caustic
Stab+50% H202
Temp 980
c
Run= 90mins
Cooling at 40o
c
BvB +BUBZAM
Dosing time 30mins
Temp 98o
c
Run 30mins
Shade check

5757 | P a
g e
Dyeing program for WHITE color (With enzyme):
SCF+2UD
ACN+CBA
Stab+ Caustic+Peroxide
Dosing at 60o
c temp
BVB
Temp 900
c
Run= 10mins
Shade check at 80o
c
Hot wash
Gacid
Temp=55
o
c and run=10min
MKL Temp=55o
c and
run=1hour
SQS Temp=80o
c and run=20mins

5858 | P a
g e
Dyeing program for Disperse Dyes:
Fabric treated with oxalic acid at 70°C for 20min
Rinse for 5 min
pH is controlled at 4.0-4.2
Dyeing at 130°C temp for 40-50 min
Hot wash for 5 min
Reduction cleaning 80-90°C temp for 30 min
Neutralization/Hot wash
Softener at 60°C temp for 20 min
Drain the bath
Unload the fabric

5959 | P a
g e
Re-dyeing Process:
When shade is not matched then fabric is treated again in dyeing machine for shade
matching is known as re-dyeing.
Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur
when the fabrics absorb one or two colors more or less. One re-dyeing process is
described below.
- Drain the let off solution
- Hot wash at 70
0
-80
0
C
- Acid wash at 60
0
-70
0
C(60
0
for light shade & 70
0
for deep shade).
- Soda ash washes at 900
-1000
C for 60mins to reduce the depth of shade.
- Acid wash at 600
C.
- Addition to required dyestuffs.
- Salt addition.
- Soda ash addition.
Other operations are same as previous described dyeing operations.

6060 | P a
g e
Stripping process:
Add water Fabric load
TPA+G.ACID
Temp=90o
C run=20min
Drain
Fill water SCF+NaOH
Temp=98o
C run=30min
Cooling at 80O
C
Hydrose
Temp=98o
C run=60min
Drain
Hot wash
Half scouring
Temp=98o
C run=35-50min
Dyeing
Recipe:
Antifixing agent (TPA)= 3.0g/l
A.Acid (G.Acid)= 3.0g/l
Wetting agent(SCF)= 0.2g/l
Hydrose= 4.0g/l
Caustic= 3.0g/l
Half scouring recipe:
SCF=0.26g/l
InSA=0.6g/l
ACN+CBA= 0.26+0.26g/l
Stab= 0.088g/l
Caustic= 0.72g/l
50% H2O2=0.7g/l
G.acid= 1.0g/l
OEM=0.12g/l

6161 | P a
g e
After Treatment Of All Program:
For light color For Deep / Medium color
C Neutralizer=0.425g/l
Temp=60c-65c Run=20min
Hot Wash
(AW-501=0.17g/l)
Temp=80c-90c
FS(10% Solution)=3-4g/l
Temp=50
O
c-For light color
Temp=60O
c –For deep color
PH=4.0-4.5
Run =20min
Hot Wash
C Neutralizer=0.425g/l-0.552g/l
Hot Wash 90O
c-
run 10min
(AW-501=0.255-0.425g/)
Fixing agent =0.425g/l
Temp=50o
c-60o
c Run=20min
PH
=5.0-5.5
FS(10%solution)=3-4g/l
Temp=60
o
c run=20min
PH
=4.0-4.5

6262 | P a
g e
After dyeing for neutralization:
For white
(without
enzyme)
For white
(with
enzyme)
For
light color
For
medium color
For
deep color
A.Acid=1.5g
/l
Temp 65
o
c
Run=20min
PH
=4.5-
4.8(By using
A.Acid)
Temp 55o
c
Run=60min
C.Neutralizer=
0.425g/l
Temp 63-65
o
c
Run=20min
C.Neutralizer=
0.425-0.552g/l
Temp 63-65o
c
Run=20min
C.Neutralizer=
0.552g/l
Temp 63-65
o
c
Run=20min
For fixing:
For medium color For deep color
SR=0.425-0.85g/l
Temp 50-60o
c
Run=20min
PH
=5.0-5.5(By using C.neu)
SR=1.275-1.7g/l
Temp 50-60o
c
Run=20min
PH
=5.0-5.5(By using C.neu)
Softener solution(10% solution):
For white For light color For medium/deep color
WCS(10%Soln
)=2.55-
3.4owf
Temp 60o
c
Run=20min
PH
=4.0-4.5(By using
A.Acid)
FS(10%Soln
)=2.55-
3.4owf
Temp 50o
c
Run=20min
PH
=4.0-4.5(By using
C.neu)
FS(10%Soln
)=2.55-
3.4owf
Temp 60o
c
Run=20min
PH
=4.0-4.5(By using
C.neu)

6363 | P a
g e
Necessary calculations used in textile dyeing processes:
Molarity
When one mole or gram molecutar weight of solute is dissolved in one litre of
solution is known one-molar (1M) solution.
For example,
1M HCl contains 36.5 gm HCI/lit
1M H2SO4 contains 98 gm H2SO4/lit
1M NaOH contains 40 gm NaOH/lit
0.1M HCl contains 36.5x 0.1= 3.65 gm HCI/lit
0.01M H2SO4 contains 98x 0.01= 0.98 gm H2SO4/lit
0.001M NaOH contains 40x 0.001= 0.04 gm NaOH/lit
Normality
When one gram equivalent weight of solute is dissolved in one liter of solution is
known one-normal (1N) solution. lt is calculated from the molecular weight divided
by the hydrogen equivalent (maximum valency of ion) of substance. For example,
1N HCI contains 36.5 gm HCI/lit
1N H2SO4 contains 49 gm H2SO4/lit
1N NaOH contains 40 gm NaOH/lit
0.1N HCI contains 36.gm 0.1= 3.65 gm HCI/lit
0.01N H2SO4 contains 49x 0.01= 0.49 gm H2SO4/lit
0.001N NaOH contains 40x 0.001= 0.04 gm NaOH/lit
Stock solution preparation
ln practice 1% stock solution is very common in dyeing process. in laboratory
work,1.0 gm solid (powder, 100% concentration) dye stuff/chemicals is taken in a
conical flask and pour 100m1 of warm (around 45o
c) water and stir to dissolve the
reagent to make 1% stock solution of that dyes/chemicals. To prepare 0.1% stock
solution - 10ml or 1ml of 1.0% solution need to mix with
90ml or gml water respectively.
ln the case of liquid reagents -
For example, take 10ml acetic acid in a beaker; making it 100mr by pouring
necessary amount of water is prepared 10% v/v acetic acid solution.
Dyeing calculation
Amount respect to owg (on the weight of goods):
ln recipe, the % (on the weight of goods - fiber, yarn, fabric, garment) amount respect
to the material is calculated with the following formula :
Required amount reagent = (Material weight x recipe amount %)

6464 | P a
g e
For example, the batch weight is 100 kg and shade percentage is 1.5%. so, the
required amount of dyes = 100 kg x 1 .5 % = 1.5 kg.
ln laboratory dyeing, the necessary amount of dyes and chemicals are very tiny -
taking of this tiny amount contain higher error percent. Accordingly the required
amount of reagents is taken in diluted form of different concentration such as 0.1%,
1.0%, 10.0%,20.0% etc. ln that case, the required amount of reagent is calculated by
using the following formula :
Required amount reagent = {(Material weight x recipe amount %)/stock solution %}.
For example, 5.0gm sample need to dye where as the shade (recipe amount) is
2.0%and stock solution concentration is 1.0%.
so, the required amount reagent = {(Material weight x recipe amount %)/stock
solution %) = {(5.0 x 2.0 %)/1.0%} = 10 ml.
Common textile auxlliaries used in dyeing:
Acid - The chemical compounds that dissolve in water and provide H+(proton). It
changes the color of litmas paper from blue to red.
Strong acids - completely ionized in water;
For example: HClO4, Hl, HBr, HCl, HNOs, H2SO4, H3PO4
Weak acids - partial ionized in water;
For example: HF, H2S, HCN, HC2H3O2 and most organic acids.
Alkalis - The chemicaL compound that dissolve in water and provide 0H-
. It changes
the color of litmas paper from red to blue.
Strong alkalis - completely ionized in water;
For example: NaOH, KOH, LiOH, Mg(OH)2 most metallic hydroxides
Weak alkalis - partial ionized in water;
For example: NH4OH and most organic alkalis
Buffer - lt is a saturated solution of acid-salt or alkali-salt mixture. lt resists the
change of pH on addition of acid or alkali. Usually it is used to control the any bath
solution. Buffer solutions are solutions containing mixtures of a weak acid or base and
a salt of that acid or base. For exampre, the mixture of acetic
acid and sodium acetate, which dissociates as:
CH3COOH CH3COO -
+ H+
CH3COONa CHs COO -
+ Na+
Oxidizing agent - The chemical compound which provide oxygen during chemical
reaction and converting to oxide, They gain electrons in a redox chemical reaction, for
example, O3, H2O2, Ca0Cl2.
Reducing agent - The chemical compound which losses electron during chemical
reaction. lt reduces other substances chemically, especially by donating an electron or
electrons, for example, Hydrose (Na2S2O4), Rongalite C.

Industrial attachment of micro fibre ltd

Industrial attachment of micro fibre ltd

Recommandé

Recommandé

Contenu connexe

Tendances

Tendances (20)

En vedette

En vedette (20)

Similaire à Industrial attachment of micro fibre ltd

Similaire à Industrial attachment of micro fibre ltd (20)

Plus de Md. Mazadul Hasan Shishir

Plus de Md. Mazadul Hasan Shishir (20)

Dernier

Dernier (20)

Industrial attachment of micro fibre ltd