Firstly, we would like to express our sincere gratitude and appreciation to the Almighty God for his divine blessings that enabled us to complete this project successfully. We would like to express our thanks and best wishes to our supervising teacher Prof. Mahbubul Haque, Professor and Coordinator Department of Textile Engineering, Faculty of Engineering, Daffodil International University, Dhanmondi, Dhaka.
Our supervisor's deep knowledge and deep interest in field development has influenced us to run this project. His immense patience, scientific direction, unwavering enthusiasm, constant and energetic supervision, constructive criticism, valuable advice, reading a lot of inferior drafts and revising them at every stage have made this project possible. We would like to express our sincere gratitude to the other faculty members of the Department of Textile Engineering at Daffodil International University.
To find out more about Denim's productivity, we must turn to NZ Tex Group's sister company NZ Denim Limited. At the end of this project, we came to the result that we had to focus on these factors that affected production in weaving and dyeing, and the best factor is the quality of the yarn.
Table: 06: Details Information about Slasher dyeing and gluing 22 Table: 07: Machine specification for Slasher dyeing and gluing machine. Table: 08: Weaving Specification of Loom Floor 24 Table: 09: Details Data of Weaving Section (Slasher Dyeing 25-26 Table: 10: Finishing Machine Specification 27. Table: 14: Information from Finishing Section 29 Table: 15: Machine Specification of Inspection 30 Table: 16: Details Information from the inspection section.
CHAPTER-1
INTRODUCTION
Introduction
LITERATURE REVIEW
Denim
Denim is produced with the structure S Twill, Z Twill, Dobby, Broken Twill and the weight is 4oz to 16oz/sq. Different types of denim are manufactured using different types of washes such as hand wash, stone wash, bleach wash, over dyed etc. Denim is preferred by consumers of all ages as it not only looks good but is also comfortable.
Flow chart of Denim
Warping
There are two types of weaving system are used-
Objective of Warping-
Function of Warping Machine-
Direct Warping
Warp Yarn Consumption: [3]
Types of Dyeing system-
Slasher Dyeing
Purpose of Dyeing
- Flow Chart of Slasher Dyeing: [6]
- Sizing
- Method of Sizing
- Different types of sizing following to application
- Recipe used at NZ Denim Ltd
- Weaving
- Basic Weave Design used for Denim
- Modern Weaving Machines Classification
- Finishing Method
- Purpose of Finishing
- Inspection process of denim
Slasher is a type of coloring in which the process of coloring and sizing is done in a single method. Here the warp thread is passed through various dye baths and finally the sizing bath and wound into a beam. The method by which sizing material is applied to the thread surface is called Sizing.
To increase weaving efficiency and reduce weaving breakage, this size material is used. Pure size: Pure size is a type of size where the size is committed to yarn that produced unbleached fabric. Medium Size: The size ingredient is used (16 to 40)% based on yarn weight to increase yarn weight and strength.
Heavy size: The amount of size ingredients used based on the yarn weight is more than 40% to increase the weight. The process of interlacing using two sets of yarn (warp and weft) and providing a fabric texture is called weaving. As of today, weavers have a wide range of options to use, right from the simplest weaving to the most complex weaving.
Then singeing is done with the help of flame to reduce hairiness and to make the fabric surface smoother than before by this process. First inspection is done just after weaving and second inspection is done after finishing process. Finished material is Input of Inspection and output is inspected material Inspected material meets the best quality for delivery. Some waste is found here.
Here it is rated as Class A, Class B. In general, Class A and B are approved for delivery.
CHAPTER-3
Methodology
Methodology is the organic, empirical analysis of practical strategies for a field of study. It is related to the subject of the thesis which means that the relative result of the set of methods and principles related to the field of research and a branch of knowledge can come with theoretical analysis.
Productivity of Slasher Dyeing Denim
- Denim fabric production sequence
Productivity of Direct Warping
- Machine Specification of Direct Warping
- Machine wise Data of NZ Denim Ltd
Daffodil International University 19 | P a g e We follow up on the twist production and collected data from this section.
Machine-2
Machine-3
- Productivity in Slasher Denim Dyeing & Sizing
- Machine Specification of Slasher Dyeing & Sizing
- Production in Weaving
- Details Data About Weaving Section
- Calculation
- Production in Finishing
- Inspection
- Grade =6003 B-Grade = 3007
- Grade = 8995 B-Grade = 3200
- Grade = 7100 Total length = 18390
- Grade = 5990 Total length = 14995
- Grade =3475 Total length = 9400
That machine RPM is very high 700 to 1000 RPM. Air-jet machine has the highest 1000 rpm, so that Air-jet machine has a high efficiency as there is minimal amount of weft breakage. Due to improper dimensions, warp breakage is more in weave, causing lower quality of fabric. NZ Denim has named two weaving floors as weave-i and weave-ii. Finishing is a process that is one of the most important and essential process for fabric production.
The main purpose of finishing is to make the surface of the fabric smoother. During our internship, including while collecting data for the thesis, we saw the Cibitex Enhancing finishing machine used for finishing fabrics. There are also other machines for mercerization, brushing, singeing, stenter, pad steam machine and warping is done during the finishing process. In NZ denim, shrinkage is generally controlled, warping and sometimes over-dying depending on buyer recruitment.
This machine is used to remove protruding fibers and hair with the help of flame. Fabric inspection is a process where the fabric is checked to find defects if any in the fabric then classification is done so that the quality of the fabric can be easily identified. A grade refers to the best quality of fabric; Grade B means that the quality of the fabric is less than A, which means that a mistake is made here.
By using this method, anyone can understand the material quality whether good or bad, also the fault can be found out. During internship we saw Tubular Inspection Machine and how the machine runs and four lights are used so that faults can be easily seen.
CHAPTER-4 DISCUSSION
- Productivity Analysis of Slasher Dyeing Denim
- Productivity in Direct Warping Section
- The Mechanical Causes of Production Loss
- Operational Causes
- How to decrease the Problems-?
- Production in Slasher Dyeing & Sizing Department
- Mechanical Causes
- Operational Causes
- Some other Reasons
- Decreasing this problems
- Productivity of Denim Weaving
- Factors Effecting productivity in Weaving
- Our Comments to increase productivity in Weaving;
- Mechanical Causes
- Operational Causes
- Others Causes
- Productivity in Finishing Section
- Productivity of Inspection
When the machine starts this time, the machine runs very slowly, after the time is over, the machine runs very fast. If the machine stops due to breakage, then the worker knots it after which the machine is run again. Here we saw that when the production is going on, some workers put the cone package beyond the spool to save time.
1.Average machine stoppage rate: In Denim Production, the machine stoppage is average 4-6 times for Denim Production dignity to yarn count, number of length and regular length. When we collected the data of the warped floor, we saw that in the case of one cone after making a beam, they put the cone off with some yarn because they can't use this yarn. Before using the machine, check the beam flange and set the beam correctly.
Daffodil International University 34 | P a g e If we maintain this, the production will be higher, just as the twisting quality will be good. When we saw the dyeing and gluing process, we realized that there are some reasons to reduce production. In NZ Denim Ltd we saw that the production loss is very small but I think by following this thing we can increase the productivity more.
In New Zealand, the denim warp yarn is dyed in a slasher dyeing machine and then further sized and delivered to the weaving department. Weaving is carried out by omniplus800, Omni plus and Optimax-I, all Picanol brands. The lack of a production engineer hinders production also due to the laziness of the machine operator.
In our data collection period, we saw that chemical finishing such as mercerization, softening and different types of cold and hot wash washing. Then send to the Steam Pad Machine According to the buyer's request to check the shrinkage and Stenter for over the paint is done. First, the inspection is done after the weaving is done on the weaving floor, then the second inspection means final.
CHAPTER-5
CONCLUSION
Conclusion
THE END
