I would like to thank the management of Zaara composite Textile Ltd for giving me the opportunity to successfully undertake the industrial training and also for their valuable suggestions. I preferred this attachment in Zaara Composite Textile LIMITED which is a 100% export oriented composite knitwear dyeing industry.
Factory Location
CHAPTER- 2
KNITTING SECTION
- Process Definition
- SOURCE OF YARN FOR KNITTING
- CLASSIFICATION OF KNITTING SECTION
- CIRCULAR KNITTING SECTION
- FABRIC INSPECTION SECTION
- PROCESS FLOW CHART OF KNITTING IN ZAARA
- DESCRIPTION OF PRODUCTION PROCESS
- PRODUCTION PARAMETER 1. Machine Diameter;
- RELATIONSHIP BETWEEN KNITTING PARAMETERS
- Production/shift in kg at 100% efficiency
- Production/shift in meter
- Fabric width in meter
Feeding the cone of yarn to the spindle Feeding the yarn to the feeder via trip-tape positive feed and tensioning devices Knitting. If he thinks or is sure of any defect in the fabric, he calls the fitters on duty.
Changing of GSM
Factor that should be changed in case of fabric design
Maintain all procedure of his department and incorporate changes as and when. required in the procedure. If the number of feeders increases on the circumference of the cylinder, then the number of courses .. will increase by one revolution at a time.
Needle Mark Causes
If the latch breaks or bends, it can leave a hole in the fabric. This lint can stick or adhere firmly to the surface of the fabric during the production of knitted fabrics.
Yarn Faults
- Fabric Inspection system
- DIFFERENT FABRIC GSM AND THEIR YARN COUNT
- Figure of knitting machine
- QUALITY ASSURANCE SYSTEM OF KNITTING DIVISION
- INTRODUCTION TO QUALITY ASSURANCE SYSTEM
- SOME POINTS ARE NEEDED TO MAINTAIN FOR HIGH QUALITY FABRIC
05 VDQ pulley Change the length of the stitch. Thus the G.S.M. is preserved.. 06 Thread guide Feeds the yarn to the needle from a very short distance.. 07 Needle The main part of the machine, helps to form the loop.. 08 Needle bed It can be a cylinder. or the dial that holds the needle. 10 Needle detector Can detect needle breakage, sticking, etc. 11 Take-up roller Pull the formed fabric down.
CHAPTER - 3
BATCHING SECTIOIN
- Batch process follow-up
- General Instructions for the final inspection
- GRADING PROCEDURE
- OBJECT OF BATCHING
- PROPER BATCHING CRITERIA
- BATCH MANAGEMENT
- M/C S IN BATCH SECTION
- FORMULA FOR BATCH SELECTION
All defects of one meter in length or more are cut from the piece. For tubular goods, all defects are included. a) All open defects or major defects are counted with 4 points per defect.
CHAPTER - 4
LAB DIP DEVELOPMENT
Lab Dip Development
- DEVELOPMENT OF LAB DIP IN ZAARA COMPOSITE
- PREPARATION AND STORAGE OF STOCK DYES AND CHEMICALS
- PROCEDURE OF LAB DIP
- FOR 100% COTTON FABRIC (ALL IN ONE METHOD)
Then the required amount of dyes, water, salt, soda and other chemicals are taken to the pot by pipe.
CHAPTER - 5
DYEING SECTION
DYEING SECTION
ORGANOGRAM OF DYEING AND FINISHIG IN ZAARA COMPOSITE
Sources
RECIPE AT DIFFERENT STAGES IN DYEING COTTON FABRIC
COTTON DYEING STEPS
Uneven dyeing
Make sure operators are adding the right bulk chemicals at the same time and temperature during the process. Poor opening of fabric rope - Impact cooling of synthetic material - If pump pressure and reel speed are not equal - Due to high speed of m/c. By passing the dissolved dye through a fine mesh stainless steel strainer so that large undissolved particles are removed.
CHAPTER - 6
FINISHING SECTION
- Process flow Chart for Finishing Section
- Tube compactor Machine
- Inspection machine
- FINISHED FABRIC INSPECTION
The machine can cover the function of hydro extractor, wet calender, so it requires less space and manpower. The machine consists of overfeed heating chamber, net conveyor drive and folding part which allows to control the speed of individual parts. Set the transfer % as required; to increase GSM, overfeeding must increase to a certain limit.
CHAPTER - 7
GARMENT SECTION
Garments machinery and Equipment
Plain Machine Typical Machine 235 Set Typical Lock Machine 176 Flat Lock Machine 86 Sets Typical Machine Buttonhole Machine 10 Sets Typical Pegasus Machine Insert 10 Sets Lock Stitch (2 Needle) Typical 6 Sets Chain Stitch 2 Needle ) Typical machine 20 Zig-zag machine 6 sets Straight knife cutting machine 1 set Eastman 11 sets Veit steam iron 100 sets Button sewing machine Typical machine 10 sets Rib cutting machine Typical 4 sets snab button machine Typical machine with 12 sets Metal detector Insta 1 set.
Garments
Total Apparel Manufacturing is Driven in the Following Flow Chart
Apparel design, Sketch and Measurement sheet
Pattern
- On pattern the following instructions must be marked-
- The following tools and equipments are used for pattern construction-
Sample Garment
- Production pattern
Grading
Marker Making
- Marker is made of fulfill the following objects
- Marker is made by two methods as follows-
While making a marker we need to consider marker efficiency – Marker Efficiency =(Area Covered by Pattern Piece/Total Area of Marker) x 100 There is a link.
Fabric spreading
- There are two methods are used for spreading-
Fabric Cutting
- List of cutting tools
- During cutting following points should be checked-
- Cutting Problems
Sewing /Assembling
Difference between normal thread and sewing thread
- To select a sewing thread the following factors should be considered _
The number used to express the fineness of a sewing thread is called needle thread number or ticket number.
Sewing Problems
Seam pucker : It is caused for five purposes as follows :-
- Fabric consumption (Basic T-shirt, Trouser) and Thread consumption
- Consumption formulas
It is visible after washing and wear which is mainly caused by needle bending or incorrect needle size selection. It is very important for fabric consumption calculation because fabric reservation depends on consumption. It is mentioned that the accuracy of fabric and thread consumption can reduce the excess fabric, which helps to reduce the cost of the fabric.
S.M width
- Fabric consumption for Basic T-shirt
- Calculation – 02: Formula in Inch
- Fabric consumption for Basic Trouser Calculation: Formula in Inch
- Thread Consumption for garments sewing
- Type of Carton
- SEWING SEQUENCE OF T-SHIRT
- Finishing : To be checked
- The defects identified in garments finished fabric
Number matching front 2 back (back on top) Solder seams (with over lock m/c). Neck rib truck (By plain m/c) Neck rib sewing with plain m/c Neck rib joins body pants Neck top sin. Sleeve flap to body part (sleeve mark point and solder point) Sleeve joint to body part.
Side stitching and care mark joining Bottom seam (at the end side) Bottom seam.
CHAPTER- 8
- The major functions/steps of a merchandiser
- The steps are shown as diagramacally
- Scope of Merchandiser
- Production planning and pre production meeting
- Quality Control and Inspection (AQL)
- Production: sample development, planning, quality control and inspection (AQL)
- Costing/Pricing
For complete garment that is not in batch form, statistical inspection based on AQL is recommended. The term "Merchandising" can be defined as: Person who sells the goods, specifically for export purposes. Dealing with the buyer and convincing the buyer is the main duty of marketing officer.
To maintain a good relationship between all departments and to get the best result from each department is also important and marketers play a vital role in getting good results from each department. Based on sample approval and delivery date, the production department only makes production planning. Planning is done by following the product styling and machine layout to calculate the number of production pieces per hour.
Before production begins, pre-production meetings are necessary with all concerned departments to get the correct productions. Quality control is mainly handled by the quality control department, but the merchants must be aware of this so that it does not affect the delivery dates. In terms of customer, the quality requirement will vary, and the dealers are responsible for. communicate with customers to get the correct quality requirements and need to coordinate with the factory quality control department so that they understand the requirement well and can take care of the bulk productions.
CHAPTER – 9
QUALITY ASSURANCE SYSTEM
- Quality Assurance
- Some points that are needed to maintain for high quality fabric
- Quality assurance Procedure
- Body & Rib Inspection
- Collar &cuff inspection
- Quality Standard
The fabric is spread over a white revision board, which ensures high transparency and uniform light reflection. Any major or minor defects are recorded in the inspection report to classify the fabric based on a four-point system. Any major or minor defects on the collar/cuff such as incorrect insert, hole, stitch cord, nicks, problems in the first round, etc. are counted and recorded.
If the score is 40 or less, the fabric is fine. If the score is greater than 40 points, notify the GM or appropriate dealer. During fabric inspection, if the m/c reports the length of any roll more or less than that stated in the roll, the roll will be measured manually using measuring tapes.
CHAPTER - 10
QUALITY CONTROL
- QUALITY CONTROL
- object of quality control
- List of equipment for quality control
- Quality control Flow chart
- Quality management System
- On-line quality control
- Raw material control
- Process control
- Finish fabric inspection
- off line quality control
Quality control deals with the evaluation of test data and its use in textile process control. It is not only about the level of quality and the cost of maintaining that level of quality, but also Online quality control includes raw material control, process control and finished fabric inspection.
Since the quality of the product depends on the quality of raw materials, the quality assurance department must ensure that the best quality of raw materials are used in production. The fabric must be free from defects with proper absorbency, whiteness as per the requirement for subsequent process. During dyeing, samples are taken and the shade matches with laboratory dip and when it matches, bath drops are allowed.
To ensure that only an acceptable quality fabric is used for the manufacture of the garments and the appropriate delivery quality is obtained from the supplier. The responsible store will check the fabric received with the reported length, color and type of fabric with the quality of the shipping document and the actual order quantity. The finding will be recorded in the inventory report and the discrepancy regarding the type, color and length of the clothes will be reported to the factory manager.
1.Physical test
Chemical test
Final inspection
If final inspection is ok, we can say quality is good and clothes are under control.
CHAPTER -11
UTILITY SECTION
Utility Services Available
Capacity & Other Technical Details
- Electricity -
- Gas -
- Water-
- Steam-
- Compressed Air
- Source of Utility
Gas is mainly used for the production of electricity, steam production and is also used in generators and boiler. Pure steam of required temperature has to be produced to meet the continuous demand of steam in different sections. There is a gas boiler used for steam generation, to meet the requirements of different departments.
In this m/c, natural gas is pumped through a pipe through a filter above the compressor and the air is compressed. In doing so, the cold water is slightly heated and transferred to the upper tank through the drain pipe. The water is then allowed to slowly fall through the reservoir to the compressed air to produce moist compressed air.
The moist compressed air is transferred to the dryer and a light warm compressed air is supplied to the required sections of The Delta Composite Knit Ind.
CHAPTER - 12
MAINTAINCE SECTION
- Machine: Gas Boiler
2 F.W. and standby system check 3 Automatic pump operation check 4 Photocell check and cleaning 5 Control check.
Machine: Gas Generator Machines
- Machine: Compactor, dryer machines
- Maintenance Tools and Equipments
CHAPTER - 13
EFFLUENT TREATMENT
- The main objective of ETP
- Type of Effluent Treatment plant follows zaara
- Flow diagram of The Zaara E.T.P
- The used chemicals in Zaara E.T.P
- The chemical treatment stages with their function
- Product Quality Checked
- Amount of Chemicals are used for 125 m3/hour
02 Anti-foaming agent It is used at distribution tank as if there is no foaming to be created. 04 Bacteria These are used at biological oxidation unit to eat the organic compounds of waste water. The employees of the E.T.P always check their pH value every day at inlet and outlet.
Here the activated sludge water (via recycling process) and pH-controlled water are combined. Anti-foam agents are used in this unit to remove foam formation. Good contact between organism and wastewater Provide plenty of oxygen through many pipes. Polyelectrolyte and Na hypochlorite are used to increase herd size and remove residual wastewater from the sedimentation tank.
Activated sludge process It is a process in which a mixture of wastewater and microorganisms is mixed and aerated from a secondary clarifier to a distribution tank. The maintainers handle all the problems in a short time due to the smooth operation of the E.T.P. Here, the nutrients are used at a time when dyeing wastewater is not coming in, so as not to dye.
CONCLUSION
