First of all we would like to pay homage to almighty Allah due to whose grace we have successfully completed our Industrial Bonding. Kabir, Senior Manager (Knitting) and Senior Production Director, Ahamed Khizir Mahbub Elahi (Dyeing) and Finishing for their valuable advice, cooperation, guidance, encouragement and inspiration throughout the training period. Finally, we would like to acknowledge that we remain responsible for inadequacies and errors that undoubtedly remain.
Because this industrial training minimizes the gap between theoretical and practical knowledge and makes us accustomed to the industrial environment. I had the opportunity to complete a two-month industrial training course at The Delta Knit Composite, a 100% export-oriented composite knit dyeing industry. It has well-planned and equipped units for dyeing, finishing of fabrics and garments, to facilitate the production of knitting and knitting fabrics.
Quality is always the combination of the highest goal, sincere effort with an accurate execution. To reach the pinnacle or be the market leader in supplying knitted garments to our valued customers across the globe.
Management Organization Chart
Management system
Company Policy
Other Facilities
Bonus: Two festival bonuses equivalent to two months' basic salary are paid to every employee who has completed one year of service. Sick leave: All staff and workers are entitled to 7 days of sick leave after submitting a medical certificate. Maternity Leave: Female employees are entitled to 12 weeks (6 weeks before and 6 weeks after delivery) of maternity leave with 100% pay/salary.
Earned leave: For adult worker, 1 day leave for 22 days work (but they must work minimum 1 year for the entitlement). Promotion: Performance based promotions or After 3 years car promotions Safety: Compliance department handles these criteria.
Knitting Department)
Section Layout
PROCESS DEFINITION (KNITTING)
ORGANGRAM OF KNITTING SECTION
Chairman Executive Director
Production Engineer Ass. production officer
Senior Technician Fitter man
Helper
Labour
SEQUENCE OF OPERATION
RAW MATERIALS OF KNITTING SECTION IN MKL
CIRCULAR KNITTING SECTION
YARN PATH FROM CREEL TO NEEDLE
Knot catcher
Feeder
Needle
PASSES OF YARN IN CIRCULAR KNITTING MACHINE
PRODUCTION FLOW CHART
PRODUCTION FLOW CHART OF KNITTING SECTION
Sample fabric
Design analysis
Machine selection
Setting the machine for the specific design
Sample Knitting
Sample approval
Bulk Production
Grey fabric inspection
- DESCRIPTION OF PRODUCTION PROCESS
- PRODUCTION PARAMETER
- Method of Increasing Production
- By increasing m/c speed
- By increasing the number of feeder
- By using machine of higher gauge
- By imposing automation in the m/c
- By imposing other developments
- Necessary Information
- G.S.M.: It is technical term that indicates the weight of the fabric per square meter
- Factors that should be considered for changing of fabric design on
- Gauge numbers that are usually seen in different m/c
- Knitting Variable
- Yarn twist: - It is the torsion of yarn which helps the fibers to ad hear with each other
- Spinning system: - This is the systematic way of giving torsion to the fibers
- Yarn ply: - It is the number of ply of the yarn which depends on the required gsm of the fabric
- Stitch length: - It is the length of the yarn which forms a single loop in a knitted fabric
- Take down tension: - It is the tension created by increasing fabric take up roller speed
- Machine gauge: - It the number of needle in one inch area of a cylinder
Production worker with experienced mechanical technician adjusts the required stitch length and gray GSM for the required final GSM. Yarn Twist:- It is the torsion of yarn that allows the fibers to belong together. Yarn ply:- It is the number of plies of the yarn which depends on the required gsm of the fabric.
Stitch length:- It is the length of the yarn which forms a single loop in a knit fabric. Yarn tension: - It is the given tension on the yarn during feed in the circular knitting machine. If the yarn tension is increased, the stitch length is reduced and the gsm of the fabric is increased.
And if yarn tension is reduced, stitch length is increased and fabric gsm is reduced. Remove tension:- This is the tension created by increasing the rolling speed of dust pick up.
The Delta Composite Knitting Ind. Ltd
MACHINE SPECIFICATION
Rib & Interlock Machine = 21 Sets
Three End Fleece Machine = 5 Sets
Collar Machine = 25 Sets
- Relation between Grey GSM & Finished GSM
- Relation between Finish GSM & Yarn Count (S/J)
- Relation between Finish GSM & Yarn Count (D/J Interlock)
- Relation Between Fabric Diameter And Machine Diameter
- Yarn Count Used According To Grey Gsm
- Different parts of Circular Knitting machine
- Description Of Knitting Parts With Figure
- Yarn Path of Circular Knitting m/c
- GSM depends on
- Machine Specification
- General practice of yarn count and machine gauge
Loop forming sinker: This sinker is used to sink or kink the newly laid yarn. Overturning Sinker: This sinker supports the old loop as the new loop is pulled through it.
Yarn count used Machine gauge
Relation between cotton count & machine gauge
Knitting Equation
Production calculation
Some conversions
- G.S.M calculation
- Industrial Calculation of DCKIL
- From finish G.S.M calculating grey GSM, SL, count
- Cam Arrangement of some Design
- Flow Chart of Greige Knit Fabric Inspection
- Equipment used for greige inspection process
- Inspection Procedure
- Investigation
If the greige fabric is cleared from inspection, it is sent for dyeing as per P.O. Generally, a fabric roll is cut when it reaches its 'set cut length' in the circular knit m/c, but the roll can be cut before it reaches the preset length if required and the weight is recorded other count, quantity, GSM, Knitter, Shift , Style, Yarn lot, Roll quantity, Machine revolutions, m/c no. All rolls are kept in front of the inspection m/c from time to time and inspected over the greige inspection visually at a preset speed (m/min) against light.
For any major/minor faults such as thick-thin spot, bar mark, fallout, contamination/flying, holes, oil lines, needle lines, slubs, etc. In the case of fly and contamination, fabric is approved for color while minor needle lines or minor streaks, fabric is approved for white. The relevant inspector records all the details of inspection result on the knitting card and greige inspection report.
Collar and cuff are cut when it reaches its 'set cut no of pieces' in the flat knit m/c. Any major or minor faulty collar/cuff such as wrong design, first round problem, etc. The defects found and marks given against them are recorded in the daily body and rib inspection report and daily collar and cuff inspection report.
Rejection criteria for body & rib
Classification of inspection Fabric
Different Types of Knitting Faults that are identified by Greige Inspection
Holes or cracks Bad needle, take-down mechanism too light, high thread tension, bad thread, needle too tight in slits, dial height too high or too low, knots tied poorly, wrong stitch setting. Takedown mechanism is too loose, defective needles, incorrect needle timing set and needle tricks closed. Vertical lines Defective needle, dirt in needle openings, needle too loose or too tight in slots, needles not lubricated enough.
Bare or horizontal stripes Poor thread, uneven tension, thread slippage during positive feed, incorrect setting of the stitch cam. Oil Lines Fibers and lint that accumulate in the needle tricks remain soaked in oil. Needle stuck in the grooves. Incorrect needle selection (wrong order of needles, placed in the barrel or dial).
Contamination The presence of dead fibers and other foreign materials such as; dyed fiber, husk and synthetic fiber etc.
BATCHING
- BATCH PREPARATION
- Type of Batch
- Function or purpose of Batch Section
- Proper Batching Criteria
- Batch management
- Batch Preparation
- Information Check Point
- Process flow chart of Batch preparation
The main function of batching department is to prepare batch for dyeing according to machine capacity, order and emergency. This section receives gray fabric from the knitting department and makes a batch to order for a specific shade. Take the collar/cuff according to size and keep the total weight. Take the necessary amount of body goods from the store.
DYEING
DYEING SECTION LAYOUT
ORGAN GRAM OF DYEING
Process Flow Chart of Dyeing
Bleaching is another important step used to reduce the natural color of the raw materials. Different types of printing are done to give special look on colored or white fabric.
ESSENCIAL CONSIDERATIONS BEFORE DYEING
PROCESS CONTROL PARAMETERS
Loading Capacity of Dyeing Machines
Bulk Dyeing Machine Specification
- Sample Dyeing Machine Specification
- Lab Dyeing Machine Specification
- Operation Process
- Before operation
- Starting operation
- During operation
- Nozzle installation
- After operation
- Maintenance
- Production Parameters
- Dyeing Recipe
- Dyeing Flow Chart
Start the main pump and feed all the fabric with the valve feed adjustment to the remaining end of the fabric 2 -3 meters. Make sure if the fabric circulation is normal, then close the gate door, (Check the roller speed again) .. put the pattern in the program controller. Enter 'stop'. button when finished the bell will ring 3) Open the door and take out the fabric.
Add wetting agent, sequestering agent, caustic soda and hydrogen peroxide and run at 1100 C for single yarn and 1150 C for double yarn for 20 min. Shade of the textile material depends on the dye percentage used for coloring.
FINISHING
- P ROCESS SEQUENCE OF F INISHING M ACHINERIES
- Objects of Finishing
- Classification of Finishes
- F INISHING M ACHINE P ROFILE (DCKIL) D E -W ATERING M ACHINE
The most common classification is- Aesthetic finishes: These types of finishes change or modify the appearance of the fabric or hand/drape properties of the material. Permanent finishes: These involve a chemical change in fiber structure and do not change throughout the lifetime of a fabric. Durable finishes: Usually last throughout the life of a fabric, effectiveness is reduced after each cleaning and near the end of normal use of the material, the finish is almost removed.
Semi-durable finishes: Usually last several washes or dry clean and many are removed in household laundry or dry clean. Temporary Finishes: Remove or significantly reduce the first time an article is washed or dry cleaned.
B RUSH & P EACH
D ESCRIPTION OF D IFFERENT F INISHING M ACHINE Hydro Extractor m/c
Dewatering Machine
Ruckh Relax Dryer (Germany)
Santex Relax Dryer (Switzerland)
Slitter Machine
Objectives of Slitting
Stenter Machine
Process diagram
Tubular compactor 2. Open compactor
Shade control: The shade of the compression fabric is controlled on the delivery side of the machine. The operator collects the fabric and compares the shade of the fabric with the buyer's approved pattern. Width Control: The operator measures the width of the fabric with the tape measure and compares it with the buyer's requirements.
Design and skew: The operator checks the design and skew of the fabric on the output side of the machine. Fabric Defects: Different types of fabric quality are measured at the goods side upon delivery.
CONCLUSION
