Presentation on Industrial Attachment
Presentation on Industrial AttachmentSQUARE Textiles
LimitedSardagonj , Kashimpur , GazipurDhaka , Bangladesh
Presenting Students Md. Saidur Rahman ID : 2011-1-146Taukir
Kabir Tusar ID : 2011-1-169
Bangladesh University of Textiles (BUTex)
Welcome
Special Thanks ToDr. Hosne Ara Begum Associate Professor Head of
the department of Yarn Manufacturing Engineering (YME) Bangladesh
University of Textiles (BUTex)Dr. Mohammad Ali Associate Professor
Head of the department of Industrial Production & Engineering
(IPE) Bangladesh University of Textiles (BUTex)
Thanks for creating friendly training environmentMr. Suresh
Chandra Bala General Manager (Production) SQUARE Textiles
LimitedMr. Golam Rabbani Assistant General Manager (Production)
Unit -01 SQUARE Textiles LimitedMr. Shihab Uddin Khan Production
Officer Unit 01 SQUARE Textiles Limited & All officials ,
employees & workers
Company ProfileCompany Name : SQUARE Textiles Limited &
SQUARE Yarns LimitedYear of Esablishment : Unit 01 : 1995 Unit 02:
1998 Unit 03: 2000 SYL : 2006Address :Corporate Office : Square
Centre 48 , Mohakhali Commercial Area DhakaHead Office : Mascot
Plaza (10th floor) 107/A , Sonargoan Janapath Road Sector -07
Uttara , Dhaka Factory : : Vill Sadarganj , Post -Kashimpur Thana
Kashimpur District - Gazipur
No of spindles (Ring and Rotors)Ring Section Unit 01 - 36816
Unit 02 23184 SYL - 41328 (SQUARE Yarns Limited)Total -101328Rotor
Section Unit 02 - 768 ( Autocoro Heads ) Unit 03 3192 ( Autocoro
Heads )Total - 4960
Different DepartmentsProduction DepartmentQuality Assurance
DepartmentUtility DepartmentMaintenance DepartmentHR &
Administration DepartmentCivil DepartmentStore DepartmentIT
DepartmentMarketing Sales DepartmentPlanning & Procurement
DepartmentFinance & Accounting
Product Mix Unit 01 : Card Hosiery & Comb Hosiery , organic
, siro , slub , inject , core spun , duo spun , 100% manmade
(viscose , modal , polyester)Unit 02 : Card Hosiery & Comb
Hosiery , compact , organic & rotor card wovenUnit 03 : Rotor
card wovenSYL : Blended (PC , CVC , melange, combed)
Flow Chart of various yarn manufacturing process Ring yarn
(Carded)
Flow Chart of various yarn manufacturing process Ring yarn
(Combed) cont.
Flow Chart of various yarn manufacturing process Ring yarn
(Combed)
Flow Chart of various yarn manufacturing process Rotor yarn
(Carded)
Segment 1 Machine Description
Blowroom Line Machine Name : UniflocModel No : A10 &
A11Company : Rieter Origin : SwitzerlandProduction : 1100
kg/hrMachine Speed : 5-20 m/min Fig : Unifloc A11Take up depth :
4-10 mmNo of m/cs : 4Function : To open the bales into smaller and
lighter tuffs or floc.
Blowroom Line Machine Name : UnicleanModel No : B11Company :
Rieter Origin : SwitzerlandProduction : 1100 kg/hrCleaning
Intensity : 0-1 Relative waste amount : 1-10 Fig : Uniclean B11 No
of m/cs : 4Function : To remove dust , trash , foreign matters ,
seed contents etc. from fiber flock
Blowroom Line Machine Name : UnimixModel No : B7/3 & B70
Company : Rieter Origin : SwitzerlandProduction : 500
kg/hrEfficiency : 75-80% Fig : Unimix B70 No of m/cs : 4Object :
Homogeneous & Effective mixing of fibres
Blowroom Line Machine Name : UniflexModel No : B50 , B60 &
B70Company : Rieter Origin : SwitzerlandProduction : 450-500
kg/hrEfficiency : 75-80% No of m/c : 4 Fig : Uniflex B60Function:
to optimize waste extraction to suit his requirements without any
mechanical intervention (VARIO set )
Blowroom Line Machine Name : The Cotton SorterModel No : SP-FPU
, HRS-120 & ED-351_1200T & JossiCompany : Truzschler ,
Loptex & JossiOrigin : Germany , Italy &
SwitzerlandProduction : 400-450 kg/hrEfficiency : 75-80% Fig :
SP-FPUNo of m/cs : 3Object : To sort out the Poly propylene (PP)
contaminents from fibre using optical method
Blowroom Line Machine Name : CondenserModel No : LA5/6 , A20
& A21 Company : LAKSHMI & RieterOrigin : India &
Switzerland No of m/cs : 7Function : To control the width of the
fibre strand Fig :Condenser A21
Carding Section Machine Name : Carding MachineModel No : C50 ,
C51, C60 Company : Rieter Origin : Switzerland Flat speed :
0.22-0.29m/minCylinder Speed 450-550 rpm No of m/cs : 64 Fig :
Carding C60Function : To individualize , parallalize , cleaning ,
reduction of neps , aligning , blending & elimination of short
fibres
Drawing Section Machine Name : Breaker Draw frameModel No : SB-2
, RSB-1, RSB-951 SB-D-10 , SB-D -40 Company : RieterOrigin :
Switzerland Drafting system : 4/3 Doubling Ratio : 5:1 , 6:1 , 8:1
Delivery speed : 650-800m/min No of m/cs : 18 Fig : Breaker Draw
frameFunction : To stretch or straighten the fed card sliver to one
single sliver , blending of different slivers
Drawing Section Machine Name : Finisher Draw frameModel No :
SB-2 , RSB-1, RSB-40 RSB-D -45 Company : RieterOrigin : Switzerland
Drafting system : 3/3 , 4/4 Doubling Ratio : 5:1 , 8:1Delivery
Speed : 650-750m/min No of m/cs : 24 Fig : Finisher
DrawframeFunction : To arrange the fibres in parallel fashion , to
reduce irregularty of silvers by auto levelling device
Lap Formers Machine Name : UnilapModel No : E5/3 , E30 , E32
Company : RieterOrigin : Switzerland Drafting roller : 24 mm
Calendar Roller : 30 mmDelivery Speed : 100 m/min No of m/cs : 3
Fig : Unilap E5/3Function : forming the interfacing or lap , which
is employed to feed thecombing machine , lighter draft is provided
here (1.5-2)
CombersMachine Name : ComberModel No : E60H , E62 , E65Company :
RieterOrigin : Switzerland Drafting system : 3/3 Feed/Nip : 4.7-5.2
mmNip/min : 350-360 Doubling Ratio : 8:1 Noil% : 8-15Lap length :
220-230mLap weight : 800-1000gr/yds Fig : Comber machineNo of m/cs
: 18 Function : To produce more smoother , softer sliver by
eliminating short fibres
SimplexMachine Name : SimplexModel No : FL-16, FL-100,
ELECTROJETCompany : TOYOTA , Electrojet Origin : Japan , SpainFlyer
rpm : 1100 No of flyer : 120,120,128Drafting system : 4/4 Fig :
Simplex ElectrojetFunction : To convert the drawn sliver into much
fine sliver called roving by drafting and slight twist
insertion
Ring FrameMachine Name : Ring frameModel No : FA-507A, RX-240 ,
LR60/AXCompany : ERFANJI,TOYOTA , LAKSHMIOrigin : China , Japan ,
IndiaDrafting system: 3/3 No of spindle : 504,1008,1008Spindle
speed : 18000 rpm No of m/cs : 117 Fig : Ring frame Function : To
convert the roving into yarn of definite/respective count by
creeling , drafting , building , twisting , winding and doffing
operation
Rotor FrameMachine Name : Rotor frameModel No:BT-903, Autocoro
288 , Autocoro 360Company : Rieter & SchlafhorstOrigin :
Switzerland & GermanyDrafting system: No No of pos :
192,288,312No of m/c : 15 Fig : Rotor frameFunction : To produce
yarn from the low quality fibres by the process of open end
spinning
Winding m/cMachine Name : Winding m/cModel No: AC 338 , SAVIO
Polar Muratec , Orion M Company : Schlafhorst , SAVIO Polar ,
MuratecOrigin : Germany , Italy , JapanNo of drum : 64,60,60Drum
speed : 1100-1400 rpmNo of m/c : 24Automatic splicing system Fig :
Winding machineFunction : To rewound the yarn from ring bobbin into
suitable package
Heat SettingMachine Name : Heat Setting m/cCompany :
Elgi-ElectricOrigin : IndiaHeat set time: 55 minuteTemp. : 60
degree celciusNo of m/c : 01Pressure : 5kg/cm*cm Fig : Heat Setting
m/cFunction : To increase yarns moisture content
Daily Production of SQUARE Textiles Limited ( Approx. )Unit 01 -
18522 kgsUnit 02 - 10385 kgsUnit 03 - 5550 kgsUnit 03 - 29735 kgs
(autocoro)SYL (Ring)- 14951 kgsExpansion - 3982 kgs (Ring)
Total - 83125 kgs Approximately 80 Tons per day
Different ring attachments used to produce special yarns Slub
AttachmentCore spun yarn attachmentLycra(Core) slub attachmentSIRO
attachmentSlub AttachmentInject Yarn AttachmentInject Slub
AttachmentDuo core spun Attachment
Segment 2 Quality Assurance System
What is Quality Assuarance ?Quality assurance (QA) refers to the
systematic activities implemented in a quality system so that
quality requirements for a product or service will be fullfilled
.It is well knowned by the term Quality Control
Quality Control EquipmentsMachine name FunctionUSTER HVI
Spectrum Raw cotton inspection , SCI , MIC value , Rd+b
gradingUSTER HVI 900 Upgrade version of previous one , maturity and
moisture extra USTER Tester 5 Yarn and sliver inspection ,
unevensess , thick thin place hairiness , nepsCovatest Same as
USTER Tester 5USTER AFIS Pro Length , UQL , SFC , Spun length IFC ,
maturity , neps, SCN, NRE, Trash
Quality Control Equipments (cont.)Machine name FunctionUSTER
AFIS Same as USTER AFIS Pro
Dynajet Yarns weak point test Ustertensojet Single yarn strength
test Zweigle G566 Yarn inspection , hairiness
Eureka EY12 Warp reel yarn count Mesdanlab Yarn twist testerNTDA
Raw material trash ,neps, dust analysis Board Wrapping (MAG) Same
as Eureka EY12 Auto stretch 5c Yarn lea strength tester HVI Rapid
Conditioning Cabinet Cotton Conditioning
Segment 3 Maintenance Department
What is maintenance ? Maintenance is a procedure by means of
which we can maintain active functioning in operation according to
the behavior utility of a particular element/ substance
Maintenance procedure in SQUARE Textiles LimitedMaintenance for
Blowroom -Periodic Maintenance After 10-15 daysMaintenance for
Carding -Schedule Maintenance Cleaning of components like cylinder
, flat , doffer , Fixed carding segment , lubrication of gear ,
belt cleaning and alignment checking etcGrinding 1st : After 90tons
production 2nd : After 80 tons production 3rd : After 70 tons
production 4th : After 60 tons production4 times grinding possible
IGS grinding for doffer and cylinderEmery fillet grinding for
flat
Maintenance procedure in SQUARE Textiles Limited (cont.)Mounting
removal of faulty wires after its lifetime (300-350 tons
production) Emery cloth for rust removal of wire Acetone wash
Lakshmi mounting machine for flats Graft mounting machine for
cylinder , doffer & taken inLubricating Done in yearly schedule
basis
Maintenance procedure in SQUARE Textiles Limited
(cont.)Maintenance of Lap former , Comber , Drawframe , Simplex
& Ringframe - Scheduled Maintenance Cleaning machine & its
parts , gear , belts , top, bottom , feed , calendar rollers ,
winding drums , lap , cut , weight plate , suction line &duct
cleaning , cleaning the drafting zone , pressure roller cleaning ,
apron resetting, change & resetting as per requirement etc.
Lubricating Gears , rollers etc .
Cot Grinding MachineName : Berkol Cot Grinding MachineOrigin :
SwitzerlandOrigin: SwitzerlandPer grinding reduce : 0.02 mmStone
dia at frist: 200 mm Stone dia when out: 150 mmStone auto cleaning:
after 100 grinding Fig :Cot Grinding Stone is dressing: after 1000
cot grinding MachineGrinding rate: 3 cot/ minute
Segment 4 Utility
What is Utility ?Utility is the set of services provided by the
organizations consumed by the public like electricity , natural gas
, water & sewage
Utility Facilities of SQUARE Textiles Limited Utilities Amount
Electricity (PDB & Generator) 15MW Steam (Boiler) 3000 kg
HFO Plant (Generator)
HFO means heavy fuel oil or Furness oilType : 4.1 MW Man
Gegilski power plant Company : MAGNUS Power PVT ltdCapacity : 4.1
MW Engine type : V typeNo of cylinder: 16There is 5 oil tank in HFO
plant 1. Storage tank 2. Buffer tank 3. Day tank 4. Diesel tank 5.
Sludge tank. Fig : MW Mega Gegiski Power Plant
A/C Plant At SQUARE all A/C type is sameBrand: LUWAOrigin:
Switzerland AtUNIT 1 8 A/CUNIT2 4 A/CUNIT3 4A/CSYL 4A/CTotal 20
A/C
ChillarIn Square textiles ltd Unit 01 has 3 chillars (all 400
tons capacity) Unit 02 has 3 chillars( 1 vapour absorption chillar
500 tons 500 tons 1 steam fired chillar 500 tons 1 Hot water
absorption chillar 500 tons Unit 03 has 3 chillars( 1 hot water and
2 steam fired all 260 tons ) SYL has 1 chillar (direct gas
absorption type) Total 10 chillars
BoilerIn SQUARE Textiles Limited , Type : Exhaust Gas Boiler
Capacity: 2.5 ton Consume: Natural gas Safety valve: 2 Wt of safety
valve: 9.5 kg/ cm2 Cell & tube type : in cell there is water
& in tube hot water Exhaust temp: 450/500 C Out temp: 200 C
Some other utility thingsAir Compressor DryerWater Softening
plant PLC ( Progammable Logic Control )Circuit Breakers
Thanks all for your kind patience
