ACKNOWLEDGEMENT

A number of people have made significant contributions to the preparation of this

report. Their insights, advice and suggestions helped us a lot. Firstly, we are very
much thankful to our head of the department Prof. Dr. A.B.M Abdullah for his
encouragement and valuable suggestions for incessant improvement of the report.
We would also like to thank Prof. Golam nur for all necessary information
delivery as well as for many technical help.
We are extremely delighted to express our indebtedness and deepest sense of
gratitude to The VP (Anlima Yarn Dyeing) Engr. Sumayel Muhammad Mallik
. For his able guidance, untiring efforts, stimulating influence and valuable
comments during the training period .We would like to offer sincere thanks to the
our supervisor Mrs. Nazma Sultana (Sr. Executive, Yarn Dyeing lab) for her
invaluable suggestions and guidance regarding this training period. The authority
of the Anlima Yarn Dyeing who gave us the opportunity to complete our
industrial attachment with great success is remembered with honor. Thanks are
due to all Engineers, officers, technicians, employees, stuffs, all section in-charges
for their cordial behavior. We are really lucky that we have gotten such helping
hand without whom, this attachment could not be completed. We also like to
thank AVP A.S.M. Jubayer, for his encouragement, valuable suggestion, and for
the completion of this Industrial attachment successfully.
Last but not least, thanks goes to my precious family for their never-ending
support and loves in every stages of my life which has motivated me to do such
type work.

EXECUTIVE SUMMARY
The internationally recognized Buyers or clients are looking for those countries
for producing their apparel products where different types of mills have
established as a one stop source for the global apparel market, 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. And also assure complete compliance with the international quality
standards and also to provide the employees internationally acceptable working
condition/standards. In Bangladesh, there are different types of Textile Industry
those are producing high quality textile and apparel product. Anlima Yarn
Dyeing Ltd is one of them.
Anlima Yarn Dyeing Ltd is a Yarn dyeing factory, having all state of the art
facilities with the annual turnover BDT. 52,499,484 (1st July, 2014 to 30th Sep,
2014). They have different types of Winding, Dyeing, Hydro-extraction, Dryer
machines supplied by mostly Germany, China, Italy, Switzerland, U.K. etc.
which are very latest. It has high production where 08 tons of dyed and finished
yarn are produced per day. The production is controlled by technical persons. All
of the decision makers of production sector in Anlima Yarn Dyeing Ltd are
textiles graduates. All the chemicals and dyes use for dyeing and finishing are well
branded. Their customer profile is big and top end. They follow all the system for
their machines maintenance so production cannot hamper.
In this report, we have tried to give some information about Anlima Yarn
Dyeing Ltd and we have observed that Anlima Yarn Dyeing Ltd produce
high-quality yarn and fulfill the special requirements from the different types of
buyers by following different internationally recommended standard method.

INTRODUCTION
The industrial attachment is the process, which builds understanding, skills and
attitude of the performer, which improves his knowledge in boosting productivity
and services. University education provides us vast theoretical knowledge as well
as more practical attachment, in despite of all these industrial attachment helps us
to be familiar with technical support of modern machinery, stillness about various
processing stages. By means of practical knowledge its not possible to apply the
theoretical knowledge in the practical field. For any technical education, practical
experience is almost equal important in association with the theoretical
knowledge. It also provides us sufficient practical knowledge about production
management, work study, efficiency, industrial management, purchasing, utility
and 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 unreliable to be accustomed with the
industrial atmosphere and improve courage and inspiration to take selfresponsibility. Textile education cant be completed without industrial training.
Because this industrial training minimizes the gap between theoretical and
practical knowledge and make us accustomed to industrial environment. I got an
opportunity to complete 6 weeks long industrial training at Anlima Yarn
Dyeing Ltd, which is a 100% export-oriented well known Yarn Dyeing
Industry. It has well planned & equipped yarn winding dyeing-finishing, drying
units.

TABLE OF CONTENT

GENERAL INFORMATION ABOUT THE FACTORY

Name of factory

Anlima Yarn Dyeing Ltd. (AYDL)

Type

Export Oriented Yarn Dyeing Industry

Registered Office

Suite# 4/3, City Heart, 67,Naya Paltan, Dhaka-1000

Phone: 9349881-4, 9341373, 8317216
Fax: 88-0208317184
Email: info@anlima.com
Web site: http://www.anlima.com

Factory

Karnapara, Savar, Dhaka.

Phone: 7745007, 7746095, 7745009
Fax: 88-02-7748614, 7746095

Sponsors

Sonali Bank.

Year of Incorporation

24th October 1995

Commercial Operation

30 March 1998

Status

Private Limited Company

production capacity

08 ton/day (approx.)

Production line

Yarn Dyeing Services, Sewing Thread.

Authorized capital

Tk. 200,000,000

Paid-up capital

Tk. 178,678,000

Number of Shareholders

4,157 (As on 30th June, 2014)

Stock Exchange listing

Dhaka Stock Exchange

Chittagong Stock Exchange

Professional Membership

Bangladesh Textile Mill Association

Dhaka Chamber of Commerce and Industry

Number of Employees

257

Certification & awards

A) ISO 9001:2000 certified

B) WRAP certified

C) OEKO-TEX-100 certified
Land

About 2.5 Acre (10,117sqm)

Sister Concerns
Anlima Textile Limited 100% export oriented knitting, dyeing, finishing and
Garments manufacturing composite unit
Allied Enterprise (Pvt.) Limited Developer of commercial buildings and complexes
Anlima Buildtech Limited Developer of residential apartments
Precision Energy Limited Power Generation

Anlima Yarn Dyeing Ltd is Oeko-Tex

Standard 100 Certified.

Corporate philosophy of the company

VISION
AYDLs relentless endeavor is contributing to Bangladeshs economic advancement in a global
context by enhancing the country's image as an international provider of quality products and
services.
MISSION
To strive hard to be a provider of world class textile and garment products and services and
position the country in the higher value segment of the international textile market.
GOALS
To satisfy the customers through technological superiority and synergic synchronization of man
and machine tailoring quality products and services to harvest the reward of responsibility.
QUALITY POLICY
Anlima Yarn Dyeing Ltd. is committed to be a provider of world class textile products and
services by offering unrivalled and satisfying the customers. The company is continuously
striving hard to dye yarn as per international standard by reducing the processing time, delivery
lead time and re-dyeing rate. The company also endeavors to make optimum use of dyes and
chemicals by reducing wastage and process loss. The company is committed to avoid use of dyes
and chemicals that are health hazard and harmful for the mankind and environment. In the
process the company will ensure required training to enhance productivity and skill of its human
resources.The company will review its performance periodically and take measures to
continuously improve quality, work environment and employees satisfaction.

Profile of the product

The Business

Anlima Yarn Dyeing Limited was incorporated in 1995 as a public limited company for setting
up a yarn dyeing plant equipped with latest state-of-the-art technology from Europe. The
company is listed in Dhaka and Chittagong stock exchanges. The company commenced
production in 1998 providing international quality cotton, polyester and filament yarn dyeing
facilities and enjoying reputation as one of the best yarn dyeing houses in the country catering to
the higher value export market need. The company is capable of dyeing all types of yarn for
countrys export oriented knitting and weaving industry and supplying polyester sewing thread to
export oriented garments factories.
Products
The companys product line consists of ---------Yarn Dyeing Service for various types of cotton and blended yarn used by woven
and knit textile factories.
Sewing Thread for use by garments industries under the brand name AN Thread.
The specifications of the companys products are:
Yarn Dyeing Service
Capable of dyeing all types of yarn ( Cotton , CVC , PC)
ISO/AATCC/BS Standard.
Environment-friendly echo-soft dyes and chemicals.
Moisture Content: Cotton 6-7%, PC 4%, CVC 5%, Polyester 0.5-0.7%.
Process-weight loss: Cotton - white 5%, colored 3%, TC/CVC white 4%
colored 2%, Polyester 1%
Sewing Thread

English Count (NE) 20s/2, 20s/3, 40s/2, 40s/3, 50s/2, 60s/2, 60s/3
High tenacity staple fiber of 1.1 D for knot-free yarn
Accurate length wound on plastic cone with air-tight poly-packing
Tipping-thread that endures enzyme/hot wash and hypo-chloride/per-oxide

bleaching
Quality
The companys products offer unrivaled quality coupled with production economy that makes
the company an ultimate choice for textile and garments manufacturers. The key quality features
are:
Azo-free : Azo compound in textile materials are seriously harmful to human health and
Anlimas products are Azo-free ensuring total safety against that health-hazard. The
products are Oeko Tex Standard 100 certified.
Knot-Free: Knots are detrimental to knitting/sewing speed and productivity. Anlimas
thread/yarn is knot-less that ensures higher productivity.
Color-Fastness: Anlimas thread/yarn are color-fast that ensures washing, light, rubbing,
bleaching and perspiration fastness. Being absolutely bleach-proof, it prevents all chances
of color-bleeding or fading of fabrics.
Color-Matching: We offer perfect color matching with computerized facility and offer
DTM (Dye to Match) service within 72 hours.
Needle-Saving: Anlimas products are immaculately processed saving it from becoming
hard or sticky and thus avoiding the extra cost in time and needle-breakage during
knitting/weaving/sewing.
Yarn-Saving: Weight-loss during dyeing in Anlima is only 1-2% that is 4-5% less than
other competitors resulting in substantial yarn saving.
Gliding Efficiency: Anlimas superior and sophisticated lubricating winder ensures better
gliding efficiency and lower friction contributing to higher productivity.
Computerized QC Report: Every delivery is accompanied by a QC report to give you a
real idea about color matching and color fastness.

Name of the buyers:

1

Knit Horizon

Teranova

Al-Muslim Group

Aboni Tex.

Mim Fashion.

Interstoff.

Land Mark.

Uttah Group.

Turag.

10

Interstoff

11

HR Tex.

12

Nova Knit.

13

H&M.

14

Tesco.

15

Wall Mart.

16

Impress Wear.

17

Jara.

18

Li & Fung.

19

Aristo Fashion Etc.

Location of the factory

Location of the Factory

Different departments :
Production oriented Departments:

Soft & random Winding Section

Lab Section
Dyeing Section
Quality Control Section

Supporting Departments

Marketing
Maintenance
Accounting & Financing & administration
Store

In a glance of Anlina Yarn Dyeing Ltd.

Anlima Yarn Dyeing Ltd. is not far from Airport. It is 25.5 km from airport. Thats why
buyers are interested to make work here.

Picture : Anlima Yarn Dyeing

Ltd.

CHAPTER THREE
MANPOWER MANAGEMENT

Maintenance
Dept.

EXECUTIVE
RECEPTIONIST
PEON

SR. EXECUTIVE
EXECUTIVE
SUPERVISOR
ASST. STORE
KEEPER
HELPER
DAILY LABOR

EXECUTIVE
JR. EXECUTIVE
P.OFFICER
SR. LAB OFFICER
LAB ASST.

CLEANER

Factory Organogram of Production & Operation :

President
EVP

V.P (Production)

A.V.P

Sr. EXECUTIVE

EXECUTIVE

JR. EXECUTIVE

SR. PRODUCTION

OFFICER

PRODUCTION

Administrative
Dept.

Store Dept.

Lab & Q.C

V.P
A.V.P
SR. EXECUTIVE
EXECUTIVE
JR. EXECUTIVE
OFFICER
JR. OFFICER
FOREMAN
SR. FITTER
FITTER
ASST. FITTER

OFFICER

SR. SUPERVISOR

OPERATOR
OPERATOR

ASST. OPERATOR
HELPER

3.2-Shift :
Anlima Yarn dyeing Ltd. Runs for 24 hours. All the men power works in three shifts. So the
shifts are changed at every 08 hours as follows:
Shift
A
B
C
General

Start
6:00 AM
2:00 PM
10:00 PM
9.00 AM

End
2:00 PM
10:00 PM
6:00 AM
6.00 PM (Rest time 01 hr)

Management system:

Intercom telephone
Fax
E-mail
Written letters
Oral

Job Description :

Duties & Responsibilities of Executive & Production Officer:

1. To collect the necessary information and instruction from the previous shift for the
smooth running of the section.
2. To make the junior officer understand how to operate the whole production process.

3.
4.
5.
6.
7.
8.
9.

To match production sample with target shade.

To collect the production sample lot sample matching next production.
To observe dyed yarn during finishing running and also after finishing process.
To identify disputed yarns and report to AVP/VP for necessary action.
To discuss with AVP about overall production if necessary.
Any other assignment given by the authority.
Write loading / unloading time from machine.

Duties & Responsibilities of AVP & Sr. Executive :

1.
2.
3.
4.
5.
6.

Overall supervision of dyeing and finishing section.

Batch preparation and pH check.
Dyes and chemicals requisition issue and check.
Program making, sample checking, color measurement.
Control the supervisor, operator, asst. operator and helper of dyeing machine.
Any other work as and when required

Duties & Responsibilities of VP (Production):

1.
2.
3.
4.
5.
6.
7.
8.

Overall supervision of dyeing and finishing section.

Check the sensitive parameters of different machines for smooth dyeing.
Check the different log books in different areas and report to management.
Check the plan to control the best output.
To trained and motive the subordinates how to improve the quality production.
Control the supervisor, operator, asst. operator and helper of dyeing machine.
Maintenance the machinery and equipments.
Any other work as and when required.

CHAPTER FOUR
LAYOUT PLAN

CHAPTER FIVE
RAW MATERIALS

RAW MATERIALS

Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in continuous production and for high quality fabric. Anlima Yarn Dyeing Ltd. uses the
best Quality raw material of the market.
Types of raw material:
1.

Yarn

2.

Dye stuff

3.

Chemical and auxiliaries

Yarn:
1.

100 % Cotton Yarn

2.

100% Polyester Yarn

3.

PC Yarn

6.

Viscose

9.

CVC Yarn

10.

Grey mlange etc.

Dyes :
The following dyes are used:
1.Reactive
2.Disperse

Some dyestuff that are used in Anlima Yarn Dyeing Ltd.

For cotton

For Polyester

Levafix Blue CA

Terasil Blue WBLS

Levafix Red CA

Terasil Navy GRLC

Levafix Yellow CA

Terasil RED W4BS

Novacron Navy WB

Terasil Yellow W6GS

Novacron Dark Blue WR

Terasil Black SRLN

Novacron Red SB

Foron Blue SE-2R

Novacron Deep Red SB

Foron Scarlet RD-FRS

Novacron Orange W-3R

Foron Rubine RD-GFL

Novacron Yellow WR

Foron Yellow RD-4GRL

Benza Brilliant Orange 3R

Foron Yelloe Brown S-2RL

JAKA.Scarlet CF-HC

Starcron Red 4BSHWF

Remazol Br. Blue R Special

Starcron Black EXFS

Remazol Br. Blue BB New

Lumacron Yellow S-4G

Remazol T/Blue G

Lumacron Yellow S-6GL

Remazol Red 3BS

Dianix Blue SBB

Remazol Red RGB

Dianix Blue XF

Remazol Yellow 3RS

Dianix Navy XF

Remazol Golden Yellow RGB

Dianix Red E PLUS

Starfix Red 3BFN

Dianix Yellow E-PLUS

Starfix Yellow 3RFN

Dianix Black XF

Kerazol Black SBG

Dianix Crimson SF

AYDL uses the following Chemicals:

Hydrogen Peroxide:It is a bleaching agent, to remove the natural color of cotton it uses.
JL 906 AA:It is a scouring agent to remove the impurities, wax, oil of natural fiber of cotton. It
performs the function of caustic, Stabilizer.
Caustic Soda:It is a scouring agent to remove the impurities, wax, oil of natural fiber of cotton.
Invatex CRA:This is a wetting agent. It helps to wet the fiber to get the facilities while dyeing
process is going on.
JINYEX SQ:-

This is a wetting agent. It helps to wet the fiber to get the facilities while dyeing process
is going on.
Tinoclarite G-100:This a stabilizer agent, it uses to control the power of hydrogen Peroxide.
Invatex PC:This a peroxide clearer agent.
Acetic acid:To neutralization, this acid uses.
Soda Ash:It uses as a fixing agent, to dye the material in an Alkali media it always uses. It
also helps to hold the dye molecule into the fiber.
Gluber Salt:It helps the dye molecule to enter into the fiber.

Alcosperse AD:This is not only an antifoaming agent but also a leveling agent.
Triplex:This is a sequestering agent for removing the water hardness.
Cibacel DBC:This is a leveling agent.
Cibaflow/ Albaflow CIR:This is used Antifoaming and wetting agent.
Eriopon R-Liq:This is a washing agent.
Albafix/Cibafix ECO/ Fixing agent:This is a fixing agent, this agent mostly used for dark shade, because most often
time it is hard to maintain the colour for dark shade, so this is a good fixer for dark shade.
Sapamine KL New:This is a softening agent. It removes hairiness, yarn hardness.

Soulbio GRS:This is a softening agent. It removes hairiness, yarn hardness.

Cibatex AB:This is a leveling agent.

CHAPTER SIX
LABORATORY AND QC

Laboratory Section:
Laboratory is an essential part of any wet processing industry. Before going into bulk production
it is essential to produce the required sample in small quantity in the laboratory. It helps to avoid
production loss in higher quantity. Besides it ensures the required quality of the product.
The AYDL has a highly modern and well equipped laboratory.. The LAB also fascinates with 2
sample dyeing machines and modern spectrophotometer.
Machines Using In The Laboratory:
SL.No.

NAME OF MACHINE

MANUFACTURER

Sample dyeing machine

(AHIBA NUANCE)
Sample dryer and incubator
Light box (D-65, TL-84, UV
,Artificial)
Spectrophotometer (SPECTRA
FLASH SF- 600)
Electronic Balance

Datacolor International
(U.S.A)
Carbolite (U.S.A)
Datacolor International
(U.S.A)
Datacolor international
(U.S.A)
Mettler Toledo (SWISS)

2
3
4
5

NUMBER OF
MACHINE
2
1
1
1
2

Besides there are pocket PH meter (digital PH meter), Sample winding machine, quality kit and
other necessary chemicals to carry out different types of tests.
Sequence of operation:
Defining the colour as buyer wanted

Recipe formulation by spectrophotometer/

From previous history

Lab dip preparation

Send to buyer for approval

Send the recipe of approved sample to Dyeing section

Recipe formulation
Buyer can give fabric sample or colour code or pantone number. So at first
the colour is to identify if the buyer gives colour code or pantone number. It

is easier to formulate recipe by spectrophotometer from colour code or

pantone number because they are very specific. But if it is fabric sample
then with the help of spectrophotometer several numbers of recipes are to
formulate.
Flow chart of recipe formulation by spectrophotometer:
Click on Match & Correct

Press F5 to input

Load a sample

Give a name for standard

Click Measure

Select cotton/ polyester for recipe

Select Dyes Group

Click on Accept

Choose suitable dyes( at least 2)

Click on Match

Choice any recipe according to metamarism

Sample dyeing :
With these recipes several numbers of samples are to be dyed. At AYDL Lab
stock solution and pipetting is done manually. Now using this solution we can
dye 14 samples at a time by a single dyeing m/c. After dyeing these samples
are dryed by Woven and combed then compare with the standard sample
under recommended Light box.

Samples send to buyer:

Now for every separate sample dyeing with separate recipe are send to
buyer for approval. The buyer approves one sample and the recipe of that
approved sample is now send to dyeing section for bulk production.

Available Stock Solutions:

Red 0.1%, 0.5%, 1.0%, 2.0% (very common)

Yellow 0.1%, 0.5%, 1.0%, 2.0% (very common)
Blue - 0.1%, 0.5%, 1.0%, 2.0% (very common).

Dyes and Chemicals Measuring Formula:

Sample weight Shade %

Dyes =
Conc. Of stock % of dyes solution

Total Liquor Chemical amount (gm/lit)

Chemical =
1000 Conc. Of stock % of chemical

Spectrophotometer:
Standard features include the following:
Pulsed xenon light source
Multiple aperture sizes to accommodate samples of different sizes
Automated zoom lens

 Automated, adjustable ultra-violet filter used to control the UV component in the

light source
Automated UV cut-off filters for three wavelengths
Features and Benefits:
Reduce errors and increase productivity
Save time with an easy to use, accurate system
Conforms to ISO 2469 Paper, board and pulps
Measurement of Diffuse Reflectance Factor
Advanced SP2000 Technology
Data compatibility with the Elrepho 3000 series
Long-life Pulsed Xenon Lamp
Automatic Zoom Lens
Machine Name : Spectrophotometer
Brand name: Data Color
Model : Spectroflash SF600
Version: 3.7
Country of origin : USA

Machine type: Sample dyeing machine

Brand name: Data Color

Country of origin : USA
No. of cylinder: 14
RPM: 50

Oven and incubator

Brand name: Oven
Country of origin : USA
Machine type: Oven and incubator

Instrument Name: Light Box

Brand :Datacolor
Illuminants: D65,TL84, TL83, UV,Artificial

Recommended Salt Soda Concentration:

Format of Labdip Submission:

CHAPTER SEVEN
PRODUCTION PLANNING
SEQUENCES & OPERATION

Production Planning :
Marketing

Lab dip

Lab dip approval

Sample production


Sample approval & Order for bulk production

Sample production according to buyer recommendation

Soft Winding

Batching

Pressing

Dyeing & Finishing

Hydro Extracting

Drying

Random Winding

Packing

Store & Delivery

CHAPTER EIGHT
SOFT WINDING SECTION

SOFT WINDING SECTION:

The soft package winding is the most important pre dyeing operation ,which directly affects not
only the dyeing quality but also post dyeing operations such as rejects, wastages and poor
unwinding ,thread breakages etc. Well wound is half dyed, is the popular saying which is very

correct in the context of package dyeing ,because we cant expect miracles from the most
advanced dyeing machinery ,if the packages are of poor quality.
Hard and soft places can occur within a single package if a poor winding is chosen, causing some
parts to dye lighter or heavier. The most compact part of any package is edges or shoulders,
where the yarn turns the corner and this is the most difficult place to wet out and to penetrate.
Incomplete penetration will cause will cause it to dye lighter or not at all, Cupping or crimping is
the only workable solution to this problem

Objectives of soft winding:

Softly winding the package.

Make a suitable package for dyeing machine.
Paper Bobbin wound softly in steel Bobbin or spring bobbin.
To enter the dye molecule evenly into the fibre inner molecular surface.

Machineries available in winding section At AYDL:

Soft packages for Dyeing are made on precision winders from SSM of Switzerland.

Name of machine
Soft winder (For
filament)
Soft winder(For
cotton, sewing thread,
p.c, c.v.c)

Number of machine
1

Brand Name
Preciflex

Number of spindle
60

S.S.M

372

Machine No. : 001-1

Machine Brand : SSM
Origin: Switzerland
Type: PS6
Total No. of Head: 60

Machine No. : 01 - 04
Machine Brand : SSM
Origin: Switzerland

Type: PSM-51
Total No. of Head: 48/ machine

Machine No. : 05
Machine Brand : SSM
Origin: Switzerland
Type: PS6
Total No. of Head: 35
Machine No. : 06,07
Machine Brand : SSM
Origin: Switzerland
Type: PS6
Total No. of Head: 60/ machine

Machine No. : 08
Machine Brand : SSM
Origin: Switzerland
Type: PS6
Total No. of Head: 25

In soft winding section package diameter is fixed, so length and r.p.m are varying with count.
Using length, Package diameter & r.p.m are as follows.
English Count
(cotton)
20/2
30/2
60/2
10/1
12/1
16/1
20/1
22/1
24/1

Length (In meter)

22,000
32,000
62,000
20,000
24,000
28,000
34,000
37,000
41,000

26/1
28/1
30/1
32/1
34/1
40/1

44,000
48,000
51,000
54,000
58,000
68,000

English Count
(sewing thread)
20/2
40/2
50/2
60/2
20/3
40/3
60/3
20/9

Length (In meter)

22,000
45,000
55,000
62,000
15,000
28,000
42,000
5,000

Points which are considered during Soft Winding at AYDL:

Winding angle:
It is the angle at which the yarn crosses each other on a wound package, smaller the crossing
angle denser will be the package.
Winding ratio:
It is number of turns of yarn per revolution of the package, or distance between the threads of
layer. More the number of turns per revolution more is the density. Increasing the distance
between the threads of a layer decreases the density.
Package stability:
It is the tendency of wound yarn on the package holder to remain stable. It the yarn layers does
not hold good on the package holder, the package may deform easily in subsequent processing.
For example on precision winding machines the winding angle reduce with increase in package
diameter thus making the packages a little bit harder from outside layer, which may fall off
during handling.

Package weight and density

The package weight and density are two important parameters which are to be standardized for
uniform and trouble free dyeing .The packages may be soft or hard these should conform to the
standards, when too soft liquor flowing through it will find the course of least resistance and
cause channeling, which leaves some parts of the package relatively un dyed or lighter. If the
packages are wound too hard, a point can be reached where the flow of liquor is impeded to such
an extent that poor dyeing or none may occur. The package weight and dimensions depends upon
the type of the machine, its flow rate, automation, type and construction of the yarn to be dyed,
dye class to be used and type of package holder to be used. The most important requirement of
soft package for dyeing is,
Density of the package should be uniform throughout of the package diameter, ie the
layer to layer density is controlled.
The packages should not have the hard edges, or these must be broken or cupped by a
suitable device or manually.
The package weight must be controlled and all the packages must fall within the standard
norms.
The density variation from one package to another must be controlled statistically and
CV5% should not exceed 5% Following factors affect the flow of liquor through the
packages
Standard package density is 0.32-0.35 gm/cm3
The calculation of package density of cotton:

The package density is expressed in gm/cm3

Let, the gross weight of the package = W1 gm = 1000 gm
The weight of the cheese/spring = W2 gm = 190 gm
Net weight of the yarn W = W1-W2 gm = 810 gm
Height of the package in cm = h cm = 16.5 cm

Outer radius of the cheese /spring = r1 cm = 3.35 cm

Outer radius of the package = r2 cm = 8.15 cm
Volume of the package V = (r22 r12 ) h
= 3.1416 {(8.15)2 (3.35)2} 16.5
= 2861.369cm3
Density of the package = W/V gm/cm3
= 810/2861.369
= 0.30 gm/cm3
The calculation of package density of polyester:
Total package wt.= 1.475kg
= 1475gm
Spring wt

= 190gm

Yarn wt

= 1286 gm

Height of the package in cm = h cm = 17.5 cm

Outer radius of the cheese /spring = r1 cm = 3.35 cm
Outer radius of the package = r2 cm = 8.25 cm
Weight
Density of the package =
3.1416 h (r2 2 - r12)
1286
=
1416
=

17.5 (8.252-3.252)

0.406 gm/cm3

At AYDL We measure the package density of different bobbins in this section which are :
Count (Ne)

Package density (gm/cm3)

20s

0.36

24s

0.35

26s

0.33

28s

0.35

30s

0.345

34s

0.36

40s

0.378

For filament (Polyester):

Count (denier)

Package density (gm/cm3)

30

0.44

75

0.376

100

0.46

Production Calculation of soft winding section:

Production calculation of soft winding m/c:
M/C No.6
Number of spindle

-60

R.P.M

-1000

Count

-40/1

Time

-24 hours

Ans:
We know,
Production /m.c/day
R.P.M 39.37 60 24 No.of spdl
=
Count 840 36 1 lb

1000 39.37 60 24 60 0.4536

=
40 840 36

=1275 kg/day

M/C No.6
Number of spindle

-60

R.P.M

-1000

Count

-40/1

Time

-24 hours

Total package wt = 1194 gm

Spring wt = 190gm
Yarn wt = 1004 gm
= 1.004kg

1.004 60 24 60
Actual Production per day =

= 1156.6kg
75

Actual Production

Efficience% =

100%
Calculated Production
1156.6
=

100%
1275

= 90%

M/C No.2

Number of spindle

-48

R.P.M

-1000

Count

-50/2

Time

-8 hours

Efficiency

-85%

Ans:
We know,
Production /m.c/day@85% efficiency
R.P.M 39.37 60 8 No.of spdlefficiency %
=
Count 840 36 1 lb
1000 39.37 60 8 60 0.85 0.4536
=
25 840 36
=

462 kg/shift

Remarks:
The AYDL maintain different Factors like count of the yarn, angle of winding, yarn tension
during winding, diameter and traverse of the package, the stability of the package, the winding
ration, the compactness and size of the feed package considered while selecting a machine for
soft package winding. Operators are very conscious about the package & machine & well
experienced.

CHAPTER NINE
BATCHING

Batching:
Batching is the process to get ready the yarn packages which should be dyed and processed for a
particular lot of a particular order. Batching is arranged according to the shade% and color.
Batching is important for yarn dyeing. If batching is not correct then production is lost.

9.2 Batching and Pressing Section:

1. Reeciving of soft winded yarn and check soft winded yarn weight, count type and lot
no. as per buyers requirements.
2. Weightting to packages and make a batch for a particular dyeing machine.
3. Loading the packages in carrier.
4. Pressing the packages with pressing machine.

M/C NO:

CARRIER

SPINDAL NO:

SPRING NO:

01+02

03+04

44

05+06

99

07+08+09

18

198

10

15

165

11

23

253

12

32

352

13

60

600

14

90

900

PACKAGES ARE COMPRESSING% :

Package no= 11
Spring height= 18 cm

Before height - After height

Compression percentage =

100%
Before height
198 -165

100%
198

16.67%

Here , At AYDL By pressing M/c packages are compressed around 15 %, which gives stability
to the package into the dyeing m/c under high temperature & pressure.
Anlima yarn dyeing section consist of two pressing m/c.
To prepare the batch of Yarn for dyeing according to the following criteria

Order sheet (Received from buyer)

Dyeing shade (color or white, light or dark)
M/C capacity
M/C available
Type of Yarns(100% cotton, PC, CVC)
Emergency
1. To send the Yarn Packages to the dyeing floor with batch card.
2. To keep records for every previous dyeing.

Proper batching criteria:

2. To use maximum capacity of existing dyeing m/c.

3. To minimize the washing time or preparation time & m/c stoppage
time.
4. To keep the no of batch as less as possible for same shade.
5. To use a particular m/c for dyeing same shade.
Batch management:
At AYDL, usually batching plan is done by AVP taking the above criteria under
consideration. Batch section in charge receives this primary batch plan from PO. Some time
planning is adjusted according to m/c condition or emergency.

CHAPTER TEN
DYEING SECTION

Dyeing Section
Yarn dyeing
There are many forms of yarn dyeing. Common forms are the at package form and the at hanks
form. Cotton yarns are mostly dyed at package form, and acrylic or wool yarn are dyed at hank
form. In the continuous filament industry, polyester or polyamide yarns are always dyed at
package form, while viscose rayon yarns are partly dyed at hank form because of technology.[6]
The common dyeing process of cotton yarn with reactive dyes at package form is as follows:
1. The raw yarn is wound on a spring tube to achieve a package suitable for dye penetration.

2. These softened packages are loaded on a dyeing carrier's spindle one on another.
3. The packages are pressed up to a desired height to achieve suitable density of packing.
4. The carrier is loaded on the dyeing machine and the yarn is dyed.
5. After dyeing, the packages are unloaded from the carrier into a trolly.
6. Now the trolly is taken to hydro extractor where water is removed.
7. The packages are hydro extracted to remove the maximum amount of water leaving the
desired color into raw yarn.
8. The packages are then dried to achieve the final dyed package.
After this process, the dyed yarn packages are packed and delivered.
There are mainly two fibers are dyed here. These are:
I Cotton fibres and
II Polyester fibers

The total process for cotton is divided into 4 steps :

1
2
3
4

Pretreatment
Dyeing
Soaping and
Finishing

MACHININARIES AVAILABLE IN THIS SECTION

Name of machine
Packages dyeing machine
Packages dyeing machine

Brand & Manufacturer

SCHOLL
(Switzerland)
Galvanin
(Italy)

Number of Machine
12
2

Sample dyeing machine

Galvanin
(Italy)

Main parts of the machines

o Main kier or the main vat in which the actual dyeing is being carried out.
o Expansion or addition tank
o Stock or preparation tank
o Main pump
o Injector or dosing pump
o Dyeing carrier
o Sampling device
o Back cooler in fully flooded models
o Control panel

SCHOLL
Brand name: Scholl
Country of origin : Swetzerland
Machine type: HTHP machine
Machine capacity : 6-440 Kg

GALVANIN:

Brand name: Galvanin

Model: 737XL
Country of origin : Italy
Machine type: HTHP machine
Machine capacity : 730 KG &1100Kg

Factors in Selecting Dyes:

Economy
Shade (brightness or dullness)
Fastness Requirements
Level Dyeing Properties
Ease of Dispersion Dissolving
Dusting
Environmental Concerns
Bonding stability

Scouring and Bleaching:

Objects of scouring:
1.

To remove the natural and added impurities like oil, wax, gums, fatty materials as
completely as possible.

2.

To get a clean and even Yarn suitable for the xext processes ie; dyeing, printing, finishing
etc.

3.

To increase the absorbency of the Yarn ie; to make the fabric hydrophilic, so that it can
sbsorb dye molecules, water and other chemicals casily.

4.

To make the Yarn ready for bleaching ie; for removing natural coloring matters.

Objects of Bleaching:
1. To ensure a pure and permanent white color in Yarn.
2. To ensure that the Yarn does not undergo any physical r chemical damage due to bleaching
likes loss of tensile strength.
3. To increase absorbency for further operations.
In clariant. One bath Souring & Bleaching (exhaust) was done.
10.5 Recipe for Scouring & Bleaching:
H2O2

2.5 g/l

JL-906 AA

3 g/l

Jintex SQ

1.5g/l

Stabilizer

0.50 g/l

Hot Wash:
Invatex PC

0.5g/l

Neutralization:
Acetic Acid
Estimating effects:
Absorbency
Immersion test:

1g/l

Immersion test was done for the estimation of absorbency. This test is a very easy test and is
commonly used in industries. It gives result very fast.
Test:
Sample is cut & it is left on the water surface. With the help of stop watch the time of the yarn
for immersion is recorded.
Result:
The standard time of immersing is 5 second.
Whiteness:
When a Yarn is bleached, its light reflecting capacity increases. The reflectance of a
bleached fabric is measured by spectrophotometer.
Acceptable range of reflectance: 84%-86% (very common).
A range of 90%-92% reflectance is also possible in bleaching at high temperature (100C).
In high temperature we can get high range of reflectance but high temperature bleaching is risky.
Evaluation:
Absorbency: Good
Degree of Whiteness: CIE Wht 77.96%
Yarn pH: 7
Description of Production Process:
Cotton scouring & bleaching Process:
The yarn is loaded in machine& fills with required water.
1
2

Now auxiliary chemicals are added.

Caustic soda is added when the temperature reaches at 50C.

3

Then H2O2 is added.

Now temperature is raised to 96C & the process is carried out for 60
minutes.
5
6 Drained the liquor

Again fill with water. Then peroxide killer( invatex PC) is added & the
process is carried out at 80oC for 10 minutes.
8
The dye bath is then cooled to 60oC and rinsing is done for 20 minutes.
10 Now acetic acid is added and neutralize for 10 minutes.
11 Again rinsing is done for 10 minutes.
12 Unload

Process of Cotton whitening:

The yarn is loaded in machine& fills with required water.
Now auxiliary chemicals are added.
Add H2O2
Then add caustic soda
Add OBA in the bath & raise the temperature & run the process at 1000for 60mins
Cooling at 600
Drain the liquor & fill with water
Hot wash with chemical(invatex PC) to kill H 2O 2 at 800 for 20 min
Drain the liquor & fill with water
Run with acid to neutralize at 600 for 10 mins
Then rinse
Add finishing chemical & run at 450for 40 mins
Rinsing is done for 10 mins
Unload

Process of cotton dyeing with turquoise color (bleached):

The yarn package carrier is loaded in machine & fills with required water.
Auxiliary chemicals and color are added and run 20 mins at 600
turquoise color added by dosing (30 mins) at 500
Salt added by dosing (30 mins) at 500
Soda added by dosing (30 mins) at 500
Raise the temp at 800 & run for 20mins
Drain the liquor & fill with water
Rinse
Wash with Acid at 600 & run for 10 mins

Chemical Wash ( Alcospers AD) at 80 for 20 mins

Rinsing for 10 mins
Finishing
Unload
Polyester whitening:
The yarn package carrier is loaded in machine & fills with required water
Hot Wash at 600for 20 mins
Auxiliary chemicals & polywhite are added
Raise the temp at 1300 & run for 30 mins
Drain the liquor & fill with water
Rinse
Unload

Polyester dyeing:
The yarn package carrier is loaded in machine & fills with required water.
Hot Wash at 600for 20 mins
Auxiliary chemicals are added
Dyes injection or dosing(in case of light or critical color)
Raise the temp at 1300 (Dark Shade at 1350 ) run for 30(Dark Shade for 40) mins
Cooling at800 or 850 temp
Drain the liquor & fill with water
Rinse
In case of dark shade reduction clearing is done at 80 0for 10mins & washed with acid at 60 0
for 20 mins
Rinsing
Unload

Process of CVC dyeing :

The yarn package carrier is loaded in machine & fills with required water.
Hot Wash at 60 for 20 mins
Auxiliary chemicals are added
Dyes injection or dosing(in case of light or critical color)
Raise the temp at 1300 for 30 mins
Drain the liquor & fill with water
Rinse
In case of dark shade reduction clearing is done at 900 for 20 mins & washed with acid at 800
for 10 mins
Rinsing
Drain the liquor & fill with water
Auxiliary chemicals are added to dye cotton part
Color added by dosing (30 mins) and run for 20 mins
Salt added by dosing (30 mins)
Soda added by dosing (30 mins)
Raise the temp at 600 & run for 40 mins
Drain the liquor & fill with water
Rinse
Wash with Acid at 600 & run for 10 mins
Chemical Wash ( Alcospers AD)
Rinsing for 10 mins
Finishing
Unload

Dyeing process of Viscose fabric:

The yarn package carrier is loaded in machine & fills with required water.
Auxiliary chemicals are added
Color added by dosing (30 mins) and run for 20 mins
Salt added by dosing (30 mins)
Soda added by dosing (30 mins)
Raise the temp at 600 & run for 40 mins
Drain the liquor & fill with water
Rinse
Wash with Acid at 600 & run for 10 mins
Chemical Wash ( Alcospers AD)
Rinsing for 10 mins
Finishing
Unload

Additional process:
*Addition:
Only add the color with required amount which is needed to get the correct shade

*Re-dyeing:
When the dyed Yarn is carried out after finishing process & dyeing is done is called redyeing.
#Checking points:
Checking instrument/type
Ph: measured by digital ph
meter & ph measurement
srip/paper

points
1)
2)
3)
4)
5)
6)

Residual peroxide: by
peroxide measurement strip
Hardness: by hardness
measurement strip & titration
process
Specific gravity: by hydro
meter
Weighting of colors &
chemicals: by digital weighing
balance
Sample check

After per oxide killer

Information

Before start dyeing

1)
2)
3)
1)
2)

Cotton leveling
Salt in side tank
Dye bath
Fixing
Softening
Unload

Line water
Dye bath
Salt/soda
Salt in side tank
Dye bath

requirements
4.5
6.5
7.0
As per alkali
5.5
5.5
6-6.5
0-10 mg/v
Less than 30 ppm

As per SG graph
As per requirements

1)
2)
3)
4)
5)
6)

Before load
Bleaching
Dyeing shade check
Hot wash
Fixing
Unload and attached in batch card

1)
2)
3)
4)
1)
2)

Batch parameters in dye line

Operator name
Load/unload date/time/shift, total duration
Informations attached in unload batch card
Condition of machine
Pressure of air, steam, water line etc

During dyeing

3)
4)
5)
1)

Machine ok from maintenance

Batch ready for dyeing
Lap dip, color, batch information etc ready for dyeing
Programme & process for that particular batch and
color
2) Liquor ratio, chemical & color amount, time and
temperature of specific process steps
3) Color &chemical dissolving, transferring & dosing.
filtration of color, checking monitor information during
processing whatever necessary to maintain
4) Responsible operators,helping must be present in front
of machine during processing specially for dyeing.

Recipe for dyeing:

Here Some Dye line is attached which are currently used at AYDL.

Common dyeing faults With their remedies:

a. Package un-level:
Causes:
Tension variation while soft winding of the package
Uneven pretreatment (uneven scouring & bleaching).
Improper color dosing.
Using dyes of high fixation property.
Uneven heat-setting in case of synthetic fibers.
Lack of control on dyeing m/c

Remedies:
By ensuring even pretreatment.
By ensuring even heat-setting in case of synthetic fibers.
Proper dosing of dyes and chemicals.
Proper controlling of dyeing m/c
b. Batch to Batch Shade variation:

Causes:

 Fluctuation of Temperature.
Improper dosing time of dyes & chemicals.
Batch to batch weight variation of dyes and chemicals.
Dyes lot variation.
Improper reel speed, pump speed, liquor ratio.
Improper pretreatment.
Remedies:
Use standard dyes and chemicals.
Maintain the same liquor ratio.
Follow the standard pretreatment procedure.
Maintain the same dyeing cycle.
Identical dyeing procedure should be followed for the same depth of the Shade.
Make sure that the operators add the right bulk chemicals at the same time and
temperature
in the process.
The pH, hardness and sodium carbonate content of supply water should check
daily.
c.Diffarent shade inside in the centre and outside:
Causes:
Poor migration property of dyes.
Improper dyes solubility.
Hardness of water.
Faulty m/c speed, etc
Remedies:
Use standard dyes and chemicals.

 Proper m/c speed.

Use of soft water.

d. color spot:

Causes:
Improper Dissolving of dye particle in bath.
Improper Dissolving of caustic soda particle in bath.

Remedies:
By proper dissolving of dyes & chemicals
By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the
large un-dissolved particles are removed .
e.RingMark.
Causes:
Improper drying of the package
Improper peroxide killing
Remedy: should use proper peroxide killing.
f.Dirt Mark.
Causes:
Dirt handling of the package
Presence of dust in the air

CHAPTER ELEVEN
HYDRO-EXTRACTION & DRYING

Hydro-extraction
Hydro Extractor works under the unique principle of centrifugal force. The versatile, centrifugal
Hydro Extractor is known for its ruggedness yet silent vibration less operation. This inimitable
extractor completes water extraction up to 95% in around 5 minutes ensuring very low moisture
retention.
Machineries available:
Brand name: Dettin
origin :Italy
No. of Spindle : 32
Capacity : 60 kg
RPM : 1500

Brand name: Galvanin

origin :Italy
No. of Spindle : 8(4 packages per
spindle)
Capacity : 65 kg
RPM : 1250

Yarn package dryer:

Category: Hot air dryer

Machine type: Textile dryer
Power output: 100 KW
Frequency: 50MHz
Origin: ITALY

Fig: Hot air dryer.

Machine Name: RF dryer

Brand Name : Proctor Stray Field
Machine type: Textile Yarn dryer
Model: S085/T
RF power output : 85 KW
Max weight : 4500 Kg
Volt: 380-420
Frequency: 27MHz

Fig: RF dryer.

Origin: UK
RF DRYER REFERENCE DOCUMENT FOR OPERATING

1.
2.
4.
5.

Yarn type
Cotton white
Cotton colour
PC/CVC white
PC/CVC colour

1. white
2. colored

Electrode
Conveyor speed
340mm
5.6m/hr
340mm
5.8m/hr
340mm
8m/hr
340mm
8.2m/hr
For 20/2 & 30/2 cotton sweater yarn
340mm
5.5m/hr
340mm
5.7m/hr

The Benefits of RF Drying:

Water is more receptive than any other dielectric material. So in process of RF drying RF
power will absorbed in higher amount from wetter areas which resulting Uniform Moisture
Distribution.
In conventional drying process many times, uneven shrinking consequences into
surface cracking. In RF drying due to uniform moisture distribution Surface Cracking
is reduced.
In RF drying Radio Frequency is direct form of applying heat so in this process No
Wastage of Heat.
Radio Frequency Dryer required one fifth or one eighth space required over
conventional dryer.
RF drying is 2 to 20 times faster than conventional drying methods.
Here heating begins directly to the product so the Dwell Time is far less than in a
conventional dryer.
This process is Eco Friendly process.
Maintenance Cost is low as compare to other drying process.

Remarks:
1. In RF dryer black color package is not dry in AYDL.
2. In AYDL. White and light shade is not dry in hot air dryer.

CHAPTER TWELVE
RANDOM WINDING SECTION

Random Winding
Hard or Random Winding is the last steps of Yarn dyeing process. The process which is started
by soft winding section , it comes in end by re winding section. After re winding , Dyed yarn
becomes ready for packing for delivery to the destination.
In random winding section dyed and dried yarns are transferred from spring tube to cone
package.
Objects:
Objects of re winding are given below:
-

To transfer the dyed yarn from spring tube to cone packages.

To clean the yarn.
To make the yarn in continuous form.
To prepare the cone package for delivery.

Available Machines:

Machine No.: 01-03

Machine Name: Coral
Origin : China
No. of Head : 108/ machine

Machine No.: 04
Machine Name: Classic
Origin : Swetzerland
No. of Head : 120

Machine No.: 05
Machine Name: Haccuba
Origin : Swetzerland
No. of Head : 120

Machine No.: 06
Brand: SSM
Machine Name: TCI
Origin : Swetzerland
No. of Head : 96

Sewing Thread:

Machine Name: Lubricating machine

Origin : Swetzerland
Brand: SSM
RPM: 650-700
No. of Spindle : 40
Machine Name: Finishing Winding machines
Origin : Swetzerland

Brand: SSM
RPM: 1000
No. of Spindle : 32

Machine Name: Lubricating & Winding machines

Origin : China
Brand: Changli
No. of Spindle : 12
No. of machines : 08
REFERENCE DOCUMENT
Operating/ Program Chart for
LUBRICATION WINDING
SI. NO.

YARN TYPE

COUNT

M/C SPEED

%LUBRICATION

(M/MIN.)
01

Sewing thread

50/2 & 60/2

850

04

02

Sewing thread

60/3 & 40/3

850

03

03

Sewing thread

40/2

850

04

04

Sewing thread

20/1 & 20/3

950

03

REFERENCE DOCUMENT
Operating/ Program Chart for
FINISH WINDING PROGRAM
(SEWING THREAD)
Prog. No.

COUNT

TICKET NO.

LENGTH

01

20/2

50

3000

02

20/3

30

2000

03

40/3

75

3000

04

60/3

110

4000

05

50/2

120

4000

06

40/2

07

120D/2

08

60/2

130

4000
3000

180

5000

Points need to consider during random winding:

1. Trash is one of the big problem in random section. Different shaded yarns are rewind in
this section , so color trash fly in the section and enter in the packages of other color or
same color, which destroy the quality. Especially it is harmful for the white or off white
color.
2. Wax: Waxes are use in this section , yarn passes through the wax. Wax gives softness and
lubricity of the yarn, which facilates better in knitting section.
3. Tension: Tension is the another important factor. Improper tension can make the package
too hard or too soft.
4. Wet Package: Wet Package should not rewind because wet package become harder after
rewinding. It also makes beets in the cone package.
5. Cone: cone should be available
6. Blower: Blower should work properly because cleaning performance depends on blower
performance.
7. Operator: Operator should aware about the cleanliness.

CHAPTER THIRTEEN
QC SECTION

QC Section
The Quality Assurance Department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing.
Quality assurance procedure:
The daily Work parameter of QC section of AYDL are following:
Collect sample ( after Drying from Random m/c)
Make total identification on sticker attached with sample
Check the fastness manually
Check fastness by m/c( wash fastness+ rubbing fastness)
Reporting ( if color change or Staining)Give decision for continuity of batch i.e pass or fail
Weight package ( check proper dry, wet, over dry by moisture meter)
Check package ( even, uneven, any spot)
If hard then make soft then re coning
If uneven then re process
If wet then re dry
Random m/c
If all ok then inform OK for delivery
Report on daily ok sheet
Maintain files according to buyer, work order, date ,batch

Wash fastness test :

Hot water = 900

Wetting agent (Alcosper-AD) = 1cc/l

Then staring

Colorfastness (Multifiber test) :

M:L = 1:50
Sample weight = 2.5 gm
Ece detergent = 5 gm/l
Soda = 2gm/l
Temperature = 600
Time = 30min

CHAPTER FOURTEEN
COSTING & MARKETING

Costing
Costing is a process by which the setting price of a product is calculated. It is a very important
task for a factory which runs for business purposes. Costing of the products considering the raw
materials expenditure, salary and wages of officers and workers, distributions and advertisement
expenses etc. all direct and indirect expenses is done in this factory. It is determined by a troop of
accountants with advice and consultancy of executive director. Costing system mainly describes
how the cost of the final product is fixed by the company/beneficial. According to
buyer/customers requirement at first the fabric is collected from local and foreign suppliers. Then
it id calculated how much dyestuff and chemical is required to the end of the processing of that
specific fabric .After that, the final cost is fixed including some profit. Then the unit price is
offered to the buyer for approves it.

Costing of the product is done by the consideration of the following factors:

1. Amount of raw materials consumed.
2. Direct labor.
3. Indirect labor.
4. Factory cost.
5. Office and administrative cost.
6. Sales and distribution cost.
7. Total dyes & chemical cost
8. Total utility cost
9. Payment
10. Transport cost
11. Lunch
12. Entertainment cost
13. Miscellaneous cost
14. Government cash incentive

The AYDL offers the following Prices for Yarn dyeing Service to the Buyers:
For Cotton:
White : 1$/ kg

Light Shade ( up to 0.5%) : 1.6 $/ kg

Medium Shade ( up to 0.5 - 2.0%) : 1.8 $/ kg
Dark Shade ( up to 2 - 4.5%) : 2.4 $/ kg
Special ( Above 4.5 % ) : 2.6 $/ kg
For Polyester:
50/2
40/2
20/2
20/3

:
:
:
:

0.87 $/ 4000m
0.9 $/ 4000m
1 $/ 3000m
1 $/ 2000m

Marketing Information:
The declining retail sales and the losses shows by big retailer's worldwide and consequent drop
in order in the world wide garment industry proved to be a major challenge to our marketing
efforts and strategy. In an uncertain world market, AYDL doubled their efforts with our design
team leading the way; they increased their calls as the customers & looked for ways to add new
ones also. Having established a strong relationship with Buyer and becoming one of their core
suppliers,AYDL targeted Europe & USA also and made in roads there. AYDL added new and
dynamic designers to the existing team & can proudly say that their spring and autumn
collections were hailed as some of the best to be presented. These meetings boosted the
confidence of existing buyers and attracted new customers. AYDL continued with their strategy
to market value added products like dyed fabrics with special finishes. This is reflected in the
increase in average price per linear meter.
AYDL now in a strong position to take on the challenge of WTO in the end of 2004 when quotes
will be abolished and only those company's with a reputation for innovative, creativity and
reliability and the ones havng strong strategic relationships and business alliances will survive
and benefit.
Manpower of marketing:
Marketing plays a vital role in the field of displaying / showing the goods criteria of the products
to the buyer & to communicate with the buyer. There are about 15 people in the marketing
section of the industry.

Importing Countries:
There are some countries which are importing goods from AYDL. The Name of the Countries are
given belowGermany
Spain
Denmark

Europe
USA Etc.

As AYDL is a 100% export oriented industry. All most all the goods produced in this industry are
exported into various foreign countries.
Marketing Strategy:
Marketing strategy is a very important factors to sale the products to the buyer. If the marketing
strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing
the dealings with the buyer is a very important factor.

In AYDL mainly senior marketing officers, merchandiser & higher officials deal with the buyer.
There are some fixed buyers of the industry. The buyers give their orders continuously all over
the year. The marketing officers & the merchandisers communicate with the buying houses to
collect the orders. By both side understanding the rate & the order quantity are fixed.
Duties & Responsibilities of Marketing Officer:
Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A
marketing officer also has some other duties. The main duties & responsibilities of a marketing
officer are given below:
1.
2.
3.
4.
5.
6.
7.

To prepare cost sheet by dealing with the buyer.

To take different steps by discussing with the higher officials & merchandisers.
To maintain a regular & good relationship between commercial officer & merchandisers
To maintain a regular communication with the buyers & buying houses.
Communicate with the new buyers.
Display the better criteria of the products.
Display the better criteria of the products .

Actually the responsibilities & duties of marketing officer begins from getting order of buyer &
ends after receiving goods by the buyer. So he should be always smart energetic & sincere.

The factory is full compliance with ILO and Bangladesh Labor Law. Their company policy is as
follows:
1.
2.
3.
4.

No child labor.
No forced labor.
Transport facilities for Officers
Hours of work.

5. Voluntary over time.

6. Intervals for rest.
7. Weekly holidays.
8. Annual leave.
9. Festival holidays & leaves with bonus.
10. Worker's welfare committee.
11. Mineral drinking water.
12. Sanitary facilities.
13. First aid box.
14. Canteen services.
15. Day care centre.
16. Health care activities for the worker & employ company doctor.
17. Fire extinguisher each & every floor & conduct fire drill at least 12 times a year. We are
giving a top priority on prevention of fire and eventual evacuation.
18. Other safety department (no discrimination).
19. Compensation cases department.
20. The development of compliance programmer.
21. Environmental developer.
22. Smoking free zone.

Remarks:
AYDL has a well learned marketing & merchandising team. They always communicate with the
buyers. The marketing section also looks for the quality and quantity buyers.

CHAPTER FIFTEEN
WTP

WATER TREATMENT PLANT:

Basically Base Exchange water softening process is used in ATL consists of 3 tanks.
NaCl IS used for brine wash which is done to remove the dirties taken by resin in time of
reaction
Capacity of the water treatment plant is 100 m3/hour
There are two deep tubeweel by the two side of the treatment plant. There are also two
submersible pumps in the deep tubeweel one is 100 ft deep and another is 140 ft deep. The
submersible pump transfer raw water in the water tank by creates force. The formation of
oxidation of the water by showering with the help of another two pimps in the water tank. Iron
content removes by the oxidation.
Two circular transfer raw water in the (vessel no-1) Multigrade filter unit. The large size plastic,
iron that means solid content are removed in the multigrade filter unit. The water is transferred to
the (vessel No-2) Activated carbon filter unit. In the (vessel No-2) Activated carbon unit to
remove chlorine that means bad smell. The water then transfer in to the (vessel No-3) softener
unit from the activated carbon unit at the presence of cationic resin (Zeolite) is reacted with
water to remove the hardness of water.
The water is transferred in to the reserve tank from the softener unit. The soft water is supplied
from the reserve tank by the 7 Boosting pump in the different section of the factory.

The back wash & regeneration process:

The back wash process to clean the vessel no-1,2 & 3. The back wash process should be done
after 8-12hrs. After 40-48 hrs later the regeneration process should be done. It should be done
after back wash process. After back wash the common salt dissolved with water in to the STT
(salt saturated tank) the solution of common salt is ringing the resin by the injector. The use of
18% salt in the total solution. (Suppose, 5000 lit of solution the amount of salt 600kg). The resin
is activated by the salt rising. Here used cationic resin (NaHSO 3). If the PH of the water increase
or decrease it should be control by the dosing chemical (Sodium Hypochlorite) from the
chemical tank.

Figure: Water treatment plant

Where,
A=Hard water storage tank

B=Stone filter
C=Carbon filter
D=Resin filter
E=Soft water storage tank
F= Pump

Standard water quality for dye house:

Minimum standard

Permissible concentration

Color

Colorless

Smell

No bad smell

Water hardness

< 50dH

PH Value

7-8 Neutral

Dissolved solid

< 1 mg/1

Inorganic salt

< 500 mg/1

Iron (Fe)

< 0.1 mg/1

Copper (Cu)

< 0.005 mg/1

Nitrate (NO3)

< 50 mg/1

Nitrite (No2)

< 5 mg/1

Hardness check:
The hardness should be checked after every 6 hrs. It should be checked by the hardness test kits.
The using hardness test kits are Hanna Instrument. Made in Italy. If the hardness is going to be
0.5 on the syringe scale. Then have to do the regeneration process. The capacity of the vessel
115m3/ hr or 115 ton/hr

EFFLUENT TREATMENT PLANT (ETP):

Flow chart of ETP:
Effluent
Water
from
Dyeing

Equalize
r
Tank

PH
Contro
l
Tank

Reaction
Tank

Flocculation
Tank

Primary
clarifier

Sludge
Bed

Discharge
Effluent

Chlorination
Tank

Multi filter

Secondary
clarifier

Aeration
Tank

Reserve tank
For Re-using
Effluent
treatment
Water.

plant (ETP):

Process: Biological.
Capacity: 110 m3 / hour.
The major sources of liquid discharge are:
- scouring.
- Bleaching.
- Dyeing.
- Washing.

Stepwise function of different unit of E.T.P:

Equalizer Tank:
Use chemical: Acid solution.
Function: To neutralize raw waste water by dozing smaller particle.
PH Control Tank:

Use chemical: Fe2SO4, Fitcary.

Function: To control PH.
Reaction Tank:
Use chemical: Lime

Ca(OH)2.

Function: To agglomerate smaller particle.

Flocculation Tank
Use chemical: Polyelectrolyte & alum.
Function: To produce flock.
Primary Clarifier:
Function: To monitor performance of flocculation clarifier & separate solid waste.
Sludge Bed:
Function: Solid waste dried & send to outside for burial
Aeration Tank::
Use chemical: Bacteria, Urea, Cow dung.
Function: Bio logical oxygen demand & Chemical oxygen demand reduced here & diffused
aeration system ensures high oxidation efficiency.

Secondary Clarifier:
Function: Remaining solid waste separate here. Reduced total solid.
Chlorination Tank:
Used chemical: Sodium hypo chloride
Function: Disinfection done here.
Multi filter:
Function: Extra suspended impurities separation by passing into the sand.
Here removed suspended solution and correction the water color.

The characteristics of waste water assumed at NRG Composite Yarn Dyeing Ltd
as follows:
-

pH = 11
BOD = 300 mg/L

COD=200 mg/L
Suspended solid (SS) = 200 mg/L
Color = dark

Final treated Quality of NRG Composite Yarn Dyeing Ltd discharge is:
-

PH = 6-9
BOD = 35 mg/ L
COD = 170 mg / L
Suspended solid = 50 mg/L
Color = color less.

BSTIS standard:
-

Ph = 6-9
BOD = 50 mg/L
COD= 200 mg/L
Suspended solid = 150 mg/L
Color = Light brownish.

Remarks:
Hardwater causes shade variation and faulty dyeing and wastage of chemicals that is unexpected.
Dye house required water less than 5dH to avoid these problem. AYDL fulfill this objective.

CHAPTER SIXTEEN
MAINTENANCE & UTILITY

Maintenance:
Maintenance is a process by which equipment is look after in such a way that trouble free,
Service & increased machine life can be ensured & specific product quality required by
customers is sustained. On time maintenance increase m/c lifetime & ensures trouble tree
services.

Objective of maintenance:
To keep the factory plants, equipments, machine tools in an optimum working condition.
To ensure specified accuracy to product and time schedule of delivery to customer.
TO keep the downtime of machines to the minimum thuds to have control over the
production program.
To keep the production cycle within the stipulated range.
To modify the machine tools to meet the need for production.

Maintenance of machinery:

Maintenan
ce

Schedule
maintenan
ce

Mechanical
maintenan
ce

Electrical
maintenan
ce

Break
down
maintenan
ce
Mechanical
maintenan
ce

Electrical
maintenan
ce

Schedule 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

Break down maintenance:

In this case repairs are made after the equipment is out of order & it can not perform its normal
functions.
Dyeing m/c maintenance Schedule:
Daily:
Check steam or water system & air supply
Check chemical pump
Machine clean
Weekly:

Check leakage of air, steam &

 Water line
Add gland packing at pump
Monthly:
Greasing bearing points
Replace bearing points (if required)
Gasket check
Clean steam trap
Lubricating all chemical pump
Quarterly:

Replace belts
Repairing of pulley, shaft & bearing housing
Painting m/c & pipe line
Clean steam trap
Replace seals (if leakage)
Change gasket of steam of water lines

Half yearly:

Replace belts
Repairing pulley, shaft & bearing housing
Painting m/c, pipe line
Replace seals
Machine body repairing

Half yearly:

Replace belts
Repairing pulley, shaft & bearing housing
Painting m/c, pipe line
Replace seals
Machine body repairing

Yearly:

Machine overhauling
Maintenance: Mechanical

Utility Services
Available facility of utility:

Utility
Electricity
Gas
Compressed air
Steam
Water
Temp, control

Source
REB & generator
TITAS
Air Compressor
Boiler
Pump
AC chiller

Electricity
Source :
1. Generator
2. REB (Rural Electrification Board)
No. of generator : 03
Equipment used
Gas Generator

Specifications

1. Gas Generator
Company
Country
Year
No. of machine
Cylinder capacity
Stroke of engine
Type of fuel used
Machine RPM
Rated Power
Rated current

: G.E Jenebacher
: USA
: 2006
: 02
: 20
: 4 stroke engine
: Natural Gas
: 1500
: 1064 Kw
: 1536 A

Rated Voltage
Maximum Power
Cooling Syestem

: 400 V - AC
: 1600 Kw
: Cold Air and water cooling by Cooling tower
Gas

Gas is mainly used for steam production.

Gas is bought from TITAS.
Generally 36-m3 gas is required to produce 1-ton steam.
Compressed air
Machine name
: Screw type Air Compressor
Company
: INGERSOLLRAND
Country
: USA & England
No. of machine
: 05
Capacity
: 222 CFM (Per machine)
Rated Operating pressure
: 140 PSI
Maximum Discharge Pressure : 142 PSI
Maximum Modulate Pressure : 150 PSI
Normal Drive Motor
: 60 H.P
Normal fan Motor
: 3 H.P
Steam
No. of boiler
Type of boiler

: 01
:Water tube boiler

Specifications
1. Water tube boiler
Manufacturer
Country
Efficiency
Heat recovery
Steam pressure
Steam temperature
Water source
Maximum Capacity

: BAUMGARTE
: Germany
: 75-80%
: Cooling pond
: 45bar
o
: 450 C
: Demineralization plant
: 10Ton
AC Chiller

AC chiller is used to control the temperature & humidity of the loom shed.

Manufacturer
Country
No. of machine
Capacity :
Medium used
Temperature
Humidity

: COOLINE
: Dubai
: 02
: Water
0
0
: Indoor: 18 C- 30 C
: 76% - 78%
Others

Electrical wirings
Here the electrical wiring system is Bulbar tanking system where copper plate is used for
electricity transmission instead of copper wire
Pipelines
There are 6 different pipes in the floor.
1 1. For high pressure steam
2 2. For return steam.
3 3. For pressure balance
4 4. For Hot water- grey pipe
5 5. For Cold water-white pipe
6 6. For compressed air-blue pipe

CHAPTER SEVENTEEN
CONCLUSION

Conclusion
I have completed my industrial attachment successfully by the grace of Allah.
Industrial attachment sends me to the expected destiny of practical life. The completion of the
two months Industrial attachment at ANLIMA Yarn Dyeing Ltd., we have got the impression
that factory is one of the most modern export oriented knit composite complex in Bangladesh. it
has earned very good reputations for its best performance over many other export oriented
textile mills.
During My training period, talking with the clients of this mill I knew that the mill is fulfilling
the countrys best export oriented white finished Yarn as well as very good colored Yarn due to
its modern machinery & good management system.
Mill is settled with utility to give all convenient supports to the productions for twenty-four
hours. It had self-power generator system to satisfy total power consumptions of the mill.
I am enough fortunate that I have got an opportunity of having a training in this mill. During the
training period I received co-operation and association from the authority full & found all man,
machines & materials on appreciable working condition. All stuffs & officers were very sincere
& devoted their duties to achieve their goal.