Académique Documents
Professionnel Documents
Culture Documents
TEX-500
Supervised by
SHEIKH NAZMUL HOQUE
Lecturer, Department of Textile Technology
Submitted by
Mir Mahbub Alam
ID:06.01.06-146
Lutfor Rahman Shanzid
ID:06.01.06-105
4 TH YEAR 2 ND SEMESTER, FALL 2009
Table of content
Section
Topics
Contents
Page
number
Section 1
Section 2
Introduction
General information of
the factory
Introduction
Name, status, nature of
business, address,
sponsor, project
money, year of
establishment, year of
production, floor area,
7
9
Section 3
Section 4
Knitting Description
Section 5
Section 6
Machine profile
Machine & knitting
elements description
Section 7
Section 8
Section 9
Section 10
Section 11
Maintenance
Utility services
Conclusion
15
19
23
29
40
45
58
61
65
List of tables
Table no.
Table name
Page no.
3
1
2
3.1, 3.2, 3.3,
4.1, 4.2, 4.3
5
6
7
8
9
10
11
12
List of machinery
Generally used yarn & their
count
Relation between GSM & count
12
17
28
52
20, 21, 22
54
54
56
62
63
64
List of figures
Name of figures
S/J machine
Double jersey machine
Auto stripe machine
Cotton & polyester yarn
Lycra yarn
Circular knitting machine with different system
Page no.
30
31
33
Knitting elements:
Needle, sinker
35
36
37
38
39
Equipments:
41
Tools:
Adjustable wrench
41
42
43
Pliers
44
46
55
List of abbreviation
abbreviation
elaboration
CKM
S/J
S/L
MKL
F. Terry
F.F lycra S/J
M/C or m/c
Fab.
GSM
SL
D
G or Gg
P/I or P/Int
75 D/72 F
mm
R&D
AUST
DTT
Avg.
No.
Strct
PS
VDQ
Fig
K
T
M
H
L
RPM
TQ
Int. mesh
Target Quantity
Interlock mesh
Section:1
INTRODUCTION
INTRODUCTION
Industrial training is an important part for textile students for minimizing the gap between theoretical & practical
knowledge. For completing the 8 week long training, we were attached at Mondol Knitwears Ltd.,at
Kashimpur,Gazipur. From an industrial training vast knowledge can be achieved from the bulk production as well
as the production planning. In our training, we tried to receive more technical information from different views.
In this report we tried to point out our observation & learning in a small volume.
Section:2
Head Office:
5. Financed by:
6. Project Money:
7. Year of Establishment:
24 Dec 2006
8. Year of Production:
24 Dec 2006
9. Floor Area:
Engr.Al-Amin Sheikh
Asst.Manager (Production)
Mob: 01716-671452
alamintex29th@gmail.com
Engr.Ishaque Hossain
Factory manager
Mob: 01713-314898
11. Turn Over:
2.50 billion
Single Jersey
Pique
Single lacost
Double lacost
11 Rib
22 Rib
Drop needle
Lycra Rib
Thermal rib
Plain Interlock
Fleece
Terry Fleece
Lycra Single Jersey
100% Polyester
CVC (Chief Value Cotton)
Interlock mesh
Grey Melange
Eyelet
475
15
INSTYLE
MONTECARLO
JOB S.P.A
FRANK Q
DEPA S.R.L
BASKA
FRANSA
GOOATEX
B-YOUNG
BURGER KING
PTB SRL
4-YOU
TERRAVOVA
BENGLER
VEGOTEX
TRACK & GO
ESPIONAGE
EL & BI
JOMAS
FEUVERT
- Italy
- Spain
- Mexico
- Denmark
- Norway
- USA
- Denmark
- Italy
- Norway
- Spain
- Italy
- Denmark
- Italy
- Italy
-Belgium
- Italy
- Italy
- Italy
- Spain
- Spain
Machine category
Circular Normal CKM
Knitting ( without stripe)
Machin Auto stripe CKM
e
Flat bed Knitting machine
Total nos.
185
Grand total
261
24
52
Power system:
Gas Generator (1064 KW)
Diesel Generator (900Kw)
REB(Rural Electrification Board)
Compressor
Dryer
SDB(Sub Distribution Board)
20.Date of information collection:
: Jenbacher
: 01
: 01
: 01
: Worthington Creyssemsac : 05
: Worthington Creyssemsac : 05
: 11
June 05,2010.
11
12
Section:3
KNITTING DESCRIPTION
13
Knitting section
Knitting is the method of creating fabric by transforming continuous strands of yarn into a series of
interlocking loops, each row of such loops hanging from the one immediately preceding it. The basic
element of a knit fabric structure is the loop intermeshed with the loops adjacent to it on both sides &
above and below it.
Knitted fabrics are two types. One is weft & another is warp.MKL produces weft knit
fabrics.
Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension device
Knitting
14
Withdraw the rolled fabric and weighting
Inspection
Numbering
Types of yarn
Count
20 , 22 , 24 , 26 , 28 , 30s, 32s, 34s, 40s
75D,150D
20D, 40D, 70D
24s, 26s, 30s
24s, 26s, 28s, 30s
24s, 26s, 28s, 30s
s
Cotton
Polyester
Lycra
Grey Mlange
PC (65% polyester & 35% cotton)
CVC
Delta
Square
Badsah
Aman
Akbar
Prime
Protiva
Kamal
Thermax
Karim
JK
NZ
GPI
SN
15
2) Double jersey
a) Rib fabric
i. 1x1 Rib
ii. 2x1 Rib
iii.
Drop needle
iv. Thermal
b) Interlock fabric
i.
Plain interlock
ii.
Interlock mesh
iii.
Eyelet
3) Different types of collar & cuff
16
Section: 4
17
From the m/c we have practically collected some data (table no. 4.1, 4.2, 4.3) on relation between GSM, SL &
Count. And from manager of the factory we collected data (table 3.1, 3.2, 3.3) only relation between GSM &
count. These are given below.
Yarn Count
30/1
28/1
26/1
24/1
20/1
Yarn Count
34/1
30/1
28/1
26/1
24/1
Yarn Count
40/1
34/1
18
240 260
260 280
280 300
30/1
28/1
26/1
count
24/1
26/1
28/1
30/1
GSM (finished)
SL (mm)
180
17-180
175
160
160
160
150-155
160
160
nill
2.73
2.85
3
2.94
2.95
2.85
2.9
2.9
2.82
2.53
Dia(inch) x Gauge
34 x 24
34 x 24
23 x 24
34 x 24
30 x 24
30 x 24
25 x 24
24 x 24
24 x 24
22 x 24
150
160
160
160
160
160
160
160
150
2.78
2.7
2.67
2.7
2.7
2.7
2.7
2.75
2.8
30 x 24
32 x 24
36 x 24
32 x 24
24 x 24
30 x 24
30 x 24
32 x 24
32 x 24
140-145
140
145
140
140
140-145
150
150
150
140-145
140-145
140
145
145
2.75
2.7
2.62
2.7
2.96
2.75
2.75
2.75
2.75
2.75
2.78
2.75
2.72
2.72
19 x 24
19 x 24
19 x 24
19 x 24
19 x 24
23 x 24
22 x 24
23 x 24
24 x 24
29 x 24
24 x 24
24 x 24
24 x 24
29 x 24
Count
GSM(finished
)
SL (mm)
230
2.65
Fab. type
Dia (inch) x G
36 x 18
19
26/1
28/1
30/1
32/1
34/1
40/1
230
220
220-230
200
220
210
200
200
180
180
180
180
150-155
2.65
2.9
2.58
2.6
2.6
2.5
1.9
1.7
2.6
2.5
2.5
2.58
2.86
1.85
1 x 1 rib
1 x 1 rib
2 x 1 rib
1 x 1 rib
36 x 18
34 x 18
36 x 18
36 x 18
2 x 1 rib
1 x 1 rib
Stripe 1 x 1 rib
1 x 1 rib
1 x 1 rib
1 x 1 rib
Thermal rib
36 x 18
Fab.type
D(inch) x G
32 x 18
32 x 18
Count
34/1
75 D/72 F
75 D/72 F
GSM(finished
)
SL (mm)
200
200
210-220
210
210-220
145
1.78
1.7
3.7
1.58
3.07
P/Int
1.25
1.15
Eyelet
30 x 24
30 x 24
34 x 24
32 x 24
36 x 24
34 x 24
140
1.12
1.11
Int.Mesh
36 x 24
140
1.4
1.2
Int.Mesh
32 x 24
140-145
1.12
1.1
Int.Mesh
38 x 24
20
Section: 5
MACHINE PROFILE
21
22
23
24
25
Machine type
MASA
Jiunn long
Ssang yong
Fukuhara
Fukuhama
Ta-yu
Pai-lung
Circula
r
Total
Floo
r1
Floo
r2
Floo
r3
Floo
r4
Floo
r5
10
5
2
6
3
8
45
10
8
31
53
27
31
Floor 6
(auto stripe
floor)
Auto
Non
stripe
auto
stripe
3
21
21
4
8
16
6
29
7
10
59
82
24
33
209
7
10
6
24
17
Total
Flat bed
52
26
Section: 6
27
28
Lycra yarn
Production card
We collected some production cards during the production. Sample of one card is given below.
M/C no. 107
Card ID: 55658
PS:491
T.Q: 880 kgs
Buyer: Abony
Order no. 002453
Party: Abony Textile Ltd.
Strct.: S/J
Dia: 33 inch
Gg: 24
Fab.D:71 inch (open)
Fab. GSM (finished):190
Color: Vert pique
Count
Type
22 Ne
comb
Brand
Akbar
Lot
10
S.L (m.m)
3.02
30
Creel
Cone
Tube
Knot Catcher
Magnet Pressure
Sensor
Yarn Wheel
Guide
31
Sensor
Guide
Feeder
NEEDLE
Needle is the primary knitting element. It is a thin metal bar.
SINKER
Sinker is the second primary knitting element. It is a thin metal plate.
32
KNITTING CAM
Cam is the device which converts rotary machine drive into a suitable reciprocation action for the needle.
Knitting cams (raising) are three types. These are:
i.
Knit cam
ii.
Tuck cam
iii.
Miss cam
KNIT CAM:
TUCK CAM
MISS CAM
CAM BOX:
VDQ PULLEY:
34
OILING POINT:
AIR PIPE:
35
Section:7
Equipments:
Electronic balance
Scissors
Measuring tapes
GSM cutter
Inspection m/c
Fig: scissors
Tools:
For adjusting and or tightening or loosing different types of nuts & bolts some tools are used. These tools are:Adjustable wrench
Double head spanner
Single head spanner
For fitting the cam box and other machine parts as well as tightening or loosening of nuts & bolts some L-keys
are used. These are:T-type L-key
I-type L-key
Allen key
38
Fig: pinsetter
39
Fig: Hammer
To hold machine parts, to cut metal wire & to set nut-bolts Multi pliers are used.
Fig: Multi-pliers
To hold and set machine parts in thin or narrow space Long nose pliers is used.
40
Section:8
SAMPLE ANALYSIS
41
Sample
POLO PIQUE
Sample
DOUBLE LACOST
42
sample
11 RIB
sample
Dial
Cylinder
structure & cam arrangement
22 RIB
sample
43
Dial
Cylinder
Structure & cam arrangement
PLAIN INTERLOCK:
Sample
Image(s)
44
S/L
Fleece
F.Terry
Eyelet
Int.mesh
45
Heavy S/J
F.F.Lycra S/J
46
Plain
Rib
Interlock
Unroving
Curling
Tendency to curl
No tendency to curl
Thickness &
warmth
Same on both
sides
Only from end
knitted last
No tendency to
curl
Very much
thicker &
warmer than
plain
Structure
Properties
Appearance
End-uses
Underwear,
shirts,
Suits,
sportswear,
Dresses.
47
TEST PROCEDURE:
Carefully mark a single wale line with the fine pen. Count 100 wales and mark the 100 th. Make
cuts along the wales about 1 cm each side of the marked wales.
Then we unrobed the yarn.
Now we measure yarn length between two marked points.
At last we divide yarn length by needle number.
Stitch length = course length/ total number of needle
GSM CONTROL
GSM means grams per square meter. It is one of the most important knitting
variable which need to be controlled to increase fabric quality.
48
We can control GSM by controlling the stitch length. The stitch length can be controlled
by the following ways By changing VDQ pulley diameter
By adjusting the Central stitch cam
If we increase dia of VDQ pulley then GSM decreases and vice versa.
SL
Decrease
Increase
Increase
Decrease
Quality Standard
Most of the knitting factories follow 4-point grading system for quality standard. Though MKL is a 100% export
oriented sub-contracting factory but they do not follow any standard system like 4-point or 10-point
system.MKL standardize their products by checking of their skilled inspection team, visual inspection of every
product if any problem is occurred & negotiation with buyers. But some officials of MKL suggest 4-point
grading system with big problem in product; but it is rare case.
Table: 8
Penalty
3 inches or less
1 point
2 point
3 point
Over 9 inch
4 point
49
Production Calculation
MKL follows the following formula for production calculation at 100% efficiency in kg per shift:-
Defects
Causes
Sample
50
Star mark
Un-effectiveness or buckling
of latch of needle.
Low GSM.
Yarn tension variation.
Hole
Set-up
Yarn breakage.
Needle mark
Barrie
Oil mark
Drop stitches
Slubs
Packy
Thicked yarn.
51
Black spot
Loop
Yarn contra
Lycra drop
Lycra out
Breakage of yarn.
Dusted yarn.
GSM variation
Count variation
Design variation
Section:9
MAINTENANCE
52
Maintenance:
Defination:
All actions essential in order to retain a product in or restoring it to a satisfactory operational condition.
Aims of a maintenance programme:
To maintain equipments at the maximum operating speed & production efficiency
To ensure the best possible level of quantity of the product
To minimize the idle time resulting from machinery breakdowns
To reduce to a minimum the cost of maintenance consistent with te above objectives
Maintenance system can be categorized into two types,
- Break down maintenance
Planned maintenance
53
In this system alternation is given to a m/c only when it breaks down. Un-planned system but finds favor of
course. But this system suffers from two main draw backs,
Deterioration in the quality of the product
Productivity loss increase gradually
Planned maintenance:
It is a scientific & technical approach. The basic principles are taken out of production on a time programming &
detailed scheduled work done so as to maintain their productive potential quantitatively & qualitatively until the
next servicing data.
Servicing:
In servicing point at MKL, most of the fitters, servicing men worke in the following ways:
- Open the belt of the MPF
54
Section:10
UTILITY SERVICES
55
UTILITY SERVICES
Utility Services:In MKL, the following utility services are available. These are given below:
Water
Electricity
Gas
Compress air
Technical Data
No. of M/C
Manufacturer
Country of origin
Type
Reference
SI. No.
Compressor Data
05
Worthington C reyssensac
FRANCE
RLR60B7YD
6250315600
WCF250879
Bar maxm
m3/h
10
432
56
Kg
KW
975
45
v/ph/Hz
400/3/40
Gas Generator:There are two parts of Gas Generator. They are1) Alternator
2) Enginator
Specification of Alternator:
Table:11
Technical Data
Manufacturer name
Country of origin
Model
SI. No.
EMI
KVA
KW
PF
VOLTS
AMPS
Over speed
Rotation
Hz
RPM
PHASE
RATING
Date
AMB
ALT
EXC AMPS
TEMP. RISE
Enclosure
Weight
Insulation
STATOR CONN
Arrangement
Alternator Data
WAUKESHA ENGINE DRESSER INC.
USA
MTG846
CB5L5505
68604200
1125
900
0.8
240/415
1565
125 0/0
CCW
50
1000
3
PRIME
2006
40C
100 M
7.0
105C
1P-22
4763 Kg
H
WYE
P316099A
Input voltage:
Maxm current:
Maxm temperature:
Waukesha part no.:
ECU SI. No.:
12-36 VDC
0.7A
70C
740824B
1314
Specification of Enginator:
Table:12
Technical Data
Manufacturer name
Country of origin
Model No.
SI. No.
Date
Weight
RPM
PHASE
VOLTS
PE
Hz
DUTX
KW
KVA
AMPS
Maxm Site Attitude
Maxm Ambient Temp.
Performance Class
Enginator Data
WAUKESHA ENGINE DRESSER INC.
USA
VHP5904GSID
C-94890-901/1
2006
17650 Kg
1000
3
415/240
0.8
50
Continuous
900
1125
1565
5 meter
36C
No Overload Allowed
GAS:
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section from the main line of the TITAS
GAS LTD.
SOURCES OF UTILITY:
Electricity
Water
: Pump
Compressed air
: Compressor
Gas
Section:11
CONCLUSION
59
Conclusion:In the conclusion point, we can discuss the conclusion in three sub-section like achievements, imitations &
comments.
Achievements:
In the industrial training we have learnt various things in more practically but our prime achievements are,
Being familiar with knit factory.
Being familiar with process sequence of knitting.
Gathering vast knowledge on fabric structure & design, GSM, SL, count.
Detecting & minimizing the fabric faults from technical point of view.
Knowing how the order is received & go to bulk production.
Learning on textile machineries & equipments.
Controlling & operation of industrial management.
Limitations:
We had faced a big problem from the officials of MKL; they did not want to help or supervise to the
private university students.
For ignoring to private university students, we could not collect various technical information from the
technically sound person.
Some of the points of different section are not included due to limitation of factory help.
Comments:
Though MKLs higher management did not offer full support for us, but we got a lot
of technical help, suggestions and informations from lower level of management &
stuffs. It was impossible for us to complete our training successfully without their
support. We got acclimatized with the industrial environment during this period.
Besides, it gives us the first opportunity to work in an industry.
60