Industrialattachmentofepyllionknitexltd 140511094926 Phpapp01 PDF

SOUTHEAST UNIVERSITY
School of Science and Engineering, Department of Textile Engineering
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
Epyllion Knitex Ltd
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ACKNOWLEDGEMENT
A number of people have made significant contributions on preparing this
report. Their advice and suggestions helped us a lot. During the attachment with
Epyllion Group(Textile Division). We worked in all the departments related
with the Wet Processing section. We are not only give priority to the Wet
Processing but also worked sincerely in the Knitting Section, Maintenance and
Finished Fabric Inspection Section, warehouse & Store & Inventory, finishing
& specially dyeing.
I would like to pay special thanks to Professor Syed Fakhrul Hassan Chairman,
Department of Textile Engineering, Southeast University, for continuously
guiding us about the development and preparation of the report. He has
enriched me with necessary ideas and concepts for incessant improvement of
the report.
I would like to express our sincere gratitude to, Managing Director of Epyllion
Group who has allowed us to work in his organization.
I recognize Mr. Syed Sayeed Munir G.M. Epyllion Fabrics & Knitex Ltd, Mr.
Md. Sadrul Amin Bhuiyan AGM Pocurement, Mr. Engr. Rothin Pallab
Chakraborty, (DGM, Maintenance), Mr. Khairul Islam (Sr. Manager, Knitting),
Mr. Najmul(Asst. Manager, Knitting), Mr. Sumon( Managaer, Dyeing),Mr. M.
Aminul Islam GM HR & administration & Mr. M.A Hashem DGM HR, admin
& CSR for providing sincere help in all administrative & technical matter while
working in the organization.
My heart fell thanks to Mr. Hasan and Mr Samsujjan (Executive, Dyeing)Mr.
Tanbir (Executive, knitting), Mr. Robiul (Executive. Finishing), Mr. Robiul
and Mr. Talha (Executive, Finishing QC) Mr. Sayed (Executive, Lab), We also
grateful to all other Sr. Executives & Executives for assisting us to gather
information about various processes.
However, we have prepared our industrial Training report overcoming all the
difficulties & also the shortage of time. Here I would like to present the report.
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SPECIAL THANKS
TO
&
2|Page
Location for going to the Epyllion Knitex Ltd and Epyllion

fabrics Ltd
BANANI
GAZIPUR CHOWRASTA
RAJANDROPUR CHOWRASTA
BANGLABAZAR
(EPYLLION FACTORY)
3|Page
Table of Contents
INTRODUCTION ................................................................................................5
PROJECT DESCRIPTION...................................................................................6
INTRODUCTION TO EKL & EFL ...................................................................12
KNITTING DEPARTMENT..............................................................................14
QUALITY ASSURANCE SYSTEM .................................................................35
LAB & TESTING DEPARTMENT...................................................................49
DYEING DEPARTMENT OF EKL & EFL ......................................................58
FINISHING.........................................................................................................80
STORE & INVENTORY CONTROL ...............................................................91
MAINTENANCE ...............................................................................................95
UTILITYIES .....................................................................................................104
EFFLUENT TREATMENT PLANT ...............................................................112
BUYER COMPLAIANCE ...............................................................................122
CONCLUSION .................................................................................................123
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INTRODUCTION
By means of practical knowledge it is possible to apply the theoretical
knowledge in the practical field. For any technical education practical
experience is almost equally important in association with the theoretical
knowledge.
The industrial attachment is the process which builds understanding skill and
attitude of the performer, which improves his/her knowledge in boosting
productivity and services. Academic education provides us vast theoretical
knowledge as well as more practical attachment, despite all these industrial
attachment help us to be familiar with the technical support of modern
machinery, skill ness about various operation stages.
It also provides us sufficient practical knowledge about production
management, Productivity evaluation, work study, efficiency, industrial
management, production planning & control, production cost analysis,
inventory management, purchasing, utility & maintenance of machinery and
their operation techniques etc. The above mentioned cannot be achieved
successfully by means of theoretical knowledge only. This is why it should be
accomplished with practical knowledge in which it is based on industrial
attachment makes us reliable to be accustomed with the industrial atmosphere
& improve courage & inspiration to take self- responsibility.
From fiber to fabric, the TEXTILE division of Epyllion group is a truly
integrated undertaking. The Textile Division has the capability to offer a
complete product range for the export textile markets. The goal of Textile
Division is to become the preferred partner for sourcing high quality fabrics and
clothing from Bangladesh. With this goal Epyllion Fabrics Ltd. is advancement
of this journey. With highly advanced technology and an emphasis on
developing local human resources, the Textile Division has the potential to
make an important contribution to the nation's growing readymade garments
export sector keeping green environment into close consideration.The rationale
behind the existing structure and future expansion of the Textile Division is to
pure value-added at each stage of the textile manufacturing process.
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PROJECT DESCRIPTION
Company Name:
Epyllion Fabrics Ltd.

Epyllion Knitex Ltd.
Status: Private Ltd. Company

Type: 100% Export oriented composite knit Dyeing Industry.
Product Mix:
100% cotton
100% polyester
a) Spun
b) Filament
Nylon
Polyester Cotton blend
(15% Viscose 85% cotton

10% Viscose 90% cotton
30% Viscose 70% cotton)
Year of establishment: 2003, Commencement of Production in month

2004.
Address: It is situated in Banglabazar, Joydebpur, Gazipur. Bangladesh.
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Website: www.epylliongroup.com
Vision:
To establish as a one stop source for the Global knit Apparel market and to
satisfy and meet customer's expectation by developing and providing products
and services on time, which offer value in terms of Quality, Price, Safety &
Environmental impact.
Assuring complete compliance with the international quality standards and also
providing the employees internationally acceptable working condition and
standards.
To promote the development and to use human talent & equal opportunity of
employment.
They procure the most advanced & sophisticated technology suitable for
producing desired product and attain highest level of competence through
continuous development of the professional, management system and to ensure
complete transparency in an aspects of business.
Mission:
'Epyllion realizes the need to stake out a competitive segment in the changing
global market of today through technological excellence and human expertise.
Epyllion is committed to transpose its local success to the world scene.
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History of project development:

Epyllion Group started with first venture DEKKO KNIT WEARS Ltd (DKL) in
1993 with 2 sewing lines and total of 200 work forces at Mirpur area.
Now it has 7000 wprk force with 36 sewing lines in several areas of Dhaka and
Gazipur. Combining modern technology with skilled manpower under
Epyllion's unique inspiring, atmosphere, this new Epypllion venture soon rose
to the top of the local textile industry. Today it has one of the most sophisticated
vertically integrated set-ups.
Concern of Epyllion group:

Textile Industries
Garments Industries
Garments Accessories.
Real Estate.
Group Members:
Textile Industries
1. Epyllion Fabrics Ltd.
2. Epyllion Knittex Ltd.
Garments Industries
1. Epyllion Style Ltd.
2. Epyllion Knitwears Ltd.
3. Dekko Knitweaers Ltd.
4. Dekko Knitweaers Ltd. Unit-2
8|Page
5. Mirabella Dresses Ltd.

6. Epyllion Jeans Ltd.
Garment accessories
1. Epyllion Limited.
2. Epyllion Washing Ltd.
Real Estate:
1. Nima Holdings Ltd.
Other facilities are
Own network Server.

Own power management,
Own utility management.
Transport facilities.
Medical centre.
Fire service facility.
Effluent Treatment Plan.
Shift change
shift is 8 hrs
: 6:00 A.M-2:00P.M
: 2:00 P.M- 10:00 P.M
: 10.00 P.M-6:00 A.M
General shift : 9:00 A.M - 5:00 P.M
9|Page
Product:
Single Jersey
Heavy Jersey
Pique
Lacoste
Interlock
Rib
French Terry
Cotton Fleece /Cvc Fleece
Flat Knit
Auto man
Cotton Viscose
Polyester
Cotton polyester
CVC
Organic Cotton
Clients:
CELLIO
G-STAR
10 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n
ID:2008000400093
Certificate & Achievement:
BGMEA
BKMEA
BTMA
SEDEX
Oeko-Tex
C&A Best Supplier Award 2004
Capacity:
Production capacity in knitting:

27175 Kg of knitted fabrics per day
Production capacity in knit dyeing:
32500 Kg per day
Cost:
Investment 500 Core (Approximately)
Remarks:
Epyllion Fabrics Ltd. is greatest concerned with the quality of its product. Better quality has
come buyers to pay more. The infrastructure and land asset has the greatest possibility to
extension
Contact Information:
Corporate Office:
Plot # I/1, Road # 06, Section # 07,
Mirpur I/A, Dhaka-1216. Bangladesh
Tel:+880-2-9006028, 9006747, 8013883, 9013897,
Fax # 880-2-9007978, 9016994,
Web: www.epylliongroup.com
Factory: Banglabazar, Joydebpur, Gazipur.
ID:2008000400093
INTRODUCTION TO EKL & EFL
Front view of Epyllion Knitex Ltd
ID:2008000400093
ORGANOGRAM OF EPYLLION GROUP

HR & Administration
Operation & Planning
Knitting
Production
Grey Inspection
Batch Preparation
Wet Processing
Dyeing Section
Finishing Section
Quality Assurance
R&D
Laboratory
Fabric Inspection
Maintenance
Electrical
Mechanical
Utility
Compressed Air
Water
Electricity
Steam
ETP
ID:2008000400093
KNITTING DEPARTMENT
ID:2008000400093
LAYOUT OF KNITTING DEPARTMENT OF EKL & EFL
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Types of Fabric Produced by EKL & EFL:

Epyllion Knitex Ltd. is able to produce high quality circular weft knitted fabric with great
flexibility to produce a wide range of fabrics. The main products are :
Plain Jersey
Polo Pique
Single Lacoste /Single tuck back pique
Double Lacoste / Double tuck back pique
Herringbone
Creap
Twill pique
Lapique
Fred Perry
Two thread fleece
Rib
Yarn dyed feeder stripe
Waffle
Two tone pique
Pop Corn
Bubble Knit
Mini box design fabric
Vertical design
Drop needle
Honey Comb
ID:2008000400093
CAPACITY OF KNITTING SECTION:

FABRIC TYPE
EKL
EFL
DAILY CAPACITY
MONTHLY
CAPACITY
JERSEY
11
36
16,500 KGS
4,95,000 KGS
INTERLOCK
05
05
3,500 KGS
1,05,000 KGS
RIB
05
05
3,500 KGS
1,05,000 KGS
FLEECE
10
3,500 KGS
1,05,000 KGS
AUTO-STRIPE
01
175 KGS
5,250 KGS
27175 KGS
815250 KGS
TOTAL
ID:2008000400093
Knitting machine details of EKL:

m/c no
m/c type
Dia*gauge
No of feeder
No of needle
Brand
origin
01
S/J
30*28
90
2580
Orizio paolo
Italy
02
S/J
30*28
90
2580
Orizio paolo
Italy
03
S/J
30*28
90
2580
Orizio paolo
Italy
04
Interlock
30*24
72
2220
Orizio paolo
Italy
05
S/J
32*24
90
2412
Well knit
China
06
S/J
32*24
90
2412
Well knit
China
07
S/J
32*24
96
2412
Well knit
China
08
S/J
30*28
90
2580
Orizio paolo
Italy
09
S/J
30*28
90
2580
Orizio paolo
Italy
10
P/L
30*24
72
2220
Orizio paolo
Italy
11
P/L
30*24
72
2220
Orizio paolo
Italy
12
P/L
34*24
120
2562
Terrot
Germany
13
P/L
34*24
120
2562
Terrot
Germany
14
S/J
32*24
96
2410
Terrot
Germany
15
S/J
30*28
90
2580
Orizio paolo
Italy
16
S/J
30*28
90
2580
Orizio paolo
Italy
17
1*1Rib
30*18
60
1680
Orizio paolo
Italy
18
1*1Rib
30*18
60
1680
Orizio paolo
Italy
19
1*1Rib
30*18
60
1680
Orizio paolo
Italy
20
Rib
36*18
64
2040
Terrot
Germany
ID:2008000400093
21
Rib
36*18
64
2040
Terrot
Germany
Circular Knitting machine details of EFL:

m/c no
m/c type
Dia*gauge
Brand
Origin
30*28
No of feeder No of
needle
90
2640
01
S/L
Well knit
China
02
S/L
30*28
90
2640
Well knit
China
03
S/L
30*28
90
2640
Well knit
China
04
S/L
30*28
90
2640
Well knit
China
05
S/L
30*28
90
2640
Well knit
China
06
S/L
30*28
90
2640
Well knit
China
07
S/L
30*28
90
2640
Well knit
China
08
S/L
30*28
90
2640
Well knit
China
09
S/L
30*28
90
2640
Well knit
China
10
S/L
30*28
90
2640
Well knit
China
11
S/L
30*28
90
2640
Well knit
China
12
S/L
30*28
90
2640
Well knit
China
13
S/L
30*28
90
2640
Well knit
China
14
S/L
30*28
90
2640
Well knit
China
15
S/L
30*28
90
2640
Well knit
China
16
S/L
30*28
90
2640
Well knit
China
17
S/L
30*28
90
2640
Well knit
China
18
S/L
30*28
90
2640
Well knit
China
19
S/L
30*28
90
2640
Well knit
China
20
S/L
30*28
90
2640
Well knit
China
21
S/L
30*28
90
2640
Well knit
China
22
S/L
30*28
90
2640
Well knit
China
23
Rib
30*24
60
2256
Well knit
China
24
Rib
30*24
60
2256
Well knit
China
ID:2008000400093
25
Rib
34*24
68
2544
Well knit
China
26
Rib
34*24
68
2544
Well knit
China
27
Rib
34*24
68
2544
Well knit
China
28
S/L
30*28
90
2640
Well knit
China
29
S/L
30*28
90
2640
Well knit
China
30
S/L
30*28
90
2640
Well knit
China
31
S/L
32*28
96
2812
Well knit
China
32
S/L
30*28
90
2640
Well knit
China
33
S/L
30*24
90
2640
Well knit
China
34
S/L
28*24
84
2112
Well knit
China
35
S/L
30*28
90
2640
Well knit
China
36
S/L
30*20
90
1896
Well knit
China
37
Interlock
36*24
64
2712
Well knit
China
38
Interlock
36*24
64
2712
Well knit
China
39
Interlock
36*24
64
2712
Well knit
China
40
Rib
36*24
64
2712
Well knit
China
41
Rib
30*18
54
2256
Well knit
China
42
Rib
30*18
54
2256
Well knit
China
43
S/J
28*24
84
2112
Well knit
China
44
S/J
28*24
84
2112
Well knit
China
45
2T Flece
28*24
84
2112
Well knit
China
46
3T Flece
30*20
90
1896
Well knit
China
47
3T Flece
30*20
90
1896
Well knit
China
48
3T Flece
30*20
90
1896
Well knit
China
49
3T Flece
30*20
90
1896
Well knit
China
50
S/J
30*28
90
2640
Well knit
China
51
S/J
30*28
90
2640
Well knit
China
52
S/J
30*28
90
2640
Well knit
China
53
3T Fleece
30*20
90
1896
Well knit
China
ID:2008000400093
54
3T Fleece
30*20
90
1896
Well knit
China
55
3T Flece
30*20
90
1896
Well knit
China
56
3T Flece
30*20
90
1896
Well knit
China
57
Rib
32*18
64
2712
SSANGYONG Korea
58
Rib
44*18
88
2812
SSANGYONG Korea
Auto striper machine details:

m/c no
m/c type
Dia*gauge
No of feeder
No of needle
Brand
origin
01
Auto striper
30*24
48
2268.
Mayer &
Cie
Taiwan
02
Auto striper
30*24
48
2268
Mayer &
Cie
Taiwan
03
Auto striper
30*24
48
2268
Mayer &
Cie
Taiwan
04
Auto striper
30*24
48
2268
Mayer &
Cie
Taiwan
05
Auto striper
30*24
48
2268
Terrot
Germany
06
Auto striper
30*24
48
2268
Terrot
Germany
07
Auto striper
30*24
48
2268
Terrot
Germany
08
Auto striper
30*24
48
2268
Terrot
Germany
09
Auto striper
30*24
48
2268
Well knit
china
ID:2008000400093
RAW MATERIALS:
Raw material used in EKL & EFL:
SL no. Yarn Type
Yam count
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Hi
17
18
19
20
21
22
23
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Combed Yarn
Carded Yarn
Carded Yarn
Carded Yarn
Carded Yarn
Carded Yarn
Carded Yarn
Carded Yarn
Carded Yarn
Girded Yam
16CC
18CC
20CC
22CC
21CC
26CC
2BCC
30CC
32CC
36CC
36CC
40CC
50CC
60CC
16KC
1SKC
20KC
22KC
21KC
26KC
28KC
30KC
32KC
24
25
26
27
Carded Yarn
Carded Yarn
Carded Yarn
Carded Yarn
34KC
36KC
40KC
50KC
ID:2008000400093
28
29
30 31
32
33
34
35
86
37
38
39
40
41
42
43
44
45
Carded Yarn
CVC Yarn
CVC Yarn CVC
Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
CVC Yarn
G.M. Yarn
G.M. Yarn
G.M. Yarn
60KC
16CVC
18CVC
20CVC
22CVC
24CVC
26CVC
28CVC
30CVC
32CVC
34CVC
36CVC
40CVC
50CVC
60CVC
20GM 5V
20GM 10V
20GM
1.5V
Knitted fabrics specifications:

Knitting Parameters consists of1. G.S.M.
2. Yarn count.
3. Stitch length.
4. Fabric width.
5. Fabric thickness.
ID:2008000400093
1. G.S.M:
The weight of fabric in gram per square meter is called G.S.M.
2. Yarn count:
It is a numerical expression of coarseness or fineness of yarn which can be measured in two
systems. One is direct system and another one is indirect system.
For direct system:
Count =
For Indirect System:

Count =
3. Stitch length:
The length of yarn knitted into one stitch in a weft knitted fabric. Stitch length is theoretically
a single length of yarn which includes on needle loop & half the length of yarn (Half a sinker
loop) between that needle loop & the adjacent needle loops on either side of it. Generally, the
larger the stitch length the more elastic & lighter the fabric, & the poorer its cover capacity &
bursting strength.
4. Fabric Width:
Along the fabric width there presents the Wales. The total no. of needle is fixed for the same
cylinder having the equal gauge as well as diameter.
Fabric width
= No. of Wales X Wales space.

= No. of needle X Wales space.
= dg X Wales's space.
d = Cylinder diameter,
ID:2008000400093
g = Gauge.
The above concept clarifies that Fabric width closely depends on total no. of needle not
directly related to machine diameter machine gauge.
5. Fabric Thickness:
In the dry and wet relaxed states fabric thickness (t) is depends upon fabric tightness, but in
the fully relaxed state, it is more or less dependent of the fabric tightness factor. In the fully
relaxed state t= 4d.
Where d is the yarn diameter
For single jersey,
t = 2d
Technical Specification:
1. Machine gauge:
No. of needles per inch present in a needle bed of a knitting machine is called machine gauge
for that knitting machine. A term giving a notational indication of the no. of needles per unit
length along a needle bed or needle bar of a knitting machine in current practice, a common
unit length of one English inch (25.4mm) is used for all types of warp and weft knitting
machine.
Selection of machine gauge depends upon yam diameter. Yam diameter depends upon the
following:
1. Yarn count.
2. Yarn type.
ID:2008000400093
3. Yarn twist.
4. Yarn finished.
Generally practiced in different industries in Bangladesh given below:
yarn count used
Machine gauge
16
18
18
20
20
20
20
24
24
22
24
24
26
20
26
22
26
24
26
28
28
22
28
25
28
28
30
22
30
24
30
28
30
34
34
28
34
28
ID:2008000400093
2. V.D.Q Pulley (Variable Dia Quality):

In a knitting m/c to supply the specific length of yarn, there are two or more adjustable
pulleys which are known as V.D.Q. Pulley. By adjusting the V.D.Q. pulley we can control the
speed of accumulator which supplies the required amount of yarn.
V.D.Q. pulley is very important to set up the correct loop length.
The amount of yarn wound on accumulator by one revolution of cylinder is called the course
length of fabric
VDQ Pully Measurement:

For Orizio machine,
VDQ =
For an Exp:
S.L = 2.90
No of needle = 2580
ID:2008000400093
.
VDQ =
-2
= 187-2 = 185
For well knit m/c
140 for S.L 2.62
EXP:
For S.L 3.10
2.62----------------140
1 ----------------140/2.62
3.10----------------140*3.10/2.62 =165.65166
For Terrot m/c
For Mayer m/c
for each S.L 0.10 VDQ will increase 1mm.

for each S.L 0.10 VDQ will increase 10mm.
Some VDQ measurement of Different Brand m/c:

NO
BRAND
S.L
01
Orizio
2.85
02
Orizio
3.10
03
Orizio
2.76
04
Orizio
2.72
05
Orizio
2.10
06
Well knit
2.70
07
Well knit
2.65
08
Well knit
2.74
09
Terrot
3.25
10
Terrot
2.30
11
Terrot
2.70
VDQ
181
197
175
147
118
145
140
149
192
158
144
3. Machine Diameter:
Machine diameter is mainly diameter of cylinder. It is important for fabric width. Only
diameter does not determine the fabric width. It need helps machine gauge and Wales space
which is depend upon yarn count and loop length.
ID:2008000400093
4. Needle gauge:
Thickness of needle express by the needle gauge. It is important for selection of machine
gauge. Needle gauge is different for the different gauge and different Brand.
Some needle gauges found in industries are given below:
Machine gauge Needle thickness in mm
24
0.52
28
0.41
PRODUCTION PLANNING, SEQUENCE AND OPERATIONS

Production Equipment
EPYLLION FABRICS LTD (EFL) & EPYLLION KNITEX LTD are capable to knit Weft
Knitted fabrics only. Machine description is given before.
Quality Control Equipment

Following equipment are used to ensure proper quality of the produced fabric:
Starfish Computer Programme
Yarn Tension Metre
Stitch Length Metre
Magnifying glass (to check Wales or Course/Unit)
GSM Cutter etc.
Key Accessories:
Key accessories used for circular knitting process are:
ID:2008000400093
Needle: The commonly used needle types are Vo 154.41 G001-4, Vo 154.50
G001-4, VoTA 60.58 G01, and Vo 92.62 G01.
CAM : KNIT, TUCK and MISS
Sinker: Commonly used types are 0.250 mm and 0.200 mm.
MPF
Positive feeder
Dial
Cylinder
Manager tooth belt
Timing belt for motor and take down.
Minimum requirement of other parameters are:

For Yarn :
Yarn strength 13 gm/Tex (minimum)
Should be waxed 0.1 % - 0.3% (on the weight of the material)
Yarn should not be dried.
Cone angle should be accurate.
A tail should be kept during winding.
Packing density must be maintained.
For Sewing Thread

Sewing thread should be bleach proof.
ID:2008000400093
For Spandex
Should have good elasticity.
Yarn should be uniform.
Elastic recovery 100%.
Elongation 500%.
Should be Acid, Alkali and temperature stable
Should be moisture free (i.e. without containing water).
Other Materials
Needle Oil: Should be water soluble.
Belt,
Grease,
Kerosene oil, etc.
The acceptable limits for Mellange and Polyester depend on customer's specification. These
yarns are rarely used (based on buyer's demand) at EKL. The international standards for these
yarns are mentioned
Operation Staff
Operation stuffs of Circular Knitting Process include:
1. Manager
2. Sr. Production Executive / Production Executive
3. Operator
4. Assistant Operator
5. Helper
ID:2008000400093
Machine Set-up:
Operator sets the following parameters prior to operation:
Parameters
Range
Speed
26 ~ 28 RPM (for Solid dyed)

20 ~ 25 RPM (for Yarn dyed &
designed)
Yarn Tension
4-5 gm/tex.
Stitch Length
2.60 -3.00 mm
Weight
100 - 240 GSM (as required)
Yarn (Cotton)
16~40Ne
Yarn (Polyester)
75 - 300 Denier
Checklist Before Operation

Operator checks the following points prior to operation:
1.
Machine condition.
2.
Power supply and air availability.
3.
Yarn availability.
4.
Buyer's specification.
5.
Yarn quality.
6.
Machine adjusted with given parameter (Yarn count, Stitch length/GSM).
7.
Oil inlet clean or not.
8.
Oil drip metre should be adjusted.
9.
Door should be close.
10.
PC controller is set for record keeping.
ID:2008000400093
Factors to Be Considered during sample analysis Before Producing a Fabric:

Before production few factors but be considered:
1.
Design of the fabric( expressed by notation diagram),
2.
Needle arrangement according to Notation diagram,
3.
Cam arrangement according to Notation diagram,
4.
Feeding,
5.
Drive &
6.
Stitch length.
7.
Machine gauge & dia
Design of the fabric;

We have analyzed a fabric, the drew notation diagram which is attached in following page.
Needle arrangement & Cam arrangement:

Needle arrangement & Cam arrangement for the design is shown following page.
Feeding:
Well-knit brand has Single jersey machines with positive feed system. We fed yarn in
following sequence:
Type of yarn
Count
No. of yarn
Color of yarn
Cotton
30 cc
14
Orange
Polyester
175 den
White
Cotton
30 cc
Orange
Polyester
175 den
White
Cotton
30 cc
14
Orange
Cotton
30 cc
48
Orange
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Drive:
Today the belt system has by far become most common positive feed system. The belt makes
the spool rotate and the no of rotating spools corresponds to the no of feed systems. By
adjusting the belt RPM, the quantity of yarn per loop can be increased or reduced. This
system grants an accurate control of the yarn tension. We know knit loops more yarn than
tuck loops. To produce this fabric we use 3 belt drive. Two drive for knit loops & one drive
for tuck loops.
Stitch length:
Stitch length of each loop is controlled by VDQ pully . VDQ pully was adjusted to give 3.1
mm length for knit loops & 2.65 mm for tuck loops. Thus we produced the fabric.
Lycra attachment:
There are several methods to calculate lycra percentage in fabric sample. Some of them are
described below-
Manual method:
5 gm sample fabric is taken & withdrawn the lycra yarn from sample fabric Then the sample
fabric is weighted. From difference weight, we calculate the lycra percentage of the sample
fabric
100%
ID:2008000400093
QUALITY ASSURANCE SYSTEM
ORGANOGRAM
BODY PART
Tube & Collar Cuff
Quality Manager
Executive
Sr.Executive (2)
Supervisor
Executive (3)
Helper
Supervisor
Sr. Inspector
Inspector
Helper
ID:2008000400093
The Quality assurance Department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing. Epyllion Fabrics Ltd. is more
about concern about quality. In this factory quality assurance is more preferred than quality
control, but both are in advancement.
After collecting fabric rolls from different m/cs, they are needed to be inspected or assured
required quality by the quality inspectors as if there were no big production hampered and no
complain from the buyers. Here are the details about it.
Objects of Quality Control:

1. Research.
2. Selection of raw materials.
3. Process control.
4. Process development.
5. Product testing.
6. Specification test
Scope for quality control, quality assurance and testing:

1. Testing lab
2. Machine auditing system
3. A good training system
4. Excellent analytical back up
5. Technical expertise
ID:2008000400093
Quality Control in Grey Fabric Inspection:

Some Points Are Needed To Maintain For High Quality Fabric:
a) Brought good quality yarn.

b) Machines are oiled and greased accordingly.
c) G.S.M, Stitch length, Tensions are controlled accurately.
d) Machines are cleaned every shift and servicing is done after a month.
e) Grey Fabrics are checked by 4 point grading system.
List of Equipments:
In this factory this is the list of equipments to assure quality:1) Inspection m/c# 1
2) Inspection m/c #2
3) Scissors
4) Electronic balance
5) GSM cutter
6) Indication sticker
7)
Measuring tape
1) Body & Rib Inspection:

All rolls are kept in front of the inspection m/c time to time and are inspected over the
inspection m/c visually in a pre-set speed against light. For any major or minor faults like
thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etc are
recorded in inspection report to classify the fabric which is based on the four point system.
ID:2008000400093
2) Collar & Cuff Inspection:

Collars cuff are inspected visually under the light box, any major or minor faulty collar/cuff
like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly
counted and recorded.
Quality Standard:
Epyllion Fabrics Ltd. maintains the ISO: 9002 standard in case of quality. Therefore, the four
point system is followed to inspect the body & rib fabric. The defects found and points given
against are recorded in the inspection sheet.
Following table shows the four point grading system followed by inspection at Epyllion
Fabrics Ltd.
Four point grading system
Size of defects
Penalty
3 inches or less
1 point
Over 3 inch but not over 6 inch
2 point
Over 6 inch but not over 9 inch
3 point
Over 9 inch
4 point
ID:2008000400093
Following table shows common body and rib faults and response by inspection section at
Epyllion Fabrics Ltd:
Rejection criteria for body & ribs
No
Faults
Response
1.
Needle mark
Major needle line is rejected
2.
Stripe
Major needle line is rejected
3.
Barre mark
Rejected
4.
Contamination & fly
Approved for color but for white shed

1 point is assigned
5-
Slubs
1 point
6.
Thick thin place
Reject
7.
Birds eye
1 point
8.
Pin holes
1 point
9.
Wrong design
Reject
"10.
Mixed yarn
Discuss with manager
11.
Sinker mark
Major sinker mark is rejected.
12.
Missing yarn
Use 4 point
13.
Holes
Do
14.
Oil line/stain
Do
15.
Chemical
Do
16.
Dirt stain
Do
17.
Crease line
Do
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18.
Uneven tension
Following table shows common collar and cuff fault and response taken by inspection section
at Epyllion Fabrics Ltd.:Rejection criteria for collar & cuff
Response
No.
Faults
1.
Wrong ply
Reject
2.
Hole
Reject
3.
Needle line
Reject
4.
Slubs
Reject
5.
Wrong design
Reject
6.
Wrong tripping
Reject
7.
Fly & contamination
8.
First round problem
Acceptable for color but not for

white
Reject
9.
Uneven tension
10.
Missing yarn
Reject
11.
Crease line
Reject
12.
Rust line
Reject
13.
Oil stripe
Reject
14.
Thick-thin
Reject
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15
Wrong tube
Reject
Following table shows the acceptance calculation followed by the inspection section at
Epyllion Fabrics Ltd.:
Acceptance calculation
Factory: Roll yardage (A) & Total points pounds (B)
Formula: B/A X100 =points per 100 yard
Classification:
40 points
= A type
41-60
= B Type
61-80
= C type
Above 80point = Reject
Quality Standard:
Epyllion Fabrics Ltd follows the quality standard: ISO-9002:2000.
List of Equipments: In the lab Department the followings equipments are used
Yarn Grade Tester
78-1 Magnetic Stirrer
KERN Electronic Balance
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Spray Rating Tester

Incubator
Iron
Button Tester
Ahiba Nuance Lab. Dip Dyeing Machine
Thermostatic Water Bath
Digital Pipette
Creda Dryer
Rota Wash
Electrolux Washcator
Orbitor Pilling & Snaging Tester
Marks & Spencer Holoscope
True Burst
Crock Meter
Push - pull tester
Megasol (Light fastness tester)
Spectra Photometer with software (Data Color)
Thermo hygrograph
PH meter
ID:2008000400093
PRODUCTION SUMMARY
PRODUCTION
(TON)
UNIT
EFL
713
EKL
317
Subcontract
Grand Total
451
1482
SERVICE
PRODUCTION
(TON)
COLLAR
& CUFF
(TON)
TOTAL
PRODUCTION
(TON)
57
20
(285715
Sets)
791
39
8
(112680
Sets)
364
1
(14285
Sets)
452
97
29
(412680
Sets)
1607
OVERALL SUMMARY
Particulars
Qty (Ton)
INHOUSE
1058
66%
SERVICE
96
6%
SUBCONTRACT
452
28%
TOTAL
1606
100%
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1058
1200
1000
800
452
600
400
96
200
0
IN HOUSE
SERVICE
SUBCONTRACT
FABRIC TYPE WISE PRODUCTION
F. Type
Pro. Qty
Fab. %
SJ
714,815
47.33
3TFL
318,818
21.11
LSJ
137,467
9.10
SP2RIB
70,061
4.64
1RIB
56,069
3.71
IRRGDNI
47,179
3.12
IN
46,483
3.08
IN Ply
32,842
2.17
SPRIB
31,188
2.07
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Collar & Cuff
28,127
1.86
STBPQ
14,287
0.95
2TFL
6,913
0.46
LSTBPQ
2,186
0.14
WFL
2,130
0.14
DNI
566
0.04
2TBPQ
559
0.04
2RIB
322
0.02
L2TFL
90
0.01
Mesh
54
0.00
Grand Total
1,510,153
100.00
INHOUSE PRODUCTION ANALYSIS
FLOOR
CAPACITY PRODUCTION CAPACITY

MCS
REJECT
REJECT%
(TON)
(TON)
UTILIZATION UTILIZATION (TON)
EFL
1539
770
50%
54%
0.95
0.12%
EKL
521
356
68%
72%
0.38
0.11%
TOTAL
2060
1126
55%
58%
1.33
0.12%
ID:2008000400093
Total (KG)
560,000
540,000
520,000
Total (KG)
500,000
480,000
460,000
440,000
Jan11
Feb11
Mar11
ID:2008000400093
Month
Unit
Total
Target
Total
Delivered
Performance %
Jan ' 11
EFL
385250
341714
89%
Feb ' 11
EFL
357000
342924
96%
Mar ' 11
EFL
374000
289626
77%
Jan ' 11
EKL
189750
171582
90%
Feb ' 11
EKL
168000
197828
118%
Mar ' 11
EKL
176000
185750
106%
Floor wise
average %
Quarterly perfm %
87%
96%
105%
ID:2008000400093
Rejects
EFL
Month
January
Delivery
Qty (Kg)
EKL
Reject Qty
Reject In %
(Kg)
Delivery Reject Qty

Reject In %
Qty (Kg)
(Kg)
259355.2 Kg 604.0 Kg
0.23%
171582 Kg
924.4 Kg
0.53%
February 286267.4 Kg 376.0 Kg
0.13%
197828 Kg
679.1Kg
0.34%
0.22%
185750 kg
364.9 Kg
0.19%
555160Kg
1968.4
Kg
Avg 0.35%
March
Total
268178.0 kg
611.0 Kg
813809.6 Kg 1591.0 Kg Avg 0.19%
ID:2008000400093
LAB & TESTING DEPARTMENT
ID:2008000400093
COLOR FORMULATION LABORATORY:

S
Machine Name
L
Ahiba Nuance Dyeing
1
M/C
Ahiba Nuance Dyeing
2
M/C
Brand
20
Beakers
15
Data color U.S. A
Beakers
China
12
Fongs
(Hong
Beakers
kong)
Data color U.S. A
3 Fongs Dyeing M/C
Manf.
Date
Erection Remark
Date
2003
2003
2003
2003
2002
2003
2006
2006
2003
2003
2002
2003
Origin Capacity Unit
Automatic Dispenser &

Data color U.S. A 80 Bottles 1
Solution Maker
Spectrophotometer SF
5
Data color U.S. A
2
600 Plus CT
6 Veri-Vide Light box
Verivide UK
2
4
FABRIC TESTING LABORATORY:

S
Machine Name
L
Origin
Capacity
Electrolux Washing M/C
UK
1 Unit
Erect!
Manuf.
on
Remarks
Date
Date
2002
2003
Ariston Washing M/C
UK
1 Unit
2002
2003
Elba Washing M/C
Korea
2 Units
2002
2003
Tumble Dryer
UK
1 Unit
2002
2003
Crock meter
UK
1 Unit
2002
2003
SDL Tumble Dryer
UK
1 Unit
2002
2003
ID:2008000400093
Tests:
There are two types of tests are done in Quality Assurance Department.
They are 1. Physical Tests
2. Chemical Tests
Physical Tests:
Yarn grade
GSM test
Shrinkage test
Spirality test
Tensile strength
Abrasion resistance
Pilling resistance
Button strength testing
Lycra% determination
Crease resistance
A. Measuring the Dimensional Stability (Shrinkage & Spirality):

Sample:
Two piece of 50 cm x 50 cm fabric is taken for test.
Procedure:
a) Conditioning: Put the sample in table for 4 hrs for conditioning before starting test.
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b) Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample (3
sides) by over lock sewing machine.
c) Put sample in washing machine and run according to buyer's choice.
d) Drying: All Buyers' requirement is tumble Dry except ECHO SCOURING is flat dry.
Shrinkage test calculation:

Before wash - After wash
Shrinkage % =
100
Spirality test calculation:

S = (S1+S2) / 2
Spirality = (S+S x L)/100.
Suppose,
B1 =
the right side distance of the specimen from the stitch line after wash.
S2 = the left side distance of the specimen from the stitch line after
L = Length before wash
Washing fastness:
Recipe:
ECE phosphate = 4 g/L
Sodium parborate = 1 g/L
M:L=1:10
Sample weight = 10gm
40Cx45 min
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Procedure:
1. Stock solution is prepared according to recipe in a beaker & 10 steel balls are kept in
beaker.
2. Then the fabric is dropped into the beaker.
3. The beaker is set up in Rota wash m/c in 40nc for 45 min.
4. Then the sample is washed off.
5. Then the sample is dried and compared with standard.
Water fastness:
Procedure:
1. The colored fabric is attached with finished fabrics unfinished fabric.
2. Then it is kept in water in beaker for 10 min
3.
Then the fabric is kept on template board of perspiration tester where 5 kg weight is
added.
4. Then it is put in over dry m/c in 35nc for 4 hrs.
5. Then the dried sample is compared with standard.
Rubbing fastness:
Procedure:
1. The sample fabric is kept on Crock meter & the fabric is rubbed by handle of Crock meter
with Crock meter cloth.
2. 10 times rotated the handle on the sample fabric.
3. It is done both dry & wet condition of crock meter cloth.
ID:2008000400093
4. Then it is compared with standard.
Perspiration test:
For alkali,
Recipe:
L-Histidine monohydrochloride = 0.5 g/L
Sodium chloride =5.0 g/L
Di Sodium hydrogen phosphate =2.5 g/L
pH = 8.0
Water =1Lt
For acid,
Recipe:
L-Histidine monohydrochloride = 0.5 g/L
Sodium chloride =5.0 g/L
Sodium hydrogen phosphate dyhydrate =2.2 g/L
pH = 5.5
Water =1Lt
NB: pH for alkali not less than 8 & pH for acid not above than 8.
Procedure:
1. Stock solution is prepared according to recipe in a beaker.
2. Then the fabric is kept in beaker & to measure the pH of liquor.
3.
Then the fabric is kept on template board of perspiration tester where 5 kg weight is
added.
4. Then it is put in over dry m/c for 4 dry.
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5. Then the dried sample is compared with standard.
Lab. Deep Dyeing

Sample:
Type -100 % cotton fabric
-
Weight - 5 gm
Procedure:
-
At first the recipe for the sample is calculated according to the sample weight.
The fabric is kept in the dyeing chamber.
Then the dyes, chemicals, salt & required amount of water is taken in that dyeing chamber
by digital pipeting on the basis of stock solution.

-
Then the beaker is set into the lab. Deep dyeing machine for dyeing. The program for
dyeing is started for 20 min at 40C.

-
After 20 min soda is added by pipeting.

-
Then the dyeing program is set for 60 min at 60C.

When the dyeing time is finished the sample is taken out from the machine at
40C.
Then the sample is washed off. At first cold wash & then hot wash is done. After
it soaping is done.
Then the sample is dried and compared with standard.
Progressive Process for Lab Deep Dyeing:

Recipe Calculation:
A dyeing recipe for purple color is given below:
Sample Weight - 5 gm
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M:L-1:10
Liquid Required - 50 c.c.
Sunfix Yellow S3RD - 9.3 c.c. (Shade - 1.86%)
Sunfix Red S3BD - 10.2 c.c. (Shade - 4.08%)
Sunfix Yellow S3RD - 9.3 c.c. (Shade - 1.86%)
Salt (80 g/L) - 10 c.c. (40% stock)
Soda (20 g/L) - 2.5 c.c. (40% stock)
Water-11.5 c.c.
Salt and soda is taken on the basis of the shade%. The salt and soda is used according to the
following table:
Shade %
Salt g/l
Soda g/l
0.001-0.100
20
0.101-0.500
24
0.501-1.000
30
10
1.001-2.000
40
12
2.001-3.000
50
14
3.001-4.000
60
16
Above 4.000
80
20
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CDA:
All chemical have to test. Such as 1. H2SO4
2. Acetic acid.
3. Soda ash
4. Salt
5. H1O2
6. Color
7. Sequestering agent.
8. Water
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DYEING DEPARTMENT OF EKL & EFL
ID:2008000400093
Organogram of Dyeing Section

Manager (01)
Assistant Manager (02)
Senior Executive (03)
Executive (03)
Production Officer (03)
Senior Supervisor
Supervisor / Jr. Supervisor
Production Operator
Production Helper
ID:2008000400093
Dyeing m/c of Epyllion knitex ltd:

Dyeing m/c s no. Brand name: Origin:
Capacity:
01
Fangs
China
10 kg
02
Thies
Germany 350 kg
03
Fangs
China
500 kg
04
Fangs
China
500 kg
05
Fangs
China
750 kg
06
Fangs
China
250 kg
07
Fangs
China
750 kg
08
Fangs
China
100 kg
09
Son Tech
China
75 kg
10
Son Tech
China
150 kg
Raw Material for Dyeing:

Raw materials used in the dyeing section are:
1. Grey fabric
2. Dyes
3. Chemicals
ID:2008000400093
1.Grey fabrics:
Following types of grey fabrics are dyed:
Single jersey
Single jersey with lycra
Polo pique
Back pique
Single lacoste
Double lacoste
Fleece
Terry fleece
Rib
Rib with lycra
11 Rib
22 Rib
Different types of collar & Cuff
Machine Description
Technology of the dyeing machine:
In EKL and EFL dyeing unit used special types of dyeing machine. In these
machine, the Jet and Winch technology is combined i.e. during dyeing, dye liquor
circulate through the machine like jet dyeing machine also the fabric is circulated
through the winch as like winch dyeing machine. This combination is made for
better dyeing of the fabric.
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Main parts of dyeing machine:

The main parts of the dyeing machine are1. Main tank
2. Reserve tank/PT
tank
3. Additional/Mixing
tank
4. Main pump
5. Heat exchanger
6. Filter
ID:2008000400093
The description of the main parts of the machine is as follows Main tank:
Main tank is the largest part of the dyeing machine. This is the main dye bath which
contains the dye liquor & the fabric. The size of the tank depends on the capacity of the
machine. Liquor & fabric circulates in the main tank during dyeing process. There may
have different number of nozzle connected to main tank according to the machine
capacity. Each nozzle may handle 300- 900m of fabric.
Fig: Main Tank
Reserve/PT tank:
This tank is mainly used for storage of hot water that will be used for the dyeing of
fabric. The temperature of water in the P.T. tank is maximum 80 0C. By using this hot
water in the machine during dyeing there is a reduction of time for heating the water in
the main tank which results in the reduction of total dyeing time.
ID:2008000400093
Additional/Mixing tank:
This tank is mainly used for storage of hot water that will be used for the
dyeing of fabric. The temperature of water in the P.T. tank is maximum 80 0C.
By using this hot water in the machine during dyeing there is a reduction of
time for heating the water in the main tank which results in the reduction of
total dyeing time.
Fig: Mixing tank

Main pump:
This is one of the essential parts of the dyeing machine. This is used for
displacing of dye bath liquor causing a flow from main tank to heat exchanger
through filter. That means the pump ensures the liquor circulation throughout
the dyeing process.
Heat exchanger:
During the different stage of dyeing (also pre-treatment, after-treatment), there
is a need of increasing or decreasing the temperature of dye liquor gradually.
We cannot use liquor of required final temperature directly because there may
be possibilities of thermal shocking of the fabric. So, the temperature should be
increased or decreased in a controlled manner. This controlling is done by heat
exchanger. Actually it is an indirect heater. During the circulation of dye bath
liquor, the liquor passes through the heat exchanger.
64 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3
Mechanism of Heat-exchanger:
1.
2.
3.
4.
Heat-exchanger consists of no. of tubes surrounded by a shell body.

Two fluids of different temperature flow through the heat exchanger. The
fluids can be either gas or liquid on either the shell side or the tube side.
One flows through the tube other flows through the shell.
The temperature of the two fluids is different, so transfer of heat occurs
from one fluid to another through shell.
5. The fluids which flow through the tubes come in and pass out from the
heat-exchanger on the same side. On the other hand the fluid used in
shell comes in and pass out from the different side of the shell.
Filter:
During the treatment of fabric in the machine, lots of lose fiber is produced
from the fabric. To eliminate these lose fibers, filter is used. It also reduces the
lose fibers loads from the fabric. If the lose fibers are not eliminated, then the
running of fabric is disturbed & entanglement can be occurred.
Ways of Liquor Flow from Additional Tank:
Liquor from additional tank flow to the main tank is mainly done in two ways.
They are 1.
2.
3.
Inject: In this system, all amounts of liquor flows directly to the main
tank at a time. This is done when the chemicals need to pass at short
time. This system ensures high rate of flow of the liquid.
Dosing: In this system, the liquor does not pass to the main tank at a
time. There are few chemicals which have very severe action to the fabric
if it flows directly like sodium hydroxide (NaOH). These chemicals pass
to the main tank in an increasing or decreasing way with time so that the
harsh effect of these chemicals is minimized. There are three
types of dosing:
- Linear Dosing - Progressive Dosing - Decreasive Dosing
T
Linear dosing
Progressive dosing
Decreasive dosing
Liquor circulation system:

During the treatment of fabric, the liquor is circulated throughout the
machine. At first, the required amount of liquor is taken in the main tank.
Then the liquor goes to the filter through pump and then it goes to the heatexchanger. From the heat-exchanger, the liquor goes to the main tank through
nozzle. The schematic diagram of liquor circulation system is given below-
1 Dyestuffs
and auxiliaries feeding container

2 Heat exchanger
3 Pump for the circulation of the liquor
4 High pressure pipe work
5 Dyeing drum
6 Winch
Figure: Liquor circulation system
Types of machine according to temperature:
Atmospheric machine
High temperature machine
There are one atmospheric machine of Fong's brand in EKL and EFL.
Others are high temperature machine (both Fong's and Thies). Also there
are special types of high temperature machine used in named as Fong's
High Speed Jumbo (HSJ) Machine.
Features of Fong's atmospheric machine:
The machine is designed for pre-treatment, dyeing & after-treatment

under atmospheric condition.
Nozzle is sized for smooth passing through by the fabric and extensive
exchange with the liquid.
Two standard nozzle sizes with sufficiently large diameter are available.
Circulation pump is sized for heavy fabric
Production capacity: 500 kg maximum per batch.
Maximum temperature: 98o C.
Maximum pressure: 1 atm.
Features of Thies atmospheric HTHP machine:
The machine is designed for the pretreatment, dyeing and after treatment
which can provide temperature up to 1400C.
Nozzle lead gets interlocked after temperature exceeds 80 0C.
Loading per nozzle 250kg
Design pressure: 350-550kpa
Design Temp : 1400C
Hydraulic Test Pressure: 585Kpa
Manufacturer: Germany (Thies), China (Fong's)
No of nozzles: 1-8.
Flow Chart For Dyeing:

Grey fabric receive from knitting section
Batching
Select m/c no
Fabric loading
Select production program
Pre treatment
Select recipe for dyeing
Recipe confirm by D.M / S.P.O
Dyeing
Post treatment
Unload
Different shade:
Dyeing Sequence for Turquoise Color:
Level In (Water from p.t at 800 )

Check ph
Leveling agent injection
Run 10 min
Color dosing linear (800 c x 40 min)
Run 20 min
Salt dissolving (800 c x 15 min)
Run 200
Soda dosing (70% Progressing) (800 c x 50 min)
Check ph
Sample check
MIR rising 10 min
Bath drop
Dyeing Sequence for Black Shade:
Level In

Run 10 min
Salt dosing (600 c x 10 min)

Run 15 min

Run 20 min

Check ph
Sample check
MIR rising 10 min
Bath drop
Dyeing Sequence for 80 0C Light Shade:

Check ph

Run 10 min

Run 20 min
Salt dissolving (600 c x 15 min)

Run 20 min

Check ph
Sample check
MIR rising 10 min

Bath drop
Dyeing Sequence for 800 C Medium Shade :

Check ph

Run 10 min
Salt dosing (600 c x 10 min)

Run 20 min
Color dosing (600 c x 30 min)

Run 20 min

Check ph
Sample check
MIR rising 10 min

Bath drop
Some dyeing recipe:

Description
Color Type: Dark
Color: Black.
Dyeing Polyester part
T Vell W 3R 0.24000%
T Red W4BS 0.2400%
T Black BFE 3.00%
Reduction cleaning
Hydrose-2 g/l
Caustic- 2 g/l
Dyeing Cotton part
S VELL MF3RD-0.7282%
S RED MF3BD- 0.3542%
RS BLACK WM- 5.6416%
Salt 90 g/l
Soda 5 g/l
Caustic-1.75 g/l
Nature of fabric: CVC Fleece
GSM: 280
M:L-1:6
Color: White.
BAM (OBA) 0.90%
Caustic-2.5 g/l
H2O2 -10 g/l
Nature of fabric: S/J
GSM: 160
M:L-1:7
Color Type: Dark
Color: LT-NAVY
R.G. Yellow RGB 0.2068%
R. UL. Car RGB 0.3520%
R. Blue R.R
1.800%]
Salt 60 g/l
Soda 18 g/l
Nature of fabric: Fleece
GSM: 260
M:L-1:6
Color Type: Dark
Color: Mountain Lake
R. Yellow RR 0.1540%
R. TURQG 2.0370%
R. BLUE RR-2.6400%
Salt 80 g/l
Soda- 20 g/l
Nature of fabric: S/J
GSM: 160
M:L-1:7
Color: Black Newyork 1102B.
R. G. Yellow RGB 0.4959%
R. UT. Car RGB 0.131%
R. Deep Black RGB 6.84%
Salt 90 g/l,
Soda 5 g/l
Nature of fabric:100% Cotton Fleece
GSM: 260
M:L-1:7
DYEING PRODUCTION (EFL)
MONTH
PRODUCTION
JANUARY
412 TONS
FEBRUARY
381 TONS
MARCH
341 TONS
TOTAL
1,134 TONS
450
412
381
400
341
350
300
250
200
150
100
50
0
JANUARY
FEBRUARY
MARCH
DYEING PRODUCTION (EKL)
MONTH
PRODUCTION
JANUARY
232 TONS
FEBRUARY
206 TONS
MARCH
209 TONS
TOTAL
647 TONS
235
230
225
220
215
210
205
200
195
190
JANUARY
FEBRUARY
MARCH
FINISHING
A fabric finishing process is a process for providing specific quality to

the fabric that is required by the customer. Textile finishing, in a
restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed fabrics are subjected before they are put to
market. It's one of the most important operations in knit processing.
Objectives of Finishing:
Improving the appearance, luster, whiteness etc.
Improving the feel, this depends on the handle of the
material & its softness, suppleness, fullness etc.
Wearing qualities, non- soiling, anticrease, antishrink
comfort etc.
Special properties required for particular uses like waterproofing flame-proofing etc.
Covering of the faults in the original cloth.
Increasing the weight of the cloth.
Types of Finishing:
Mechanical Finishing (Used to control dimension to improve appearance

& handle)
Chemical Finishing (Used to make glossy protection. To improve
performance or service ability)
Finishing process:
Knit fabrics require finishing process after dyeing. During dyeing all
knit fabrics are dyed in tubular form. According to buyers requirement
dyed fabrics are finished in either tubular form or Open-width form.
Depending on which Finishing sections are separated into two sections - OPEN
& TUBE section.
1.
Tubular finish:
Dewatering
Dryer
Tube Compactor
2.
Open finish:
Slitting
Stenter
Open Compactor
3.
Special Finish (Raising & Sueding):

Slitting
Stenter
Compacting
Raising/Sueding
No. of Machines of finishing section:

Name of the m/c
Dewatering
Slitting
Dryer
Stenter
Open compactor
Tube compactor
Rasing m/c
Sueding m/c
No. of the m/c

2
5
3
3
3
2
1
1
1. Dewatering Machine
Machine Specification:
Brand - CORINO
Origin Italy
Function of Dewatering m/c:
Removal of excess water (70-75%)
Removal of residual dirt
De-twisting of the rope fabric
Make the fabric Tubular from Rope form
Improve the hand feel of the fabric by using
softener
Controlling points:
Width control (can be increased up to 3")
Pressure variation according to GSM (higher GSM- 3-3.5bar,
Lower GSM-2-2.5bar)
Fabric speed - 15m/min
Checking points:
Hand feel
Color spot
Softener spot
De watering machine
Fabric Path of Dewatering machine
2.Slitting machine
Brand - FERRARO
Origin - Italy
Function of the machine:
Slit the fabric to make it open form.
Removal of excess amount of water.
De-twisting of the tube fabric.
Fabric Path of slitting machine
3.Dryer Machine
Brand - ENTEMA
Origin - TURKIYE
Function:
To dry the fabric
To control the shrinkage
To control the fabric GSM (can be increased 10-15 GSM)
Controlling points:
Overfeed
Temperature
Fabric speed - Maximum 30m/min
Checking Points:
Shade check
Fabric width
Temperature:
White/light shade: 100-120'C
Medium shade; 110-130 C
Dark shade: 140-160'C
4. Stenter Machine
Brand - Monforts
Origin GERMANY
Brand - LK and LH co. LTD
Origin TAIWAN
Chamber:7
Function:
To dry the fabric.

Heat-set the synthetic fiber fabric.
Controlling the width of fabric or maintain dimensional stability.
Controlling the GSM of fabric.
Skew ness & Bowing controlling of stripe fabric.
Spirality & Twisting control.
Fabric hand-feel modification-like-Softening or Hardening.
Shade control.
Stenter machine
Controlling Points:
Overfeed (0 - 50%)
Temperature
Speed
Padder pressure
Checking Points:
Shade
Width
GSM
Faults
Finishing parameters for different types of fabrics in Monforts stenter:
s/j
Temperature Overfeed Padder

pressure
115-150 110-140C 40-45% 2 bar
s/j
160-220 120-170C
40-45%
2.5 bar
L.s/j
160-220 130-160C
50%
2 bar
L.S/J
200-250 140-160C
50%
2 bar
Fabric type GSM
Speed Blower
RPM
15-20 11001300
25-30 12001400
25-30 12001400
24-28 12001400
Utility for stenter machines:

Gas
Electricity
Compressed air.
5.Compacting machine
Two types of compacting machines are used in EKL and EFL
1. Open compacting machine
2. Tube compacting machine
Brand tube-tex compector
Origin USA
Brand - FERRARO
Origin ITALY
Function:
Fabric compaction.
To dry the fabric.
To control the shrinkage.
Controlling the width and GSM of fabric.
Shade control.
Controlling Points:
Overfeed
Temperature
Speed
Checking Points:
Fabric Diameter
GSM
Shrinkage
Fabric faults
Main parts of the machine:

Heating chamber
Blower (2, one at the entry chain zone for
uncurling and another at the entry of compacting
zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder
7. Belt cylinder
8. Uncurling device at entry of compacting zone.
9. sensor
1.
2.
Finishing parameters for different types of fabrics in compactor

(Ferraro, open width compactor):
Color
Speed
Overfeed
White
color
L.s/j
White
color
Pique
White
color
Fleece/terr White
y
color
1*1 rib
White
color
2*2 rib
White
color
Interlock White
color
15-18
25-30
Teflon
Temperature Blanket
pressure pressure
90-100C
1.5-2(bar) 33(P.S.I)
12-16
12-16
90-100C
1.5-2(bar) 33(P.S.I)
15-18
30-35
100-110C
1.5-2(bar) 33(P.S.I)
15-20
25-30
100-110C
1.5-2(bar) 33(P.S.I)
15-20
20-30
110-120C
1.5-2(bar) 33(P.S.I)
12-15
25-30
100-110C
1.5-2(bar) 33(P.S.I)
12-16
Full over
feed
100-110C
1.5-2(bar) 33(P.S.I)
Fabric
type
s/j
Special Finishing machine:

01.Brussing machine
Brand Lafer SPA
Origin ITALY
Function:
To produce pile on fabric surface
To increase hand feel of the fabric
To make the fabric soft
Controlling Points:
Drum speed
Fabric tension
Plaiter tension
fig: Brussing machine
02.Piece finish machine

Brand Lafer SPA
Origin ITALY
Function:
To produce heat insulation on fabric surface
To increase hand feel of the fabric
To make the fabric soft
Controlling Points:
Drum speed
Fabric tension
Plaiter tension
Fig:Piece finish machine
STORE & INVENTORY CONTROL

Epyllion Group Textile Division Store & Warehouse Department
STORE
General
Store
CDA
Store
Yarn
Store
Grey fabric Finished fabric Leftover CDA sub
Store
Store
Store
Store
Functions of store:
General store:
PR against indent
Preparation of MRIR after QC

Issue against SR
Input in to the ledger
Physical arrangement by type
First in first out policy
CDA store:
PR against indent
Issue against SR
Physical arrangement by type
Yarn store:
Received against PO
Physical arrangement by count & lot
Grey fabrics store:
Received from knitting & subcontract

Issue to batch against SR
Physical arrangement by location & order wise
Finished fabrics store:
Received from finishing after QC

Delivery against booking of merchandiser
Physical arrangement by order & color
Leftover store:
Received from all garments & floor

Sorting by item wise
Preparation of packing list
Delivery against DO
CDA sub store:
Received from main store

Issue to production against SR
Main the ledger
Physical arrangement
Difficulties of store:
Product lead time
Space of storage
Authorization for issue
Procedures: General store, CDA store &yarn store

Indent
Storage
PR
Purchase
QC
MRIR
Issue to production
Procedures: Grey fabrics store

Rec. from knitting/sub contractor after QC
Storage
Issue to Batch
Procedures: Finished fabrics Store

Rec. from finishing after QC
Storage
Delivery
Procedures: Leftover store

Rec. all excess/rejects/wastages
Sorting & packing List
Delivery against DO
MAINTENANCE
Maintenance:
Machine, buildings and other facilities are subjected to deterioration due to their
use and exposure to environmental condition. Process of deterioration, if
unchecked, culminates in rendering these service facilities unserviceable and
brings them to a standstill. In Industry, therefore has no choice but to attend
them from time to time to repair and recondition them so as to elongate their life
to the extent it is economically and physically possible to do so.
Objectives of Maintenance:
1.
To keep the factory plants, equipments, machine tools in an optimum
working condition.
2.
To ensure specified accuracy to product and time schedule of delivery to
customer.
3.
To keep the downtime of machines to the minimum thus to have control
over the production program.

4.
To keep the production cycle within the stipulated range.
5.
To modify the machine tools to meet the need for production
Maintenance of Machinery:
Maintenance
Preventive Maintenance
Electrical
Mechanical
Break Down Maintenance
Electrical
Mechanical
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time
inspection / checking of facilities to uncover conditions that may lead to
production break downs or harmful description.
Break Down Maintenance:

In this case, repairs are made after the equipment is out of order and it cannot
perform its normal functions.
Routine Maintenance:
Maintenance of different machines are prepared by expert engineer of
maintenance department. Normally in case of dyeing machine maintenance after
30 days complete checking of different important parts are done.
Manpower Set-Up for Maintenance

A Shift
6AM -2 PM
B Shift
2PM -10 PM
General Shift
9PM 6 PM
Maintenance Manager
Mechanical
Electrical
Mechanical In charge -02
Electrical Foreman -02
Diploma (Mechanical)-02
Diplomas (Electrical) -02
Welder and fitter -01
Electrician -02
Fitter -01
Maintenance Procedure:
Normally preventive maintenance should be done. During maintenance
procedure following points should be checked:
Maintenance of knitting machine/flat knitting machine:

SL. No.
Items need to be checked & Serviced
Check and tightening all motor terminals.
Check and clean pressure sensor and tightening terminals
Clean the ventilation fans of panel board and circular fan on

top of machine
Check and clean the interfacing and data cables.
Check and tightening the proximity switch terminals.
Inspection, cleaning and tightening all the terminals in the

panel
Check and tightening limit switch, safety door guard and the
emergency switch.
Functional test of the yarn detector.
Check List of Different Parts

Maintenance: Mechanical
Machine
: Dyeing machine
SL. No.
Crease the m/c bearing.
Complete cleaning of machine.
Cleaning of drain valves, replace seals if required.
Check air supply filters, regulators auto drain seals
Clean filters element and blow out
Greasing of unloading roller bearing.
Checking of oil level and bolts of unloading roller

gearbox.
Checking of unloading roller coupling and packing.
Checking & cleaning (if required) of main vessel level

indicator.
10
Check the oil level of pump bearing and refill if

required.
11
Check the function of heat and cool modulating valves
12
Check all door seals
Machine : Dyeing machine

SL. No.
Check & clean fluff and dirt at dirt at all motor fan covers.
Check all motor's terminals
Check main panels (by using compressed air)
Check panel cooling fan & clean its filter
Clean main pump inverter and its cooling fan.
Check all circuit breaker, magnetic conductors and relays.
Check current setting of all circuit breaker & motor over

load.
Visual checking of all power & control cables.
Check all pressure switches
10
Check calibration of main vessel & all addition tank
11
Check all pneumatic solenoids
12
Check calibration of heating/cooling modulating value
13
Check setting of tangle sensor.
14
Check setting & operation of lid safely switches.
15
Check setting & operation of lid safely switches.
16
Check all emergency switches
17
Check all indicating lamps
18
Check all on/off switches
Maintenance: Mechanical
Machine: Boiler
SI. No.
1
Item needed to be checked & Serviced

Checking of gas pressure and gas supply line
2.
Dosing of softening chemicals to supply water
3.
Checking of all steam lines
4.
Cleaning of burner tank (after six month interval)
5.
Checking and replacement of valves
6.
Cleaning of feed water tank
7.
Checking and replacement of filters
8.
Cleaning of sight glass
Maintenance Tools & Equipments:

1. Combination tools / spanner
Function: Tightening & loosening of nuts & bolts.
2. Socket ratchet set
Function: Tightening of nuts & bolts.
3. Slide range
4. Monkey pliers
5. Pipe threat cutting tools
Function: To cut the threat in pipe.
6. Bearing puller
Assist the opening of bearing from shaft.
7. Pipe range
Function: Tightening & loosening of pipe joint.
8. Pipe cutting tools
Function: For pipe cutting.
9. Hole punch
Function: Punching the hole.
10. Divider
Function: For circle marking on metal & wood.
11. Easy opener
Function: To open the broken head bolt.
12. External threat die
Function: For external threat cutting.
13. Heavy scissor
Function: Cutting of gasket & steel sheet.
14. Oil can
Function: Oiling of moving parts.
15. Drill machine and drill bit.
Function: For drilling.
16. Grease gun
Function: For greasing of moving parts of m/c.
17. Grinding m/c
Function: For grinding & cutting of mild steel.
18. Welding m/c
Function: For welding & cutting.
19. Spirit leveler
Function: For perfect leveling.
20. File
Function: For smoothing the surface.
21. Hammer
Function: For scaling & right angling.
22. Circle tools
Function: Circle opening & closing.
23. Hacksaw blade
Function: For metal cutting.
24. Handsaw (wood)
Remarks:
Maintenance of m/c's are very essential to prolong the m/c life and good
maintenance is important consideration. It is necessary to check that all routine
maintenance is being done regularly and properly otherwise efficiency of each
department will be reduced.
UTILITYIES
Introduction:
EPYLLION GROUP is a big project and so of course having a vast project of
utility service. Here the total accounts of utility facilities are available. The
utilities are
a) Water
b) Gas
c) Electricity
d) Compressed Air
e) Steam.
S
Machine Name
L
Brand
1 Generator
Deutz
2 Generator
Perkins
FG
Wilson
Roll Air
Roll Air
Roll Air
Roll Air
Cleaver
Brooks
Matcon
3 Generator
4
5
6
7
Compressor
Compressor
Compressor Dryer
Compressor Dryer
8 Boiler
9 Water Treatment
Plant
1 Water Treatment
0 Plant
1
1
1
2
Effluent Treatment
Plant (Chem-Bio)
Effluent Treatment
Plant (Biological)
Origin
Re
Unit Manuf. Erection
Capacity
ma
(PCS) Date Date
rks
German
1344KW 2
y
UK
340 KW 1
2006
2006
2002
2003
UK
750 KW 1
2003
2003
France
France
France
France
281 m3/h
508 m3/h
3.5 Kg
4.8 Kg
2
3
1
1
2002
2006
2002
2006
2003
2006
2003
2006
USA
9.5 Ton 2
2002
2003
India
30 m3/h 1
2003
2003
Epyllion
Banglad
70 m3/h 1
esh
Dorr
Oliver
India
SiememS Italy
720
m3/day
2400
m3/day
Under
Construction
2003
2003
2006
2006
ELECTRICITY
Gas Generator is used for supplying electricity for the dyeing, knitting & office
of the EPYLLION GROUP.
Total power produced by Gas Generator - 1344KW = 1724 KVA
Factory (Dyeing & Knitting) Power Needed for Installation -About 1200 KW
Factory (Dyeing & Knitting) Power needed at running stage - About 720 KW
Power Needed for Office - About 250 K
Technical Details
Generator Data
Type
V-TYPE
Manufacturer
DUTZ
No. of Gas Generator
02
Model No.
315GFBA
Manufactured Country
England
Year of Construction
2006
Rated Power
Prime
Rated
1340KW-2nose
Power Factor
0.8
Voltage
400
Rated Current (amp)
568
Frequency (Hz)
50
Rotating Speed (RPM)
Isoo
Battery Volts
24
Control System
, PCCP
Site altitude before derate
800 MASL
Site ambient temp, before

derate
No of Cylinder
40C
16
Source of Power used for Garments - Own Supply Power Capacity - 750 KVA
= 900 KW There is a diesel Generator in the industry. Capacity of Diesel
Generator - 800 KW
Specification of Diesel Generator is given below

Technical Details
Generator Data
Type
Diesel Generator
Manufacturer
CATERPILLAR
No. of Diesel Generator
02
Model No.
SR4BISR4
Manufactured Country
U.S.A
Year of Construction
2004
Rated
649 H.P. or 484.0 KW
Rotating Speed (RPM)
1500
Voltage
400
Rated Current (amp)
723
Maximum Temp.
105 C by Resistance
COMPRESSED AIR
Compressed air is produced by air compressor.
There are two air compressors for producing compressed air.
STEAM
Steam is produce by Boiler.

Form the water treatment plant water is stored in a reserve tank and from there
water goes to boiler & steam in produced
GAS
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section (Boiler- for heating
water) from the main line of the TITAS GAS LTD.
Sources of Utility:
Electricity
: PDB & Generator
Steam
: Boiler
Water
: Pump
Compressed air: Compressor

Gas
: Titas gas transmission & Distribution Ltd.
EFFLUENT TREATMENT PLANT

The stream of excess chemical liquor extracted from an industry after using in
original purpose is called Effluent industrial effluent generated from different
process are treated with various chemicals to remove or neutralize the
environmentally toxic materials present in it. The plant where this job is done is
called Effluent Treatment Plant or ETP.
Now days, for an export oriented factory it is very common to have an ETP as it
is a part of compliance & also Government is very strict in Environmental issue
right now.
Effluent Treatment Plant

At
EPYLLION KNITEX LTD.
Chlorine ETP
Chemical ETP
Bio-logical ETP
Brief on Epyllion ETP:
It posses the above three types of ETP.
But right now only Bio-logical ETP is used as other two is very cost
consuming process.
Capacity of bio-logical ETP is 2400 m3day.
Oxidation tank capacity is 48000 m3.
Epyllion group is very concern about environment, as they never stop

their ETP or can be said they keep it running 365 days in a year.
Explanation of Bio-logical Effluent Treatment Plant

Inlet water:
From dyeing floor an inlet water line is directly connected to ETP.
There is separate line for pre-treatment water like dyeing water, soaping
water,
Usually other wash water directly discharges to the environment.
Water Filter
At the entrance of effluent water to ETP .water goes through a filter.
Its try to remove solid materials like waste threads. Fabric pieces lints
Enzyme waste etc.
Storage/Equalizing tank:
Water from different inlet pipe store there finally.
There occur equalizing of gathered water as they come from different line,
by a mixer.
Feed Pump:
There are three submersible pumps for feeding this raw water from
Equalizing tank to homogenization tank.
The feed pipe of these three pumps is in three different heights. Pumps
are automatically on-off depending on the level of water.
Storage & Homogenization Tank:

Feed pump. Feed raw water to this tank.
There are number of air supplier [Aero jet] below water level for
supplying air to water.
Also there occurs the cooling of water & good mixing.
This air dosing is vitally important as water will subsequently face
oxidation.
Thus from this tank we get a Cool. Well-mixed & oxygen enriched
effluent water.
Retention time of water in this tank is 20hr,
Storage capacity 2000 m3.
Neutralizing tank:
There occurs drop wise dosing of 98% pure Sulphuric acid. [Never less than
95% pure]
This operation is important as at adverse pH bacteria or other microorganisms will be killed.
Here Hydrochloric acid should not be used as it will kill micro-organisms
when there is more than 0, 3 mg/ 12 in the water.
Feed Tank:
From Neutralizing tank water is supplied to feed tank by a pump.

By the over-flow of this feed tank water goes to oxidation tank.
Fig-Feed Tank
Oxidation Tank:
In Epyllion size of the oxidation tank is 48000 m3.
A certain amount of micro-organism is maintained in oxidation tank.
1.5-2.5 mg/l oxygen is supplied to oxidation tank to maintain a 4.5-8 mg/l
O2 which is necessary for oxidation.
In these tank bacteria reacts with dyeing chemical & their bonds are
broken down. As a result BOD, COD, TDS, TSS value of water falls
down.
Due to breaking of chemical bond of dyeing chemicals .energy produced
which supply living energy to micro-organisms.
Sometimes anti-foaming agent is used in this tank:

If bacteria become weak, then nutrient is fed in this tank. Usually 0.5 kg in 50
liter water [especially when water processing remains shut down]
Na-hypochlorite is added to this tank sometimes if any insects attack in this tank
[specially when water processing remain shut down]
Temperature of this tank is 25-30 C.
Before Clarifier Tank:

Water deodorant dosing is done in this tank.
Maintain pH 3.0-5.0 & M:L is 1:4
Retention time is 10-15 min,
If water deodorant is not used than micro-organisms will be

killed.
From this water goes to deifier & sedimentation tank,

Clarifier & Sedimentation Tank:
Here occurs the sedimentation of sludge by the slow rotation of the clarifier.
By overflow water goes to discharge line.
Sludge Recycling Tank:

All sediment sludge are finally comes to this tank.
From this, to maintain continuous supply of micro-organism sludge is
supplied to the feed tank.
Excess Sludge Storage Tank:

In the oxidation tank, if it is found more amount of sludge
than the necessary. at that time some excess amount of
sludge is supplied to excess sludge recovery tank.
Here from sludge water is removed & make the
sedimentation of sludge at the bottom of tank.
Here dosing of polymer is done which assist the job of
sedimentation.
M: L is 1:80 for polymer.
Filter Press:
Sediment sludge comes to this machine.
Here, all the water is removed from sludge & make it dry as cake.
Required Chemicals of Biological ETP:

98% H2S04.
Function:
Neutralize the waste water by controlling pH.lt is auto dispensed in the
neutralization tank.
Polyelectrolyte
Function:
Used
for
sedimentation/sludge
coagulation
and
also
killing
bacteria.[Coagulation in water treatment, the use of chemicals to make

suspended solids gather or group together into small flocks.]
It is used auto/manually in sludge thickener tank.
De colorants
Function:
Used for removing color.lt is used auto/manually in sludge thickener tank.
Anti foaming agent
Function:
Used for reducing/controlling foam.lt is used auto/manually in the oxidation
tank.
Sodium hypochlorite:
Function: It is used to killing harmful bacteria/insect. It is used in the
Biological Oxidation tank.
Nutrients:
Function:
When bacteria become weak it is added to a certain quantity. It is added in the
oxidation tank.
Condition of effluent for discharge to drain at EPYLLION

KNITEX LTD:
Bio-logical ETP
Name of factors Standard
amount
PH
7.0-9.0
Color
Reddish
BOD
<50 mg/l
COD
<200 mg/l
IDS
<2100mg/l
TSS
<1 50 mg/l
DO
4.5-8.0
Chlorine
<600 mg/l
Biological ETP
of EPYLLION
7.74
reddish
16 mg/l
67 mg/l
1869 mg/l
112 mg/l
4.23
342 mg/l
Chlorine ETP
amount
PH
6.0-9.0
BOD
<50 mg/l
COD
<200 mg/l
IDS
<2 100 mg/l
TSS
<150 mg/l
DO
4.5-8.0
Chlorine
<600 mg/l
Chlorine ETP
of EPYLLION
3.23
240 mg/l
626 mg/l
1942 mg/l
220 mg/l
5.22
390 mg/l
Chemical ETP
amount
PH
6.0-9.0
Color
150
BOD
<50 mg/l
COD
<200 mg/l
TDS
<2 100 mg/l
TSS
<150 mg/l
DO
4.5-8.0
Chemical ETP
of EPYLLION
9.78
59
21 5 mg/l
283 mg/l
5361 mg/l
13 mg/l
6.21
Testing of ETP:
Color of sludge:
If it is brown, then ok.
Measurement of sludge:
From oxidation tank 1 liter water is brought & kept undisturbed for 30
min. Then the amount of sludge is measured.
Strength of micro-organism:
It is determined by smell of water. If there is any bad smell in water it
noticed that bacteria becomes weak & need to add nutrients.
Condition of oxidation bath:

If there occurs attack of insects in oxidation tank, then need to add
sodium-hypochlorite in that tank.
COST OF EFFLUENT TREATMENT:

Per kg water processing cost in BDT-0.39 Tk
Per m3 water processing cost in BDT-3-4 Tk
BUYER COMPLAIANCE
The factory is full compliance with ILO and Bangladesh Labor Law. Their
company policy
is as follows:
No child labor.
No forced labor.
Transport facilities for worker.
Hours of work.
Voluntary over time.
Intervals for rest.
Weekly holidays.
Annual leave.
Festival holidays & leaves with bonus.
Maternity protection.
Worker's welfare committee.
Mineral drinking water.
Sanitary facilities.
First aid box.
CONCLUSION
The industrial training gives us the opportunity to work in mills. It is an
experience of normal academic learning,
This training gives us actual picture about man, machine, material, methods and
market. We have earned the direct knowledge about the raw materials, actual
running condition of the m/cs. Works technologist and administration.
This mill is a well planed with enough expansion facilities. There are wonderful
employer and worker relation. Working environment for the labors is also good.
During our training we visited knitting section, dyeing & finishing section,
store, maintenance, boiler section, generator room, compressor section,
administration section etc. Everywhere we got cordial behavior from all
employees.
Above all this training for 60 days in the Epyllion Group Ltd. has given us a
new experience for practical life.
Southeast University has given me the field to perform the industrial attachment
with Epyllion Group Ltd. This attachment seems to me as a bridge to minimize
the gap between theoretical and practical knowledge. Undoubtedly, this
attachment paved us the way to learn more about Textile engineering, industrial
practices, and industrial management and production process.
Besides this attachment gave us the first opportunity to work in an Industry and
acquainted us with the internal sight and sound of Textile Industries. We believe
with all these, the experience of the industrial attachment will help our future
life as a Textile Engineer.

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SOUTHEAST UNIVERSITY

School of Science and Engineering, Department of Textile Engineering

Course Code: Tex -4036

Location for going to the Epyllion Knitex Ltd and Epyllion

Epyllion Fabrics Ltd.

Status: Private Ltd. Company

Polyester Cotton blend

(15% Viscose 85% cotton

Year of establishment: 2003, Commencement of Production in month

Address: It is situated in Banglabazar, Joydebpur, Gazipur. Bangladesh.

History of project development:

Concern of Epyllion group:

5. Mirabella Dresses Ltd.

Other facilities are

Own network Server.

General shift : 9:00 A.M - 5:00 P.M

Certificate & Achievement:

Production capacity in knitting:

Investment 500 Core (Approximately)

INTRODUCTION TO EKL & EFL

Front view of Epyllion Knitex Ltd

ORGANOGRAM OF EPYLLION GROUP

LAYOUT OF KNITTING DEPARTMENT OF EKL & EFL

Types of Fabric Produced by EKL & EFL:

CAPACITY OF KNITTING SECTION:

Knitting machine details of EKL:

Circular Knitting machine details of EFL:

Auto striper machine details:

Knitted fabrics specifications:

For Indirect System:

= No. of Wales X Wales space.

2. V.D.Q Pulley (Variable Dia Quality):

VDQ Pully Measurement:

for each S.L 0.10 VDQ will increase 1mm.

Some VDQ measurement of Different Brand m/c:

PRODUCTION PLANNING, SEQUENCE AND OPERATIONS

Quality Control Equipment

Minimum requirement of other parameters are:

For Sewing Thread

26 ~ 28 RPM (for Solid dyed)

100 - 240 GSM (as required)

Checklist Before Operation

Power supply and air availability.

Machine adjusted with given parameter (Yarn count, Stitch length/GSM).

Oil inlet clean or not.

Oil drip metre should be adjusted.

Door should be close.

PC controller is set for record keeping.

Factors to Be Considered during sample analysis Before Producing a Fabric:

Design of the fabric( expressed by notation diagram),

Needle arrangement according to Notation diagram,

Cam arrangement according to Notation diagram,

Machine gauge & dia

Design of the fabric;

Needle arrangement & Cam arrangement:

QUALITY ASSURANCE SYSTEM

Tube & Collar Cuff