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Faculty of Engineering

Department of Textile Engineering


REPORT ON
Industrial Attachment
At

DBL Group (Jinnat Apparels Ltd)


Sadarganj, Kashimpur, Gazipur, Dhaka

Course Title: Industrial Attachment


Course Code: TE-410

Submitted by:
Md. Rabbi Hasan ID: 162-23-4745

Supervised by:
Md. Abdullah Al Mamun
Designation: Assistant Professor

This report submitted in partial fulfillment of the requirements for the degree of
Bachelor of Science in Textile Engineering
Advance in Apparel Manufacturing Technology

Duration: From February 28, 2019 to April 27, 2019.

©Daffodil International University


Declaration

I hereby declare that this industrial attachment is done by me and all the information is collected
during my industrial training. And I have also declare that neither this Industrial Attachment nor
any part of this Industrial Attachment has been presented anywhere for any degree or diploma.

Name: Md. Rabbi Hasan

ID: 162-23-4745

Signature:

©Daffodil International University i


Department of Textile Engineering

Approval Sheet

This industrial attachment is prepared from DBL Group (Jinnat Apparels Ltd) and submitted by
Md. Rabbi Hasan (ID No 162-23-4745) in partial fulfillment of the requirement for the degree of
BACHELOR OF SCIENCE IN TEXTILE ENGINEERING has been examined and hereby
recommended for approval and acceptance.

Supervisor

_____________________

Md. Abdullah Al Mamun


Assistant Professor
Department of Textile Engineering
Daffodil International University

©Daffodil International University ii


Acknowledgement

At first my gratefulness goes to almighty ALLAH to give me strength and ability to complete the
industrial report.

I have also wanted to thanks those peoples who helped me during my training period and
inspired me.

Md. Abdullah Al Mamun, Assistant Professor of Daffodil International University, was my


supervisor. Without his help this attachment will not complete. From the beginning to the last he
helped me a lot. Not only helped to make my industrial report but also guide me properly during
my industrial training. All the things like what need to learn, how to collect information, what to
learn in individual sector and most importantly what will be behavior during training. I am very
grateful for his guidance and support.

I have also expressing my gratings to Prof. Dr. Mahbubul Haque Head, Department of Textile
Engineering, for his support and continuous guidance throughout my long journey in Daffodil
International University

I should thanks the management of DBL Group and want to also thanks for giving me the
opportunity to complete the industrial training successfully and also their helping hands.

©Daffodil International University iii


Dedication

At first I want to dedicate this Industrial Training report to almighty ALLAH.

I have also dedicated this report to Md. Abdullah Al Mamun, Assistant Professor of Daffodil
International University who helped me a lot to complete me industrial training report.

At last I want to dedicate this industrial report to my parents who were the main supporting hand
and also the encouraging persons.

©Daffodil International University iv


Contents
1. Executive Summary.................................................................................................................1
2. Information about factory:..................................................................................................... 2
2.1 Factory layout:................................................................................................................... 3
2.3 General information about factory:.................................................................................5
2.5 Location of DBL group (Jinnat Apparels Ltd):...............................................................7
2.6 Products of DBL Group:...................................................................................................8
2.7 Production Analysis:..........................................................................................................8
2.7.1 Monthly Production Capacity:..................................................................................8
2.7.2 Daily Production capacity:.........................................................................................8
2.7.3 Daily Sample Production Capacity:..........................................................................8
2.7.4 Lead Time for Sample:...............................................................................................8
2.7.5 Major Production:...................................................................................................... 9
2.8 Major Buyers with their logo:...........................................................................................9
2.9 Management System:...........................................................................................................11
2.9.1 Shift Change:.................................................................................................................11
2.9.2 General Shift:................................................................................................................ 11
2.10 Vision, Mission & Values of DBL Group:....................................................................11
3. Details of Attachment:.......................................................................................................12
3.1.5.2 INITEX Machine description:..................................................................................16
3.2.1.3 Dyeing laboratory:.....................................................................................................21
3.2.1.4 Objectives of laboratory:...........................................................................................21
3.2.1.5 Sequence of lab operation:........................................................................................21
3.2.2 Finishing Section:..............................................................................................................23
3.2.2.1 Finishing:.................................................................................................................... 23
3.2.2.2 Flow chart of finishing process:................................................................................23
3.2.2.3 Objectives of finishing:..............................................................................................24
3.2.2.4 Types of finishing:......................................................................................................24
3.3 Garments Washing:.............................................................................................................29
3.3.1 Dry process:...................................................................................................................29
3.3.1.1 Machine Name: 3D Wrinkle..................................................................................29

©Daffodil International University v


3.3.1.2 Machine Name: Industrial Oven...........................................................................30
3.3.2.1 Machine Description..............................................................................................32
3.3.2.2 Machine Name: Sample Washing Machine.........................................................33
3.3.2.3 Machine Name: Industrial Washing Machine.....................................................34
3.3.2.4 Machine Name: Modern Washing Machine........................................................36
3.3.2.5 Machine Name: Industrial Dryer..........................................................................38
3.3.3 Washing Process:.......................................................................................................... 39
3.3.3.1(Normal Washing):................................................................................................. 39
3.3.3.2 Pigment wash:........................................................................................................ 41
3.3.3.3 Enzyme Wash:........................................................................................................43
3.3.3.4 Chemical use in the washing plant:..........................................................................46
3.3.3.5 Washing Fault in production section:.......................................................................47
3.3.3.5.1 Crease Mark:.......................................................................................................47
3.3.3.5.2 Dye Spot:..............................................................................................................48
3.3.3.5.4 Fabric Hole:.........................................................................................................49
3.4.2 Some Advantage of Generator:................................................................................52
> Industrial Generators are developed to ensure that there is a continuous supply of power
in the event of failure of the grid systems. Thus, these equipment’s have the capacity to
guarantee an efficient performance of the equipment, in case there are breaks of electric
supply.................................................................................................................................. 52

©Daffodil International University vi


1. Executive Summary
The internationally recognized buyers are looking for those countries for producing there apparel
products where different type of mills have established as a non-stop source for the global
apparel market, satisfy and meet customer expectation by developing and providing products and
services on time, which offer value in terms of quality, price, safety &environment impact. And
also assure complete compliance with the international quality standards and also to provide the
employees internationally acceptable working condition. In Bangladesh there are different types
of textile industries those are producing high quality textile and apparel product. They have
different type of cutting, sewing, and finishing machines supplied by mostly Japan, Singapore,
Taiwan, Germany, Greece etc. which are very latest. It has high production rate finished
garments are produce per day. The production is controlled by skill persons. The entire decision
maker of the production sector in DBL group is not textile graduate. Finishing is well branded.
They produce their product for their buyer and client those are coming from international market
like America, Spain, Italy, and Canada. They follow all the system for their machines
maintenance’s so production cannot hamper. In this report, I tried to give some information
about DBL group and I observed that DBL group Produce high quality garment and fulfill the
special requirements from the different types of buyers according to different internationally
recommended standard method.

©Daffodil International University 1


2. Information about factory:

DBL Group started its business in 1991. The group diversified its business includes spinning,
knitting, dyeing, all over printing, garments washing, packaging, ceramics, tiles, telecom and
garment accessories. DBL Group is one of the largest and 100% export oriented composite knit
garments and textiles manufacturing industry in Bangladesh. DBL group is supplying quality
apparels across the world to the best of the retailers and the biggest brands of the fashion
industry. Total export of the group reached USD 320 million in 2014-2015. DBL Group
currently employs about 23,400 people. The vision of DBL group is to "Extend leadership
through World Class Performance". Mission of DBL group is to develop a progressive,
empowered and consumer focused corporate culture to enhance market leadership along with the
passion of corporate social responsibility.

DBL Group is using energy efficient machinery with less environmental impacts in all of its
projects. DBL Group has a biological ETP (Effluent Treatment Plant) which has a capacity of
4000 cubic meters and is the largest ETP in the country. Moreover, the group is in process of
installing another ETP with the capacity of 7500 cubic meters soon. DBL Group has a captive
power plant of 35MW and is in the process of expanding its infrastructure.

Their vision 2020 aim to sustain the confidence which has been endowed on us by the society
and grow further as a distinctive business house for its customers, employees, associates and
stakeholders.

©Daffodil International University 2


2.1 Factory layout:

Fig: 2.1: Factory layout

©Daffodil International University 3


2.2 Fire Safety Plan:

Fig: 2.2: Fire Safety Plan

©Daffodil International University 4


2.3 General information about factory:

Company Name DBL Group (Jinnat Apparels Ltd)

Established 1991

Type Knit composite(100% Export)

Location Sadarganj, Kashimpur, Gazipur, Dhaka

Employee 23400

Power plant 35 MW

ETP capacity 4000 cubic meters

Installing new ETP capacity 7500 cubic meters

Total Export(2014-2015) USD 320 million

Table: 2.1: General information about factory

©Daffodil International University 5


2.4 Concerns of DBL Group:

1. DBL Telecom Ltd


2. Mawna Fashion Ltd
3. Matin Knitwears Ltd
4. DBL Ceramics Ltd
5. Color City Ltd
6. Jinnat Knitwear Ltd
7. DB Tex Ltd
8. Atelier Sourcing Ltd
9. Than bee Print World Ltd
10. Hamza Textiles Ltd
11. Jinnat Fashions Ltd Parkway Packaging & Printing Ltd
12. Matin Spinning Mills Ltd
13. Flamingo Fashion Ltd
14. Jinnat Apparels Ltd
15. Mymun Textiles Ltd
16. Fashion Concern Ltd
17. Dulal Brothers Ltd

Managing Director: Mr. M. A. Jabbar

©Daffodil International University 6


2.5 Location of DBL group (Jinnat Apparels Ltd):
Jinnat Apparels Ltd is located in Sadarganj, Kashimpur, Konabari under the district of Gazipur,
about 36 kilometer distance from the Daffodil International University, Dhaka, Bangladesh. A
well-developed road communication is there to reach the factory from Dhaka.

Fig: 2.3: Traffic map of site


location

©Daffodil International University 7


2.6 Products of DBL Group:
Knit garments for Men, Ladies Children’s dresses are basically produced in this factory. As a
dyeing, printing, finishing & washing unit of DBL group, it has some common order for

 T- shirt
 Polo shirt
 Vest
 Tank tops
 Shorts
 Skirts
 Trousers
 Jogging suits
 Jackets
 Night wears

2.7 Production Analysis:


2.7.1 Monthly Production Capacity:
 Total 30, 00,000 Pcs

 Cut & Sew: 11, 80,000 Pcs; Intimate: 18, 20,000 Pcs

2.7.2 Daily Production capacity:


 Total 60,000 Pcs

 Cut & sew: 45,000 Pcs; Intimate 70,000 Pcs

2.7.3 Daily Sample Production Capacity:


 Polo: 55 Pcs;  T-Shirt: 125 Pcs  Panty: 50 Pcs

2.7.4 Lead Time for Sample:


 Cut & Sew: 02 Days  Intimate: 01 Day

©Daffodil International University 8


2.7.5 Major Production:
 Cut & Sew: All Kinds of knit items specially T-Shirt, Polo Shirt, Jersey, Leggings, and Jacket
Panty.

2.8 Major Buyers with their logo:

1. H & M

2. Wal-Mart

3. Puma

©Daffodil International University 9


4. Esprit

5. G-Star

6. ZARA (SPANISH)

©Daffodil International University 10


2.9 Management System:
The manpower engaged in this project to carry out the day to day business are all
highly skilled, purely professional, vastly experienced. The unique combination of
organized managerial and technical term in one hand and latest, advanced and balanced
technology on the other hand has made the project one of the top to be referred in this field in
our country.
The best use of continuous development of Human Resources by providing them
International Standard Environment and equal opportunity is the keys for achieving
comprehensive competence in all the level of the Organizational Hierarchy.

2.9.1 Shift Change:


There are three shifts in this factory and each shift is of 8 hours, shift is changed for each person
in the production floor after every seven days. Also general shift is available for employees of
other departments.

A – Shift: From 6.00 am – 2.00 pm


B – Shift: From 2.00 pm – 10.00 pm
C – Shift: From 10.00 pm – 6.00 am

2.9.2 General Shift:


From 9.00 am – 6.00 pm

2.10 Vision, Mission & Values of DBL Group:


2.10.1 Vision: They envision sustaining and growing as a diversified global conglomerate.

2.10.2 Mission: We strive to attain our vision by practicing corporate governance,


empowering and inspiring our associate, being transparent in our work process, continuously
developing expertise, meeting & exceeding customer needs, demands & expectations,
maintaining quality & consistency of our products & services, engaging with community, caring
for environment and maintaining networks with our global partners.

©Daffodil International University 11


2.10.3 Values: Our values are a priority in all of DBL's practices. This not only improves
business operations but also creates transparent and long term relationships with our co-workers
and stakeholders.

©Daffodil International University 12


3. Details of Attachment:

©Daffodil International University 13


3.1. Knitting:

3.1.1 Knitting Organogram:

Knitting Manager

Knitting Assistance Manager

Production Master

Production Officer

Knitting In charge

Knitting Supervisor

Knitting Technician

Knitting Operator

©Daffodil International University 14


Knitting Helper

3.1.2 Process Flow Chart:

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension deice

Knitting

Withdraw the roller fabric and weighting

Inspection

Numbering

3.1.3 Number of Machines:

3.1.3.1 Single jersey circular knitting machine.

©Daffodil International University 15


> PAILUNG (16 PCS)

> INITEX (25 PCS)

> SANTONI (5 PCS)

3.1.3.2 Double jersey Circular knitting machine.

> PAILUNG (10 PCS)

> INITEX (7 PCS)

> SANTONI (2 PCS)

3.1.3.3 Flatbed collar knitting machine.

> SHIMA SEIKI (5 PCS)

3.1.4 Machine Brand Types:

> PAILUNG

> INITEX

> SANTONI

> SHIMASEIK

3.1.5 Machine Description:

©Daffodil International University 16


3.1.5.1 PAILUNG Machine Description:

> Model: PLX3 3R/A/CE

> Origin: Taiwan

> Diameter: 30

> Gauge: 24

> Feeder no: 90

> Needle no: 2256

> Needle type: latch needle

> Creel capacity: 180

Fig: 3.1: PAILUNG Machine

©Daffodil International University 17


3.1.5.2 INITEX Machine description:
> Model: UDX2.1DE

> Origin: Singapore

> Diameter: 30

> Gauge: 24

> Feeder no: 62

> Needle number: 2260

> Needle type: latch needle

> Creel capacity: 124

©Daffodil International University 18


Fig: 3.2: INITEX Machine

3.1.5.3 SHIMA SEIKI Machine Description:

> Model no: SFF152

> Origin: Japan

> Machine type: Flatbed Rib machine

> Needle bed width: 60 inch

> Needle number: 1680

> Gauge: 14

Fig: 3.3: SHIMA SEIKI Machine


©Daffodil International University 19
3.2 Dyeing & Finishing:

3.2.1 Dyeing section:

©Daffodil International University 20


Fig: 3.4: Dyeing Section

3.2.1.1 Dyeing organogram:

Chairman

GM

AGM (Dyeing) AGM (Printing)

SPM PO

PM
APO

APM
In-charge
PO

Operator
APO

Helper
Supervisor

Sr. Operator

Operator

Helper

©Daffodil International University 21


3.2.1.2 Some Machineries Figures of Dyeing Section:

Fig: 3.5: Dyeing Machine

Fig: 3.6: Sample Dyeing Machine


©Daffodil International University 22
Fig: 3.7: Tumble Dyeing Machine

3.2.1.3 Dyeing laboratory:


An efficient lab can increase the efficiency of dyeing floor. So, the role of a lab in-charge is very
crucial. Before bulk production, a sample is sent to buyer for approval. Lab supplies the
approved recipe to the floor with minimum deviation between bulk production and lab dip.

3.2.1.4 Objectives of laboratory:


1. Get color approval from the buyer
2. Shade correction
3. Supply recipe to the floor

3.2.1.5 Sequence of lab operation:


At first buyers give fabric sample, color order or pantone number. The color could be identified
with color order or pantone number. It is easier for spectrophotometer to make recipe with the
help of pantone number. In case of fabric sample different recipes are provided by
spectrophotometer. The process in laboratory is given below:

1. At first the sample is collected from buyer.


©Daffodil International University 23
2. Then different parameters are checked (shade, pantone number).
3. Recipe prepared with spectrophotometer.
4. Fabric is dyed with the recipe.
5. They are compared with standard and recipe is corrected.
6. After exact match recipe is sent to the production floor.

3.2.1.6 List of different lab machines:

Machin Equipment Name Manufacture Quantit


e No. r y

1 Spectro Flash SF 600 PLUS CT Data Color, 1


USA

2 Spectro Flash SF 650 Data Color, 1


USA

3 AhibaNunce Lab Dyeing Data Color, 5


USA

4 Dryer Siemens 1
5 Indesit Dryer Siemens 2
6 Verivide Light Box (CAC-60) For _ 1
Visual color assessment

7 Micro Pipette B59 Rainin 2


8 pH Meter _ 1
9 Balance (50 gm) Kern 1
10 Balance (150 gm) Kern 1

Table: 3.1: List of different lab Machines

©Daffodil International University 24


3.2.2 Finishing Section:
3.2.2.1 Finishing:
Finishing is the process of making the fabric good looking, good hand feeling, lusture to fulfill
the buyer requirement. In this process G.S.M, diameter, shrinkage can be controlled. It is done
after dyeing to meet the buyer requirement.

3.2.2.2 Flow chart of finishing process:

Fig: 3.8: Flow chart of finishing process

©Daffodil International University 25


3.2.2.3 Objectives of finishing:
The aim of finishing is to render textile goods fit for their purpose or end use. Besides that,
finishing can be done for achieving the following purposes-

To improve fabric attractiveness

 By altering fabric handle (Softening)


 Control of fabric dimension (Diameter, GSM)

3.2.2.4 Types of finishing:


 Chemical finishing: Softener
 Mechanical finishing: Raising and Shearing etc

3.2.2.5 Finishing machine specification:

Machine name Band name Quantit Origin


y
Slitting Corino 2 Italy

Slitting Bianco 2 Italy

Stenter Bruckner 3 Germany

Dryer Santex 1 Switzerlan


d
Raising/Brushing Lafer 2 Italy

Shearing Lafer 1 Italy

Sueding Lafer 1 Italy

©Daffodil International University 26


Open width compactor Tubetex 2 USA

Open width compactor Farraro 1 Italy

Tube compactor Tubetex 2 USA

Back sewing Sperato 2 Italy


Rimer
De-watering Sentex 2 Switzerlan
d
Table: 3.2: Finishing Machine Specification

3.2.2.6 Description of Slitting Machine:

The object of this machine is to slit the tube fabric in open width form. Tube type fabrics e.g.
single jersey, Lycra jersey, pique, interlock, terry, fleece are subjected to slitting machine. Some
more information of slitting machine is given below:

3.2.2.7 Information of slitting machine:

Voltage 400V
Frequency 50 Hz
Current 12 amp

Table: 3.4: Information of slitting machine

3.2.2.8 Different parameters for different fabric structure

Fabric structure Pad pressure Speed(m/min)

Single jersey 1-1.5 bar 40-50

PK 2 bar 40-50

1x1 rib 2 bar 50-60

Table: 3.5: Different parameters for different fabric structure


©Daffodil International University 27
3.2.2.9 Types of Finishing:

3.2.2.9.1 Two types of finishing:


1. Mechanical (Used to control dimension, and to improve appearance and handle)
> Calendaring

> Brushing

> Shearing

> Dolly press

> Tunnel press

2. Chemical (Used to make glossy protection and to improve performance)

> Softening
> Soil release

> Root-proofing

> Anti-bacterial

> Resin finishes

> Fiber retardant

3.2.2.10 Some Machineries of Dyeing Finishing:

Fig: 3.9: Finishing Machine

©Daffodil International University 28


Fig: 3.10: Stantering Machine

Fig: 3.11: Compactor Machine

©Daffodil International University 29


Fig: 3.12: Inspection Table

©Daffodil International University 30


Fig: 3.13: Brushing Machine

3.3 Garments Washing:


3.3.1 Dry process:
3.3.1.1 Machine Name: 3D Wrinkle
No of machine: 10

Manufacturing Company: Method

Manufacturing Country: Turkey

Features:

1. Number of heads can be increase up to the expected capacity

2. Thanks to the adjustable heat-time control unit and ergonomic usage of the control panel
which is located on the body .it’s very easy to complete the process according to the receipt

3. there is an defected failed result expected on the product .which has one leg on the left and
another leg on the right – thanks to the optimum vacuum blow of the machine

4. There is one emergency stop button on the hot air blower group which can move towards front
– back and right – left

5. Vacuum blower can be controlled by pedal system

6. Pre- curing process for every single jean is appromately 2-25 min and daily capacity is 600
Pcs

©Daffodil International University 31


Fig: 3.14: Industrial 3D Machines

Specifications:

Model: 3D-CEF4

Weight: 200 kg

Voltage: 220v

Air: 6 bar

Capacity: around 2000-2500 Pcs

3.3.1.2 Machine Name: Industrial Oven


Number of Machine: 03

Manufacturing Company: Airflow

Manufacturing Country: UK

©Daffodil International University 32


Fig: 3.15: Industrial Ovens

Features:

These two ovens heat treat automotive side impact bars in baskets. They are loaded with a
standard fork truck, then a process timer ensures the correct heat treatment time. A single chart
recorder, in one of the oven's control panel, logs temperature, time and batch number for
traceability of both ovens

Specifications:

Model: DTS380

Manufacturing Date: 2010

Voltage: 400 KW

Frequency: 50 H

©Daffodil International University 33


3.3.1.3 Machine Name: Tag Gun

Number of Machine: 10

Manufacturing Country: China

Features:

 Machine body is generally made of plastic.


 Inside the tag gun there is a pin which is made of metal.

Fig: 3.16: Tag Gun

3.3.2 Wet Process:

3.3.2.1 Machine Description


There are 8 sample washing machine and 20 industrial machine (side loading) and 5 (font
loading) & modern industrial washing machine 2 in confidence industry ltd Here also 8 (gas) and
12 (steam) dryer. And 3 hydro-extractor machine this washing plant

©Daffodil International University 34


3.3.2.2 Machine Name: Sample Washing Machine
Number of Machine-12

Manufacturing company: Bengal Heavy Electric Engineering.

Manufacturing country: Bangladesh.

Fig: 3.17: Sample Washing Machine

Features

1. Single door design for general washing, sample washing.


2. Machine body and essential parts are made of stainless steel.
3. Preset front and backward rotation.
4. Conventional machine.

©Daffodil International University 35


Specifications:

Capacity: 30 pieces

Inner Cylinder: 28”X34”

Thickness of inner drum: 3mm

Motor (HP): 1HP, 0.75KW

Power Consumption: 2.3 AMP

Steam Consumption: 2 HP, 31 Kg

Water Inlet: 2”, way in.

Steam Inlet: 1”, way in.

Water Discharge: 3”, 1 way out.

3.3.2.3 Machine Name: Industrial Washing Machine


No of machine-30

Manufacturing company: local

Manufacturing country: Bangladesh.

©Daffodil International University 36


Fig: 3.18: Washing Machine

Feature of machine

1. Single door design for general washing, sample washing.


2. Machine body and essential parts are made of stainless steel.
3. Preset front and backward rotation.

Specifications:

Capacity: 250 pieces

Inner Cylinder: 42”X88”

Thickness of inner drum: 3 mm

Outer Cylinder: 54”X960”

Motor (HP): 10HP, 7.5KW

©Daffodil International University 37


Power Consumption: 17 AMP

Steam Consumption: 15 HP, 230 Kg

Water Inlet: 2”, 2 ways in.

Steam Inlet: 1”, 2 ways in.

Water Discharge: 3”, 2 ways out

3.3.2.4 Machine Name: Modern Washing Machine


No of machine-5

Manufacturing company: YILMAK

Model: F-21 HBM3860

Manufacturing country: Europe

Fig: 3.19: Modern Washing Machines

©Daffodil International University 38


Features:

 Single door, front-loading, open pocket.


 Machine body and essential parts are made of stainless steel.
 Automatic timed. Auto reverse. Automatic 5 water levels& auto digital temperature
control.
 Electric solenoid water & steam valves.
 Non-clog motorized drain valve.
 Full electric protection.

Specifications:

Capacity: 250 pieces

Inner cylinder: 1878 mm dial x 1490 mm

Wash motor: 7.5 KW

Exact speed: 110 RPM

Main door opening: 300 mm dial

Inspection door opening: 300 mm dial

Water consumption: 45 Liter/Kg

Drain: 115 mm dial, 2 ways out

Power consumption: 0.127 KWh/kg

Thermal fluid connection consumption: 1.5” X 1.5” BSP, 8000 KCAL/hr.

Overall dimension: 1950mm (W) X 2500mm (D) X 2100mm (H)

©Daffodil International University 39


3.3.2.5 Machine Name: Industrial Dryer
No. of machines: 28

Manufacturing Company: TRIVENETA GRANDI

Manufacturing Country: ITALY

Specifications:

Capacity: 150 Pieces

Volt: 400

Serial No: 16615

Frequency: 50Hz

Fig: 3.20: Industrial Dryer

©Daffodil International University 40


Features

 Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body painted.
 Low spin extract. Vibration less during extraction. Low spin extract makes articles lighter
to unload.
 Automatic timed. Full electrical protection against single phasing & motor.

3.3.3 Washing Process:


3.3.3.1(Normal Washing):
1St step (Washing recipe):

Lot size: 100 kg

Add water 800-1000 L

Run the machine

Add detergent: 400-500L

Temperature (40-60) C

Time: 5-10 mts

Drop the liquor

Cold wash

©Daffodil International University 41


2nd step (Softening):

Add water: 600 L

Run the machine

Add flax softener

Add acetic acid: 360gm/L

Time: 5-10 mts

Drop the liquor

Unload the garments

3rd step (Hydro extractor) 700-900 RPM

4th step (steam dryer):

Load on steam dryer (50kg)

Temperature: (60-70) C

Time: (40-50) mts for dry


(10-15) mts for cold dry
5th step:
After the drying quality is checked and good quality garments will be delivery to
garments factory.

©Daffodil International University 42


3.3.3.2 Pigment wash:
1St Step (washing recipe):

Lot size: 50 kg

Add water: 400 L

Run the machine

Add caustic soda: 320gm

Add soda ash: 600gm

Add detergent: 320gm

Temperature: (50-60) C

Time: (20-60) minutes

Drop the liquor

Hot wash: 5 minutes

©Daffodil International University 43


Cold wash: 5 minutes

2nd step (Softening):

Add water: 300 L

Run the machine

Add acetic acid: 150gm

Add flax softer: 180gm

Add silicon: 120 gm

Time: 15-20 minutes

Drop the liquor

Unload the garments

3rd step (Hydro extractor) 700-900 RPM

Time: 2-4 minutes

©Daffodil International University 44


4th step (steam) dryer:

Load on steam dryer (50kg)

Temperature: (60-70) C

Time: (40-50) minutes for dry

(10-15) minutes for cold dry

5th step

After the drying quality is checked and good quality garments will be delivery to garments
factory.

3.3.3.3 Enzyme Wash:


1St step (Washing recipe):

Lot size: 100kg

Add water: 900L

Run the machine

Temperature: 60C

Add designing agent: 450gm

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Add detergent: 720gm

Time: 10-20

Drop the liquor

Washing time one minutes by cold wash

2nd step (Bio abrasion):

Add water: 800L

Temperature: 45C

Add acetic acid: 480gm

Add anti back staining: 580gm

Add acid enzyme: 1600gm

Add pumic stone: 20 to 100%

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Time: 40-60 minutes

Increase the temperature up to 90C & 1 minute

Drain the bath

Rinse twice each 3 minutes

3rd step (softening):

Add water: 800L

Add acetic acid: 480gm

Cationic softener: 1gm/L

Temperature: cold

Drain the bath

Then unload the garments

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4th step (Hydro extractor) 700-900

Time 2-4 minutes

Remove the extra water

5th step (drying):

Load 60 kg garments to gas dryer machine

Temperature: 75C

Run the machine

After the run 10 minutes in cold drying

6th step

After the drying, a garment goes to quality section for quality checking and good one is
delivered.

3.3.3.4 Chemical use in the washing plant:


 Enzyme
 Detergent
 Acetic Acid
 Antistain
 Bleaching powder
 Sodium hyposulfite

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 Caustic Soda
 Soda Ash
 Sodium Bicarbonate
 Potassium permanganate
 Cationic / nonionic Flax softener
 Micro Emulsion Silicon
 Salt (sodium chloride)
 Buffer
 Hydrogen peroxide
 Stabilizer
 Fixing agent
 Catanizer
 Optical Brightener
 Resin
 Sodium Metabisulphite
 Desizing agent

3.3.3.5 Washing Fault in production section:


3.3.3.5.1 Crease Mark:
Cause:

 More cycle time


 Faulty planning device
 Improper fabric movement
 Variation of heating and cooling rate
 Incorrectly set bowed-expander

Remedies:

 Anti-creasing agent are used to avoid crease mark problem


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Fig: 3.21: Crease Mark

3.3.3.5.2 Dye Spot:


Cause:

 Improper mixing and dissolving of dyestuff


 Dye bath hardness

Remedies:

 Mixing and dosing dyestuff should be done properly


 Water of dye bath should hardness free

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Fig: 3.22: Dye Spot

3.3.3.5.4 Fabric Hole:


Cause:

 Machine fault
 Fabric fault

Remedies:

 Reduce machine fault

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Fig: 3.23: Fabric Hole

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3.4 Utility:

3.4.1 Generator:

Industrial generators are highly specialized pieces of equipment. Individuals who work with
them on a regular basis should have adequate training to properly evaluate the condition of the
machine, as well as have the knowledge and expertise to fix any problems they find. Generators
built for industrial use are normally powered by natural gas or diesel. Knowing the power source
used will determine a lot as to how the machine will have to be repaired.

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Fig: 3.24: Generators

3.4.2 Some Advantage of Generator:

> Industrial Generators are developed to ensure that there is a continuous supply of power in the
event of failure of the grid systems. Thus, these equipment’s have the capacity to guarantee an
efficient performance of the equipment, in case there are breaks of electric supply

> There are several generators for the industrial application with different solutions to meet the
requirements of a continuous power supply and according to the types of emergency or need.

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> Industrial generators are robust equipment, which must be designed with some legal rights to
which they are complying. For them to perform efficiently and properly, their design pattern is
very high. This is because, as equipment that acts as a reserve in cases of energy failure, they
must be able to respond with maximum efficiency.

> As far as the industrial branch is concerned, electric energy is usually derived from mechanical
generators, which are the ones that perform better, as their energy conversion capacity is higher.
And in the case of the industrial sector, it is extremely important to ensure maximum
performance. For example, in the health sector, the continuous supply of energy is vital.

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4. Impact of Internship:
4.1 Knitting:
> Learned about the knitting process

> Learned about some knitting machine

> Understand how to work single jersey circular knitting machine, double jersey knitting
machine & flatbed collar knitting machine

4.2 Dyeing & Finishing


4.2.1 Dyeing:
> Learned about dyeing section & dyeing process

> Learned about some dyeing machine

> learned about the dyeing laboratory

4.2.2 Finishing:
> Learned about final inspection

>Learned about how to remove spot

>Learned about ironing

>Learned about how to measurement check

4.3 Washing:
> Learned about washing process

> Learned about some dyeing machine


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> Learned about Normal wash, Pigment wash, Enzyme wash

4.4 Utility:
> Learned about generator

> Learned about how to work generator

> learned about the advantage of generator

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5. Conclusion:
Industrial training is an essential part for textile education because it minimizes the gap between
theoretical and practical knowledge. Undoubtedly, this industrial training give us an idea about
textile technology, production process, machineries, industrial management and made us
comfortable with industrial life. Besides it give us the first opportunity to work in industry.

The completion of the two months industrial attachment at DBL group (Mymun complex) gave
us the inspiration that factory is one of the appropriate destiny to implement the theoretical
knowledge. From this industrial attachment we got the details idea about the factory
environment, production process, total management, store & inventory process, maintenance,
utility etc.

DBL group is well equipped and the working environment is excellent. The relation between top
management to bottom level is so nice. We are lucky to get the opportunity of having training in
this mill. The factory runs by a number of efficient Textile Engineers, Skilled technical & Non-
technical persons.

All the Textile Engineers, technical & Non-technical persons are very sincere, co-operative and
helpful. We wish good luck of them and also for this factory.

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