Jamal Abdun Naser, Technical Director, Shasha Denims Ltd for giving us the opportunity to complete our Industrial Annex at this reputed factory. Majharul Islam, AGM, Shasha Denims Ltd for giving us the special guidance to complete our Industrial Annexure.
Executive Summary
Introduction
About Shasha Denims ltd
Company profile
Sponsor of the project
Vision & mission of the project
Name of some Buyers of Shasha Denims Ltd
Factory Location
Factory layout plan
Organograms
Textile
Denim
Flow Chart of Denim Production in Shasha Denims Ltd
Fibre used for warp yarn in Shasha denims ltd
Fibre used for weft yarn in shasha denims ltd
Types of Yarn used
Name of yarn suppliers for shasha denims ltd
Definition
Objects of Warping
Importance of Warping
Types of Warping
Direct Warping/ High speed warping
Warping in Shasha Denim Ltd
Machine Specification
Briefly discussion about different parts of warping machine
Creel
Chain system
Control Devices
Different parts of headstock
The required width of the deformer beam can be set with the help of this comb. The lateral extension of the comb to the beam and the setting to the correct warp width are motor driven.
Warping Plan
Warping Procedure
Count wise Drum Pressure
Following points should be maintained carefully
Defects may be occur during warping
This occurs due to burrs and notches on the surface of the shear beam flanges. This is due to malfunction of the counter, and the brakes of the measuring device and skew bars.
Pre wetting
Object of Pre wetting
Function of the chemicals used in Pre wetting
Pre wetting Recipe maintained in Shasha Denims ltd
All commercial textile dyeing processes take place by applying a solution or dispersion of the dyes to the textile material, followed by some type of fixing process. Dyeing mainly depends on the type of fabric, the structure of the fabric and the properties of the dyes.
Objects of Dyeing
Otherwise, the process by which a textile material is to be physically or chemically changed so that it appears monochromatically uniform is called dyeing. The main objective of the fixing step is usually to ensure that the dyed fabric has a satisfactory fastness to post-treatment in aqueous washing liquids.
When cotton yarn is dyed with indigo, it leaves a ring dyeing effect, whereby the outer layer of the base yarn is coated with indigo, leaving the core yarn undyed. Originally, the warp threads or ends were passed through the dye bath side by side to form a sheet of yarn that passed.
Dyes use for Denim in Shasha Denims Ltd
Vat Dyes
Once inside the polymer system of the fiber, the leuco form of the vat dye must be oxidized and converted to its original color and the insoluble form of the dye. During the previous stage, insoluble vat dye can be deposited on the surface of the textile material.
Sulphur Dyes
Polysulphides in the leuco dye bath prevent premature oxidation of the dye and reduce the tendency to bronzing in deep dyeing of blues, navy blues and blacks. Addition of a sequestering agent such as EDTA avoids precipitation of the leucothiolate with calcium and magnesium ions.
Denim Dyeing Process
This is a dye bath that is reused for subsequent dyeings after adding more reduced dye. Any free sulfur that tends to accumulate is dissolved by adding sodium sulfite, forming thiosulfate.
Dyeing process used in Shasha Denims Ltd
Specification of Dyeing and Sizing machine-01 for Shasha Denims Ltd
Flow chart of dyeing machine -1 in Shasha Denims Ltd
Flow chart of dyeing machine -2 in Shasha Denims Ltd
Specification of Dyeing and Sizing machine:02
Beam creel section for Shasha Denims Ltd
Dyeing process that is maintained in Shasha Denims Ltd as follows
Chemical used in dyeing For Shasha Denims Ltd
Color Codes for piping in Shasha Denims Ltd
Details of figure of Color Codes for piping in Shasha Denims Ltd
Dyeing recipe
List of some chemicals are used in Shasha Denims Ltd for dyeing with their function
Different lab tests
Equipments used in Shasha Denims Ltd for dyeing lab
Definition of weaving
Weave Designs produced in Shasha Denims Ltd
In Denim Fabrics Twill Weave are most widely used
Fabric Construction in Shasha Denims Ltd
More fabric construction used in Shasha Denims Ltd
Classification of Modern Weaving Machines
Weaving in Shasha Denims Ltd
Types of loom in Shasha Denim`s Ltd
Description of different parts of loom used in Shasha Denims Ltd
- Main motor
- PC Suite
- Automatic full pick finding
- Let-Off and Take-Up motion in Shasha Denims Ltd
- Easy fitting and removal of warp beam and cloth roll
- Perfect lubrication
- Emery roller
- Optimized sley drive
- Electronic Selvedge System and Electronic Rotary Leno
- Quick Step filling presenter (Rapier)
- Prewinders
- Programmable Filling Tensioner (Airjet)
- Clamp on the movable main nozzle (Airjet)
- Fixed and movable main nozzles (Airjet)
- Stretch nozzle (Airjet)
- Selvedge produced for different loom in Shasha Denims Ltd
- Leno device used is the different looms of Shasha Denims Ltd
This can also be done while the machine is running, so the weaver can immediately see the result of the new settings. The electronic rotary idle (ERL) transition time can similarly be programmed while the machine is running. The extendable nozzle is located on the right side of the tab and extends the tip.
Various machine manufacturers incorporate different types of edge forming devices according to end product requirements.
Valve and relay nozzle setting for different airjet loom
The position of the fixed and movable main nozzles is easy to adjust. With air pressure, the yarn passing through the profile reed is stretched to the point of impact. In combination with the programmable filling tensioner, the stretch nozzle ensures the best filling yarn insertion.
For picanol omni and picanol omni plus, the rotating leno device is used, which was.
Meaning of the light signal of Air jet
Looming
Drawing-In
Tying-In
Basic Motion
Primary Motions
There is also a spring on the side of one disc so that the discs can be adjusted according to the number of weft yarns. The alignment of the disk and the cone is such that the weft yarn has a free path. In its forward movement, the last pickaxe is beaten to the ground.
The reed is made with any number of indentations per inch, according to the requirements of the fabric to be woven.
Secondary Mechanisms
A good manager is the one who manages his weaving shed with a minimum number of canes rather than investing a large amount on canes and storing them. The take-up motion withdraws the cloth from the weaving area at a constant rate to give the required pick-up spacing (in pike/inch or pike/cm) and then winds it onto a cloth roll. The main part of the mechanism is the take-up rollers, which pull the cloth at the usual rate, and the number of picks per inch determines this rate.
The drive to the take-up roll is by a train of gear wheels set in motion directly from the main shaft.
Tertiary motion
Figure: Front page of the assignment on warp and weft yarn passage diagram of an air jet loom in Shasha Denims Ltd. The diameter of the measuring tape can be adjusted according to the width of the loom. In the case of denim, control of the shrinkage and the warping of the fabric is mainly done.
Softeners are often used in the chemical treatment to give a soft feel to the fabric. The unsteady dye on the surface of the fabric can cause stains on other fabrics. As air temperature rises - which occurs during compression - the air's ability to hold moisture also increases.
Warp Yarn Path Diagram (Airjet)
Weft Yarn Path Diagram (Airjet)
Warp Yarn Path Diagram (Rapier) ...................................................... Error! Bookmark not defined
Specification of Airjet loom used in shasha denims ltd
Picanol omni
Specification of Rapier used in shasha denims ltd
Picanol Gamma
Picanol Optimax
Accessories used for each loom
Specification of cam used in Shasha Denims Ltd
Specification of cam used in Shasha Denims Ltd For picanol optimax
Specification of dobby used in Shasha Denims Ltd For picanol optimax
Because of this problem, the leg to the laundry is turned in the opposite direction of the twill of the fabric. First, gray fabric is thoroughly examined with the help of the inspection machine if there is any defect. The denim clothes must be washed several times to completely remove the stones.
The enzyme breaks down the surface cellulose fibers of the denim fabric and removes them during washing. During enzymatic washing, a certain amount of indigo dye and cellulose fibers are removed from the surface of the fabric. The main goal of security is the safe handling of goods from/to the premises of the mill.
Knotting machine
Definition of finishing
Generally, before marketing, all the process applied to the fabric after weaving is called finishing. Briefly, finishing is the process by which the fibers, yarns and fabrics are made presentable to the customer, and these processes are implemented after dyeing. The term finishing covers all the treatments that serve to give the textile the desired end-use properties.
Objects of Finishing
Types of finishing
Denim Finishing
Finishing In Shasha Denims Ltd
Specification of finishing machine: 01
Features of Monfort finishing machine
Drying in a hot chimney allows significantly more precise temperature control than with conventional drying methods and thus a more accurate residual moisture content before shrinkage. Drying jeans in a hot tube requires significantly less space than with other systems. For denim products with elastane fibers, a fixing step is possible to stabilize the fabric by heating the fabric in a hot tube and fixing the width under control on a short stretch section.
Also for woven fabrics with elastane fibers in the weft, if they have previously been washed and dried.
Process flow chart of Finishing machine-1
Specification of finishing machine: 02
Process flow chart of Finishing machine-2
Specification of finishing machine: 03
Process flow chart of Finishing machine-3
Specification of mercerizing machine
Process flow chart of mercerizing machine
Process Sequence of Denim Finish Line
Skew is a condition in fabric that can result from the angular displacement of filling yarns or knitted webs from a line perpendicular to the edge of the fabric. But in the case of twill, on the part of a float; there is a gap or free space equal to the actual diameter of the yarn. For a right 2/2 twill, the location of the clearances as shown in Fig.
With herringbone or other types of zigzag twill there is no risk of the fabric warping as in such weaves the floats (in-plane levers) work opposite to each other.
Finishing report of shasha denims ltd
The two forces acting opposite each other in the floats make them resemble an ordinary lever (Fig. A). The position of the free spaces on either side of the float determines the direction in which the float will be tilted. The degree of skew depends on the yarn properties, weave tensions and fabric structures.
Inspection
Inspection in Shasha Denim
Inspection Process
Four (4) Point System
Machinery Description
Specification of inspection machine used in Shasha Denims Ltd
Major Fabric Faults found in inspection section of Shasha Denims Ltd
Reasons: knot is tied, when the yarn breaks, the yarn tension does not match with other yarn, resulting in loose or tight. Make sure that the fabric rope in each batch passes through the nozzle of the machine for an equal amount of time during the actual dyeing process.
Quality Assurance Procedure
Specification of the roll packing machine of Shasha Denims Ltd
Heat seating of fabric roll
Specification of the heat setting machine
Denim Washing
- Basic Concept
- Types of Denim Wash
- Bleach wash
- Stone wash
- Enzyme wash
- Sand Blasting
- Acid wash
Bleached fabric materials should be properly antichlorinated or after peroxide washed to reduce subsequent yellowing or softening of the bleached denim fabric. During washing, these stones remove the dye particles from the surface of the denim thread, which shows a faded, worn and shiny effect on the denim fabric. Stones can cause fabric wear and can damage the washing machine due to stone rubbing against fabric or machine parts.
A solution of sodium hypochlorite or potassium permanganate is often sprayed on the desired area of clothing to achieve the same look.
Denim washing in Shasha Denim Ltd
Machine used in washing unit
The acidification of denim clothing was normally performed by tumbling the garments with pumice stones previously soaked in a solution containing sodium hypochlorite (5 to 10%) or potassium. However, the manganese can be removed by washing with the addition of ethylene-diamine-tetraacetic acid as a chelating agent. Acid washing jeans involves soaking porous pumice stones and chlorine or potassium permanganate (PP) bleach.
Some important steps in the process of Denim Washing
Pre treatment
Methods of Removing Sizes from Denim Jeans
Desizing
Water Extractor
Specification of other machine used in finishing department
Definition
Water Supply
Boiler
Specification of Boiler
Generator
Air Compressor
Air Dryer
Chiller
Recently, the wastewater created more to increase the production rate, which they cannot process in their ETP. Machinery, buildings and facilities are subject to deterioration due to their use and exposure to environmental conditions. Deterioration process, if not controlled, culminates in rendering these service facilities unusable and brings them to a standstill. In the industry, therefore, one has no choice but to attend to them from time to time to repair and refurbish them to extend their life so that it can be extended. is financially and physically possible to do so.
It is in this context that maintenance is important as an engineering function. It is responsible for providing a condition of these machines, buildings and services that allows the uninterrupted implementation of plans that require their use.
Objectives of maintenance
Types of maintenance
- Reactive/Break-down Maintenance
- Preventive/Schedule Maintenance
- Predictive/Planned Maintenance
- Capital Replacement
- Maintenance Department of Shasha Denims Ltd
If it is seen that the repair cost of machine parts is more or equal to or slightly less than buying a new one, then the old one is replaced instead of repair. Because there is some mechanical fault on the machine which is responsible for production inhibition, the operator informs mechanical fitters on duty. Mechanical fitters first come and observe the problem, and then they begin to fix it.
Because there is any electrical problem of machine or serious foundation mechanical problem, mechanical and electrical department are informed, they come and fix the problem.
R & D Department in Shasha Denims Ltd
Developed Samples
- Samples according to Weave
- Samples according to yarn used
- Samples according to Weight
- Samples according to Width of finished fabric
- Samples according to Color
- Samples according to Finish
Laboratory reports contain information about various tests carried out according to the buyer's requirements and their results with comments from responsible personnel about the substance.
The tests that can be performed in R& D department
Equipments Used in R&D of Shasha Denims Ltd
Scope of inventory control
Inventory System for Raw Material maintained in Shasha Denims Ltd
Inventory System of Spare Parts maintained in Shasha Denims Ltd
Inventory System of Finished Goods maintained in Shasha Denims Ltd
Other Inventories maintained in Shasha Denims Ltd
Procedure of Export Business by Shasha Denims Ltd
To get order
Sample preparation
Issuing of P.I (Performa invoice)
L.C. (Letter of credit) opens by the buyer
Security Section
Security Main Gate
During the training period, we have received full cooperation and association from the authority & found all men, machines & materials in notable functional condition.
