ACKNOWLEDGEMENT:We are extremely delighted to express our indebtedness and deepest sense of gratitude to our supervisor Muhammad Sydul Krim(in-charge,Sales & Distribution).for his able guidance, untiring efforts, stimulating influence and valuable comments during the training period . We would like to offer sincere thank to the Abdul Wadud(Chief Operation Officer) for his invaluable suggestions regarding this training period. The authority of the VIYELLATEX GROUP who gave us the opportunity to complete our industrial attachment with great success is remembered with honor. Thanks are due to all Engineers, officers, technicians, employees, stuffs, all section in-charges for their cordial behavior. We are really lucky that we have gotten such helping hand without whom, this attachment could not be completed. We also like to thank Md.Shahadat Hossain Saikat(Executive 2,Knitting), for his encouragement, valuable suggestion, and for the completion of this Industrial attachment successfully. Last but not least, thanks goes to my precious family for their never-ending support and loves in every stages of my life which has motivated me to do such type work.

EXECUTIVE SUMMARYThe internationally recognized Buyers or clients are looking for those countries for producing their apparel products where different types of mills have established as a one stop source for the global apparel market, satisfy and meet customer's expectation by developing and providing products and services on time, which offer value in terms of Quality, Price, Safety & Environmental impact. And also assure complete

compliance with the international quality standards and also to provide the employees internationally acceptable working condition/standards. In Bangladesh, there are different types of Textile Industry those are producing high quality textile and apparel product. VIYELLATEX GROUP is one of them. VIYELLATEX GROUP is a Knit Composite Garments, having all state of the art facilities with the annual turnover US$ 106.6 Million (2006-2007). They have different types of Knitting, Dyeing, Cutting, Sewing, and Finishing machines supplied by mostly Germany, Japan, Taiwan, China, U.K, U.S.A, Singapore, etc. which are very latest. It has high production where 30 Metric tons of dyed and finished fabrics are produced per day. The production is controlled by technical persons. All of the decision makers of production sector in VIYELLATEX GROUP are textiles graduates. All the chemicals and dyes use for dyeing and finishing are well branded. They produce their product for their buyer and client those are coming from international market like U.K, Sweden, Netherland, France, U.S.A, Germany and Spain. Their customer profile is big and top end such as Esprit, M&S, SOliver, Puma, G-star, Gap, Tesco and Grew waver etc. They follow all the system for their machines maintenance so production can not hamper. In this report, we have tried to give some information about VIYELLATEX GROUP and we have observed that VIYELLATEX GROUP produce high quality fabric and fulfill the special requirements from the different types of buyers by following different internationally recommended standard method.

GENERAL INFORMATION ABOUT THE FACTORYIt all started as a small family business of knit apparel manufacturing in 1996. Since then, it has grown manifolds as one of the leading multi-dimensional business conglomerates of Bangladesh with spinning, knitting, dyeing, accessories and printing facilities, and emerged as VIYELLATEX group in 2002. VIYELLATEX is now looking towards a more vibrant future by diversifying the business in different sectors. Starting as a quality fashion and garment manufacturer, it has come a long way to venture into logistics, agriculture, power and energy sectors. VIYELLATEX considers corporate sustainability as an important edifice of its ethics. It gives special importance to all its corporate sustainability activities. It values environmental protection and conservation, and realizes that only by being responsible to nature can we truly be responsible to the people and planet. It considers corporate sustainability as an investment for the future, both for business and nature. VIYELLATEX has one of the best, dedicated and skilled workforces in the country. These are the people with the best talents, commitments, and expertise with the blend of experience and enthusiasm. They work hard closely with stakeholders and are fully committed to deliver the best results, ensuring their satisfaction underpinned by the VIYELLATEX Values.

PROJECT DESCRIPTIONName of the Company : Status : Type : Dyeing Year of establishment : year of starting production : Location : VIYELLATEX GROUP Private Ltd. Company 100% Export oriented composite knit 2001 2002 Gazipura, Tongi

CORPORATE OFFICE AND FACTORY ADDRESS297, Khortoli, Tongi, Gazipur-1712 Tel : No: 88192812 Fax No: 880-2-8810445 E-mail: info@viyellatexgroup.com Web address: www.viyellatexgroup.com

LAYOUT FOR GOING TO THE VIYELLATEXTILE

AWARDS & ACHIEVEMENTSAs part of The Social and Environmental Excellence Award 2012 -- an initiative of Bangladesh Brand Forum and GIZ, VIYELLATEX have received award in the Resource Use Efficiency sub-category for its environment-friendly production practices. In addition, VIYELLATEX have also received Honorable Mention - Best Worker & Management Relationship in Social Compliance Category.

2011o

Plan A Award Awarded by Marks & Spencer for Biggest contribution to plan A & innovation

2010

o

o

o

o o

o

HSBC-The Daily Star Climate Award Green Business Entrepreneurship and for adopting green and energy saving technology in Manufacturing Garments BGMEA-BATEXPO Award Outstanding contribution to BGMEA and CSR activities, workers welfare and overall image lifting of Readymade Garments HSBC Export Excellence Award Excellence in Export Business Performance awarded to Interfab Shirt Manufacturing Limited Best Workers Friendly knitwear Industry For Workers friendly knitwear industry CIP (Commercially Important Person) Status Awarded to Vice Chairman Ahsan Kabir Khan by the Ministry of Industry, Bangladesh PVH Gold Award Outstanding performance of delivery and controlling production

2009

Industrial Relations Award Awarded by local labor union "Awaj Foundation" Strategic Partner Award Awarded by PUMA PVH Gold Award Outstanding performance of delivery and controlling production CIP (Commercially Important Person) Status Awarded to Chairman and CEO of VIYELLATEX group, K.M.Rezaul Hasanat by the Ministry of Industry, Bangladesh

2008

CSR Award Awarded by Standard Chartered Bank & Financial Express Workers Friendly Factory Awarded by Awaj Foundation

2007

Best Business Award Awarded by DHL-The Daily Star Award for CSR & Export Performance in RMG Sector Awarded by Bangladesh Garments Manufactures & Exporters Association

2006

National Export Trophy Awarded by Export Promotion Bureau

2005

National Export Trophy Awarded by Export Promotion Bureau

Product Mix100% cotton 100% polyester Spun Filament Nylon Chief Value Cotton (CVC) Polyester Cotton (PC) Grey mlange (15% Viscose 85% cotton) 10% Viscose 90% cotton Ash mlange (1% Viscose 99% cotton)

VIYELLATEX SPINNING

CHUTE FEEDING OR AERO FEED SYSTEMPneumatic fiber transport system used in linking textile processing equipment or operations, especially opening, blending, and carding.

Advantages of flock feeding or chute feed sytem :The automatic continuous feed directly linked to the blow room eliminates the lap formation. This increses the working efficiency of the blow room. The main power requirement in doffing the lap, weighing, transportation to card and feeding at the card is eliminated. The processing of rejected laps in the blow room is avoided.

Production flowchart of yarn manufacturing COTTON BALES

BLOW ROOMBlowroom Blowroom consists a number of machines used on succession to open and clean the cotton fibre. Since the tuft size of cotton becomes smaller and smaller, the required intensities of processing necessitates different machine configuration. Objects of Blowroom: 1. Opening: a) To open the compressed bales of fibres.b) To make the cotton tuft as small as far as possible. 2. Cleaning:To remove dirt, dust, broken seeds, broken leaves, and other foreign materials from the fibre. 3. Mixing & Blending: To make good value of yarn and to decrease production cost mixing and blending is done. 4. Lap or flocks formation: To transfer opened and cleaned fibre into sheet form of definite width and length which is called lap...

CARDINGROOMCarding is a mechanical process that disentangles, cleans and intermixes fibers to produce a continuous web or sliver suitable for subsequent processing. This is achieved by passing the fibers between differentially moving surfaces covered with card clothing. It breaks up locks and unorganised clumps of fibre and then aligns the individual fibres to be parallel with each other. Carding can also be used to create blends of different fibres or different colors. When blending, the carding process combines the different fibres into a homogeneous mix. Commercial cards also have rollers and systems designed to remove some vegetable matter contaminants from the wool

DRAWING FRAMA machine in which several strands of SLIVER are combined into one strand and drawn out so that the combined strands approximate

SIMPLEXSpeed Frame: Simplex is an intermediate process in which fibers are converted into low twist lea called roving. The sliver which is taken from draw frame is thicker so it is not suitable for manufacturing of yarn. Its purpose is to prepare input package for next process. This package is to prepare on a small compact package called bobbins. Roving machine is complicated, liable to fault, causes defect adds to the production costs and deliver the product. In this winding operation that makes us roving frame complex. There are two main basic reasons for using roving frame. Speed frame Necessity of Speed Frame: 1. The first reason is related to the required draft. Sliver is a thick, untwisted strand that tends to be hairy and to create fly....

RING FRAMESpinning process is done by the machine called Ring frame. Ring frame converts the bobbin into a yarn. The bobbin taken from the previous process Fly frame is mounted on Ring frame either automatically or manually. The Ring frame stretches the material using a drafting system and then twist is imparted to the material coming out from the drafting system of Ring frame. Once twist is imparted, the material is converted into a yarn. The yarn is then subsequently wound on a package called Bobbin or Cop. Recent days there were more than 1000 simultaneous cops wound in a Ring frame. A Ring frame contains two sides. For example, if a Ring frame contains 1008 yarn delivery positions, then there will be 504 deliveries on both sides. The delivery cop will revolve continuously with the help of an element called Spindle which usually revolve at a speed of about 20,000 rpm. Recent days, the maximum possible speed limit is 25,000 rpm. Delivery yarns are classified as "Counts" based on the linear density (thickness) of the yarn.

AUTOCONERAuto Winding is the process of converting the cop yarn from Ring frame into a larger package, especially cones by combining many Ring cop yarns together. There are many Auto Winder manufacturers like Muratec, Schlafhorst, Veejay Lakshmi and Savio. There is a special component in Auto Winder which is called as Electronic Yarn Clearer. This clearer clears the faults from yarn. Faults like Mass faults and color faults are cleared by this clearer. Popular clearer manufacturers are Premier Evolvics, Uster and Loepfe.

HEAT SETTINGHeat setting is a textile industry process for removing spinning- and cabling-induced torque and impart dimensional stability in fibers and yarns. The process may also cause synthetic fibers to gain bulk or volume and is also used to stabilize fibers after processes such as friezing. Heat setting is a thermal process which utilizes either steam or a dry convection heat source to set the fabric or yarn. This process is typically carried out in an enclosed pressure chamber or autoclave or on open conveyors exposed to steam sprays. Steamsetting is a standard post-production process for a wide selection of natural and synthetic fibers intended for the garment and carpet industries.

YARN CONE

VIYELLATEX SPINNING LIMITED. MULAID, SREEPUR, GAZIPURLIST OF RING SPINNING MACHINERIES:

PRODUCTION MACHINERIES:

Sl No.

Section

Machine Name

Model/ Type

Manufacturer

Country of Origin

Quantity

Capacity (KG)

1

Blow room Line-1 & 2

Blendomat

BDT 019

Trutzschler

Germany

1

34560

SP-MF CL-P MXI-10 CLC-3 SP-F Trutzschler card Draw frame Rietu Draw frame Unilap Comber Roving frame Ring frame

1 2 2 2 2

2 3

Carding DSC

TC--03 SBD-15

Trutzschler Rieter

Germany Germany

18 6

27000 27000

RSBD-35 E-32 E-65

Rieter Rieter Rieter

Germany Switzerland Switzerland

6 2 10

27000 16000 12000

4 5

Simplex Ring

FL-100 LR 6/A

Toyota Lakshmi

Japan India

9 40

27000 21800

6

Finishing

Winding m/c Heat setting m/c

AC-338 RM

Schlafhorst

Germany

14

24800

LT-0

Xorella A.G

Switzerland

1

27000

OTHER EQUIPMENTS:

Sl No. 1

Section Baling

Machine Name Bale pressing Cot grinding & mounting m/c Lubricating m/c Concentricity Tester

Model/ Type

Manufacturer Laxmi

Country of Origin India

Quantity 1

Capacity

2

Ringshop

Berkol

Switzerland

5

Texparts

EU

1

Berkol

Switzerland

1

UTILITY MACHINERIES:

Sl No.

Section

Machine Name

Model/ Type VHP5904GSID

Manufacturer

Country of Origin

Quantity

Capacity

1

Generator

Generator

Waukesha

USA

4

900 KW / machine

2

Boiler

Schneider Kassel Berlin

WHR290010

German Thai boiler

Germany

1

2.9 T / R

3

Chiller

Steam fired chiller

LSH-W070

LG Cable Ltd

Korea

1

670 USRT

Hot Water chiller Gas fired chiller 4 A/C plant A/C & Humidification 5 Compressor Compressor

LWMW048

LG Cable Ltd

Korea

2

250 USRT / machine

LDF-W063 IP-22

LG Cable Ltd Luwa

Korea Switzerland

1 4

490 USRT 1660 RT

CSD-82

Kaeser

Germany

4

6.9 cu.m/min

TESTING EQUIPMENTS:

Sl No.

Section

Machine Name Uster Tester

Model/ Type 4SX Spectrum 1 Pro

Manufacturer Uster

Country of Origin Switzerland

Quantity

Capacity 1 400 m/min

1 Laboratory

Uster HVI Uster AFIS Uster Autosorter Yarn reel Electronic Twist Tester Sliver roving reel

Uster Uster

USA USA

1 1 1 dtex~100 1 Ktex 1 50~300 rpm Up to 2200 1 rpm

4 Uster YRL:001 Wira

Switzerland Italy

DTT:002

Wira

Italy

SRR:001

Wira

USA

1

Portable scale Moisture Tester Tachometer Tension meter

LBP:001

Wira

USA

1 200g

HMT:001 LSR:103

Wira Wira

USA UK

1 4~22% MC 1 Up to 2M

DTMB-500

Wira

Germany

1 500 cN

ROTOR SPINNING (OPEN END) MACHINERY:

Production:

Sl. no 1

Section

Machine name Trumac

Model / Type

Manufacturer Country of No. of origin machine Trumac India

Capacity (kg/day) 10000

Remarks ( Eff)

Blow room Line-1

2

Pre

Trumac card

DK 800

Trumac

India

07

spinning

Trumac Draw frame Open End m/c

TD-03

Trumac

India

02

3

Spinning

BD380

Schlafhorst

Chech

04

(Utility):

Sl. no Section

Machine name

Model / Type

Manufacturer

Country of origin Austria Korea Turkey

No. of machine 01 01 01

Capacity

1 2 3

Generator Chiller Electrical

Generator Gas fired chiller BBT

JGS420 GS SO 32 S

Jenbacher LG Cable Ltd EAE Elektrik Asansor End Bestair Group

1416 KW 260 USRT 2000 A

4

A/C plant

A/C & Humidification

Taiwan

01

(Lab equipments)

Sl.

Section

Machine

Model /

Manufacturer

Country of

No. of

Capacity

no 1 Lab

name Sliver roving reel Portable scale

Type Manual

origin Local

machine 01

BL 2200H

Shimadzu

Japan

01

2000gm

Other equipments:

Sl. no 1

Section

Machine name Willow waste m/c

Model / Type

Manufacturer

Country of origin Local

No. of machine 01

Capacity

Blowroom

J.K Traders

LATEST PRICE OF YARN FOR VIYELLATEX SPINNING

VIYELLATEX Limited (VTL) is the composite knit apparel and textile manufacturing business unit of VIYELLATEX group. It started its journey in 1996. VTL is comprised of Design and Product Development, Sample, Knitting, Dyeing, Washing, Cutting, Sewing and Finishing sections. The Textile Testing Corporation (Testing Lab) is also a part of VTL. It caters to major buyers like Puma, S.Oliver, Espirit, Marks and Spencer, Sainsburys, etc. The products of VTL range from mens wear, ladies wear and kids wear. These are manufactured using technologically efficient machinery imported from Europe and Asian countries. VTL is FLO-Cert and Oeko-Tex certified among others. The state-of-the-art Textile Testing Corporation is accredited by Marks & Spencer and Puma. Furthermore, in collaboration with Marks & Spencer, VTL recruits and trains physically handicapped individuals to enable them to enter into the mainstream job. These employees have shown remarkable performances over time. All sustainable initiatives undertaken by VTL have been aimed towards ensuring social and environmental prosperity.

Name of The BuyerMarks & Spencer S.Oliver Tesco Gap Puma Esprit G-Star PVH Woolworths Celio Abercrombie& Fitch Gerry Weber

CountryU.K Germany U.K U.S.A Germany Germany Netherland U.S.A France U.S.A Germany

Different Departments of VIYELLATEXTILE LIMITED (VTL)

a) Knitting Section:Knitting Inspection

b) Dyeing section:Batch section Dye house Dyeing lab. Quality control Finishing

C) washing section: d) Textile Testing Corporation (Testing Lab): e) Garments section:Merchandising Sample Cutting Section Sewing Section Finishing Section

KNITTING

KNITTINGKNITTING IS THE PROCESS OF PRODUCING A FABRIC BY FORMING A SERIES OF CONNECTED LOOPS FROM A SERIES OF YARN. IN THIS METHOD FABRIC IS PRODUCED BY INTERMESHING OF LOOPS.

KNITTING TYPES Warp knitting: each loop in the horizontal direction is made from adifferent thread and the number of threads used to produce such a fabric is at least equal to the number of loops in a horizontal row.

Weft knittinga horizontal row of loops can be made using one thread and the thread runs in horizontal direction. INDUSTRIALATTACHMENTONVIYE

L L A T E X Page 2

Raw Material for KnittingThe raw material for knitting is the yarn. Different types of yarn of wide range of count are used. In yarn store section we had the chance to know about different yarns of different count used in \/IYELLA TEX knitting. We also have known different yarn manufacturer/suppliers name for this knitting section i.e. sources of yarn. Both carded and combed yarn is used for knitting. Cotton 24S, 26s,30S, 32S,34S,40S 75D, lO0D 20D,40D, 70D

Polyester=

Spandex yarn

Grey Mlange Ecru Mlange (C-85% V-15%) Anthra Mlange (C-65% V-35%) PC (65%Polyester & 35% cotton) CVC

24S,26S 24S,26S,28S 24S,26S,28S 24S,26S,28S,30S 24S,26S,28S,30S

Sources of mellange: Patartoli

Prime Shohag pur Thermax

Sources of polyester:

Kader Synthetic. China. Count: 75den, 100den, 150den.

Sources of Lycra: 1) Brand: Country: 2) Brand: Country: 3) Brand: Country: Roica Taiwan. Texlon Korea. Acelen China

4) Brand : Creora Country: Japan 5) Brand : Lioli (In Viyellatex used mostly) Country: China

ORGANOGRAM OF KNITTING SECTION

I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2

MACHINERIES LIST OF KNITTING SECTIONMachine name 1) Circular Knitting(Single jersey) m/c 2) Circular Knitting(Rib) m/c 3) Engineering Stripe m/c 4) V-bed Knitting m/c 5) Grey Fabric Inspection m/c Machine Quantity 46 22 08 28 4

Knitting section is divided in four sections,1. Inspection section 2. Flat knitting section 3. Circular Knitting section 4. Store section

1. Cloth Inspection Section: In cloth inspection section two machines are available. Specification of those machines is given below Type Manufacturer name County Model No. Quantity Cloth Inspection Machine UZU fabric Inspection Thailand UZ 900.31 4

2. Flat Knitting Section: Generally collar, cuff of knitted garments is produced in this section. In this section there are 25 flat knitting machines. all of them are same type and also have same specification. The specification of all machines is given below:

Type Manufacturer name Country Model No Gauge Quantity

Automatic Flat knitting machine Precision Fukuhara Works Ltd. Japan I-100 G14 28

3. Circular Knitting Section: This section contains 72 circular knitting machines. Circular knitting machines are of different types, made by different manufacturer and also have different specifications. In this section body fabric for knitted garments is produced. The different specifications of different machines are given one after another

Machine no: 01Machine type: Single jersey Brand: Fukuhara (vxc-3s) Origin: Kobe, Japan Machine dia &Gauge: 30; 24G Extra cylinder: 30; 20G no of needle: 1860 Machine no: 03 Industrial attachment Machine type: Single jersey Brand: Fukuhara (vxc-3s) Origin: Kobe ,Japan Machine dia &Gauge: 26; 24G Extra cylinder: No of needle: 1932 No of feeder: 78

Machine no:02Machine type: Single jersey Brand : Fukuhara (vxc-3s) Origin : Kobe, Japan Machine dia&Gauge:26.24G No of Needle : 1932 No of feeder : 78 Machine no: 04 Machine type: Single jersey Brand: Fukuhara (vxc-3s) Origin: Kobe, Japan Machine dia &Gauge: 30; 24G Extra cylinder: No of needle: 2268 No of feeder: 90

Machine no: 05 Machine type: Single jersey Brand:Pai Lung Origin: Taiwan Machine dia &Gauge: 36~ 24G

Machine no: 06 Machine type: Single jersey Brand:Pai Lung Origin: Taiwan

No of needle: 2712 \o of feeder: 108

Machine dia &Gauge:25;24G No of needle: 1872 No of feeder: 74

Machine no: 07 Machine type: Single jersey(2 truck) Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:25;24G No of needle: 1872 No of feeder: 74 Machine no: 09 Machine type: Single jersey Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:30;28G Extra cylinder: 30;24G No of needle: 2256 No of feeder: 90 Machine no: 11 Machine type: Single jersey Brand:Fukuhara (B.c-3.25) Origin: Kobe Japan Machine dia &Gauge:30;24G No of needle: 2268 No of feeder: 98 Machine no: 13 Machine type: Single jersey brand: Fukuhara (B.c-3.25) Origin: Kobe Japan Machine dia &Gauge:30-24G No of needle: 2268 No of feeder: 98

Machine no: 08 Machine type: Single jersey Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:30;28G Extra cylinder : 33, 24G No of needle : 2236 Machine no: 10 Machine type: Single jersey Brand:Fukuhara (v.c-3.25) Origin: Kobe Japan Machine dia &Gauge:30;24G Extra cylinder: 30;20G No of needle: 2268 No of feeder: 98 Machine no: 12 Machine type: Single jersey Brand:Fukuhara (B.c-3.25) Origin: Kobe Japan Machine dia &Gauge:30;24G No of needle: 2268 No of feeder: 98 Machine no: 14 Machine type: Fleece Brand: Terrot Origin: Germany Machine dia &Gauge:30~20G Noofneedle:~872 No of feeder: 96

Machine no: 15 Machine type: Terrot Brand: Terrot Origin: Germany Machine dia &Gauge:30:20G

Machine no: 16 Machine type: Rib\Interlock Brand: Terrot Origin: Germany Machine dia &Gauge:30;18G

Noofneedle:1872 No of feeder: 96

Extra cylinder: 30~22G No of needle: 3368 No of feeder: 54

Machine no:17 Machine type: Rib Brand: Terrot Origin: Germany Machine dia &Gauge:34-18G No of needle: 3840 No of feeder: 60

Machine no: 18 Machine type: Rib Brand: Terrot Origin: Germany Machine dia &Gauge:36; 18G No of needle : 4080 No of feeder :64

Machine no :19 Machine type : Rib / Interlock Brand : Terrot Origin : Germany Machine dia & Gauge : 36 28G Extra cylinder : 36` 22G No of needle : 4080 No of feeler :64 Machine no: 21 Machine type: Single jersey Brand: Mayer & Cie Origin: Germany Machine dia &Gauge:30,28G Extra cylinder: 30,24G No of needle: 2640 No of feeder: 96

Machine no : 20 Machine type : Single jersey Brand : Mayer & Cie Origin : Germany Machine dia & Gauge : 30: ; 28G No of needle:980

Machine no: 22 Machine type: Rib I N D U S Brand: Fukuhara(V-ER-22) Origin: Kobe Japan Machine dia &Gauge:36,18G No of needle: 4078 No of feeder: 64

Machine no: 23 Brand: Fukuhara(V-ER-22) Origin: Kobe Japan Machine dia &Gauge:36,18G No of needle: 4078 No of feeder: 64

Machine no: 24 Machine type: Rib Brand: Fukuhara (v.er-22) Origin: Kobe Japan Machine dia &Gauge:36,18G No of needle: 4078 No of feeder: 64

Machine no: 25 Machine type: Rib Brand: Fukuhara (v.er-22) Origin: Kobe Japan

Machine no: 26. Machine type: Rib Brand: Fukuhara (v-er-22) Origin: Kobe Japan

Machine dia &Gauge:36,18G No of needle: 4078 No of feeder: 64 Machine no: 27. Machine type: Rib Brand: Fukuhara (v-er-22) Origin: Kobe Japan Machine dia &Gauge:36-l8G No of needle: 4078 No of feeder: 64 Machine no: 29. Machine type: Rib Brand: Pai Lung(pl-xr2b\ce) Origin: Taiwan Machine dia &Gauge:38,18G No of needle: 2124 No of feeder: 76 Machine no: 31 Machine type: Rib Brand: Pai Lung(pl-xr2b\ce) Origin: Taiwan Machine dia &Gauge:38,18G No of needle: 2124 No of feeder: 76 Machine no: 33 Machine type: Single jersey Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:26;24G No of needle: 1944 No of feeder: 78

Machine dia &Gauge:36,18G No of needle: 4078 No of feeder: 64 Machine no: 28 Machine type: Rib Brand: Pai Lung (pl-xra\ce) Origin: Taiwan Machine dia &Gauge:3818G Noofneedle:2160 No of feeder: 76 Machine no: 30. Machine type: Rib Brand: Pai Lung (pl-xr2b/ce) Origin: Taiwan Machine dia &Gauge:38,18G No of needle: 2124 No of feeder: 76 Machine no: 32 Machine type: Single jersey Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:24~24G No.of needle: 1800 No of feeder: 72 Machine no: 34. Machine type: Interlock Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36,22G No of needle: 2484 No of feeder: 72

Machine no: 35 Machine type: Single jersey (Auto Stripe)(pl-xscsl 6) Brand: Pai Lung Origin: Taiwan

Machine no: 36 Machine type: Single jersey (Auto Stripe)(pl-xscsl 6) Brand: Pai Lung Origin: Taiwan

Machine dia &Gauge:30,24G Extra cylinder: 30,16G No of needle: 2256 No of feeder: 42x6 Machine No. 37 Type Auto striper Double jersey. Brand PAL LUNG. Origin TAIWAN. lodJ No PL-XDCS/6-U Machine Dia: 36 Gauge 18G

Machine dia &Gauge:30,24G Extra cylinder: 30,16G No of needle: 2256 No of feeder: 42x6 Machine No.38 TAIWAN Type Auto striper Double jersey Brand PA! LUNG. Origin TAIWAN. Model No. PL-XDCSI6-L Machine Dia 36 Gauge 18G PL \F3B-LP Machine No. 40 Type Fleece Brand PAl LUNG. Type Single jersey Brand PAT LUNG. Origin TAIWAN ModelNo. PL-XS4BACE. Machine Dia 36 Gauge 24G Feeder No. 144 Machine No. 42 Type Single jersey Brand PAT LUNG. Origin TAIWAN ModelNo. PL-XS4BACE. Machine Dia 36 Gauge 24G Feeder No. 144

Machine No. 39 Type Fleece Brand PAl LUNG. Type Single jersey Brand PAT LUNG. Origin TAIWAN ModelNo. PL-XS4BACE. Machine Dia 36 Gauge 24G Feeder No. 144 Machine No. 41 Type Fleece Brand PAl LUNG. Type Single jersey Brand PAT LUNG. Origin TAIWAN ModelNo. PL-XS4BACE. Machine Dia 36 Gauge 24G Feeder No. 144

Machine No. 43 Tvpc Single jcrscv. Brand PAl LUNG. Origin TAIWAN.

Machine No. 44 Type Double jersey Brand PAl LUNG Machine Dia 38

Model No. PL-XS4B/AICE Machine Dia 23 Gauge 24G Feeder No. 78 Machine No. 45 Tvpe Doublc jersey. Brand PAI- LUNG. Origin: TAIWAN Dia 38 Gauge I 8G Fccdcr No. 76 Machine no: 47 Machine type: Single jersey. Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x20 No of feeder: 98 Machine no: 49 Machine type: Single jersey. Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x24 No of needle: 2850 No of feeder: 144 Machine no: 51 Machine type: Single jersey. Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x24 No of feeder: 98

Gauge 18G Feeder No. 76

Machine no: 46 Machine type: Single jersey. Brand:Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x20 No of feeder: 98

Machine no: 48 Machine type: Single jersey. Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x20 No of feeder: 98 Machine no: 45 Machine type: Single jersey. Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x24 No of needle: 2850 No of feeder: 144 Machine no: 52 Machine type: Single jersey. Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x24 No of feeder: 98

Machine no: 53 Machine type: Single jersey(Auto stripe) Brand: Pai Lung Origin: Taiwan

Machine no: 54 Machine type Single jersey(Auto strip) Brand: Pai Lung Origin: Taiwan

Machine dia &Gauge: 3 0x247 No of needle:2256 No of feeder: 42x6 Machine no: 55 Machine type: Rib(Auto stripe) Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x1 8 No of needle:2040 No of feeder54x6 Machine no: 57 Machine type: Rib(Auto stripe) Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x18 No of needle: 2040 No of feeder: 54x6

Machine dia &Gawie:30x2 No of needle: 2256 No of feeder: 42x6 Machine no: 56 Machine type: Rib(Auto stripe) Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x1 8 No of needle:2040 No of feeder54x6

Machine no: 58 Machine type: Single jersey (Auto stripe) Brand: Pai Lung Origin: Taiwan Machine dia & gauge : 30x24 industrial attachment No opf needle : 2256 no of feeder 42x6 Machine no: 60 Machine type: Single jersey (Auto stripe) Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x24

Lachine no: 59 Machine type: Single jersey(Auto stripe) Brand: Pai Lung Origin: Taiwan Machine dia &Gauge:36x24 No of needle:2712 No of feeder: 50x6

Machine no: 61 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:26x24

Machine no: 62 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:26x4

No of feeder: 86 Machine no: 63 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:26x4 No of feeder: 86 Machine no: 65 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x8 No of feeder: 98 Machine no: 67 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x20 No of feeder: 30 Machine no: 69 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge8x24 No of feeder: 84 Machine no: 71 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:32x24 No of feeder: 106

No of feeder: 86 Machine no: 64 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:26x24 No of feeder: 86 Machine no: 66 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x28 No of feeder: 98 Machine no: 68 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:30x20 No. of feeder: 30 Machine no: 70 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge8x24 No of feeder: 84

Machine no: 72 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:32x24 No of feeder: 106 INDUSTRIALATTACHMENT ONVIYELLAT I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2

Machine no: 73 Machine type: Single jersey Brand: Fukuhara Origin: Kobe Japan Machine dia &Gauge:36x4 No of feeder: 118 Machine No: 75 Machine type: Single jersey Brand:Keumyong Origin:Koria M/C Dia&Gauge:30*20 No of feeder:90

Machine No: 74 Machine type: Single jersey Brand:Keumyong Origin:Koria M/C Dia&Gauge:30*20 No of feeder:90 Machine No: 76 Machine type: Single jercy Brand:Keumyong Origin:Koria M/C Dia&Gauge:30*20 No of feeder:90

4. Store section: In this section knitted fabric and yarns are stored.

PRODUT MIXSINGLE JERSEY S/J LYCRA S/J YARN DYED S/J POLO PIQUE SINGLE LACOST DOUBLE LACOST FLEECE LYCRA FLEECE DOUBLE JERSEY 1/1 RIB 1/1 LYCRA RIB YARN DYED RIB 2/1 2/2 RIB 2/2 LYCRA RIB

PRODUCTIN CALCULATION

FLOW CHART OF FABRIC KNITTING

DIFFERENT TYPES OF CAM 1) KNIT CAM

2) MISS CAM

3) TUCK CAM

CAM SETTING FOR RIB FABRIC

CAM SETTING FOR FLEECH

PRODUCTION CALCULATION

Example Calculate nominal production of a single jersey-knitting machine per hour from the data given: Machine Gauge 24 Machine Dia 30 inches Number of Feeders 90

Machine RPM 26 Yarn Count 24 Stitch length 4 mm Efficiency 85% Solution: Step one First we will calculate number of needles and number of stitches produced in one revolution. This would help us in calculating the total length of yarn consumed in one revolution. (3.14)Number of needles = machine dia * gauge * = 30* 24*3.14 =2260 (exact 2260.8 but needles are always in even number so we will take nearest even figure) Number of stitches produced in revolution Every needle is making one stitch on every feeders because machine is producing single jersey fabric (full knit fabric). Number of stitches produced in one revolution = Number of needles * number of feeders = 2260*90 = 203400 This figure shows that machine is making 203400 stitches in one revolution. Step Two Length of stitch is 04 mm (stitch length is always calculated in metric system) From this figure we can calculate yarn consumption in yards in one hour Yarn Consumption (in yards) in one hour = number of stitches * length of (mm) * RPM *60 (minutes) 1000(to convert mm into meters) =203400 * 4 * 26 * 60 1000 = 1269216 meters or = 1388015 yards Step Three In previous step we calculated quantity of yarn consumed in yards. We can easily calculate weight of this yarn while its count is known (see example 03).

Weight of cotton yarn = length of yarn Count * 840 = 1388015 840 * 24 = 68.85 pounds or = 31.23 Kilo grams Efficiency 85% = 26.55 Kilo grams

Answer: this machine can produce 26.55 Kgs fabric in one hour at 85 % efficiency

FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:1. Hole Mark Causes: Holes are the results of yarn breakage or yarn cracks. During loop formation the yarn breaks in the rejoin of the needle hook. I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2 If the yarn count is not correct on regarding structure, gauge, course and density. Badly knot or splicing. Yarn feeder badly set. Remedies: Yarn strength must be sufficient to withstand the stretch as well as uniform. Use proper count of yarn. Correctly set of yarn feeder. Knot should be given properly.

2. Needle Mark Causes: When a needle breaks down then needle mark comes along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies: Needle should be straight as well as from broken latch. 3. Sinker Mark Causes: When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes. If sinker head bend then sinker mark comes. Remedies: Sinker should be changed. 4. Star Causes: Yarn tension variation during production. Buckling of the needle latch. Low G.S.M fabric production.

Remedies:Maintain same Yarn tension during production. Use good conditioned needles. 5. Drop Stitches I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2 Causes: Defective needle.

If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook. Take-down mechanism too loose. Insufficient yarn tension. Badly set yarn feeder. Remedies: Needle should be straight & well. Proper feeding of yarn during loop formation. Correct take up of the fabric & correct fabric tension. Yarn tension should be properly. 6. Oil stain Causes: When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies: Ensure that oil does not pass on the fabrics. Well maintenance as well as proper oiling. 7. Rust stain Causes: If any rust on the machine parts. Remedies: If any rust on the machine parts then clean it. Proper maintenance as well as proper oiling. 8. Pin hole Causes:

Due to break down or bend of the latch, pin hole may come in the fabric. Remedies: Change the needle 9. Grease stain Causes: I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2 Improper greasing Excess greasing Remedies: Proper greasing as well as proper maintenance 10. Cloth fall- out Causes: Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Remedies: Make sure all the latches of needle are closed with feeding yarn after a drop stitch. 11. Barre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) Stripe. Causes: This fault comes from yarn fault. If different micro near value of fiber content in yarn. Different lusture, dye affinity of fiber content in yarn. During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics.

In draw fame different similar classes sliver is mixed and make one sliver. Remedies: We can use this fabric in white color. 12. Fly dust: Causes: In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies: Blowing air for cleaning and different parts after a certain period of time. I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2 By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor. Over all ensure that lint does not attach to the fabric. 13. Yarn contamination Causes: If yarn contains foreign fiber then it remains in the fabric even after finishing, If lot, count mixing occurs. Remedies: By avoiding lot, count mixing. Fault less spinning.

14. Yarn Faults: Neps. Slubs. Yarn count variations. Thick/Thin place in yarn. Hairiness.

BATCHING SECTIONBatching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.

Function or Purpose of Batch SectionTo receive the grey fabric roll from knitting section or other source. - Turn the grey fabric if require. - To prepare the batch of fabric for dyeing according to the following criteria Order sheet (Received from buyer) Dyeing shade (color or white, light or dark) M/C capacity M/C available Type of fabrics(100% cotton, PE, PC, CVC) Emergency - To send the grey fabric to the dyeing floor with batch card. - To keep records for every previous dyeing.

Proper batching criteria- To use maximum capacity of existing dyeing m/c. - To minimize the washing time or preparation time & m/c stoppage time. - To keep the no. of batch as less as possible for same shade. - To use a particular m/c for dyeing same shade.

Batch managementPrimarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency. I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 2

Machines in batch sectionM/c Specification: Machine Name M/c No : Origin M/c Speed Model Max up clothing Company Air turning m/c 01 China 300-500m/min DF 200 150 kg Shandong Taida Dyeing & Finishing Machinery Co.Ltd

LAB SECTION

I T T A C H M E N T O N V I Y E L L A T E X Page 62

LABORATORY MACHINERIES WITH ITS SPECIFICATION1. Tearing Strength Tester: Brand Name : Origin : Elmatear U.K

2. Button Strength Tester:Brand Name : Origin : Max.Pressure: Capacity : Titan U.K 10 bar 3000N

3. Bursting Strength Tester: Brand Name : Origin : TruBurst U.K

4. Pilling Resistant Tester: Brand Name : Origin : 5. Sprectra Flash: Brand Name : Origin : Data Color U.S.A Impulse U.K

Test Name: Colorfastness to Washing, Dry cleaning. Name of the m/c : Origin : Test Method : Rota Wash U.K ISO105-C06, ISO105-D02

Test Name: Dimensional Stability, Spirality, Appearance after washing. Name of the m/c : Eltrolux wascator. Origin : U.K

Test Method : ISO 6330, ISO 26330 I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 62 Test Name : Shrinkage Test. Name of the m/c : Origin : Eltrolux U.K

Test Name : Color Fastness to Wash Test. Name of the m/c : Origin : Test Method : Gyro wash U.K ISO 105-C06

Lab Dip m/c: No.of m/c: M/C NO- 01 Brand name : Ahiba Nuance Lab Dip Dyeing m/c Origin : U.S.A M/C NO- 02 Brad name : Ahiba Nuance Lab Dip Dyeing m/c Origin : U.S.A 02

Color Matching Cabinet (Light box):No. of Light Box: 02 Light Box no: 01

Brand : Spectralight-111 Origin : U.S.A Light Source: Day Light (D-65) Cool White Horizon UV TL-84 A (F11-10 degree)

Light Box no: 02Brand : Verivide I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 62 Origin : U.K

Light Source:Day Light (D-65) UV TL-84 A (F11-10 degree) Laboratory is the heart of dyeing Industry. An efficient laboratory can increase the efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before bulk production a sample is sent to buyer for approval. Laboratory supplies the recipe to the floor.

Off-Line Tests:I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 62 Off-Line tests for finished fabrics are divided into two groups. These are as Follows : Physical tests Chemical tests

Physical Tests:Yarn Grade GSM test Shrinkage test Spirality test Tensile strength Abrasion resistance Button Strength Testing Lycra% determination Crease resistance

Chemical Tests:Fastness to washing. Fastness to light Fastness to actual laundering Fastness to sea water Fastness to water Fastness to perspiration

DYEING

Dyeing Machine: 01(FONGS) Machine name Fongs( Atmospheric m/c) Machine NO. ECO-38-2T NO. of nozzle 2 Origin CHINA

Dyeing Machine: 02(THIES) Machine Name Thies (High temperature m/c). Type Farbekessel eco- soft Plus Origin Germany Capacity 1000 kg Model 45506 Dyeing Machine: 04(THIES) Machine Name Thies (High temperature m/c). Type Farbekessel eco- soft Plus Origin Germany Capacity 250 kg Model 41346

Dyeing Machine: 03(THIES) Machine Name Thies (High temperature m/c). Type Farbekessel eco- soft Plus Origin Germany Capacity 1000 kg Model 43891

Dyeing Machine: 05(THIES) Machine Name Thies (High temperature m/c). Type Farbekessel eco- soft Plus Origin Germany Capacity 500 kg Model 41350 Dyeing Machine: 07(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 200 kg Model No. SHI 0515416/25 Dyeing Machine: 09(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 750 kg Model No. SHI 0515416/17 Dyeing Machine: 11(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 840 kg Model No. SHI 0515416/19 Dyeing Machine: 13(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 1680 kg Model No. SHI 0515416/27

Dyeing Machine: 06(THIES) Machine Name Thies (High temperature machine). Type Farbekessel eco- soft Plus Origin Germany Capacity 750 kg Model 41354 Dyeing Machine: 08(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 250 kg Model No. SHI 0515416/07 Dyeing Machine: 10(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 1120 kg I Model No. SHI 0515416/23 Dyeing Machine: 12(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 560 kg Model No. SHI 0515416/03 Dyeing Machine: 14(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 840 kg Model No. SHI 0515416/22 Number of nozzle 03

Dyeing Machine: 15(FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 1120 kg Model No. SHI 0515416/29 Number of nozzle 04

SAMPLE DYEING MACHINEDyeing Machine: 01 (FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 25 kg Dyeing Machine: 03 (FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 30 kg Dyeing Machine: 05 (FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 30 kg Dyeing Machine: 07 (FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 60 kg Dyeing Machine: 02 (THIES) Machine Name Thies (High temperature machine). Origin GERMANY Capacity 25 kg Dyeing Machine: 04 (FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 120 kg Dyeing Machine: 06 (FONGS) Machine Name Fongs (High temperature machine). Origin CHINA Capacity 60 kg

Name of the Dyes Type Source OriginCiba Yellow FN2R Reactive Dye Swiss Color Ciba Red FNR Reactive Dye Swiss Color Ciba Red FN2BL Reactive Dye Swiss Color Drimarine Red HF2B Reactive Dye Clariant Drimarine Blue HFRL Reactive Dye Clariant DrimarineYellowCLR Reactive Dye Clariant Drimarine Red CL5B Reactive Dye Clariant Drimarine Navy CLB Reactive Dye Clariant GERMANY GERMANY GERMANY SWITZERLAND SWITZERLAND SWITZERLAND SWITZERLAND SWITZERLAND

PRINT SECTION

Process flow chart of printing

M/C NO: 3

EMBROIDERY SECTION

EMBROIDERY SECTION

Different types of fabrics fault

Lastly:We tried our best to gather all necessary information but it is true that within this short period it is quite impossible to achieve 100% success but as a whole this industrial training was a satisfactory one and once again wed would like to thank the authority of VIYELLATEX GROUP. as well as our honorable teachers far their altruistic help and advice. We are fortunate enough that we have got an opportunity to have training in this mill. During the training period we have received enough co-operation and association from the authority and found all personnel. All stuffs and officers were very sincere and devoted their duties to achieve their goal.