Industrial visit at Aaron Denim Limited

1. Introduction : Denim is a sturdy cotton warp-faced textile in which
the weft passes under two or more warp threads. This twill weaving produces
a diagonal ribbing that distinguishes it from cotton duck.
The most common denim is indigo denim, in which the warp thread is dyed,
while the weft thread is left white. As a result of the warp-faced twill weaving,
one side of the textile is dominated by the blue warp threads and the other
side is dominated by the white weft threads. This causes blue jeans to be
white on the inside. The indigo dyeing process, in which the core of the warp
threads remains white, creates denim's signature fading characteristics. Aaron
Denim Ltd. (ADL) formerly MAB spinning ltd and MAB denim ltd. Is a 100%
export oriented denim fabrics manufacturing unit. Currently it holds a
capacity of 14.35 million yards fabric per annum based on three shift of
operation having FOB value around USD 30.00 million eqv. to BDT 2.40 billion
(approx) to 24.00 million yards fabric per annum based on three shifts of
operation having FOB value around USD 50.40 million eqv. to BDT 4.00 billion
(approx) at current price. Form January 2018, with the inclusion of new
machineries , the project will be equipped with more balanced of its fabrics
manufacturing unit (with an enhanced capacity of 2.00 million yards per
month from 1.2 million yards per month) and dying unit (which has present
capacity of 2.39 million yards per day) which will help meeting the growing
demand of the buyers.

2. Location :
Factory Address :
Sukran , Mirzanagar , Savar , Dhaka-1344
Head Office :
8, Panthapath, UTC building , Level-9 , Dhaka-1215
Google Maps (Satellite view)

3. Organogram :
Product types :

4. Layout :
Factory Units :
WARPING
This is first process of the fabric manufacturing unit, No.; 01 Panon (Taiwan),
02 (Benninger, Switerland); The parallel winding of warp ends from many
winding packages (cone or cheese) on to a common package (warp beam) is
called warping. Types of warping: 1. Direct Warping Denotes the transference
of yarns from single-end yarn packages, wound packages, directly to a beam
in a one step process.

5. BALL WARPING
Ball Warping is an intermediate first process for storing yarn for transport,
dyeing or reserve; it does not produce a beam.the usual form is a cross wound
cheese in which multiple ends are wound at the same time in a ribbon which
contains perhaps 380 or 420 ends.

6. ROPE DYEING
Rope dyeing is consists of twisting the yarns into a rope that is then quickly
dipped into indigo baths. It is considered the best method for dyeing denim as
the short dyeing time does not allow the indigo to fully penetrate the fibers,
thus creating ring-dyed yarn that fades better and faster than fully dyed yarn.
SLASHER DYEING
Slasher dyeing is combines dyeing and sizing into a single process. Warp yarns
are repeatedly passed in warp beam form through several baths of indigo dye
before being sized and wound for weaving.
LCB
Once the warp yarns are rope dyed, it is then necessary to change the yarn
alignment from a rope form to a sheet form before entering the next process,
which is sizing.

7. SIZING
Sizing is any one of numerous substances that is applied to, or incorporated
into, other materials especially papers and textiles to act as a protective filler
or glaze. ... Sizing is used for oil-based surface preparation for gilding (also
known as mordant in this context).
WEAVING
Weaving is a method of textile production in which two distinct sets of yarns
or threads are interlaced at right angles to form a fabric or cloth. Other
methods are knitting, felting, and braiding or plaiting. The longitudinal threads
are called the warp and the lateral threads are the weft or filling.

8. MERCERIZING:
Mercerization is a treatment for cellulosic material, typically cotton threads,
that strengthens them and gives them a lustrous appearance. The process is
less frequently used for linen and hemp threads.
FINISHING:
In textile manufacturing, finishing refers to the processes that convert the
woven or knitted cloth into a usable material and more specifically to any
process performed after dyeing the yarn or fabric to improve the look,
performance, or "hand" (feel) of the finish textile or clothing. The precise
meaning depends on context. Some finishing techniques such as bleaching
and dyeing are applied to yarn before it is woven while others are applied to
the grey cloth directly after it is woven or knitted. Some finishing techniques,
such as fulling, have been in use with hand-weaving for centuries; others, such
as mercerization, are byproducts of the Industrial Revolution.

9. INSPECTION:
To record or to collects defects during inspection you must use a simple check
sheet. A check sheet includes general details, details of fabric lot, fabric
defects according their sizes, summary of fabric defects, quantity inspected
and total penalty points and result of the fabric lot after inspection. Use tally
marking for recording of number of defects. A sample 4 point system fabric
inspection.
DYEING LAB
At first dyeing is performed in dyeing lab and then starting for bulk
production. Dyeing lab work is called lab dip development. A lab dip is a
swatch of fabric test dyed to hit a color standard. Lab dip plays an important
role in dying process. Bulk dyeing process completely depends on the lab dip.
In the lab, lab dip or sample is developed by the textile engineer or technician.
R&D LAB:
R&D activities differ from institution to institution Conditioned by scientific
and technological progress,
WASHING SECTION:

10. Washing is a method of cleaning, usually with water and often some kind of
soap or detergent. Washing both body and clothing is an essential part of
good hygiene and health.
YARN TEST
Yarn occupies the intermediate position in the manufacture of fabric from raw
material. Yarn results are therefore essential, both for estimating the quality
of raw material and for controlling the quality of fabric produced.
The important characteristics of yarn being tested are,
 Yarn twist
 Linear density
 Yarn strength
 Yarn elongation
 Yarn evenness
 Yarn hairiness etc.
COATING & PRINTING:
Coating In binding and finishing, a finishing operation in which a printed
substrate is covered with a clear film, such as a primer (usually added as a
prelude to printing or other coating operations), a lacquer, a barrier coat, or
an overprint varnish. Alternately, only a portion of a printed material may be
coated, called spot coating or spot varnishing. Coatings applied after printing
may either be aqueous (water-based) which dry by evaporation, or electron-
beam or ultraviolet coatings which dry by polymerization when exposed to
electron beams and ultraviolet light, respectively. In screen printing, the term
coating is also used to refer to any screen printed material applied to a
substrate as a continuous film.
GENERATOR:
In electricity generation, a generator is a device that converts motive power
into electrical power for use in an external circuit.

11. COMPRESSOR:
An air compressor is a device that converts power (using an electric motor,
diesel or gasoline engine, etc.) into potential energy stored in pressurized air
(i.e., compressed air). By one of several method
ds, an air compressor forces more and more air into a storage tank,
increasing the pressure.
AC PLAN ETC:
AC Sure plan is a full service heating, ventilation, and air conditioning (HVAC)
company.
ETP:
Effluent treatment plant, a process to convert wastewater - which is water no
longer needed or suitable for its most recent use - into an effluent that can be
either returned to the water cycle with minimal environmental issues or
reused. see industrial wastewater treatment. Electrolytic Tin Plate, a tinning
process.

12. Conclusion :
Jeans has been, and is an important item of clothing for many decades.
Denim garments came into existence during the 18th
century, a time when
there was abundant production of cotton. During that period, it gained
importance due to its aspects of durability, and not easily torn which
benefited physical laborers much. During the 19th
century the garment was
popularized by Levi Strauss, a well-known name in the jean world. Denim
clothing was manufactured by them for miners. 20th
century brought jeans as
a fad of pop culture. Western cowboy movies portrayed people wearing blue
jeans. The 50s witnessed the cloth becoming a craze of the teen age
population. Manufacturers utilized the situation by coming up with innovative
designs like new colors, embroidery and patch works. During 60s and 70s bell
bottoms and hip hugger patterns became popular.