Industrial attachment of epyllion knitex ltd

SOUTHEAST UNIVERSITY
School of Science and Engineering, Department of Textile Engineering
1 | P a g e
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
Epyllion Knitex Ltd
1 | P a g e
INDUSTRIAL TRAINING
Epyllion Knitex Ltd
1 | P a g e
INDUSTRIAL TRAINING
Epyllion Knitex Ltd

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

2 | P a g e
SPECIAL THANKS
TO
&

3 | P a g e
Location for going to the Epyllion Knitex Ltd and Epyllion
fabrics Ltd
BANANI
GAZIPUR CHOWRASTA
RAJANDROPUR CHOWRASTA
BANGLABAZAR
(EPYLLION FACTORY)

4 | P a g e
Table of Contents
INTRODUCTION ................................................................................................5
PROJECT DESCRIPTION...................................................................................6
INTRODUCTION TO EKL & EFL...................................................................12
KNITTING DEPARTMENT..............................................................................14
QUALITY ASSURANCE SYSTEM .................................................................35
LAB & TESTING DEPARTMENT...................................................................49
DYEING DEPARTMENT OF EKL & EFL......................................................58
FINISHING.........................................................................................................80
STORE & INVENTORY CONTROL ...............................................................91
MAINTENANCE ...............................................................................................95
UTILITYIES.....................................................................................................104
EFFLUENT TREATMENT PLANT ...............................................................112
BUYER COMPLAIANCE ...............................................................................122
CONCLUSION.................................................................................................123

5 | P a g e
INTRODUCTION
By means of practical knowledge it is possible to apply the theoretical
knowledge in the practical field. For any technical education practical
experience is almost equally important in association with the theoretical
knowledge.
The industrial attachment is the process which builds understanding skill and
attitude of the performer, which improves his/her knowledge in boosting
productivity and services. Academic education provides us vast theoretical
knowledge as well as more practical attachment, despite all these industrial
attachment help us to be familiar with the technical support of modern
machinery, skill ness about various operation stages.
It also provides us sufficient practical knowledge about production
management, Productivity evaluation, work study, efficiency, industrial
management, production planning & control, production cost analysis,
inventory management, purchasing, utility & maintenance of machinery and
their operation techniques etc. The above mentioned cannot be achieved
successfully by means of theoretical knowledge only. This is why it should be
accomplished with practical knowledge in which it is based on industrial
attachment makes us reliable to be accustomed with the industrial atmosphere
& improve courage & inspiration to take self- responsibility.
From fiber to fabric, the TEXTILE division of Epyllion group is a truly
integrated undertaking. The Textile Division has the capability to offer a
complete product range for the export textile markets. The goal of Textile
Division is to become the preferred partner for sourcing high quality fabrics and
clothing from Bangladesh. With this goal Epyllion Fabrics Ltd. is advancement
of this journey. With highly advanced technology and an emphasis on
developing local human resources, the Textile Division has the potential to
make an important contribution to the nation's growing readymade garments
export sector keeping green environment into close consideration.The rationale
behind the existing structure and future expansion of the Textile Division is to
pure value-added at each stage of the textile manufacturing process.

6 | P a g e
PROJECT DESCRIPTION
 Company Name:
 Epyllion Fabrics Ltd.
 Epyllion Knitex Ltd.
 Status: Private Ltd. Company
 Type: 100% Export oriented composite knit Dyeing Industry.
 Product Mix:
 100% cotton
 100% polyester
a) Spun
b) Filament
 Nylon

 Polyester Cotton blend

(15% Viscose 85% cotton
10% Viscose 90% cotton
30% Viscose 70% cotton)
 Year of establishment: 2003, Commencement of Production in month
2004.
 Address: It is situated in Banglabazar, Joydebpur, Gazipur. Bangladesh.

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

8 | P a g e
History of project development:
Epyllion Group started with first venture DEKKO KNIT WEARS Ltd (DKL) in
1993 with 2 sewing lines and total of 200 work forces at Mirpur area.
Now it has 7000 wprk force with 36 sewing lines in several areas of Dhaka and
Gazipur. Combining modern technology with skilled manpower under
Epyllion's unique inspiring, atmosphere, this new Epypllion venture soon rose
to the top of the local textile industry. Today it has one of the most sophisticated
vertically integrated set-ups.
Concern of Epyllion group:
 Textile Industries
 Garments Industries
 Garments Accessories.
 Real Estate.
Group Members:
 Textile Industries
1. Epyllion Fabrics Ltd.
2. Epyllion Knittex Ltd.
 Garments Industries
1. Epyllion Style Ltd.
2. Epyllion Knitwears Ltd.
3. Dekko Knitweaers Ltd.
4. Dekko Knitweaers Ltd. Unit-2

9 | P a g e
5. Mirabella Dresses Ltd.
6. Epyllion Jeans Ltd.
 Garment accessories
1. Epyllion Limited.
2. Epyllion Washing Ltd.
 Real Estate:
1. Nima Holdings Ltd.
Other facilities are
 Own network Server.
 Own power management,
 Own utility management.
 Transport facilities.
 Medical centre.
 Fire service facility.
 Effluent Treatment Plan.
Shift change
shift is 8 hrs
: 6:00 A.M-2:00P.M
: 2:00 P.M- 10:00 P.M
: 10.00 P.M-6:00 A.M
General shift : 9:00 A.M - 5:00 P.M

10 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3
Product:
 Single Jersey
 Heavy Jersey
 Pique
 Lacoste
 Interlock
 Rib
 French Terry
 Cotton Fleece /Cvc Fleece
 Flat Knit
 Auto man
 Cotton Viscose
 Polyester
 Cotton polyester
 CVC
 Organic Cotton
Clients:
CELLIO G-STAR

Certificate & Achievement:
 BGMEA
 BKMEA
 BTMA
 SEDEX
 Oeko-Tex
 C&A Best Supplier Award 2004
Capacity:
 Production capacity in knitting:
27175 Kg of knitted fabrics per day
 Production capacity in knit dyeing:
32500 Kg per day
Cost:
Investment 500 Core (Approximately)
Remarks:
Epyllion Fabrics Ltd. is greatest concerned with the quality of its product. Better quality has
come buyers to pay more. The infrastructure and land asset has the greatest possibility to
extension
Contact Information:
Corporate Office:
Plot # I/1, Road # 06, Section # 07,
Mirpur I/A, Dhaka-1216. Bangladesh
Tel:+880-2-9006028, 9006747, 8013883, 9013897,
Fax # 880-2-9007978, 9016994,
Web: www.epylliongroup.com
Factory: Banglabazar, Joydebpur, Gazipur.

INTRODUCTION TO EKL & EFL
Front view of Epyllion Knitex Ltd

ORGANOGRAM OF EPYLLION GROUP
HR & Administration
Operation & Planning
Knitting
Production
Grey Inspection
Batch Preparation
Wet Processing
Dyeing Section
Finishing Section
Quality Assurance
R & D
Laboratory
Fabric Inspection
Maintenance
Electrical
Mechanical
Utility
Compressed Air
Water
Electricity
Steam
ETP

KNITTING DEPARTMENT

LAYOUT OF KNITTING DEPARTMENT OF EKL & EFL

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

CAPACITY OF KNITTING SECTION:
FABRIC TYPE EKL EFL DAILY CAPACITY MONTHLY
CAPACITY
JERSEY 11 36 16,500 KGS 4,95,000 KGS
INTERLOCK 05 05 3,500 KGS 1,05,000 KGS
RIB 05 05 3,500 KGS 1,05,000 KGS
FLEECE - 10 3,500 KGS 1,05,000 KGS
AUTO-STRIPE 01 - 175 KGS 5,250 KGS
TOTAL 27175 KGS 815250 KGS

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

Circular Knitting machine details of EFL:
m/c no m/c type Dia*gauge No of feeder No of
needle
Brand Origin
01 S/L 30*28 90 2640 Well knit China
23 Rib 30*24 60 2256 Well knit China
21 Rib 36*18 64 2040 Terrot Germany

37 Interlock 36*24 64 2712 Well knit China
45 2T Flece 28*24 84 2112 Well knit China
53 3T Fleece 30*20 90 1896 Well knit China

54 3T Fleece 30*20 90 1896 Well knit China
57 Rib 32*18 64 2712 SSANGYONG Korea
58 Rib 44*18 88 2812 SSANGYONG Korea
Auto striper machine details:
m/c no m/c type Dia*gauge No of feeder No of needle Brand origin
01 Auto striper 30*24 48 2268. Mayer &
Cie
Taiwan
02 Auto striper 30*24 48 2268 Mayer &
Cie
Taiwan
Cie
Taiwan
Cie
Taiwan
05 Auto striper 30*24 48 2268 Terrot Germany
09 Auto striper 30*24 48 2268 Well knit china

RAW MATERIALS:
Raw material used in EKL & EFL:
SL no. Yarn Type Yam count
1 Combed Yarn 16CC
2 Combed Yarn 18CC
3 Combed Yarn 20CC
4 Combed Yarn 22CC
5 Combed Yarn 21CC
6 Combed Yarn 26CC
7 Combed Yarn 2BCC
8 Combed Yarn 30CC
9 Combed Yarn 32CC
10 Combed Yarn 36CC
11 Combed Yarn 36CC
12 Combed Yarn 40CC
13 Combed Yarn 50CC
14 Combed Yarn 60CC
15 Carded Yarn 16KC
Hi Carded Yarn 1SKC
17 Carded Yarn 20KC
18 Carded Yarn 22KC
19 Carded Yarn 21KC
20 Carded Yarn 26KC
21 Carded Yarn 28KC
22 Carded Yarn 30KC
23 Girded Yam 32KC
24 Carded Yarn 34KC
25 Carded Yarn 36KC
26 Carded Yarn 40KC
27 Carded Yarn 50KC

28 Carded Yarn 60KC
29 CVC Yarn 16CVC
30 31 CVC Yarn CVC
Yarn
18CVC
20CVC
32 CVC Yarn 22CVC
33 CVC Yarn 24CVC
34 CVC Yarn 26CVC
35 CVC Yarn 28CVC
86 CVC Yarn 30CVC
37 CVC Yarn 32CVC
38 CVC Yarn 34CVC
39 CVC Yarn 36CVC
40 CVC Yarn 40CVC
41 CVC Yarn 50CVC
42 CVC Yarn 60CVC
43 G.M. Yarn 20GM 5V
44 G.M. Yarn 20GM 10V
45 G.M. Yarn 20GM
1.5V
Knitted fabrics specifications:
Knitting Parameters consists of-
1. G.S.M.
2. Yarn count.
3. Stitch length.
4. Fabric width.
5. Fabric thickness.

1. G.S.M:
The weight of fabric in gram per square meter is called G.S.M.
2. Yarn count:
It is a numerical expression of coarseness or fineness of yarn which can be measured in two
systems. One is direct system and another one is indirect system.
For direct system:
Count =
×
For Indirect System:
Count =
×
×
3. Stitch length:
The length of yarn knitted into one stitch in a weft knitted fabric. Stitch length is theoretically
a single length of yarn which includes on needle loop & half the length of yarn (Half a sinker
loop) between that needle loop & the adjacent needle loops on either side of it. Generally, the
larger the stitch length the more elastic & lighter the fabric, & the poorer its cover capacity &
bursting strength.
4. Fabric Width:
Along the fabric width there presents the Wales. The total no. of needle is fixed for the same
cylinder having the equal gauge as well as diameter.
Fabric width = No. of Wales X Wales space.
= No. of needle X Wales space.
= Πdg X Wales's space.
d = Cylinder diameter,

g = Gauge.
The above concept clarifies that Fabric width closely depends on total no. of needle not
directly related to machine diameter machine gauge.
5. Fabric Thickness:
In the dry and wet relaxed states fabric thickness (t) is depends upon fabric tightness, but in
the fully relaxed state, it is more or less dependent of the fabric tightness factor. In the fully
relaxed state t= 4d.
Where d is the yarn diameter
For single jersey,
t = 2d
Technical Specification:
1. Machine gauge:
No. of needles per inch present in a needle bed of a knitting machine is called machine gauge
for that knitting machine. A term giving a notational indication of the no. of needles per unit
length along a needle bed or needle bar of a knitting machine in current practice, a common
unit length of one English inch (25.4mm) is used for all types of warp and weft knitting
machine.
Selection of machine gauge depends upon yam diameter. Yam diameter depends upon the
following:
1. Yarn count.
2. Yarn type.

3. Yarn twist.
4. Yarn finished.
Generally practiced in different industries in Bangladesh given below:
yarn count used Machine gauge
16 18
18 20
20 20
20 24
24 22
24 24
26 20
26 22
26 24
26 28
28 22
28 25
28 28
30 22
30 24
30 28
30 34
34 28
34 28

2. V.D.Q Pulley (Variable Dia Quality):
In a knitting m/c to supply the specific length of yarn, there are two or more adjustable
pulleys which are known as V.D.Q. Pulley. By adjusting the V.D.Q. pulley we can control the
speed of accumulator which supplies the required amount of yarn.
V.D.Q. pulley is very important to set up the correct loop length.
The amount of yarn wound on accumulator by one revolution of cylinder is called the course
length of fabric
VDQ Pully Measurement:
For Orizio machine,
VDQ =
. ×
– 2
For an Exp:
S.L = 2.90
No of needle = 2580

VDQ =
. ×
-2
= 187-2 = 185
For well knit m/c
140 for S.L 2.62
EXP:
For S.L 3.10
2.62----------------140
1 ----------------140/2.62
3.10----------------140*3.10/2.62 =165.65≈166
For Terrot m/c for each S.L 0.10 VDQ will increase 1mm.
For Mayer m/c for each S.L 0.10 VDQ will increase 10mm.
Some VDQ measurement of Different Brand m/c:
NO BRAND S.L VDQ
01 Orizio 2.85 181
02 Orizio 3.10 197
03 Orizio 2.76 175
04 Orizio 2.72 147
05 Orizio 2.10 118
06 Well knit 2.70 145
07 Well knit 2.65 140
08 Well knit 2.74 149
09 Terrot 3.25 192
10 Terrot 2.30 158
11 Terrot 2.70 144
3. Machine Diameter:
Machine diameter is mainly diameter of cylinder. It is important for fabric width. Only
diameter does not determine the fabric width. It need helps machine gauge and Wales space
which is depend upon yarn count and loop length.

4. Needle gauge:
Thickness of needle express by the needle gauge. It is important for selection of machine
gauge. Needle gauge is different for the different gauge and different Brand.
Some needle gauges found in industries are given below:
Machine gauge Needle thickness in mm
24 0.52
28 0.41
PRODUCTION PLANNING, SEQUENCE AND OPERATIONS
Production Equipment
EPYLLION FABRICS LTD (EFL) & EPYLLION KNITEX LTD are capable to knit Weft
Knitted fabrics only. Machine description is given before.
Quality Control Equipment
Following equipment are used to ensure proper quality of the produced fabric:
 Starfish Computer Programme
 Yarn Tension Metre
 Stitch Length Metre
 Magnifying glass (to check Wales or Course/Unit)
 GSM Cutter etc.
Key Accessories:
Key accessories used for circular knitting process are:

 Needle: The commonly used needle types are Vo 154.41 G001-4, Vo 154.50
G001-4, VoTA 60.58 G01, and Vo 92.62 G01.
 CAM : KNIT, TUCK and MISS
 Sinker: Commonly used types are 0.250 mm and 0.200 mm.
 MPF
 Positive feeder
 Dial
 Cylinder
 Manager tooth belt
 Timing belt for motor and take down.
Minimum requirement of other parameters are:
For Yarn :
 Yarn strength 13 gm/Tex (minimum)
 Should be waxed 0.1 % - 0.3% (on the weight of the material)
 Yarn should not be dried.
 Cone angle should be accurate.
 A tail should be kept during winding.
 Packing density must be maintained.
For Sewing Thread
 Sewing thread should be bleach proof.

For Spandex
 Should have good elasticity.
 Yarn should be uniform.
 Elastic recovery 100%.
 Elongation 500%.
 Should be Acid, Alkali and temperature stable
 Should be moisture free (i.e. without containing water).
Other Materials
 Needle Oil: Should be water soluble.
 Belt,
 Grease,
 Kerosene oil, etc.
The acceptable limits for Mellange and Polyester depend on customer's specification. These
yarns are rarely used (based on buyer's demand) at EKL. The international standards for these
yarns are mentioned
Operation Staff
Operation stuffs of Circular Knitting Process include:
1. Manager
2. Sr. Production Executive / Production Executive
3. Operator
4. Assistant Operator
5. Helper

Machine Set-up:
Operator sets the following parameters prior to operation:
Parameters Range
Speed 26 ~ 28 RPM (for Solid dyed)
20 ~ 25 RPM (for Yarn dyed &
designed)
Yarn Tension 4-5 gm/tex.
Stitch Length 2.60 -3.00 mm
Weight 100 - 240 GSM (as required)
Yarn (Cotton) 16~40Ne
Yarn (Polyester) 75 - 300 Denier
Checklist Before Operation
Operator checks the following points prior to operation:
1. Machine condition.
2. Power supply and air availability.
3. Yarn availability.
4. Buyer's specification.
5. Yarn quality.
6. Machine adjusted with given parameter (Yarn count, Stitch length/GSM).
7. Oil inlet clean or not.
8. Oil drip metre should be adjusted.
9. Door should be close.
10. PC controller is set for record keeping.

Factors to Be Considered during sample analysis Before Producing a Fabric:
Before production few factors but be considered:
1. Design of the fabric( expressed by notation diagram),
2. Needle arrangement according to Notation diagram,
3. Cam arrangement according to Notation diagram,
4. Feeding,
5. Drive &
6. Stitch length.
7. Machine gauge & dia
Design of the fabric;
We have analyzed a fabric, the drew notation diagram which is attached in following page.
Needle arrangement & Cam arrangement:
Needle arrangement & Cam arrangement for the design is shown following page.
Feeding:
Well-knit brand has Single jersey machines with positive feed system. We fed yarn in
following sequence:
Type of yarn Count No. of yarn Color of yarn
Cotton 30 cc 14 Orange
Polyester 175 den 3 White
Polyester 175 den 3 White

Drive:
Today the belt system has by far become most common positive feed system. The belt makes
the spool rotate and the no of rotating spools corresponds to the no of feed systems. By
adjusting the belt RPM, the quantity of yarn per loop can be increased or reduced. This
system grants an accurate control of the yarn tension. We know knit loops more yarn than
tuck loops. To produce this fabric we use 3 belt drive. Two drive for knit loops & one drive
for tuck loops.
Stitch length:
Stitch length of each loop is controlled by VDQ pully . VDQ pully was adjusted to give 3.1
mm length for knit loops & 2.65 mm for tuck loops. Thus we produced the fabric.
Lycra attachment:
There are several methods to calculate lycra percentage in fabric sample. Some of them are
described below-
Manual method:
5 gm sample fabric is taken & withdrawn the lycra yarn from sample fabric Then the sample
fabric is weighted. From difference weight, we calculate the lycra percentage of the sample
fabric
%
=
ℎ − ℎ
ℎ ℎ
∗ 100%

QUALITY ASSURANCE SYSTEM
ORGANOGRAM
BODY PART Tube & Collar Cuff
Quality Manager Executive
Sr.Executive (2) Supervisor
Executive (3) Helper
Supervisor
Sr. Inspector
Inspector
Helper

The Quality assurance Department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing. Epyllion Fabrics Ltd. is more
about concern about quality. In this factory quality assurance is more preferred than quality
control, but both are in advancement.
After collecting fabric rolls from different m/cs, they are needed to be inspected or assured
required quality by the quality inspectors as if there were no big production hampered and no
complain from the buyers. Here are the details about it.
Objects of Quality Control:
1. Research.
2. Selection of raw materials.
3. Process control.
4. Process development.
5. Product testing.
6. Specification test
Scope for quality control, quality assurance and testing:
1. Testing lab
2. Machine auditing system
3. A good training system
4. Excellent analytical back up
5. Technical expertise

Quality Control in Grey Fabric Inspection:
Some Points Are Needed To Maintain For High Quality Fabric:
a) Brought good quality yarn.
b) Machines are oiled and greased accordingly.
c) G.S.M, Stitch length, Tensions are controlled accurately.
d) Machines are cleaned every shift and servicing is done after a month.
e) Grey Fabrics are checked by 4 point grading system.
List of Equipments:
In this factory this is the list of equipments to assure quality:-
1) Inspection m/c# 1
2) Inspection m/c #2
3) Scissors
4) Electronic balance
5) GSM cutter
6) Indication sticker
7) Measuring tape
1) Body & Rib Inspection:
All rolls are kept in front of the inspection m/c time to time and are inspected over the
inspection m/c visually in a pre-set speed against light. For any major or minor faults like
thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etc are
recorded in inspection report to classify the fabric which is based on the four point system.

2) Collar & Cuff Inspection:
Collars cuff are inspected visually under the light box, any major or minor faulty collar/cuff
like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly
counted and recorded.
Quality Standard:
Epyllion Fabrics Ltd. maintains the ISO: 9002 standard in case of quality. Therefore, the four
point system is followed to inspect the body & rib fabric. The defects found and points given
against are recorded in the inspection sheet.
Following table shows the four point grading system followed by inspection at Epyllion
Fabrics Ltd.
Four point grading system
Size of defects Penalty
3 inches or less 1 point
Over 3 inch but not over 6 inch 2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch 4 point

Following table shows common body and rib faults and response by inspection section at
Epyllion Fabrics Ltd:
Rejection criteria for body & ribs
No Faults Response
1. Needle mark Major needle line is rejected
2. Stripe Major needle line is rejected
3. Barre mark Rejected
4. Contamination & fly Approved for color but for white shed
1 point is assigned
5- Slubs 1 point
6. Thick thin place Reject
7. Birds eye 1 point
8. Pin holes 1 point
9. Wrong design Reject
"10. Mixed yarn Discuss with manager
11. Sinker mark Major sinker mark is rejected.
12. Missing yarn Use 4 point
13. Holes Do
14. Oil line/stain Do
15. Chemical Do
16. Dirt stain Do
17. Crease line Do

Following table shows common collar and cuff fault and response taken by inspection section
at Epyllion Fabrics Ltd.:-
Rejection criteria for collar & cuff
No. Faults Response
1. Wrong ply Reject
2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7. Fly & contamination Acceptable for color but not for
white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
18. Uneven tension Discuss with manager

15 Wrong tube Reject
Following table shows the acceptance calculation followed by the inspection section at
Epyllion Fabrics Ltd.:
Acceptance calculation
Factory: Roll yardage (A) & Total point’s pounds (B)
Formula: B/A X100 =points per 100 yard
Classification:
40 points = A type
41-60 = B Type
61-80 = C type
Above 80point = Reject
Quality Standard:
Epyllion Fabrics Ltd follows the quality standard: ISO-9002:2000.
List of Equipments: -
In the lab Department the followings equipments are used –
 Yarn Grade Tester
 78-1 Magnetic Stirrer
 KERN Electronic Balance

 Spray Rating Tester
 Incubator
 Iron
 Button Tester
 Ahiba Nuance Lab. Dip Dyeing Machine
 Thermostatic Water Bath
 Digital Pipette
 Creda Dryer
 Rota Wash
 Electrolux Washcator
 Orbitor Pilling & Snaging Tester
 Marks & Spencer Holoscope
 True Burst
 Crock Meter
 Push - pull tester
 Megasol (Light fastness tester)
 Spectra Photometer with software (Data Color)
 Thermo hygrograph
 PH
meter

PRODUCTION SUMMARY
UNIT
PRODUCTION
(TON)
SERVICE
PRODUCTION
(TON)
COLLAR
& CUFF
(TON)
TOTAL
PRODUCTION
(TON)
EFL 713 57
20
(285715
Sets) 791
EKL 317 39
8
(112680
Sets) 364
Subcontract 451 0
1
(14285
Sets) 452
Grand Total 1482 97
29
(412680
Sets) 1607
OVERALL SUMMARY
Particulars Qty (Ton) %
INHOUSE 1058 66%
SERVICE 96 6%
SUBCONTRACT 452 28%
TOTAL 1606 100%

FABRIC TYPE WISE PRODUCTION
F. Type Pro. Qty Fab. %
SJ 714,815 47.33
3TFL 318,818 21.11
LSJ 137,467 9.10
SP2RIB 70,061 4.64
1RIB 56,069 3.71
IRRGDNI 47,179 3.12
IN 46,483 3.08
IN Ply 32,842 2.17
SPRIB 31,188 2.07
0
200
400
600
800
1000
1200
IN HOUSE
1058
SJ 714,815 47.33
3TFL 318,818 21.11
LSJ 137,467 9.10
SP2RIB 70,061 4.64
1RIB 56,069 3.71
IRRGDNI 47,179 3.12
IN 46,483 3.08
IN Ply 32,842 2.17
SPRIB 31,188 2.07
SERVICE SUBCONTRACT
96
452
SJ 714,815 47.33
3TFL 318,818 21.11
LSJ 137,467 9.10
SP2RIB 70,061 4.64
1RIB 56,069 3.71
IRRGDNI 47,179 3.12
IN 46,483 3.08
IN Ply 32,842 2.17
SPRIB 31,188 2.07

Collar & Cuff 28,127 1.86
STBPQ 14,287 0.95
2TFL 6,913 0.46
LSTBPQ 2,186 0.14
WFL 2,130 0.14
DNI 566 0.04
2TBPQ 559 0.04
2RIB 322 0.02
L2TFL 90 0.01
Mesh 54 0.00
Grand Total 1,510,153 100.00
INHOUSE PRODUCTION ANALYSIS
FLOOR
CAPACITY
(TON)
PRODUCTION
(TON)
CAPACITY
UTILIZATION
MCS
UTILIZATION
REJECT
(TON)
REJECT%
EFL 1539 770 50% 54% 0.95 0.12%
EKL 521 356 68% 72% 0.38 0.11%
TOTAL 2060 1126 55% 58% 1.33 0.12%

440,000
460,000
480,000
500,000
520,000
540,000
560,000
Jan’11
Feb’11 Mar’11
Total (KG)
Total (KG)

Month Unit
Total
Target
Total
Delivered
Performance %
Floor wise
average %
Quarterly perfm %
Jan ' 11 EFL 385250 341714 89%
87%
96%
Feb ' 11 EFL 357000 342924 96%
Mar ' 11 EFL 374000 289626 77%
Jan ' 11 EKL 189750 171582 90%
105%Feb ' 11 EKL 168000 197828 118%
Mar ' 11 EKL 176000 185750 106%
Month Unit
Total
Target
Total
Delivered
Performance %
Floor wise
average %
Quarterly perfm %
Jan ' 11 EFL 385250 341714 89%
87%
96%
Feb ' 11 EFL 357000 342924 96%
Mar ' 11 EFL 374000 289626 77%
Jan ' 11 EKL 189750 171582 90%
105%Feb ' 11 EKL 168000 197828 118%
Mar ' 11 EKL 176000 185750 106%
Month Unit
Total
Target
Total
Delivered
Performance %
Floor wise
average %
Quarterly perfm %
Jan ' 11 EFL 385250 341714 89%
87%
96%
Feb ' 11 EFL 357000 342924 96%
Mar ' 11 EFL 374000 289626 77%
Jan ' 11 EKL 189750 171582 90%
105%Feb ' 11 EKL 168000 197828 118%
Mar ' 11 EKL 176000 185750 106%

Rejects
EFL EKL
Month
Delivery
Qty (Kg)
Reject Qty
(Kg)
Reject In %
Delivery
Qty (Kg)
Reject Qty
(Kg)
Reject In %
January 259355.2 Kg 604.0 Kg 0.23% 171582 Kg 924.4 Kg 0.53%
February 286267.4 Kg 376.0 Kg 0.13% 197828 Kg 679.1Kg 0.34%
March 268178.0 kg 611.0 Kg 0.22% 185750 kg 364.9 Kg 0.19%
Total 813809.6 Kg 1591.0 Kg Avg 0.19% 555160Kg
1968.4
Kg
Avg 0.35%

LAB & TESTING DEPARTMENT

COLOR FORMULATION LABORATORY:
S
L
Machine Name Brand Origin Capacity Unit
Manf.
Date
Erection
Date
Remark
1
Ahiba Nuance Dyeing
M/C
Data color U.S. A
20
Beakers
1 2003 2003
2
Ahiba Nuance Dyeing
M/C
Data color U.S. A
15
Beakers
1 2003 2003
3 Fongs Dyeing M/C Fongs
China
(Hong
kong)
12
Beakers
1 2002 2003
4
Automatic Dispenser &
Solution Maker
Data color U.S. A 80 Bottles 1 2006 2006
5
Spectrophotometer SF
600 Plus CT
Data color U.S. A 2 2003 2003
6 Veri-Vide Light box Verivide UK 2 2002 2003
FABRIC TESTING LABORATORY:
S
L
Machine Name Origin Capacity
Manuf.
Date
Erect!
on
Date
Remarks
1 Electrolux Washing M/C UK 1 Unit 2002 2003
2 Ariston Washing M/C UK 1 Unit 2002 2003
3 Elba Washing M/C Korea 2 Units 2002 2003
4 Tumble Dryer UK 1 Unit 2002 2003
5 Crock meter UK 1 Unit 2002 2003
6 SDL Tumble Dryer UK 1 Unit 2002 2003

Tests:
There are two types of tests are done in Quality Assurance Department.
They are -
1. Physical Tests
2. Chemical Tests
Physical Tests:
 Yarn grade
 GSM test
 Shrinkage test
 Spirality test
 Tensile strength
 Abrasion resistance
 Pilling resistance
 Button strength testing
 Lycra% determination
 Crease resistance
A. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample:
• Two piece of 50 cm x 50 cm fabric is taken for test.
Procedure:
a) Conditioning: Put the sample in table for 4 hrs for conditioning before starting test.

b) Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample (3
sides) by over lock sewing machine.
c) Put sample in washing machine and run according to buyer's choice.
d) Drying: All Buyers' requirement is tumble Dry except ECHO SCOURING is flat dry.
Shrinkage test calculation:
Before wash - After wash
Shrinkage % = ×100
Spirality test calculation:
S = (S1+S2) / 2
Spirality = (S+S x L)/100.
Suppose,
B1 = the right side distance of the specimen from the stitch line after wash.
S2 = the left side distance of the specimen from the stitch line after
L = Length before wash
Washing fastness:
Recipe:
ECE phosphate = 4 g/L
Sodium parborate = 1 g/L
M:L=1:10
Sample weight = 10gm
40⁰Cx45 min

Procedure:
1. Stock solution is prepared according to recipe in a beaker & 10 steel balls are kept in
beaker.
2. Then the fabric is dropped into the beaker.
3. The beaker is set up in Rota wash m/c in 40nc for 45 min.
4. Then the sample is washed off.
5. Then the sample is dried and compared with standard.
Water fastness:
Procedure:
1. The colored fabric is attached with finished fabrics unfinished fabric.
2. Then it is kept in water in beaker for 10 min
3. Then the fabric is kept on template board of perspiration tester where 5 kg weight is
added.
4. Then it is put in over dry m/c in 35nc for 4 hrs.
5. Then the dried sample is compared with standard.
Rubbing fastness:
Procedure:
1. The sample fabric is kept on Crock meter & the fabric is rubbed by handle of Crock meter
with Crock meter cloth.
2. 10 times rotated the handle on the sample fabric.
3. It is done both dry & wet condition of crock meter cloth.

4. Then it is compared with standard.
Perspiration test:
For alkali,
Recipe:
L-Histidine monohydrochloride = 0.5 g/L
Sodium chloride =5.0 g/L
Di Sodium hydrogen phosphate =2.5 g/L
pH = 8.0
Water =1Lt
For acid,
Recipe:
L-Histidine monohydrochloride = 0.5 g/L
Sodium chloride =5.0 g/L
Sodium hydrogen phosphate dyhydrate =2.2 g/L
pH = 5.5
Water =1Lt
NB: pH for alkali not less than 8 & pH for acid not above than 8.
Procedure:
1. Stock solution is prepared according to recipe in a beaker.
2. Then the fabric is kept in beaker & to measure the pH of liquor.
3. Then the fabric is kept on template board of perspiration tester where 5 kg weight is
added.
4. Then it is put in over dry m/c for 4 dry.

5. Then the dried sample is compared with standard.
Lab. Deep Dyeing
Sample:
Type -100 % cotton fabric
- Weight - 5 gm
Procedure:
- At first the recipe for the sample is calculated according to the sample weight.
- The fabric is kept in the dyeing chamber.
- Then the dyes, chemicals, salt & required amount of water is taken in that dyeing chamber
by digital pipeting on the basis of stock solution.
- Then the beaker is set into the lab. Deep dyeing machine for dyeing. The program for
dyeing is started for 20 min at 40°C.
- After 20 min soda is added by pipeting.
- Then the dyeing program is set for 60 min at 60°C.
- When the dyeing time is finished the sample is taken out from the machine at
40°C.
- Then the sample is washed off. At first cold wash & then hot wash is done. After
it soaping is done.
- Then the sample is dried and compared with standard.
Progressive Process for Lab Deep Dyeing:
Recipe Calculation:
A dyeing recipe for purple color is given below:
Sample Weight - 5 gm

M:L-1:10
Liquid Required - 50 c.c.
Sunfix Yellow S3RD - 9.3 c.c. (Shade - 1.86%)
Sunfix Red S3BD - 10.2 c.c. (Shade - 4.08%)
Sunfix Yellow S3RD - 9.3 c.c. (Shade - 1.86%)
Salt (80 g/L) - 10 c.c. (40% stock)
Soda (20 g/L) - 2.5 c.c. (40% stock)
Water-11.5 c.c.
Salt and soda is taken on the basis of the shade%. The salt and soda is used according to the
following table:
Shade % Salt g/l Soda g/l
0.001-0.100 20 6
0.101-0.500 24 8
0.501-1.000 30 10
1.001-2.000 40 12
2.001-3.000 50 14
3.001-4.000 60 16
Above 4.000 80 20

CDA:
All chemical have to test. Such as -
1. H2SO4
2. Acetic acid.
3. Soda ash
4. Salt
5. H1O2
6. Color
7. Sequestering agent.
8. Water

DYEING DEPARTMENT OF EKL & EFL

Organogram of Dyeing Section
Manager (01)
Assistant Manager (02)
Senior Executive (03)
Executive (03)
Production Officer (03)
Senior Supervisor
Supervisor / Jr. Supervisor
Production Operator
Production Helper

Dyeing m/c of Epyllion knitex ltd:
Raw Material for Dyeing:
Raw materials used in the dyeing section are:
1. Grey fabric
2. Dyes
3. Chemicals
Dyeing m/c s no. Brand name: Origin: Capacity:
01 Fang’s China 10 kg
02 Thies Germany 350 kg
09 Son Tech China 75 kg
10 Son Tech China 150 kg

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

Main parts of dyeing machine:
The main parts of the dyeing machine are-
1. Main tank
2. Reserve tank/PT
tank
3. Additional/Mixing
tank
4. Main pump
5. Heat exchanger
6. Filter

The description of the main parts of the machine is as follows -
Main tank:
Main tank is the largest part of the dyeing machine. This is the main dye bath which
contains the dye liquor & the fabric. The size of the tank depends on the capacity of the
machine. Liquor & fabric circulates in the main tank during dyeing process. There may
have different number of nozzle connected to main tank according to the machine
capacity. Each nozzle may handle 300- 900m of fabric.
Reserve/PT tank:
This tank is mainly used for storage of hot water that will be used for the dyeing of
fabric. The temperature of water in the P.T. tank is maximum 800
C. By using this hot
water in the machine during dyeing there is a reduction of time for heating the water in
the main tank which results in the reduction of total dyeing time.
Fig: Main Tank

Additional/Mixing tank:
This tank is mainly used for storage of hot water that will be used for the
dyeing of fabric. The temperature of water in the P.T. tank is maximum 800
C.
By using this hot water in the machine during dyeing there is a reduction of
time for heating the water in the main tank which results in the reduction of
total dyeing time.
Fig: Mixing tank
Main pump:
This is one of the essential parts of the dyeing machine. This is used for
displacing of dye bath liquor causing a flow from main tank to heat exchanger
through filter. That means the pump ensures the liquor circulation throughout
the dyeing process.
Heat exchanger:
During the different stage of dyeing (also pre-treatment, after-treatment), there
is a need of increasing or decreasing the temperature of dye liquor gradually.
We cannot use liquor of required final temperature directly because there may
be possibilities of thermal shocking of the fabric. So, the temperature should be
increased or decreased in a controlled manner. This controlling is done by heat
exchanger. Actually it is an indirect heater. During the circulation of dye bath
liquor, the liquor passes through the heat exchanger.

Mechanism of Heat-exchanger:
1. Heat-exchanger consists of no. of tubes surrounded by a shell body.
2. Two fluids of different temperature flow through the heat exchanger. The
fluids can be either gas or liquid on either the shell side or the tube side.
3. One flows through the tube other flows through the shell.
4. The temperature of the two fluids is different, so transfer of heat occurs
from one fluid to another through shell.
5. The fluids which flow through the tubes come in and pass out from the
heat-exchanger on the same side. On the other hand the fluid used in
shell comes in and pass out from the different side of the shell.
Filter:

During the treatment of fabric in the machine, lots of lose fiber is produced
from the fabric. To eliminate these lose fibers, filter is used. It also reduces the
lose fibers loads from the fabric. If the lose fibers are not eliminated, then the
running of fabric is disturbed & entanglement can be occurred.
Ways of Liquor Flow from Additional Tank:
Liquor from additional tank flow to the main tank is mainly done in two ways.
They are -
1. Inject: In this system, all amounts of liquor flows directly to the main
tank at a time. This is done when the chemicals need to pass at short
time. This system ensures high rate of flow of the liquid.
2. Dosing: In this system, the liquor does not pass to the main tank at a
time. There are few chemicals which have very severe action to the fabric
if it flows directly like sodium hydroxide (NaOH). These chemicals pass
to the main tank in an increasing or decreasing way with time so that the
harsh effect of these chemicals is minimized. There are three
3. types of dosing:
- Linear Dosing - Progressive Dosing - Decreasive Dosing
Linear dosing Progressive dosing Decreasive dosing
Liquor circulation system:
During the treatment of fabric, the liquor is circulated throughout the
machine. At first, the required amount of liquor is taken in the main tank.
Then the liquor goes to the filter through pump and then it goes to the heat-
exchanger. From the heat-exchanger, the liquor goes to the main tank through
nozzle. The schematic diagram of liquor circulation system is given below-
T

Figure: Liquor circulation system
Types of machine according to temperature:
• Atmospheric machine
• High temperature machine
There are one atmospheric machine of Fong's brand in EKL and EFL.
Others are high temperature machine (both Fong's and Thies). Also there
are special types of high temperature machine used in named as Fong's
High Speed Jumbo (HSJ) Machine.
1 Dyestuffs and auxiliaries feeding container
2 Heat exchanger
3 Pump for the circulation of the liquor
4 High pressure pipe work
5 Dyeing drum
6 Winch

Features of Fong's atmospheric machine:
• The machine is designed for pre-treatment, dyeing & after-treatment
under atmospheric condition.
• Nozzle is sized for smooth passing through by the fabric and extensive
exchange with the liquid.
• Two standard nozzle sizes with sufficiently large diameter are available.
• Circulation pump is sized for heavy fabric
• Production capacity: 500 kg maximum per batch.
• Maximum temperature: 98o
C.
• Maximum pressure: 1 atm.

Features of Thies atmospheric HTHP machine:
• The machine is designed for the pretreatment, dyeing and after treatment
which can provide temperature up to 1400
C.
• Nozzle lead gets interlocked after temperature exceeds 800
C.
• Loading per nozzle 250kg
• Design pressure: 350-550kpa
• Design Temp : 1400
C
• Hydraulic Test Pressure: 585Kpa
• Manufacturer: Germany (Thies), China (Fong's)
• No of nozzles: 1-8.

Flow Chart For Dyeing:
Grey fabric receive from knitting section
Batching
Select m/c no
Fabric loading
Select production program
Pre treatment
Select recipe for dyeing
Recipe confirm by D.M / S.P.O
Dyeing
Post treatment
Unload

Different shade:
 Dyeing Sequence for Turquoise Color:
Level In (Water from p.t at 800
)
Check ph
Leveling agent injection
Run 10 min
Color dosing linear (800
c x 40 min)
Run 20 min
Salt dissolving (800
c x 15 min)
Run 200
Soda dosing (70% Progressing) (800
c x 50 min)
Check ph
Sample check
MIR rising 10 min
Bath drop

 Dyeing Sequence for Black Shade:
Level In
Run 10 min
Salt dosing (600
c x 10 min)
Run 15 min
c x 30 min)
Run 20 min
c x 50 min)
Check ph
Sample check
MIR rising 10 min
Bath drop

 Dyeing Sequence for 80 0
C Light Shade:
)
Check ph
Run 10 min
c x 35 min)
Run 20 min
Salt dissolving (600
c x 15 min)
Run 20 min
c x 50 min)
Check ph
Sample check
MIR rising 10 min
Bath drop

 Dyeing Sequence for 800
C Medium Shade :
)
Check ph
Run 10 min
Salt dosing (600
c x 10 min)
Run 20 min
Color dosing (600
c x 30 min)
Run 20 min
c x 50 min)
Check ph
Sample check
MIR rising 10 min
Bath drop

Some dyeing recipe:
Description
Color Type: Dark
Color: Black.
Dyeing Polyester part
T Vell W 3R – 0.24000%
T Red W4BS – 0.2400%
T Black BFE – 3.00%
Reduction cleaning
Hydrose-2 g/l
Caustic- 2 g/l
Dyeing Cotton part
S VELL MF3RD-0.7282%
S RED MF3BD- 0.3542%
RS BLACK WM- 5.6416%
Salt – 90 g/l
Soda – 5 g/l
Caustic-1.75 g/l
Nature of fabric: CVC Fleece
GSM: 280
M:L-1:6

Color: White.
BAM (OBA) – 0.90%
Caustic-2.5 g/l
H2O2 -10 g/l
Nature of fabric: S/J
GSM: 160
M:L-1:7
Color Type: Dark
Color: LT-NAVY
R.G. Yellow RGB – 0.2068%
R. UL. Car RGB – 0.3520%
R. Blue R.R – 1.800%]
Salt – 60 g/l
Soda – 18 g/l
Nature of fabric: Fleece
GSM: 260
M:L-1:6
Color Type: Dark
Color: Mountain Lake
R. Yellow RR – 0.1540%
R. TURQG – 2.0370%
R. BLUE RR-2.6400%

Salt – 80 g/l
Soda- 20 g/l
Nature of fabric: S/J
GSM: 160
M:L-1:7
Color: Black Newyork 1102B.
R. G. Yellow RGB – 0.4959%
R. UT. Car RGB – 0.131%
R. Deep Black RGB – 6.84%
Salt – 90 g/l,
Soda – 5 g/l
Nature of fabric:100% Cotton Fleece
GSM: 260
M:L-1:7

DYEING PRODUCTION (EFL)
MONTH PRODUCTION
JANUARY 412 TONS
FEBRUARY 381 TONS
MARCH 341 TONS
TOTAL 1,134 TONS
DYEING PRODUCTION (EKL)
0
50
100
150
200
250
300
350
400
450
JANUARY
412
MONTH PRODUCTION
JANUARY 412 TONS
FEBRUARY 381 TONS
MARCH 341 TONS
TOTAL 1,134 TONS
FEBRUARY MARCH
381
341
MONTH PRODUCTION
JANUARY 412 TONS
FEBRUARY 381 TONS
MARCH 341 TONS
TOTAL 1,134 TONS

MONTH PRODUCTION
JANUARY 232 TONS
FEBRUARY 206 TONS
MARCH 209 TONS
TOTAL 647 TONS
190
195
200
205
210
215
220
225
230
235
JANUARY
MONTH PRODUCTION
JANUARY 232 TONS
FEBRUARY 206 TONS
MARCH 209 TONS
TOTAL 647 TONS
FEBRUARY MARCH
MONTH PRODUCTION
JANUARY 232 TONS
FEBRUARY 206 TONS
MARCH 209 TONS
TOTAL 647 TONS

FINISHING
A fabric finishing process is a process for providing specific quality to
the fabric that is required by the customer. Textile finishing, in a
restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed fabrics are subjected before they are put to
market. It's one of the most important operations in knit processing.
Objectives of Finishing:
 Improving the appearance, luster, whiteness etc.
 Improving the feel, this depends on the handle of the
material & its softness, suppleness, fullness etc.
 Wearing qualities, non- soiling, anticrease, antishrink
comfort etc.
 Special properties required for particular uses like water-
proofing flame-proofing etc.
 Covering of the faults in the original cloth.
 Increasing the weight of the cloth.
Types of Finishing:
• Mechanical Finishing (Used to control dimension to improve appearance
& handle)
• Chemical Finishing (Used to make glossy protection. To improve
performance or service ability)
Finishing process:
Knit fabrics require finishing process after dyeing. During dyeing all
knit fabrics are dyed in tubular form. According to buyers requirement
dyed fabrics are finished in either tubular form or Open-width form.
Depending on which Finishing sections are separated into two sections - OPEN
& TUBE section.

1. Tubular finish:
Dewatering
Dryer
Tube Compactor
2. Open finish:
Slitting
Stenter
Open Compactor
3. Special Finish (Raising & Sueding):
Slitting
Stenter
Compacting
Raising/Sueding
No. of Machines of finishing section:
Name of the m/c No. of the m/c
Dewatering 2
Slitting 5
Dryer 3
Stenter 3
Open compactor 3
Tube compactor 2
Rasing m/c 1
Sueding m/c 1

Machine Specification:
Brand - CORINO
Origin – Italy
Function of Dewatering m/c:
 Removal of excess water (70-75%)
 Removal of residual dirt
 De-twisting of the rope fabric
 Make the fabric Tubular from Rope form
 Improve the hand feel of the fabric by using
softener
Controlling points:
 Width control (can be increased up to 3")
 Pressure variation according to GSM (higher GSM- 3-3.5bar,
Lower GSM-2-2.5bar)
 Fabric speed - 15m/min
Checking points:
 Hand feel
 Color spot
 Softener spot
De watering machine
1. Dewatering Machine

Fabric Path of Dewatering machine
2.Slitting machine
Brand - FERRARO
Origin - Italy
Function of the machine:
 Slit the fabric to make it open form.
 Removal of excess amount of water.
 De-twisting of the tube fabric.

Fabric Path of slitting machine
3.Dryer Machine
Brand - ENTEMA
Origin - TURKIYE
Function:
 To dry the fabric
 To control the shrinkage
 To control the fabric GSM (can be increased 10-15 GSM)
Controlling points:
 Overfeed
 Temperature
 Fabric speed - Maximum 30m/min

Checking Points:
 Shade check
 Fabric width
Temperature:
 White/light shade: 100-120'C
 Medium shade; 110-130 C
 Dark shade: 140-160'C
4. Stenter Machine
Brand - Monforts
Origin – GERMANY
Brand - LK and LH co. LTD
Origin – TAIWAN
Chamber:7
Function:
 To dry the fabric.
 Heat-set the synthetic fiber fabric.
 Controlling the width of fabric or maintain dimensional stability.
 Controlling the GSM of fabric.
 Skew ness & Bowing controlling of stripe fabric.
 Spirality & Twisting control.
 Fabric hand-feel modification-like-Softening or Hardening.
 Shade control.

Stenter machine
Controlling Points:
 Overfeed (0 - 50%)
 Temperature
 Speed
 Padder pressure
Checking Points:
Shade
Width
GSM
Faults
Finishing parameters for different types of fabrics in Monforts stenter:
Fabric type GSM Temperature Overfeed Padder
pressure
Speed Blower
RPM
s/j 115-150 110-140°C 40-45% 2 bar 15-20 1100-
1300
s/j 160-220 120-170°C 40-45% 2.5 bar 25-30 1200-
1400
L.s/j 160-220 130-160°C 50% 2 bar 25-30 1200-
1400
L.S/J 200-250 140-160°C 50% 2 bar 24-28 1200-
1400

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

Main parts of the machine:
1. Heating chamber
2. Blower (2, one at the entry chain zone for
uncurling and another at the entry of compacting
zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder
7. Belt cylinder
8. Uncurling device at entry of compacting zone.
9. sensor
Finishing parameters for different types of fabrics in compactor
(Ferraro, open width compactor):
Fabric
type
Color Speed Overfeed Temperature Blanket
pressure
Teflon
pressure
s/j White
color
15-18 25-30 90-100°C 1.5-2(bar) 33(P.S.I)
L.s/j White
color
12-16 12-16 90-100°C 1.5-2(bar) 33(P.S.I)
Pique White
color
15-18 30-35 100-110°C 1.5-2(bar) 33(P.S.I)
Fleece/terr
y
White
color
15-20 25-30 100-110°C 1.5-2(bar) 33(P.S.I)
1*1 rib White
color
15-20 20-30 110-120°C 1.5-2(bar) 33(P.S.I)
2*2 rib White
color
12-15 25-30 100-110°C 1.5-2(bar) 33(P.S.I)
Interlock White
color
12-16 Full over
feed
100-110°C 1.5-2(bar) 33(P.S.I)

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

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

STORE & INVENTORY CONTROL
Epyllion Group Textile Division Store & Warehouse Department

STORE
General CDA Yarn Grey fabric Finished fabric Leftover CDA sub
Store Store Store Store Store Store Store
Functions of store:
General store:
 PR against indent
 Preparation of MRIR after QC
 Issue against SR
 Input in to the ledger
 Physical arrangement by type
 First in first out policy
CDA store:
 PR against indent
 Issue against SR
 Physical arrangement by type

Yarn store:
 Received against PO
 Physical arrangement by count & lot
Grey fabrics store:
 Received from knitting & subcontract
 Issue to batch against SR
 Physical arrangement by location & order wise
Finished fabrics store:
 Received from finishing after QC
 Delivery against booking of merchandiser
 Physical arrangement by order & color
Leftover store:
 Received from all garments & floor
 Sorting by item wise
 Preparation of packing list
 Delivery against DO
CDA sub store:
 Received from main store
 Issue to production against SR
 Main the ledger
 Physical arrangement

Difficulties of store:
 Product lead time
 Space of storage
 Authorization for issue
Procedures: General store, CDA store &yarn store
Procedures: Grey fabrics store
Procedures: Finished fabrics Store
Procedures: Leftover store
Indent PR Purchase QC MRIR
Storage Issue to production
Rec. from knitting/sub contractor after QC Storage Issue to Batch
Rec. from finishing after QC Storage Delivery
Rec. all excess/rejects/wastages Sorting & packing List Delivery against DO

MAINTENANCE
Maintenance:
Machine, buildings and other facilities are subjected to deterioration due to their
use and exposure to environmental condition. Process of deterioration, if
unchecked, culminates in rendering these service facilities unserviceable and
brings them to a standstill. In Industry, therefore has no choice but to attend
them from time to time to repair and recondition them so as to elongate their life
to the extent it is economically and physically possible to do so.
Objectives of Maintenance:
1. To keep the factory plants, equipments, machine tools in an optimum
working condition.
2. To ensure specified accuracy to product and time schedule of delivery to
customer.
3. To keep the downtime of machines to the minimum thus to have control
over the production program.
4. To keep the production cycle within the stipulated range.
5. To modify the machine tools to meet the need for production

Maintenance of Machinery:
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time
inspection / checking of facilities to uncover conditions that may lead to
production break downs or harmful description.
Break Down Maintenance:
In this case, repairs are made after the equipment is out of order and it cannot
perform its normal functions.
Maintenance
Preventive Maintenance Break Down Maintenance
Electrical Mechanical Electrical Mechanical

Routine Maintenance:
Maintenance of different machines are prepared by expert engineer of
maintenance department. Normally in case of dyeing machine maintenance after
30 days complete checking of different important parts are done.
Manpower Set-Up for Maintenance
A Shift 6AM -2 PM
B Shift 2PM -10 PM
General Shift 9PM – 6 PM
Maintenance Manager
Mechanical Electrical
Mechanical In charge -02 Electrical Foreman -02
Diploma (Mechanical)-02 Diplomas (Electrical) -02
Welder and fitter -01 Electrician -02
Fitter -01
Maintenance Procedure:
Normally preventive maintenance should be done. During maintenance
procedure following points should be checked:

Maintenance of knitting machine/flat knitting machine:
SL. No. Items need to be checked & Serviced
1 Check and tightening all motor terminals.
2 Check and clean pressure sensor and tightening terminals
3 Clean the ventilation fans of panel board and circular fan on
top of machine
4 Check and clean the interfacing and data cables.
5 Check and tightening the proximity switch terminals.
6 Inspection, cleaning and tightening all the terminals in the
panel
7 Check and tightening limit switch, safety door guard and the
emergency switch.
8 Functional test of the yarn detector.

Check List of Different Parts
Maintenance: Mechanical
Machine : Dyeing machine
1 Crease the m/c bearing.
2 Complete cleaning of machine.
3 Cleaning of drain valves, replace seals if required.
4 Check air supply filters, regulators auto drain seals
5 Clean filters element and blow out
6 Greasing of unloading roller bearing.
7 Checking of oil level and bolts of unloading roller
gearbox.
8 Checking of unloading roller coupling and packing.
9 Checking & cleaning (if required) of main vessel level
indicator.
10 Check the oil level of pump bearing and refill if
required.
11 Check the function of heat and cool modulating valves
12 Check all door seals

Machine : Dyeing machine
1 Check & clean fluff and dirt at dirt at all motor fan covers.
2 Check all motor's terminals
3 Check main panels (by using compressed air)
4 Check panel cooling fan & clean its filter
5 Clean main pump inverter and its cooling fan.
6 Check all circuit breaker, magnetic conductors and relays.
7 Check current setting of all circuit breaker & motor over
load.
8 Visual checking of all power & control cables.
9 Check all pressure switches
10 Check calibration of main vessel & all addition tank
11 Check all pneumatic solenoids
12 Check calibration of heating/cooling modulating value
13 Check setting of tangle sensor.
14 Check setting & operation of lid safely switches.
15 Check setting & operation of lid safely switches.
16 Check all emergency switches
17 Check all indicating lamps
18 Check all on/off switches

Maintenance: Mechanical
Machine: Boiler
SI. No. Item needed to be checked & Serviced
1 Checking of gas pressure and gas supply line
2. Dosing of softening chemicals to supply water
3. Checking of all steam lines
4. Cleaning of burner tank (after six month interval)
5. Checking and replacement of valves
6. Cleaning of feed water tank
7. Checking and replacement of filters
8. Cleaning of sight glass
Maintenance Tools & Equipments:
1. Combination tools / spanner
Function: Tightening & loosening of nuts & bolts.
2. Socket ratchet set
Function: Tightening of nuts & bolts.
3. Slide range
4. Monkey pliers
5. Pipe threat cutting tools
Function: To cut the threat in pipe.
6. Bearing puller
Assist the opening of bearing from shaft.

7. Pipe range
Function: Tightening & loosening of pipe joint.
8. Pipe cutting tools
Function: For pipe cutting.
9. Hole punch
Function: Punching the hole.
10. Divider
Function: For circle marking on metal & wood.
11. Easy opener
Function: To open the broken head bolt.
12. External threat die
Function: For external threat cutting.
13. Heavy scissor
Function: Cutting of gasket & steel sheet.
14. Oil can
Function: Oiling of moving parts.
15. Drill machine and drill bit.
Function: For drilling.
16. Grease gun
Function: For greasing of moving parts of m/c.
17. Grinding m/c
Function: For grinding & cutting of mild steel.
18. Welding m/c
Function: For welding & cutting.
19. Spirit leveler
Function: For perfect leveling.

20. File
Function: For smoothing the surface.
21. Hammer
Function: For scaling & right angling.
22. Circle tools
Function: Circle opening & closing.
23. Hacksaw blade
Function: For metal cutting.
24. Handsaw (wood)
Remarks:
Maintenance of m/c's are very essential to prolong the m/c life and good
maintenance is important consideration. It is necessary to check that all routine
maintenance is being done regularly and properly otherwise efficiency of each
department will be reduced.

UTILITYIES
Introduction:
EPYLLION GROUP is a big project and so of course having a vast project of
utility service. Here the total accounts of utility facilities are available. The
utilities are
a) Water
b) Gas
c) Electricity
d) Compressed Air
e) Steam.
S
L
Machine Name Brand Origin Capacity
Unit
(PCS)
Manuf.
Date
Erection
Date
Re
ma
rks
1 Generator Deutz
German
y
1344KW 2 2006 2006
2 Generator Perkins UK 340 KW 1 2002 2003
3 Generator
FG
Wilson
UK 750 KW 1 2003 2003
4 Compressor Roll Air France 281 m3
/h 2 2002 2003
5 Compressor Roll Air France 508 m3
/h 3 2006 2006
6 Compressor Dryer Roll Air France 3.5 Kg 1 2002 2003
7 Compressor Dryer Roll Air France 4.8 Kg 1 2006 2006
8 Boiler
Cleaver
Brooks
USA 9.5 Ton 2 2002 2003
9 Water Treatment
Plant
Matcon India 30 m3
/h 1 2003 2003
1
0
Water Treatment
Plant
Epyllion
Banglad
esh
70 m3
/h 1
Under
Construction
1
1
Effluent Treatment
Plant (Chem-Bio)
Dorr
Oliver
India
720
m3
/day
1 2003 2003
1
2
Effluent Treatment
Plant (Biological)
SiememS Italy
2400
m3
/day
1 2006 2006

ELECTRICITY
Gas Generator is used for supplying electricity for the dyeing, knitting & office
of the EPYLLION GROUP.
Total power produced by Gas Generator - 1344KW = 1724 KVA
Factory (Dyeing & Knitting) Power Needed for Installation -About 1200 KW
Factory (Dyeing & Knitting) Power needed at running stage - About 720 KW
Power Needed for Office - About 250 K

Technical Details Generator Data
Type V-TYPE
Manufacturer DUTZ
No. of Gas Generator 02
Model No. 315GFBA
Manufactured Country England
Year of Construction 2006
Rated Power Prime
Rated 1340KW-2nose
Power Factor 0.8
Voltage 400
Rated Current (amp) 568
Frequency (Hz) 50
Rotating Speed (RPM) Isoo
Battery Volts 24
Control System , PCCP
Site altitude before derate 800 MASL
Site ambient temp, before
derate
40°C
No of Cylinder 16
Source of Power used for Garments - Own Supply Power Capacity - 750 KVA
= 900 KW There is a diesel Generator in the industry. Capacity of Diesel
Generator - 800 KW

Specification of Diesel Generator is given below
Technical Details Generator Data
Type Diesel Generator
Manufacturer CATERPILLAR
No. of Diesel Generator 02
Model No. SR4BISR4
Manufactured Country U.S.A
Year of Construction 2004
Rated 649 H.P. or 484.0 KW
Rotating Speed (RPM) 1500
Voltage 400
Rated Current (amp) 723
Maximum Temp. 105 C by Resistance

COMPRESSED AIR
Compressed air is produced by air compressor.
There are two air compressors for producing compressed air.

STEAM
Steam is produce by Boiler.
Form the water treatment plant water is stored in a reserve tank and from there
water goes to boiler & steam in produced

GAS
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section (Boiler- for heating
water) from the main line of the TITAS GAS LTD.
Sources of Utility:
Electricity : PDB & Generator
Steam : Boiler
Water : Pump
Compressed air: Compressor
Gas : Titas gas transmission & Distribution Ltd.

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

Brief on Epyllion ETP:
• It posses the above three types of ETP.
• But right now only Bio-logical ETP is used as other two is very cost
consuming process.
• Capacity of bio-logical ETP is 2400 m3
day.
• Oxidation tank capacity is 48000 m3
.
• Epyllion group is very concern about environment, as they never stop
their ETP or can be said they keep it running 365 days in a year.
Explanation of Bio-logical Effluent Treatment Plant
Inlet water:
• From dyeing floor an inlet water line is directly connected to ETP.
• There is separate line for pre-treatment water like dyeing water, soaping
water,
• Usually other wash water directly discharges to the environment.
Water Filter
• At the entrance of effluent water to ETP .water goes through a filter.
• Its try to remove solid materials like waste threads. Fabric pieces lint’s
Enzyme waste etc.
Storage/Equalizing tank:
• Water from different inlet pipe store there finally.
• There occur equalizing of gathered water as they come from different line,
by a mixer.

Feed Pump:
 There are three submersible pumps for feeding this raw water from
Equalizing tank to homogenization tank.
 The feed pipe of these three pumps is in three different heights. Pumps
are automatically on-off depending on the level of water.
Storage & Homogenization Tank:
 Feed pump. Feed raw water to this tank.
 There are number of air supplier [Aero jet] below water level for
supplying air to water.
 Also there occurs the cooling of water & good mixing.
 This air dosing is vitally important as water will subsequently face
oxidation.
 Thus from this tank we get a Cool. Well-mixed & oxygen enriched
effluent water.
 Retention time of water in this tank is 20hr,
 Storage capacity 2000 m3
.

Neutralizing tank:
• There occurs drop wise dosing of 98% pure Sulphuric acid. [Never less than
95% pure]
• This operation is important as at adverse pH bacteria or other micro-
organisms will be killed.
• Here Hydrochloric acid should not be used as it will kill micro-organisms
when there is more than 0, 3 mg/ €12 in the water.

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

Sometimes anti-foaming agent is used in this tank:
If bacteria become weak, then nutrient is fed in this tank. Usually 0.5 kg in 50
liter water [especially when water processing remains shut down]
Na-hypochlorite is added to this tank sometimes if any insects attack in this tank
[specially when water processing remain shut down]
Temperature of this tank is 25-30° C.
Before Clarifier Tank:
 Water deodorant dosing is done in this tank.
 Maintain pH 3.0-5.0 & M:L is 1:4
 Retention time is 10-15 min,
 If water deodorant is not used than micro-organisms will be
killed.
 From this water goes to deifier & sedimentation tank,

Clarifier & Sedimentation Tank:
• Here occurs the sedimentation of sludge by the slow rotation of the clarifier.
• By overflow water goes to discharge line.
Sludge Recycling Tank:
 All sediment sludge are finally comes to this tank.
 From this, to maintain continuous supply of micro-organism sludge is
supplied to the feed tank.
Excess Sludge Storage Tank:
 In the oxidation tank, if it is found more amount of sludge
than the necessary. at that time some excess amount of
sludge is supplied to excess sludge recovery tank.
 Here from sludge water is removed & make the
sedimentation of sludge at the bottom of tank.
 Here dosing of polymer is done which assist the job of
sedimentation.
 M: L is 1:80 for polymer.
Filter Press:
 Sediment sludge comes to this machine.
 Here, all the water is removed from sludge & make it dry as cake.

Required Chemicals of Biological ETP:
 98% H2S04.
Function:
Neutralize the waste water by controlling pH.lt is auto dispensed in the
neutralization tank.
 Polyelectrolyte
Function:
Used for sedimentation/sludge coagulation and also killing
bacteria.[Coagulation in water treatment, the use of chemicals to make
suspended solids gather or group together into small flocks.]
It is used auto/manually in sludge thickener tank.
 De colorants
Function:
Used for removing color.lt is used auto/manually in sludge thickener tank.
 Anti foaming agent
Function:
Used for reducing/controlling foam.lt is used auto/manually in the oxidation
tank.
 Sodium hypochlorite:
Function: It is used to killing harmful bacteria/insect. It is used in the
Biological Oxidation tank.

 Nutrients:
Function:
When bacteria become weak it is added to a certain quantity. It is added in the
oxidation tank.
Condition of effluent for discharge to drain at EPYLLION
KNITEX LTD:
Bio-logical ETP
Name of factors Standard
amount
Biological ETP
of EPYLLION
PH 7.0-9.0 7.74
Color Reddish reddish
BOD <50 mg/l 16 mg/l
COD <200 mg/l 67 mg/l
IDS <2100mg/l 1869 mg/l
TSS <1 50 mg/l 112 mg/l
DO 4.5-8.0 4.23
Chlorine <600 mg/l 342 mg/l
Chlorine ETP
amount
Chlorine ETP
of EPYLLION
PH 6.0-9.0 3.23
BOD <50 mg/l 240 mg/l
IDS <2 100 mg/l 1942 mg/l
TSS <150 mg/l 220 mg/l
DO 4.5-8.0 5.22
Chlorine <600 mg/l 390 mg/l

Chemical ETP
amount
Chemical ETP
of EPYLLION
PH 6.0-9.0 9.78
Color 150 59
BOD <50 mg/l 21 5 mg/l
TDS <2 100 mg/l 5361 mg/l
TSS <150 mg/l 13 mg/l
DO 4.5-8.0 6.21
Testing of ETP:
• Color of sludge:
If it is brown, then ok.
• Measurement of sludge:
From oxidation tank 1 liter water is brought & kept undisturbed for 30
min. Then the amount of sludge is measured.
• Strength of micro-organism:
It is determined by smell of water. If there is any bad smell in water it
noticed that bacteria becomes weak & need to add nutrients.
• Condition of oxidation bath:
If there occurs attack of insects in oxidation tank, then need to add
sodium-hypochlorite in that tank.
COST OF EFFLUENT TREATMENT:
Per kg water processing cost in BDT-0.39 Tk
Per m3
water processing cost in BDT-3-4 Tk

BUYER COMPLAIANCE
The factory is full compliance with ILO and Bangladesh Labor Law. Their
company policy
is as follows:
No child labor.
No forced labor.
Transport facilities for worker.
Hours of work.
Voluntary over time.
Intervals for rest.
Weekly holidays.
Annual leave.
Festival holidays & leaves with bonus.
Maternity protection.
Worker's welfare committee.
Mineral drinking water.
Sanitary facilities.
First aid box.

Industrial attachment of epyllion knitex ltd

Industrial attachment of epyllion knitex ltd

Related slideshows

More Related Content

Industrial attachment of epyllion knitex ltd