The entire report has been written based on my insights and findings from my three-month internship at the MIS department of Beximco Textiles Ltd. This report presented several challenges and proved to be a fascinating exercise due to its multi-faceted and intriguing nature. The report has been developed within the academic framework and forms an integral part of our course requirements.
The creation of this report involved diligent efforts to harmonize theoretical concepts with practical experiences gained during my internship period. The report that I have fully summarized and compiled is a fully comprehensive analysis and study that I have successfully done for 3 months as part of my internship program for Beximco Textiles and Apparels. The primary focus is on optimizing workflow processes to better utilize the advances made in this industry, the analysis to be made to understand the composition of chemicals used, improving the factors of data entry as the input of new information is essential for calculations to be made, and one of the essentials is cost analysis and comparison which equates to better management decisions to be made.
The report also creates a detailed breakdown of the entire work process that involves from the beginning such as the raw material is obtained to the final product delivery. It is also my privilege to express deep appreciation to all those who directly or indirectly contributed to the formation of this report.
Introduction
Introduction
Blow room
Carding
Lap Process
Comb Process
Drawing Breaker
Drawing Finisher
Simplex
Ring Process
Winding
Types of Blends available
It is very important that the fabric has the desired type and then in the fabric store. One of the main purposes of mercerization is to increase the luster of the fabric, giving it a radiant and shiny appearance. Enzyme treatment is performed when dead fibers or hair are present in the fabric.
Uvitex 2b, an optical brightening agent, is added to the bath and the fabric circulated. Various defects are discovered and identified during the final inspection of the fabric for the body.
Process Flow Chart of Spinning
The process includes
Warping
There are two types of warping
Sizing
Pick up percentage
Drawing/Denting
Knotting: There is no need to perform the passing procedure on a loom if the pattern of the fabric on it is repeated after the weaver reaches beam fatigue. The worn out weaver's beam is replaced by a new weaver's beam during the binding process. The act of tying or tying involves attaching the ends of a worn weaver's beam to the ends of the new weaver's beam.
Knotting Criteria
Loom
There are several parts of loom
Greige Inspection
Figure: Process flow chart For Solid Yarn
Figure: Process Flow chart of Dyed Yarn
Article Requisition Paper
Fabric Construction
Formula
Production Calculation
Warp Consumption Calculation
Weft Consumption Calculation
Pre-treatment
Singeing & Desizing
The chemicals that are being used are
During Cold Bleach
Bleaching: It is a chemical process used to produce white or lighter fibers or fabrics by removing any added or natural color.
Mercerizing
Dyeing
There are many types of dying available
Chemicals used: hydrogen peroxide, caustic soda (removes oil), wetting agent, stabilizer (prevents casting and peroxide reaction), sequestration reduces aqueous alkali.
Pad Dye Back/Cure Process
Pad Dye Dry Process
PDTH Process- Pad Dye Thermofix
Pad Dye VAT
PDB(Pigment)
Rotary Printing/All over Printing
Print Types
Screen
A gauze can be washed and reused up to 2-3 times if necessary until it maintains its temperature. There are many types of mesh counts, with the thick mesh being used for solid designs and the more complex and thin mesh being used for complex designs and patterns.
Types of Mesh available
Digital Printing
Finishing
Stentering
Chemicals or materials used in Finishing procedure of BTL
Calendering
Four types of Calendering are done
Sanforizing
Emerizing
A warm filling is performed, raising the temperature to 80°C, and the tissue is circulated for 10 minutes.
Process Flow chart of BTL
Introduction to Denim
Types of Denim
There are two types of Denim manufacturing process
Slasher Denim
Process Flow of slasher Dyeing
Rope Denim
Warping
Pre-Dyeing
Initial-wetting
Sizing and Continuous Indigo Dyeing
Indigo
Machine Used: Continuous Dyeing and (Slasher) Machine
Chemicals Used
Weaving (Loom)
Finishing
Brushing
Singeing
Sanforizing
Operation Procedure of Finishing Denim
Introduction to Embroidery
Types of Embroidery Done
Software Used
Defects of the Embroidery
Flow Chart of Embroidery Process
Screen Printing
The Screen-Printing process includes
Printing types
Color Types
Sublimation Printing
Octopus Placement Printing
Flow Diagram of Printing Process
Introduction to Beximco Knitting Ltd
Two types of Knitting Sections
Flat Knitting Section
Circular Knitting Section
Knitting Faults
Efficiently addressing these knitting errors ensures the production of high-quality fabrics that meet the strict standards of the industry.[CITATION Azi19 \l 1033.
GRIEGE BODY & RIB INSPECTIONS
General Knitting Faults
Typically, any piece of fabric with 40 points or fewer defects per 100 square yards is considered acceptable. However, for an entire roll of fabric, the average value should not exceed 18 points per 100 square yards.
SINGEING
Objectives
MERCERIZING PROCESS
This ensures that the fabric can withstand various stresses and strains that occur during wear and washing. Mercerization significantly improves the dye absorbency of the fabric, making it more receptive to dyes during subsequent dyeing processes. While the mercerization process offers numerous advantages, it is important to be aware of potential defects that can occur.
PRE-TREATMENT
The process helps minimize shrinkage and distortion in the fabric, maintaining its original shape and size even after repeated washing or exposure to moisture. For fabrics containing a T/C blend (polyester-cotton), a warm wash is performed to remove waxes and greases and improve the absorbency of the fabric, especially in dark shades.
Enzyme Treatment
DYEING PROCESS
Reactive Dyeing
Polyester Dyeing
Process Steps for Polyester Dyeing
The temperature is gradually reduced to 90°C at a rate of 0.75°C per minute and then further decreased to 78°C at a rate of 1°C per minute.
Whitening
Prepare a mixed water filling, add acetic acid and raise the temperature to 60 °C. By carefully following these steps, the bleaching process effectively achieves the desired level of whiteness in the fabric through bleaching and optical bleaching. Proper control of factors such as pH, temperature and time ensures consistent and satisfactory results in the bleaching process.
Finishing
For Tubular Form
For Open Form
For Collar & Cuff Finishing
Chemicals Used
Inspection
Equipment Used
Faults
Four-Points System
Acceptance Calculation
Classification of Inspection Knit Fabric
Production Sequence of operation
MIS system plays a diverse and vital role in increasing the profitability of companies by using ERP based software such as DATATEX, Microsoft Excel, Kandaree Apparel ERP software, this software directly contributes to the improvement and efficiency of the company's productivity as all types of production The data of related and even other departments are entered into the ERP-based server to improve productivity, reduce manual calculation and data entry, repetitive tasks, etc. Generating profitability by order, plan and actual production based on the preliminary costs of each month and compared to the financials Accounts. Compare price discrepancies and make inquiries such as price difference with proforma invoice and subsequent costing, if any problems are found, report it to the authorized department and ask the reason for the discrepancy and solve the problem if any.[ CITATION SrG231 \l 1033 .
I have completed my 3 months internship here at Beximco Textile Limited and I am nothing short of a complete surprise as the journey has been truly engaging. The whole RMG sector may seem rudimentary from afar in the sense that if you ask someone about the process of how the industry moves, they can tell you the basics that we all assume can spin or work, but in retrospect there are intricacies, complexities, details and the flow of progress from each sector is a statement of the extreme fear that an individual receives when he first steps into this industry. The opportunity was particularly exciting as we were part of the pioneers in this industry who bought into the massive improvements to the manufacturing process and technology that was needed to help run more smoothly and better.
Retrieved from https://www.denimsandjeans.com/denim/manufacturing-process/indigo-dyeing-%E2%80%93- various-methods-explained-and-compared/1331. Retrieved from Online Clothing Study: https://www.onlineclothingstudy.com/2012/08/how-to-use-4-point-system-in- fabric.html.
