Knitting Section Overview

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INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT OF
BISWAS GROUP LTD.

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TABLE OF CONTENTS
Serial No. Topic Page No.
01 Introduction 05
02 Company Profile 06
03 Knitting Section 12
04 Quality Control 30
05 Batch Section 33
06 Dyeing Lab 35
07 Dyeing 39
08 Finishing Section 68
09 Fabric Inspection 75
10 Quality Assurance system 77
11 Maintenance 79
12 Utility 85
13 Effluent Treatment Plant 89
14 Conclusion 91

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INTRODUCTION
By means of practical knowledge its not possible to apply the theoretical knowledge
in thepractical field. For any technical education, practical experience is almost
equal importance in association with the theoretical knowledge.
The industrial attachment is the process, which builds understanding skills and
attitude of the performer, which improves his knowledge in boosting productivity
and services. University education provide us vast theoretical knowledge as well as
more practical attachment, in despite of all these industrial attachment helps us to
be familiar with technical support of modern machinery, skillness about various
processing stages.
It is also provide us sufficient practical knowledge about production management,
work study, efficiency, industrial management, purchasing, utility and maintenance
of machinery and their operation techniques etc.
Textile education cannot be completed without industrial training. Because this
industrial training minimizes the gap between theoretical and practical knowledge
and make us accustomed to industrial environment. We got an opportunity to
complete our industrial training at BISWAS SYNTHETIC LTD. It has well planned &
equipped fabric dyeing-finishing and printing unit in addition to facilitate knitting
and knitwear manufacturing.

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COMPANY PROFILE
GENERAL INFORMATION ABOUT THE COMPANY:
 Biswas Group was established in 1985
 Biswas Group deals in Apparels, Textile and Accessories.
 Biswas Group have 9 fully automated garments factories in Dhaka.
 7 associate factories in Dhaka.
Product Range- Men's Women's Boys, Girls, Kids and Toddlers, T-Shirts, Polo
Shirts, Woven Women's Blouses, Men's Shirts, Pants/Shorts Casual/Denim Men's,
Women's and kids, Jogging Suits, Swimwear, Nighwear, Winter Wear and All kinds
of Accessories.
Monthly Capacities : 43000 pcs woven bottoms, 300000 pcs woven tops, 380000
pcs pants, 600000 pcs knit tops, 30000 pcs knit bottoms.
 Work force - 9000 employees
 Sewing Lines : 100
 Sewing Machines : 4567
 Knitting Machines : 220
 Weaving Machines : 300
 Dying Machines : 47
Head office:
J.S. Bhaban, 95, BirUttam C.R. Dutta Road (New)299/2A Sonargaon Road (Old),
Dhanmondi, Dhaka-1205, Bangladesh
Tel: 9668835-7,8611796,8610685,9673065
Fax: 88028613367
Email: babu@biswasgroup.com

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Web: www.biswasgroup.com
Project location:

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Buyer:
 Aldi - Germany
 C & A - UK
 Calvin Klein- USA
 Carrera - Italy
 Defacto - Turkey
 Ecko– USA
 H & M - Sweden
 Hurley -USA
 Inditex - Spain
 JC Penney - USA
 Kenneth Cole - USA
 Kik - Germany
 LC Waikiki - Turkey/France
 Li & Fung - Internalional
 Lidl - Germany
 Oshkos -USA
 Roca Wear - USA
 Sol's - France
 Sears/K-Mart - USA
 Tema - Turkey
 Wal- Mart - Europe
 Zara – Spain

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General Manpower Organogram:
Chairman
Director
Executive Director
Production QualityAdminAccounts MarketingMaintenance Utility store security
Production QualityAdmin Accounts Marketing Maintenance Utility store security
ManagerManagerManagerManagerManagerManager Mngr. Mngr.officer
Assistant Senior AdminAccountsMarketingMaintenanceUtilitystore Assist
Manager Officer OfficerOfficerOfficer Engineer Engineer Officer Officer
Senior Assistant Cashier Fore man Assistant Helper security
Production Officer Admin Engineer Guard
Officer Officer Fitter man Worker
Production Lab Helper Worker
officer Assistant
Assistant Lab Worker
Production Boy
officer
Machine
Operator
Helper
Worker

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Shifting:
In Biswas Synthetic Ltd. the whole day production time is divided into 2shift. Per shift 12 hours.
Shift Duration
Shift A
8:00 am- 8:00 pm
Shift B
8:00pm – 8:00 am
Responsibility of Production officers:
1. To give dyeing program slip.
2. To match production sample with target shade.
3. To collect production sample lot sample matching next production,
4. To observe dyed fabric during finishing running & also after finishing.
5. To identity disputed fabrics & report to P.M/G.M. for necessary actions.
6. To discuss with P.M about overall production if necessary.
7. To sign the store requisition & delivery challan in the absence of P.M.
8. Also to execute overall floor works.
9. To maintain loading'/unloading khata.
10. Any other assignment given by higher authority.
Title :Production Office
Report To : Sr. Production Officer.
Job Summary:
To plan, execute & follows up the production activities &. control the quality … production
with related activities.
Duties & Responsibilities:
 Overall supervision of dyeing, finishing production.
 Batch preparation & pH I chock.
 Dyes & chemical requisition issue & check.
 Write Fabrics loading & unloading time from m/c
 Program making, sample checking, colour measurement
 Control the supervisors,operator, ass. operator and helper of

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 Dyeing m/c.
 And also any other over work as & when required by the management.
Title : Sr. Production Office
Report To :Manager
Job Summary:
To plan.execute& follows up the production activities & control the quality production with
related activities.
Duties & Responsibilities:
 Overall supervision of dyeing, finishing production.
 Checks the sensitive parameters of different machine for smooth dyeing
 Checks the different log books of different areas & report to management
 Checks out the plan to control the best output from supervisors & workers.
 To trained up& motive the subordinates how to improve the quality production.
 Control the supervisor, operator, Asstt. Operator & helper of dyeing.

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Knitting section layout:
Office
Store
QC
Wash
room

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Process flow diagram of knitting:
MERCHANDISER
SAMPLING
TESTING
ORDER PLACEMENT
BY BUYER
YARN PROCURED &
STORE
FABRIC MADE
(YARN TESTING)
PRE-PRODUCTION
SAMPLE
PRODUCTION
QUALITY INSPECTION

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Process control of knitting:
Yarn in cone form
Creels
Pipe
Knot catcher
Tension disk
Inlet stop motion
Yarn guide
PF Wheel
Out let stop motion
Guide
Needle
Fabric
Fabric take up roller
Inspection
Numbering

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Knitting:
Knitting is the method of creating fabric by transforming continuous strands of yarn into a series
of interlocking loops, each raw of such loops hanging from the one immediately preceding it.
The fundamental structure unit of a knitted fabric is the loop. Any circular knitted fabric is
composed of row after row of intermeshed loops. Different types of fabric are made of different
method of intermeshing the loop. The gross dimension of knitted fabric is simply a relation of
average shape and size of individual loop. There are several key variables in the production
which affect the average shape and size of the loop. After knitting the grease fabric is dyed to
required shade and finished to required weight and width.
 Classification of knitting:
Warp knitting:
A method of making a fabric by normal knitting means is which the loop made from each
warp thread is formed substantially along the length of the fabric. Characterized by the fact that
each warp thread is feed more or less in the line with the direction in which the fabric is
produced.
Weft knitting:
A method of making a fabric by normal knitting means is which the loop made from each
weft thread formed substantially along the length of the fabric. Characterized by the fact that
each warp thread is feed more or less in the line with the direction in which the fabric is
produced.
Knitting
Warp knitting Weft knitting
Circular knitting Flat knitting
Single jersey Double jersey

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Single jersey:
A fabric in which all the loops of the Wales are intermeshed in one direction is called
single jersey. Only cylinder is used to make single jersey fabric.
Double jersey:
A fabric in which all the loops of the alternate wales/wales are intermeshed in one direction and
all the loops of the other wales knitted t the same course are intermeshed in the other direction is
called the double jersey. Dial and cylinder are used to make this type of fabric.
Primary knitting elements:
Needle:
The needles are the most important stitch forming elements. They are displaced vertically up and
down and are mounted into the tricks or cuts of the knitting cylinder.
There are three types of needles namely:
1) Latch Needle.
2) Spring bearded Needle and
3) Compound Needle.
The main function of needle is loop formation.
Cams:
Cam is the second primary knitting element. The cams are the mechanical device which convert
the rotary machine drive into a suitable reciprocating action for the needles or other elements
came are carefully profiled to produce precisely time movement and dwell periods.
Types of knit cam:
1.Knit cam
2.Tuck cam
3.Miss cam

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Sinker:
Sinker is a thin metal plate with action at right angles to and fro between adjoining needles.
Functions of Sinker:
1) Loop formation: The main objects of a sinker are to assist the needles in loop formation by
sinking or knitting the newly laid yarns into a loop.
2) Holding down: It also holds down the loops at a lower level of the needles stems and
prevents the old loops from being lifted as the needles raise to clear them for their hooks.
3) Knocking over: The function is knocking over at which the needle passes through the old
loop by drawing a new loop.
End Products of Single Jersey Circular Knitting Machine:
1.S/J Plain 2.Single Lacoste
3.Double Lacoste 4.Single pique
5.Double pique 6.Terry
7. Fleece
End Products of Rib Machine:
a) 1x1 Rib
b) 2x2 Rib
c) Honeycomb

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Cam arrangement:
▲→ Knit Cam
Π→ Tuck Cam
=→ Miss Cam
Single Jersey: ▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
Rib Stracture:▼ ▼ ▼ ▼ ▼ ▼
▼▼▼▼▼▼
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
Interlock:▼=▼=▼=
=▼=▼=▼
= ▲ = ▲ = ▲
▲ = ▲ = ▲ =
Single pique: Π▲Π▲Π▲
▲Π ▲ Π▲ Π
Double pique:ΠΠ ▲▲ ΠΠ ▲▲
▲ ▲ ΠΠ ▲ ▲ΠΠ
Single Lacoste:Π▲ ▲ ▲ Π ▲ ▲
▲ ▲Π▲ ▲ ▲Π
Double Lacoste:ΠΠ▲ ▲ ▲ ▲ ΠΠ ▲ ▲ ▲
▲ ▲▲Π Π▲ ▲ ▲▲Π Π
Fleece fabric: = ▲ Π= ▲ Π▲ Π=
= ▲ Π= ▲ Π▲ Π=
= ▲ ΠΠ▲= ▲ΠΠ

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Machine profile of knitting section:
Knitting Machine (Single Jersey)
SL M/C Dia/Gauge M/C Quantity Capacity (Per Day) Origin Brand
1 17x24 GG 1 Set 200 Taiwan Min Hua
5 23x24 GG 1 Set 220 Taiwann Min Hua
Total= 9 Set 1990 kg
Knitting Machine (rib Interlock)
1 30x18 GG/24 GG 1 Set 300 Taiwan Min Hua
Knitting Machine (Micro-Polar)
1 26x18 GG 7 Set 1750 Taiwan SandaDask
3 28x19 GG/24 GG 19 Set 5320 Taiwan SandaDask

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Knitting Machine
CVC Fleece (Cross/Straight Terry)
Flat Rib
1 60x20 GG 6 Set 2400 Pcs Chaina Sen Huang
Total= 6 Set 2400 pcs

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Knitting variables:
 Yarn count
 Yarn twist
 Spinning system
 No. of ply of the yarn
 Stitch length
 Yarn tension
 Required time (M/C running time);
 Take down tension
 Yarn quality
 Machine gauge
 Machine Diameter
 Machine rpm
 No. of feeds or feeders in use
 Machine running efficiency.
Machine pitch (t) : Is defined as the distance between the centers of two adjacent
Needle of the same needle row indicated in mm.
25.4
Pitch = m.m
Gauge(E)
Machine gauge (E) : Machine gauge denotes the number of needles per inch , arranged
On the needle carrier and based on the nominal machine diameter .
25.4
Gauge (E) = mm.
Pitch
Loops : It is a basic unit consisting of a loop of yarn meshed at its base with
previously Basic unit .
Stitch : The smallest dimensionally stable unit of all knitted fabrics is the stitch . It
consists of a yarn loop which is held together by being intermeshed with another stitch or
other loops
Stitch length:Stitch length is a length of yarn which includes the needle loop & half the sinker
loop on either side of it. Generally the larger the stitch length, the more extensible & lighter the
fabric & the poorer the cover, opacity & bursting strength.

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Raw materials for knitting:
Key accessories used in Circular knitting:
 Yarn feeder guide
 Needle
 Sinker
 Cam
 Cylinder
 VDQ pulley
 Pattern wheel
 Sinker cam cap
 Sinker trick ring
 Dial
 Needle retaining spring
 Cam box
 cam plate
 Inventor
 Belt
Type of yarn Count
Cotton
20S, 22S,24s,26s,28s,30s,32s, 34S, 40S
Polyester 75D,150D
Lycra yarn 20D,40D
PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S
CVC 24S, 26S, 28S, 30S

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Production calculation:
A. Production/shift in kg
B. Efficiency:

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Relationship between knitting parameter:
1. Stitch length increase with decrease of GSM.
2. If stitch length increase then fabric width increase and Wales per inch
Decrease.
3. If machine gauge increase then fabric width decrease.
4. If yarn count increase (courser) then fabric width increase.
5. If shrinkage increases then fabric width decrease but GSM and Wales
Per inch increase.
6. For finer gauge, finer count yarn should use
7. Grey GSM should be less than finish GSM
Yarn Twist and Yarn Count:
The amount of twist is an important factor in finished consumers’ goods. It determines the
appearance as well as the durability
and serviceability of a fabric. Fine yarns require more twist than coarse yarns. If the yarn twist
increase, the yarn strength increase up to certain level after that yarn strength decrease.
The twist factor for combed cotton yarns for knitted fabrics should not exceed 3.7, whereas in
case of carded yams, a twist factor up to 3.9 is tolerated of yarns for knitted fabrics .
In case of knitting yams a part of the yarn strength has to be sacrificed for a better and softer
handle
Yarns with low twist are used for knitted fabrics, yarns with high twist are used for crepe yarns
Yarnswith average twist are used for regular woven fabrics.

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Effect of stitch length on color depth:
If the depth of color of the fabric is high loop length should be higher because in case of fabric
with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted
then. Similarly in case of light shade loop length should be relatively smaller
Knitting defect & remedies :
Fault name Causes Remedies image
1. Hole Mark
# yarn breakage or yarn
cracks.
# If the yarn count is not
correct on regarding
structure, gauge, course
and density.
# Badly knot or splicing.
# Yarn feeder badly set.
# If yarn tension too
high
#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
# When a needle breaks
down.
# If a needle or needle
hook is slightly bends .
# If needle does not
catch yarn .
# Needle should be
straight as well as
from broken latch.
3.Star Mark
# Yarn tension variation
during production.
# Buckling of the needle
latch.
# Low G.S.M fabric
production
# Maintain same
Yarn tension during
production.
# Use good
conditioned needles.

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4.Drop
Stitches
# 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.
#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.
5.Bariness
# Use of irregular yarn
having higher long term
irregularities.
# Using different count
thread.
# Remove irregular
yarn
# Use proper yarn
count
#We can use it for
white fabric
6.Loop
# If needle latch is hard
or curve.
# if yarn tension is loose
.
# Clean or change
the needle.
# Set proper yarn
tension

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7.Lycra out
Cause by If lycra is
missed or Lycra attach
with the yarn
Check the feeder and
attatchlaycra.
8.Seat up
(cloth
fallout)
# if needle latch is not
work properly/jaum
# Causes by thick yarn
# Improper/large knot
Make sure all the
latches of needle are
closed with feeding
yarn after a drop
stitch.
9.Oil mark
# Excessive oil flow in
the needle
# Leakage of oil line
# Ensure that oil does
not pass on the
fabrics.
# Well maintenance
as well as proper
oiling.

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10.Fly
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.
# Blowing air for
cleaning and different
parts after a certain
period of time.
# 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
11.Yarn
contamination
# If yarn contains foreign
fiber then it remains in
the fabric even after
finishing,
# If lot, count mixing
occurs
# By avoiding lot,
count mixing.
# Fault less spinning.
12.Sinker
Mark
# 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
Sinker should be
changed

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Quality Control
Quality assurance system of knitting division:
The quality assurance department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing. After collecting fabric rolls from
different machines, these fabrics need to inspect thoroughly by the quality inspectors to assure
required quality before dying. Quality assurance of knitted grey fabric is described here.
Quality control
On-lineOff-line
Quality control equipment:
Following equipment are used to ensure proper quality of the produced fabric
 Yarn tension meter
 Stitch length meter
 Magnifying glass
 GSM cutter etc
On- line:
1. Grey GSM of the fabric
2. Grey inspection
3. Stitch length
4. In coming good quality check
Off- line:
1. Check diameter, GSM, unevenness, dead fiber, hairiness, thick and thin place, and
contamination
2. Shrinkage %
3. Spirality
Body 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
effect, fall out, contamination, fly, holes, oil lines, needle line, slubsetc are recorded in inspection
report to classify the fabric based on the four point system.

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Collar & cuff inspection:
Collar& cuff are inspected visually under the light box, any major or minor fault in collar/cuff
like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly
counted and recorded.
Quality Control Standard Value:
Fabric inspected by 4-point system.
Shortly describe about 4-point system.
This is the universal system for the inspection of grey and finished fabric. In this system, we
count penalty point for different kind of defect as well as according to the defect size. Different
types of defect may come from yarn fault, manufacturing fault, transportation fault.
Parameter of penalty point:
 Hole-H
 Rus Stain-RS
 Oil Stain-OS
 Missing Yarn-MY
 Fly/Contamination-F/c
 Slubs-S
 Needle drop-ND
All holes, regardless of size will be penalized 4 point.
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
Any hole 4 point

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Calculate points per 100 square yards fabric:
= 100
Actual width
36
Actual Roll length
Actual points counted
 
= points/ 100 sq. yards
Classification of Inspection Fabric:
< 40 points = A
41-60 points = B
61-80 points = C
80 above = Reject.
Acceptance:
Generally any piece of fabric with 40 points or less faults per 100sq. yard is
allowed to pass however for a roll, the average value should not exceed 18point per
100sq.yard.More than 40points faults per 100sq yard is recorded as “REJECT”.
Defects For Rejection:
 Patta-P
 Continuous Star-CS
 Sinker Mark-SM
 Wrong Design-WD
 Poor Elasticity-PE
 Major thick
 Needle Line NL

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Batch section
Batching:
Primarily batching is done by batching section which is supervised by dyeing manager. The main
function of batching section is to prepare the batch for dyeing according to machine capacity,
order and emergency. This section receive the grey fabric from knitting section and make batch
according to order for particular shade. Then this batch delivers to dyeing section for dyeing.
Function or purpose of Batch section:
 To receive the grey fabric roll form knitting or other source.
 Turn the gray fabric if require.
 Prepare the batch for dyeing according to the following criteria:
 Order sheet (Received from buyer)
 Dyeing shade ( light or dark, color or white)
 Machine capacity.
 Type of fabric ( 100% Cotton, CVC, Stripe fabric)
 Emergency order.
 Fabric construction (single jersey, Rib, Lycra Rib, Lacost, Pique etc.)
 To send the grey fabric to the dyeing floor with batch card.
 To keep record.
Proper Batching Criteria:
 To use maximum capacity of existing dyeing machine.
 To minimize preparation time & machine stoppage time.
 To use a particular machine for dyeing same shade.
Batching Ratio Calculation;
Batching Ratio = (Fabric Dia × Batch quantity) / Total quantity

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Process flow chart of Batch preparation:
Deliver the Fabric to dyeing section
Receive the order sheet from in-charge
Make the batch card on the priority of shipment
date
Take the Batch card which order have to deliver
first
Check the availability of the fabric
Turn off the fabric (if necessary)
Distribute the collar/cuff or Rib in each rope
equally ensuring equal length.
Take collar/cuff as per size and keep the total
weight
Take require quantity of body fabric from the
store
Stitch the fabric
Write down weight against roll no. in the back
side of the Batch card
Write the total weight in the batch card
Fill up the Production report form

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Dyeing Lab
In every dye house, a laboratory equipped with machines & equipment is essential. It assists in
production prediction, minimization of time consumption and wastage reduction. It is also
producing the product of desired quality.
Prior to the bulk production, laboratory plays a vital role in shade matching & detecting the
characteristics of the dyes and chemicals to be used in the large scale of production.
In Biswas Synthetic Ltd. dyeing Lab is divided into two section.
Chemical Lab
Quality Lab
Quality Lab:
Quality lab performs all testing on finished fabric.
Chemical lab:
Chemical lab performs all shade matching and other chemical tests for Bulk dyeing Production.
Lab dip:
Lab dip is a process by which buyers supplied swatch is matched with the varying dyes
percentage in the laboratory with The help of “DATA COLOR” or see the previous matching
sample or give the recipe by the practical experience, Lab dip plays an important role in shade
matching & and detaching the characteristics of the dyes and chemicals are to be used in the
large scale of production so this is an important task before bulk production.
Key accessories for Lab:
 Data color computer
 Lab, receive file
 Electronic Blench
 Plastic/Glass beakers
 Steel stirrer
 Scissors
 Stainless reference & dyeing beakers
 Dryer
 Variable light box
 Electric Heater

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Lab Dip Procedure to Dyeing Floor Or Bulk Production:
Receive swatch
Spectrophotometer inspection
Ref. recipe
Stock solution preparation
Sample measuring
Dyeing
Unload and wash in cold water
Hot wash with detergent
Wash in cold water
Squeeze and Dry
Preparing Lab dip
If not ok send to buyer if ok
Send recipe for sample dyeing
Sample Dyeing
Available Stock Solutions:
For dyes:
Red –0.01, 0.1%, 0.5%, 1.0%, 2.0%
Yellow – 0.01, .01, 0.1%, 0.5%, 1.0%, 2.0%
Blue - 0.01,0.1%, 0.5%, 1.0%, 2.0%
For chemical:
 NaOH – 10% stock solution
 Salt – 25% stock solution
 Soda - 25% stock solution

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Range of Salt and Soda according to the shade %:
Shade % Glauber
salt(g/l)
Soda ash(g/l)
.001 – 0.5 20 6
0.51 – 1.0 30 8
1.01 – 2.0 40 10
2.01 – 3.0 50 12
3.01 – 3.5 60 15
3.51 – 4.2 70 18
4.21 - 5.10 80 20
5.11 above 100 20
Recipe Calculation:
 Total Liquor=4x50=200 cc
 Dye solution=(sample weight x recipe amount% )/stock solution% cc
 Salt required=(total liquor x recipe %)/ (1000 x stock solution%) cc
 Soda Solution =(total liquor x recipe %)/ (1000 x stock solution%) cc
SAMPLE CALCULATION FOR 1% SHADE:
 Sample wt. = 5 mg
 Material liquor ratio = 1: 8
 Total liquor (5  8) = 40 cc

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5  1%
 Dye solution required == 5 cc
1.0%
40  30
 Salt solution required = 4.8 cc
1000  25%
40  8
 Soda ash solution required = = 1.28 cc
1000  25%
 Water required {40 - (5 + 4.8 + 1.28)} = 28.92 cc
Machine profile of Lab section:
Laboratory Machine
SL Machine Name M/C Quantity Origin Brand
1 MSI 1 Set Taiwan Mingscape International
2
Multi Light Color Compersion
Cabinet
1 Set Taiwan Model: CT-100
3 Spector Photo Meter(Data color) 1 Set U.S.A Spectra flash SF-300
4 Rapid 4 Set Taiwan Labortex co. ltd
5 Dexter 2 Set Taiwan Yuan Shein
6 Labtec 1 Set Taiwan Newave lab equipment
7 Dryer 1 Set Taiwan Labortex co. ltd
Total= 12 Set

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Layout of Dyeing section:Dyeing m/c Symbol
Folding m/c
Folding m/c
Folding m/c
Office
Dyeing lab
Washing
m/c
Batch
section
Chemical Store
office
Office
Office
Office
Office
squeezer
Squeezer
Fabric
store
Fabric
store
Office
Squeezer
Squeezer
Squeezer

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Machine specification:
Knit Dyeing Machine
SL Machine Name
Capacity
(Per Day)
M/C
Quantity
Origin Brand
1 Dyeing M/C 300 1 Set Taiwan Toonggeng
4 Dyeing M/C 150 1 Set Taiwan Hsiang Fu
5 Dyeing M/C 150 1 Set Taiwan Hsiang Fu
6 Dyeing M/C 150 1 Set Taiwan HuanJenn
7 Dyeing M/C 90 1 Set Taiwan HuanJenn
8 Dyeing M/C 1800 1 Set Taiwan Tong wutaiwan
14 Dyeing M/C 3000 1 Set Taiwan Ak
19 Dyeing M/C 1800 1 Set Taiwan Tong geng
22 Dyeing M/C 4500 6 Set Taiwan Taiwan
Total= 29040 yds 27 Set

41
Woven Dyeing Machine
Sl Machine Name
Capacity
(Per Day)
M/C
Quantity
Origin Brand
6 Dyeinng M/C 1800 1 Set Taiwan Tong geng
Jigger Dyeing Machine
SL Machine Name
Capacity (Per
Day)
M/C
Quantity
Origin Brand
1 Jigger Dyeing M/C 3600 yds 4 Set Korea Sung Moo Korea
2 Jigger Dyeing M/C 6000 yds 4 Set Korea Shink Wang Kore
3 Jigger Dueing M/C 6000 yds 4 Set Korea Sung Moo Korea

42
Process Flow Chart:
Scouring & bleaching
Hot wash
Cold wash
Peroxide killing
Neutralization
Enzyme wash
Enzyme killing
Normal wash
Dyeing
Soaping
Acid wash
Softening

43
Dyeing:
Dyeing is the process of imparting colors to a textile material through a dye (color). Dyes are
obtained from flowers, nuts, berries and other forms of vegetables and plants as well as from
animal and mineral sources. These are known as natural dyes. The other classes of dyes are
known as synthetic dyes. These are based on a particular type of chemical composition. Some of
these dyes are- Acid (Anionic) dyes, Basic (Cationic) dyes, Neutral dyes, sulfur dyes, vat dyes,
reactive dyes, pigment dyes etc.
Pretreatment:
The term “pretreatment” covers all operations of preparing textile material for subsequent dyeing
and finishing processes.
Objective:
The preparation of goods for dyeing and printing is a far important process than the production
of white goods. Textile material to be dyed or printed must have the following properties:
 To increase the uniform absorbency all over the goods as much as possible.
 To remove all types of impurities as much as possible with minimum damage to fibres
 To make fibres fit for dyeing.
Fit for dyeing is a concept that explain a material which is completely ready for dyeing both
externally & internally & conforms several requirements. Like-
 Required uniform absorbency
 Required Ph level.
 Required H2O2 level
 Required bi-carbonate level
 Minimum damage of fibre structure.
Degree of whiteness:
In the past, it was customary to regard the degree of whiteness as the most reliable criterion for
judging the quality of the pretreatment. But now there are other factors governing the results
obtained in subsequent operations. Today, therefore, the object of pretreatment is not a full
bleach, but only a partial bleach as necessary to ensure good purity and brilliance of shade in
subsequent dyeing or printing.
Hydrophilic properties:
High and uniform absorptive of the goods is essential. It is the hydrophilic properties that govern
the evenness of uptake of the dyes and chemicals, particularly in cases where these are applied
continuously

44
Scouring:
The main purpose of scouring textile material is to remove natural as well as added impurities of
essentially hydrophobic character as completely as possible and leave the material in a highly
absorptive condition without undergoing chemical or physical damage of fibre or fabric.
Objective:
1. To remove natural as well as added impurities.
2. To produce hydrophilic characteristics.
3. To make goods cleaner.
4. To leave the material in a highly absorptive condition without undergoing chemical or
physical damage.
Basic principle:
The scouring process of cotton consists of an alkali treatment in the presence of wetting and
sequestering agents, in order to convert the impurities, other than natural coloring matter, into
products which can be removed by aqueous washing.
The processes occurring during the scouring are:
• Saponifiable oils and free fatty acids are converted into soap.
• Proteins are degraded to simple soluble amino acids or to ammonia.
• Mineral matter is dissolved.
• Unsaponifiable oils are emulsified by the soaps formed during the hydrolysis of the
saponifiable matter.
• Adventitious dirt is removed and retained in suspension by the soap.
Factors involved in scouring:
When cleaning soiled surfaces, five variables become involved that interact during scouring and
they are as follows:
1. The nature of the surfaces to be cleaned.
2. The nature of the dirt or soil.
3. The chemicals to be used.
4. The nature of the water or solvent.
5. The nature of the detergent or soap.

45
Bleaching:
In the bleaching process the colored material is destroyed and thus to confer a pure white
appearance to the fabric. Bleaching should also decolorize or remove any residual impurities left
by scouring.
An efficient bleaching process must ensure:
1. A pure and permanent white.
2. Level dyeing properties.
3. The fabric does not undergo tendering (chemical damage or degradation, which results in loss
in tensile strength and hence the durability is affected) during bleaching.
Objectives:
Bleaching of cotton is carried out with two objects in view:
1. To achieve a high degree of whiteness, for goods that are to remain white or to be dyed in
pastel shades; for goods to be dyed in dark shades, bleaching improves the brilliance.
2. To improve the even appearance of the goods by removing the husks.
Enzyme wash:
Enzymes are biological catalysts, mainly proteins, generated by an organism to speed up
chemical reactions. They have an active site on which the substrate is attached, and then broken
up or joined.
Biopolishing is an enzymatic process for finishing of cellulosic materials such as cotton, linen,
viscose, ramie and their blends with synthetic fibres. It is a process that removes fuzz and
eliminates pilling in cellulosic garments.
The enzyme performs a controlled hydrolysis of the cellulosic fibres in order tomodify the fabric
surface. This keeps the garments looking new even after repeated washes. It also enhances color,
feel and drapability. Its effects are permanent, without involving chemical coating of the fibre.
Function:
 Improved resistance to pilling.
 A clearer and fuzz less surface structure.
 Superior finish with improved drapability and
Softness

46
Classes of dyes on the basis of suitability of dyeing different fibers:
Sl.
No
Name of dyes Suitable for Fibers
01 Acid dyes Wool, silk and Nylon
02 Basic dyes Nylon, Acrylic, Acetate Rayon, Silk, Wool and
Jute
03 Direct dyes Cotton, Viscose Rayon, Linen, Nylon, Wool and
Silk
04 Azoic dyes Cotton, Viscose and Linen.
05 Vat dyes Cotton, Viscose and Linen.
06 Sulpher dyers Cotton, Viscose and Linen.
07 Reactive dyes Cotton, Viscose, Linen, Wool, Silk and Nylon.
08 Disperse dyes Polyester, Nylon, Acrylic, Acetate Rayon and
Triacetate Rayon.
Winch dyeing machine :
A dyeing machine consisting essentially of a dye vessel fitted with a driven winch ( usually
above the liquor level) which rotates and draws a length of fabric, normally joined end to end,
through the liquor.
Winch dyeing machines are a low cost design that is simple to operate and maintain, yet versatile
in application proving invaluable for preparation, washing or after treatments as well as the
dyeing stage itself.
Description and Dyeing Method on Winch Dyeing Machine:
The basic principle of all winch dyeing machines is to have a number of loops or ropes of the
fabric in the dye bath, these ropes are of equal length , which are mostly immersed in the liquor
in the bath. The upper part of each rope runs over two reels which are mounted over dyebath. At
the front of the machine , above the top of the dye liquor , is a smaller reel, which is called
jockey or fly roller. The fly roller remain free wheeling along with fabric rope. At the back of
winch tank is the winch wheel, which pulls the fabric rope from the dye bath over the jockey reel
for dropping in the dye bath for immersion. From the dropped location , the fabric rope travels
back . to be lifted and fed to winch wheel.
The dyeing process on winch dyeing machines is based on higher M:L as compared with other
dyeing machines. The process is conducted with very little tension . The total dyeing time is
lengthier as compared to other machines.

47
Advantages of Winch Dyeing :
a. Construction and operation of winch are very simple.
b. The winch dyeing machines are suitable for types of wet processing operations
c. The winch dyeing machine is suitable for practically all types of fabrics ,which can withstand
creasing in rope form processing.
d. The tension exerted on winch is less than jigger, the material thus dyed is with fuller hand.
e. The appearance of the dyed goods is clean and smooth on winch dyeing machines.
Raw Material Used for Dyeing:
 Gray fabrics
 Dyes
 Chemicals
Gray fabrics: Following types of gray fabrics are dyed:
 Single jersey
 Single jersey with lycra
 Lycra Rib
 Rib
 1 x 1 Rib
 2 x 2 Rib
 2 x 1 Rib
 Polo Pique
 Interlock
 Fleece
 Micro fleece
 Polar fleece

48
Dyes, Chemicals & Auxiliaries Used in Biswas Synthetic Ltd
Auxiliaries
1 Peroxide killer geizyme OEM
2 Peroxide tesbilizerSR/Stopa-52 chemical
3 Polyester leveling Melevel -lpf
4 Polyester leveling Melevel-BFR
5 Sequestering austol
6 Soaping asugal-ALBI
7 Wetting agent –proder-SCPC/LF
8 White softener gensoft
9 Fixing ecofix DR/SR
10 Leveling drimegen W2R/ Texotech
11 Anticrease-Pac(8460)
12 Genifoam NS
Special Chemicals
1 Brightener Leucophor BSB
2 Brightener sun white
3 Enzyme producto _EAPS-A/Genincor-Bf-1600/3500
4 Silicon softener Dowsil-DMAX
5 Silicon softener silipinwor HD/MAttaX/Tubingal/get soft –
SA852
6 Silicon softener Adilin NI
7 Silpure FBR-5
Others
1 Other apritonnchemichel
2 Other binder mtb chemical
3 Other bleaching powder
4 Other formic Acid
5 Other glycerin
6 Other oxalic acid
7 Other pocket clear
8 Other power wash Ne
9 Other sandozin EH
10 Other sodiamhydrose chemical
11 Other ultra phor BN chemical
12 Other urea chemical
13 Jintex eco GD CONE
14 JINTEX eco GS CONE
16 Benlon2900(buffer acid)
17 Chemical amound

49
Dyes
1 Ciba blue FNR Dyes
2 Ciba brill Blue FNG FyesFGFN
3 Ciba red FN3G Dyes
4 Ciba red FNR Dyes
5 Ciba red WB Dyes
6 Ciba Navy SG
7 Ciba Red C2BL
8 Ciba Navy WB
9 Ciba yellow CRG Dyes
10 Ciba yellow S3R
11 Ciba yellow H2G
12 Ciba Navy FNB
13 Ciba Yellow F4G Dyes
14 Ciba Yellow DN2R Dyes
15 Ciba Orange FNR Dyes
16 Ciba Orange W3R Dyes
17 Dianix black CCR Dyes
18 Dianix Blue SSB Dyes
19 Dianix Navy CC Dyes
20 Dianix Yellow SEG Dyes
21 Drimarine Blue HFRL Dyes
22 DrimarineBlueCLBRDyes
23 Drimarine Red CL5B Dyes
24 Drimarine Red RH3b Dyes
25 DrimarineScariate HF3G Dyes
26 DrimarineTarquise CLB Dyes
27 Drimarine Yellow CL2R Dyes
28 Drimarine Yellow HFR Dyes
29 Reactive G. Yellow 3RS/MERL
30 Reactive black B Dyes /AB/5
31 Reactive Red ME4BL Dyes
32 Reactive Yellow H4GL Dyes
33 Reactive Super black G Dyes/AG
34 Reactobond yellow HW Dyes/AEY
35 Reactobond Red Hw Dyes
36 Reactive Navy WB
37 Reattofex orange ME2RL
38 Remazol Navy RGB Dyes
39 Remazol Red RGB Dyes
40 Remazol Blue RSPL Dyes
41 Remazol RED RR Dyes
42 Remazol Blue RR Dyes
43 Remazol Yellow RR Dyes
44 Imcozin Blue VCR

50
Typical Process Flow Chart for Knit Dyeing:
Process Flow Chart Scouring &Bleaching:
Fabric Loading
Machine filling with water
Chemical Inject at 40 0C
Caustic Soda dozing at 600c for 10 min
Run time 10 min.
H2O2 Dozing at 700c dozing for 10 min
Heating at 105 0C
Run time 45 min.
Cooling at 80 0C
Drain Bath
Normal hot wash at900c for 10 min
Cold wash for 10 min
Drain
Process Flow Chart for Enzyme:
Acetic acid dozingat 40 0C
Run 10 min
Heating at 55 0C
Dozing enzyme
Run time 45 min.
Drain
PH Check

51
Process Flow Chart for Dyeing :
Heating at 40 0C
Chemical dozing
Run time 10 min.
Salt dozing
Run time 10 min
Dyes dozing for 40min
Run time 20 min.
Soda dozing for 40 min
Run time 10 min.
Color Steam at 600C for 60min
Bath drop
Drain
Process Flow Chart for softening :
Heating at 40 0C
Softener dozing
Run time 20 min at 450C
Drain
PH Check
PH Check
Sample check
after 10 min
PH Check

52
Fabric specification & Recipe (White color):
Fabric : Single Jersey Quantity : 592 kg
GSM : 160 M: L - 1:7
Color : White Water - 4100 lit
Recipe :
Sl.
No
Commercial
name of Dyes &
Chemicals
Origin name Amount
(g/l or %)
Total amount
Pretreatment:
01 NOF Detergent 0.7 g/l 2.900 kg
02 BLB Sequestering
agent
0.2 g/l 820 gm
03 OKB Stabilizer 0.8 g/l 3.280 kg
04 B.PAC Anti-creasing
agent
0.6 g/l 2.40 kg
05 Caustic soda Scouring agent 3.0 g/l 12.300 kg
06 H2O2 Bleaching agent 10 g/l 41.00 kg
07 4BK OBA 0.35% 2.072 kg
08 Acetic Acid 1.0 g/l 4.100 kg
09 NOF Detergent 0.5 g/l 2.00 kg
10 Soda 2 g/l 8.200 kg
11 Hydroze For reduction
cleaning
0.2 g/l 820 gm
12 Acetic Acid 0.4 g/l 1.600 kg
13 Bio polish Enzyme 0.3% 1.800 kg
14 T.S.W Softener 0.5% 2.960 kg

53
Process flow chart for White color:
Fabric loading
Machine Fill with required water
Detergent +sequestering agent+ Peroxide stabilizer +
Anti creasing agent Inject at 45°C Temperature.
Caustic soda dosing at 60°C Temperature for 10 minuets
H₂O₂ dosing at 70°C Temperature for 10 minuets
Optical brightening agent dosing at 80°C Temperature
Machine runs 30 minutes at 105°C Temperature
Cooling at 80°C Temperature
Sample check if not ok
if ok
Normal hot wash at 90°C Temperature for 10 min.
Cold wash for 10 min
Drained water & Machine Fill with required water
Detergent+ Soda ash + H₂O₂ dosing for Reduction clearing
Acetic acid dosing for neutralization
Cold wash for 10 minuets
Acetic acid dosing at 40°C Temperature
Enzyme dosing
Ph 6.0-7.0
Ph 4.5-5.5

54
if ok
Hot wash is done for enzyme killing
Softener dosing for softening
Drained water
Unload
Fabric specification & Recipe (Green color):
Fabric : Pique (PK) Quantity : 1310 kg
GSM : 200 M: L - 1:7 (During Pretreatment)
1.8 (During Dyeing)
Color : 13-024 texGreen Water - 9200 lit (Pretreatment)
10500 lit (During Dyeing)
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(g/l or %)
01 NOF Detergent 0.5
02 BLB Sequestering agent 0.2
03 OKB Stabilizer 0.4
04 B.PAC Anti-creasing agent 0.8
05 Caustic soda Scouring agent 3.0
06 H2O2 Bleaching agent 2.75
07 Acetic Acid 1.0
08 Ultra Per-oxide killer 0.5
09 Acetic Acid 0.4
Ph5.5

55
10 Biopolish Enzyme 1.0
13 Texotech Leveling agent 1.0
14 Yellow 4GL Dye 0.08% - 5%
15 Rea. Blue Dye .064% + 10%
16 Rema blue RR Dye .0068% + 5%
17 Salt 30
18 Soda 8
19 Acetic Acid 1.0
20 RSK Soaping agent 0.6
21 KWL Softening agent 0.7%
Dyeing process for Light shade(Green):
Fabric loading
if ok
Cold wash for 10 min.
Peroxide killer dosing

56
Enzyme dosing
If ok
Sequestering agent+ Anti creasing agent Inject at 45°C Temperature
Leveling agent dosing at 45°C Temp for 10 min.
Gluber salt dosing at 45°C Temp for 10 min.
Color dosing at 45°C Temp. for 40 min.
Machine runs 10 minutes
if ok
soda dosing at 45°C Temperature for 40 minuets
Color steam at 60°C Temp. for 60 min.
if ok
Rinse for 10 min. & then Drain
Acid wash at 45°C Temperature for 10 minuets
Soaping is done at 80°C Temperature for 10 minuets
Ph 6.0-7.0
Ph 4.5-5.5
Ph11.0- 12.0

57
if ok
Final Sample check if not ok
if ok
Unload
Fabric specification & Recipe (Black color):
Fabric : Single jersey Quantity : 1000 kg
GSM : 160
M: L - 1:7 (During Pretreatment)
1.8 (During Dyeing)
Color : Black
Water - 7000 lit (Pretreatment)
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(g/l or %)
01 Jintex GD Detergent 1.0
02 Jintex GS Sequestering agent 0.2
09 Acetic Acid 0.4
14 RB. Yellow-HW Dye 1.10% + 0%
15 RB. Red-HW Dye 0.90% - 20%
16 Rea. S. Black-KGD Dye 4.80% - 20%
17 Salt For exhaustion 80
18 Soda For fixation 8
Caustic For fixation
Ph 6.0

58
19 Acetic Acid 1.0
Dyeing process for Dark shade(Black):
Fabric loading
Detergent +sequestering agent Inject at 45°C Temperature.
if ok
Enzyme dosing
If ok
Leveling agent dosing at 45°C Temp for 10 min.
Gluber salt dosing at 45°C Temp for 10 min.
Color dosing at 45°C Temp. for 40 min.
Ph 4.5-5.5

59
Machine runs 10 minutes
if ok
soda&NaOH dosing at 45°C Temperature for 40 minuets
Color steam at 60°C Temp. for 60 min.
if ok
if ok
if ok
Unload
Fabric specification & Recipe (Critical color Turquoise blue):
Fabric : Single jersey Quantity : 570 kg
GSM : 160
M: L - 1:7 (During Pretreatment)
1.8 (During Dyeing)
Color : Black
Water - 4000 lit (Pretreatment)
Ph 6.0
Ph11.0- 12.0

60
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(g/l or %)
01 NOF Detergent 0.5
03 OKB Stabilizer 0.4
05 Caustic soda Scouring agent 3.0
07 Acetic Acid 1.0
08 Ultra Per-oxide killer 0.5
09 Acetic Acid 0.4
14 Rema Red RR Dye 0.04%
15 Rea.Turq. Blue Dye 0.32%
16 Sola blue RSPL Dye 0.82%
17 Salt 40
18 Soda 10
19 Acetic Acid 1.0
Dyeing process for Critical color (Turquoise Blue ):
Fabric loading

61
if ok
Peroxide killer dosing
Enzyme dosing
If ok
Leveling agent dosing at 45°C Temp. for 10 min.
Gluber salt dosing (1st half) at 45°C Temp. For 10 min.
Ph 6.0-7.0
Ph 4.5-5.5

62
Gluber salt dosing (2nd half) at 45°C Temp. For 10 min.
Color (critical & another 1st) + urea dosing at 45°C Temp. For 30 min.
(e.g. Turkish blue + rema red + urea)
Run time 10 min.
Color (remaining another color) dosing at 45°C Temp. For 20 min.
(e.g. blue RSPL)
if ok
soda dosing at 60°C Temperature for 40 minuets
Run time 10 min.
Color steam
if ok
if ok
if ok
Unload
Ph11.5
Ph6.0

63
Fabric specification & Recipe ( Pink color, reserve dyeing):
Fabric : Single Jersey(CVC)Lycra attached Quantity : 800 kg
GSM : 200 M: L - 1:7 (During Pretreatment)
1.8 (During Dyeing)
Color : Pink Water - 5600 lit (Pretreatment)
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(g/l or %)
01 APB-XP Detergent 1.00
02 ALBA-C 1.00
03 2146 Anti-creasing agent 0.50
04 CAUSTIC Scouring agent 3.00
05 SIFA Peroxide stabilizer 0.50
07 Acetic Acid 0.50
08 Acetic Acid 0.4
09 RTM Dispersing agent 1.00
11 HELO:G-yellow-
FW3R
Dye 0.075%
12 HELO:RED-FB Dye 0.17%
13 Hydrose 0.4
14 Caustic 0.4
15 Acetic acid 0.4
SAMPLE:

64
Fabric specification & Recipe ( Pink color, reserve dyeing):
Fabric : Polar Fleece Quantity :419 kg
GSM : 215 M: L :1.9 (During Dyeing)
Color : Olive Green Water :3500 lit (During Dyeing)
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(kg/l or %)
01 Acetic Acid 1.00
02 RTM Dispersing Agent 3.00
04 BLM Leveling Agent 2.00
05 Tai-Y-3GT Dye 0.56%
06 Lon-R-FB Dye 0.04%
07 Lon-N.B-EXSF Dye 0.56%
08 Caustic 6.00
09 Hydrose 6.00
10 Acetic Acid 1.00
SAMPLE:

65
Fabric specification & Recipe ( Black)
Fabric : Panama Quantity :566kg
Color : Black Water :4000 lit (During Dyeing)
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(kg/l or %)
01 Oxalic Acid 8.00
02 Jef 0.8
03 Mut Acid 6.00
04 BFT 6.00
05 REMAZAL JET 10.00
06 LIDABUST 2.00
07 Long-Yellow Mugl Dye 0.2%
08 Tana-Red-R Dye 0.15%
09 Tana-Black-SFTCR Dye 5.00%
10 Hydrose 6.00
11 Caustic 6.00
SAMPLE:

66
Fabric specification & Recipe (Olive)
Fabric : Polyester 190 FDY Quantity :148kg
Color : Olive Water :1200lit (During Dyeing)
Recipe :
Sl.
No
Commercial name of
Dyes & Chemicals
Origin name Amount
(kg/l or %)
01 Acetic Acid 1.5
02 RTM Dispersing Agent 4.00
03 BLM Leveling Agent 4.00
05 Lon:Yell:M4GL Dye 0.14%
06 Lon-Red-RB Dye 0.065%
Helo:R/Blue-NN Dye 0.18%
SAMPLE:

67
Dyeing faults Causes and Remedies
Uneven dyeing:
Causes:
 Uneven Pretreatment
 Improper addition of color
 Improper addition of chemical
 Using dyes of high fixation properties
 Less control of dyeing machine
 Less circulation time
Remedies:
 By ensuring even pretreatment
 By proper addition of color and chemicals
 Correct circulation time
 By controlling the dyeing machine properly
Batch to batch Shade variation
Causes:
 Using improper dyes and chemicals
 Incorrect pretreatment procedure
 Batch to batch weight variation of fabric
 Batch to batch chemicals and dyes variation (lot variation)
 Improper dosing of dyes and chemicals
Remedies:
 By using standard dyes and chemicals
 By correcting the pretreatment procedure
 By maintaining batch to batch weight variation
 By avoiding lot mixing of dyes and chemicals
 By correcting the dosing time of dyes and chemicals
 By following different dyeing parameter.

68
Dark colored spots:
Causes:
 Dyestuff precipitation during dyeing
 Incompatibility of dyestuff used for producing combined shade
 Too high dyestuff concentration in the dye bath
 Precipitation of unabsorbed dyestuff during after treatment
Remedies:
 By ensuring proper dyeing condition
 By selecting proper dyestuff
 By checking the solubility limit of the dyestuff before dyeing
 By ensuring proper after treatment
Patchy dyeing:
Causes:
 Due to hardness of water
 Due to faulty color addition
 Due to faulty injection of alkali
 Due to improper salt addition
 Due to improper PH of solution
Remedies:
 By using proper sequestering agent
 By correcting the color addition
 By correcting the salt addition
 By proper injection of alkali
 By maintaining the PH level of the solution
Crease mark:
Causes:
 Poor opening of the fabric rope
 Due to high speed of machine running
 Unequal pump pressure and reel speed

69
Remedies:
 By maintaining proper pump pressure and reel speed.
 By controlling the speed of the machine.
 Correct opening of the fabric rope.
Roll to roll variation:
Causes:
 Poor migration property of dye.
 Hardness of water.
 Improper dyes solubility.
 Faulty machine speed.
Remedies:
 Use standard dyes and chemicals
 Proper machine speed.
 Using soft waste.

70
Finishing section
Introduction of Finishing:
Textile finishing involves treating a textile material in such a way that the product has the desired
properties required for its intended useand therefore has great market value. The desired
properties may include the fabric dimensions and their stability, its weight, drape, appearance,
softness and handle, as well as any required functional properties such as resistance to creasing,
flame, water, oil, dirt or bacteria. Textile finishing is therefore an extremely diverse field
involving an extensive range of chemicals.
The degree of permanency of a particular finish for a fabric depends on its intended use. The
chemicals used may weigh the fabric to make it easy to slide and handle, or allow smooth
penetration of a sewing needle to minimize needle breakage.
Anyone involved in textile coloration must be aware of the influence of preparation process on
the dyeing behavior of the fabrics as well as the finishing chemicals on the final color of the
goods and on their color fastness properties. Without this knowledge, nobody can ensure the
ultimate color and its fastness properties.
The techniques of finishing depend on the following:
 Nature of the fabric, i.e. chemical composition, state etc. this determines the appearance,
i.e. transparency, luster, fullness, weight, whiteness etc.
After dyeing, knit fabric is required to finish. During dyeing all knit fabric are dyed in tubular
form. According to buyer's requirement knit fabric are finished in Open form or tubular form.
The tubular and open finishing sequences of Biswas synthetic Ltd. Is given bellow:

71
Flow Chart of finishing for tube fabric:
Dyed Fabric
Tube Squizer
Tube Dryer
Tube Compactor
Final Inspection
Delivery to Garments
Flow Chart of finishing for Open Width fabric:
Dyed Fabric
Open Squizer
Stenter
Ultrasoft
Compactor
Final Inspection
Hydroextractor
Tumble dryer
Delivery to garments

72
Specification of Finishing Machines:
(Floor A)
SL Machine Name
M/C
Quantity
Capacity
(Per Day)
Origin Brand
1 Compactin M/C 1 Set 12000 kg Italy Ferraro
2 Stenter M/C 2 Set 26000 kg Taiwan Cheng Fu
3 Stenter M/C 1 Set 12000 kg Taiwan Tung Yung
4 Stenter M/C 1 Set 12000 kg Taiwan Hung Jyi
5 Stenter M/C 1 Set 12000 kg Taiwan LK & LH
6 Stenter M/C 1 Set 12000 kg Taiwan Tung yung
7 Brushing M/C 18 set 15000 kg Taiwan Yantu
8 Brushing M/C 14 Set 8000 kg Taiwan Yantu
9 Semi Brushing M/C 2 Set 7000 kg Taiwan Yantu
10 High Speed Brushing M/C 2 Set 8000 kg Taiwan Chienlun
11 Shearing M/C 4 Set 40000 kg Taiwan Yantu
12 Hi Combing M/C 3 Set 40000 kg Taiwan Yantu
13 Tumbler M/C 21 Set 30000 kg Taiwan Peacock
14 Tumbler M/C 12 Set 30000 kg Taiwan Ta-Ting
15 Folding M/C 3 Set 40000kg Taiwan
16 Slitting M/C 4 Set 45000 kg Taiwan
17 Fabrics Inspection M/C 5 Set 45000 kg Taiwan Hong Chi
Total= 95 Set
(Floor B)
Sl Machine Name
M/C
Quantity
Origin Brand
1 Washing Machine 2 Set Korea+Taiwan Woo Yang+FulutaEleg
2 Stenter M/C 1 Set Taiwan Lk& LH
3 Peach M/C 2 set Taiwan I Khang
4 Fabrics Inspection & Rolling M/C 2 Set Taiwan Shiaw tai tong
5 Fabrics Folding M/C 1 Set Taiwan shiaw tai tong
6 Calander M/C 2 Set Korea Chan sain
7 WR Coating M/C 1 Set Taiwan Fun tay Electric
8 Fabrics Tention M/C 1 Set Taiwan Shiaw tai tong
9 Sweing M/C 4 Set Taiwan Maqi
Total= 17 Set

73
Observation of Different Finishing M/C:
 Squeezer or De-Watering M/C:
After dyeing process from the dyeing machine then the fabrics arc ready for dc-watering. This is
the process to remove the water from the fabric partially by squeezing. This is the main function
of the squeezing machine. But here also control the some important factor of the fabric quality.
Important parts:
• Twist detector
• Expander
• Paddcr
The basic function of the squeezing m/c:
 To remove the water from the fabric.
 To control the width of the fabric.
 To control the length of the fabric.
 To control the over feeding system.
 To increase the softness of the fabric.
 To remove the crease mark of the fabric.
Controlling points:
• Diameter setting must be accurate.
• Excess padder pressure may cause fabric damage. Padder pressure depends on fabric
construction.
• Speed must be optimum.
• Higher the fabric speed leads less removal of water.
• Overfeed.
 Dryer
Drying is defined as a process where the liquid portion is evaporated from the fabric.
Important Parts:
o Conveyor net
o Chamber
o Burner
o Exhaust air fan
o Over feed roller
o Filter net
o Fan
o Nozzle

74
The basic function of the dryer:
• To dry the fabric.
• To control the over feed system (Shrinkage control)
• To control the GSM of the fabric.
Controlling Points
• Overfeed (%): It depends on fabric structure
• Temperature: It depends on color.
• Speed: It depends on fabric construction and color. For higher GSM lower the speed.
 TUBE COMPACTOR:
Important parts:
 Overfeed roller
 Expander
 Blanket
 Steam sprayers
 Cylinder
 Teflon covers
The basic functions of the Tube compactor machine:
• To control the GSM. (Increase & decrease).
• To control the dia.
• To control the shrinkage. (Increase & decrease).
Controlling Points
a. Temperature : It depends on construction and composition &color of the fabric.
b. Speed : It depends on temperature and fabric construction.
c. Blanket Pressure : Fabric smoothness depends on blanket pressure.
d. Over feed : Over feed should be optimum. It increases GSM but higher over feed
leads to the formation of crease mark.
Observation of tube compacter setting for different fabric:
Fabric
parameter
Single jersey
1 x 1 Rib
Compaction 18 30
Overfeed 5 12
Padder pressure 30 bar 30 bar
Speed 18 m/min 18 m/ min
Temperature 100oC 100oC

75
 Slitting Machine
Important parts:
• Twist detector
• Cutting knife/device
• Padder
Main Function of Slitting m/c
 To open the tube forms of fabric
 To squeeze the fabric and remove the extra water in the fabric.
Controlling Points
• Pressure: The paddcr pressure should be according to requirement.
• Specd-Thc speed should be optimum (30-80 m/min)
 Stenter Machine:
Important parts
 Burner (Oil)
 Chamber (6)
 Overfeed roller
 Nozzle
 Chain arrangement
The basic functions of the stenter machine:
 To control width.
 To control GSM.
 To control shrinkage.
 To control spirality.
 Drying of fabric.
 To remove the crease mark of the fabric
 To increase the better shade properties
 To give belter finishing result of the fabric
Controlling Points
a. Temperature : It depends on color construction and composition of the fabric. For S/J
the temp is 150°C and 170°C for stripe fabrics.
b. Over feed : Over feed increases the GSM of the fabric.
c. Width setting : Higher width setting reduces the GSM
d. Speed : It depends on construction and amount of moisture on the fabric.

76
Observation of stenter setting for different fabric:
 OPEN COMPACTOR:
Important parts:
• Overfeed roller
• Blankct
• Steam sprayers
• Cylindcr
• Tell on covers
The basic functions of the Open compactor machine:
• To control the GSM. (Increase & decrease).
• To control the dia.
• To control the shrinkage. (Increase & decrease).
Controlling Points:
a. Temperature : It depends on construction and composition & color of the fabric.
b. Speed : It depends on temperature and fabric construction.
c. Blanket Pressure: Fabric smoothness depends on blanket pressure.
d. Over feed :Over feed should be optimum. It increases GSM but higher over feed
leads to the formation of crease mark.
Fabric
parameter
Single jersey
L – Rib
P.K.
F/T
Required Dia 88’’ 80” 54” 80”
Actual Dia 90.5” 88” 67” 84”
Required GSM 160 240 210 240
Actual GSM 148 218 185 232
Temperature 170oC 170oC 170oC 170oC
Overfeed 60% 45% 60% 40%
Machine speed 45 45 45 45
Dia setting 2310 mm 2400 mm 1720 mm 2150 mm

77
Observation of open compactor setting for different fabric:
Fabric
parameter
Single jersey
CVC S/J
L – Rib
P.K.
F/T
Required Dia 88’’ 92” 80” 104” 80”
Actual Dia 90” 94” 84” 108” 84”
Finished Dia 89” 93” 82” 106” 82”
Required GSM 160 180 240 200 240
Actual GSM 150 170 210 190 230
Finished GSM 155 175 220 200 240
Overfeed 12 12 10 12 10
Temperature 80oC 80oC 80oC 80oC 80oC
Machine speed 20 20 20 20 20

78
Fabric Inspection
Fabric Inspection:
The finished fabric may have different kinds of faults. This may occur during Knitting, dyeing or
finishing. If the fabric delivered then the quality of the fabric may not be good and the buyer will
reject the finished garments. For this reason careful inspection of this finished fabric is so
important. In finished fabric the following faults are generally found:
Faults Appearance Indicating slayable
Uneven shade US
Crease mark CR
Needle line NL
Neps N
Thick thin TT
Barre mark MB
Hairiness H
White specks WS
Penalty Points Indicating slayable
Hole H
Fly Yarn Fy
Fly contamination FC
Dye stain DS
Oil stain OS
Chemical stain CS
Dirts D
Slubs S
Water spot Ws
Lycra Out LO
Insect Spots IS
Rub mark RM
Rust stain RS

79
Biswas Synthetic Ltd. 4 points system is used for calculating fabric acceptance:
4-points system:
In four points system the points are defined on the basis of defect size as shown below:
Size of the defect Penalty
7.5 cm or less 1 points
Over 7.5 cm but less than 15 cm 2 points
Over 15 cm but less then 22.5 cm 3 points
Over 22.5 cm 4 points
Any hole 4 points
Acceptance Calculation:
Roll length in meter = A
Total points found = B
Acceptance Value = B/A x 100 points per 100 meter
Acceptance range:
Range Grade
<40 points A
41 – 60 points B
61 – 80 points C
Above 80 points Reject
If the fabric is found within acceptance limit then it is delivered to Garments section. But if the
fabric fault is so high that cross the acceptance limit then it is rejected

80
Quality Assurance system
Quality assurance system can be divided into following steps:
1. On line Quality assurance system and
2. Off line Quality assurance system.
On Line QC:
 GSM of the Fabric;
 Exact Diameter and Width;
 Grey Fabric Inspection (4 point);
 Shade Check;
 Bias and Bowing;
 Visual appearance (Enzyme performance);
 Stripe.
Off Line QC:
After dyeing the material is received by the finishing section. Before receiving the following
things are checked:
1. Shade condition.
2. Wash fastness.
3. Condition of softening.
4. Condition of enzyme wash.
Before delivery the finished fabric to the customer it should be pass against the requirements.
The following tests are done-
 GSM check.
 Shrinkage test.
 Shade check.
 Rubbing test.
 Wash fastness test.
 Color fastness to perspiration.

81
1. GSM Check: GSM of the finished fabric essentially should be check according to the
buyer’s requirement.
Checking time : at finished state.
Equipment used : GSM cutter.
Sample area : 100 sq.cm.
Manufacturer : Local brand.
2.Shrinkage and SpirilityTest:
Shrinkage and Spirility both are very important for control the quality of fabric. Buyer considers + 5%
allowance for both Shrinkage and spirility. The scale is 50 cm long. The supplied the instrument use for
this Purposes are
washing m/c, measurement tape, scissors etc. The measurement Calculation of shrinkage and Spirility test
are given below:
Before wash - after wash
Shrinkage % = x 100
Body Width
Left twisting - Right twisting
Spirility % = x 100
Body Length
3. Rubbing fastness test:
Equipment used : Crockometer.
Test method : BS EN ISO 105x12. Dry rub & wet rub is including in this method.
Testing time : Finished fabric.
4. Wash Fastness test:
Equipment used : Wascator washing m/c.
Chemicals used : 4 g/l detergent (NOF)
40 min; 60C
then the shade change is measured by color change scale & staining scale.
Test Method : ISO 105 C06.
5. Color Fastness to Perspiration:
Equipment used : Rota-Wash.
Test Method : ISO 105E04.

82
Maintenance
Maintenance:
Maintenance is a process by which equipment is looked after in such a way that trouble free.
Service and increased machine life can be ensured and specific product quality required by the
customers is sustained.
On time maintenance increase m/c lifetime & ensures trouble free services.
Maintenance of machineries is very important for any type of industries and it is must for a knit
composite factory. All machines and machine parts of knitting, dyeing and garments are
maintainedwith extreme care. Because production quality and quantity, both depends on the
maintenance with regularity.
Objective of Maintenance:
To keep the factory plants, equipments, machines. Tools in an optimum
working condition.
To ensure specified accuracy to product & time schedule of delivery to
customer.
To keep the machine down time to minimum thus to have control over the
production program.
To keep the production cycle within the stipulated range.
To modify the machine settings to meet the need for the production.

83
Maintenance Of Machinery:
Preventive Maintenance:
Preventive Maintenance is a predetermined routine activity to ensure on time inspection /
checking of facilities to uncover conditions that may lead to production break downs or harmful
depreciation.
Corrective Maintenance:
In this case, repairs are made after the equipment is out of order it cannot perform its normal
function.
Maintenance
Preventive Maintenance Break Down Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Mechanical
Maintenance
Periodic
Maintenance
Mechanical
Maintenance

84
Periodic Maintenance:
Maintenance of different machines is prepared by expert engineer of maintenance department
for a period of time. Normally in case of dyeing machine maintenance after 30 days complete
checking of different important parts are done.
Maintenance Tools & Equipment:
1. Combination Tools/Spanner:
Function: Tightening & loosening of nuts & bolts.
2. Socket Ratchet Set:
Function:Tightening & loosening of nuts & bolts.
3. SlideRange:
Function: Tightening & loosening of nuts & bolts.
4. Pipe Threat Cutting Tools:
Function: To cut the threat in pipe.
5. Bearing Puller:
Function: To assist the opening of bearing from shaft.
6. PipeRange:
Function: Tightening & loosening of pipe joint.
7. Pipe Cutting Tools
Function: For Pipe cutting.
8. Hole Punch:
Function: Punching the hole.
9. Divider:
Function: For circle marking on metal &wood.
10.Easy Opener:
Function: To open the broken head bolts.
11.External Threat Die:
Function: Forexternal Threat cutting.
12.Heavy Scissor:
Function: Cutting of gasket & steel sheet.
13.Oil Can:
Function: Oiling of moving parts.
14.Srill M/C:
Function: For drilling.
15.Grease Gum:
Function: Greasing of moving parts.
16.Grinding M/C:
Function: For grinding& cutting of mild steel.
17.Welding M/C:
Function:For welding.
18.Spirit Leveler:
Function: For perfect leveling.

85
19.File:
Function: For smooth the metal surface.
20.Hammer:
Function:For scaling & right angling.
21. Hacksaw Blade:
Function: For metal cutting.
Maintenance Procedure:
Normally preventive maintenance is done here. During maintenance procedure following points should
be checked:
Checklist for Different Machine:
Machine : Dyeing Machine
 Check the main pump oil level.
 Check all bearings, seals, gaskets.
 Check all mechanical seal flush pipes.
 Discharge the water from air filter.
 Check all m/c flange & platform bolts.
 Grease RCR rotary joints every 2 weekly
 Clean & check the control panel.
 Check the adjustment of catch basket mechanism and plaiter system.
Machine : Squeezer Machine
Maintenance: Mechanical
 Grease squeezer bearings.
 Grease all the bearings.
 Check oil level of pneumatic oilers.
 Check oil level of gearboxes.
 Check magnetic spreader adjustment.
Machine : Compactor
Maintenance:Mechanical

86
 Nuts of width adjustment spindles for wear
 Check all spindle bearings for free running
 Free running of guide rollers, deflection rollers & contact rollers
 Pressure springs of chain tensioner
Perform visual inspection: -
 Gear box oil level
 Belts, pulleys
Machine :Stentcr
 Crease all bearing with stuburg NBU-12, energrease 1002
 Complete cleaning of the machine
 Check all belt and belt tension
 Check all door sills
 Check gear box of platting and its oil.
 Check all pin bars & clean
 Check chain and give oil if required .Clean exhaust blower & duct
 All chamber blowers check and clean
 Chamber nozzle cleaning
 Check gas pressure, adjust if required
Machine : Boiler:
 Check and clean fluff & dart at all machine.
 Feed pump servicing.Main boiler servicing.
 Cheek all temperature & pressure gauge meter.
 Cheek gas strainer.
 Clean gauge glass &change if required.
 Clean feed tank.
 Clean fire tube.
 Clean all safety valves.
 Check all steam valves.
 Check all gas regulators.
Remarks:
Maintenance of m/c’s are very essential to prolong the m/c life and good maintenance is important consideration.
In this industry maintenance program is done by expert maintenance team. So very few times production are
stopped due to m/c problem.

87
Basic Procedure Of Production Planning &Control:
A planned work brings success. Without planning nothing is complete within the required time. So
planning has its own importance which is intolerable. Planning gives a scheduled task and control
completes it successfully. But production planning and control is not an easy task. Its basic working
procedure is as follows-
Taking order form marketing division,
Analyzing the orders
Planning for knitting the fabric
Planning for dyeing the fabric
Planning for finishing the fabric
It is only a basic procedure. It may change according to the type of order. Sometimes the order is planned
only for finishing the materials or only for dyeing the goods. Then some steps are minimizing for
planning.
Taking order from the marketing division:
N. A. Z Bangladesh Ltd. marketing division supplied fabric orders to the planning and control division by
a specific format.
Analyzing the orders:
After getting the fabric order, this section analyzes the orders according to buyers order quantity, type of
orders (i.e. type of fabric, color to be dyed etc.) delivery date etc. This section plans for required quantity
of fabric to be knitted, knitting balance, fabric to be dyed, dyeing balance RFD (ready for delivery), RFD
balance, delivery fabric & delivery balance.
Planning for knitting:
This section plans for knitting production. It selects m/c for knitting the fabric, no of m/c to be used, type
of yarn used, from which source of yarn will be collected, required GSM, width etc. It also gives delivery
date of knitted fabric.
Planning for dyeing of the fabric:
Production planning for dyeing is called "Batch Plan". Batch plan is prepared according to m/c capacity,
no. of nozzle batch no, fabric construction, color, width, GSM and priority of delivery etc. and written in
a batch card.
Planning for finishing of the fabric:
Finishing schedule is same as dyeing. After dyeing, materials go to the finishing section with the batch
plan. The fabric can be finished in the open line finish or tube line finish. Finishing line will be selected
according to the type of the fabric to be finished. Finishing data is written to the batch card and is
informed to the planning section. However this section always forces to all the departments to finish all
the workwithin the delivery time given by the buyers. Thus, it plays a very important role in the
success of the company.

88
Utility
Available Utility Facilities
Biswas Synthetic Ltd. is a large project. So it requires adequate utility services. In Biswas
Synthetic Ltd. the following utility services are available –
 Electricity
 Gas
 Water
 Compressed air
 Steam
Electricity:
It is impossible to continue the production without electricity. A frequent supply of electricity is
very much essential to ensure smooth production. In Biswas synthetic Ltd. the whole demanded
electricity is generated by Own Generator.
Generator Specification:
Type : Gas generator
No. of generator : 2
Manufacturer : DEUTZ
Local Supplier : KALTIMEX ENERGY BANGLADESH LTD.
Capacity :
Generator No Capacity
Generator No-1 1010 KW
Generator No-2 1344 KW
Electricity Consumption :
Season Total Consumption/Day
In Summer 1400 KW
In Winter 1100 KW
Overall efficiency :80%

89
Stroke of engine : 4 Stroke
Engine RPM : 1500
No of Cylinder :
Generator No No of Cylinder
Generator No-1: 12
Generator No-2: 16
Cooling System : Open Cycle
Ignition System : Auto
Gas
The gas is supplied to Gas Generator, Boiler .
The source of gas is TITAS GAS LTD.
Water
Continuous supply of water for Biswas synthetic Ltd. is ensured by Water pump. The deep well water is
subjected to Water Treatment Plant (WTP) to make sure the water qulity parameter suitable for Textile
Wet Processing.
Water Treatment Plant (WTP)
The goal of all water treatment process is to remove existing contaminants in the water, or
reduce the concentration of such contaminants so the water becomes fit for its desired end-use.
Some common contaminants in raw water (deep well water) is iron,Ca, Mg etc.
The water treatment plant is a vital part of the dyeing section where the supply water of the
dyeing floor is treated and cured for proper dyeing. The supply water contains various soluble
effluents like dissolved solids, metal compounds and other impurities which can lead to any sort
of fabric fault during dyeing the knitted fabrics
Optimum Hardness for Dyehouse water is 1-3 ppm.
In Biswas synthetic Ltd. water treatment is done in three steps by three filter tanks. The
circulation of water at different stages are controlled by different bulbs. Backwash bulbs are used
when the tank needs washing, Drain bulbs helps to drain out the water and Supply bulbs are used
to control the water supply among the filter tanks.

90
Water Treatment Procedure:
Multi Grade Filter:
The multi grade filter is used for removing the residual iron contained in the treated
water.
Activated Carbon Filter:
The activated carbon filter is used for removing the remaining metals and other
impurities by passing the water flow through rocks of different sizes arranged in different
layers of the tank. At first there is a layer of small rocks and next is a layer of medium
rocks and finally comes a layer of big rocks. The tank contains a carbon layer in middle.
Softener Tank:
The heart of a water softener is a mineral tank. It's filled with small polystyrene beads,
also known as resin or zeolite. The beads carry a negative charge.
Calcium and magnesium in water both carry positive charges. This means that these
minerals will cling to the beads as the hard water passes through the mineral tank.
Soft Water Reserve Tank:
The processed soft water is reserved in the soft water reserve tank.
Brine Water Tank
The brine tank is just what its name suggests, a plastic tank that contains a brine, water
saturated with salt. The brine solution is typically made with salt or sodium.
The brine tank holds a salt solution that flushes the mineral tank, replacing calcium and
magnesium ions with sodium.
Calcium and magnesium in water both carry positive charges. This means that these minerals
will cling to the beads as the hard water passes through the mineral tank. Sodium ions also
have positive charges, albeit not as strong as the charge on the calcium and magnesium.
When a very strong brine solution is flushed through a tank that has beads already saturated
with calcium and magnesium, the sheer volume of the sodium ions is enough to drive the
calcium and magnesium ions off the beads. Water softeners have a separate brine tank that
uses common salt to create this brine solution.

91
Regeneration :
In normal operation, hard water moves into the mineral tank and the calcium and magnesium
ions move to the beads, replacing sodium ions. The sodium ions go into the water. Once the
beads are saturated with calcium and magnesium, the unit enters a 3-phase regenerating cycle.
First, the backwash phase reverses water flow to flush dirt out of the tank. In the recharge phase,
the concentrated sodium-rich salt solution is carried from the brine tank through the mineral
tank. The sodium collects on the beads, replacing the calcium and magnesium, which go down
the drain. Once this phase is over, the mineral tank is flushed of excess brine and the brine tank
is refilled.
Test Performed to Ensure the Water Quality:
 Harednes Test
 Iron Test
 Silica Test
 PH Test
Compressed Air:
In Biswas Synthetic Ltd. Compressed air is generated with air compressor.
Machine Name : SWAN Air
Compressor
No. Of Comepressor : 2
Manufacturer : Tong Chen Iron Works
Co. Ltd.
Model : SWP-415
Max. Working Pressr : 9kg/cm2
Machine Name : Foam Liquid Storage
Tank
Manufacturer : Kashiwa Co Ltd.
Origin : Japan
Capacity : 3.7 M

92
Steam:
Pure steam with required temperature must be produced to meet the continuous demand of steam
in different sections. In Biswas Synthetic Ltd. Steam is generated using 2 fire tube boiler.
Boiler No-01: Boiler No-2:
Brand : Cochrn Boiler
Manufacturer : Cochran Boiler Ltd.
Origin : Scotland
Capacity : 10 ton
Brand : DMX1-900P
Manufacturer : Dapang Industry
Origin : Korea
Capacity : 9 ton

93
ETP
(Effluent Treatment Plant)
ETP (effluent treatment plant ) is used to process waste water.
There are two type of effluent treatment plant is present:
 BOD (Biological Oxygen demand)
 COD(Chemical Oxygen Demand)
In Biswas Synthetic Ltd.BOD (Biological Oxygen demand) system is used to treatment
effluent water.
Principle:
Simple bacteria (cells) eat the organic material present in the wastewater. Through
theirmetabolism, the organic material is transformed into cellular mass, which is no longer
insolution but can be precipitated at the bottom of a settling tank or retained as slime onsolid
surfaces or vegetation in the system. The water exiting the system is then muchclearer than it
entered it.
A key factor is the operation of any biological system is an adequate supply of oxygen.Indeed,
cells need not only organic material as food but also oxygen to breathe, just likehumans. Without
an adequate supply of oxygen, the biological degradation of the wasteis slowed down, thereby
requiring a longer residency time of the water in the system. Fora given flow rate of water to be
treated, this translates into a system with a larger volumeand thus taking more space.

95
Process flow chart:
Effluent water
Filtration
Equalization Tank
Ph correction Tank
Biological Oxidation Tank
Primary clearer
Water Recycle to the
Flocculation tank
Secondary clearer 01
Water PIT
Secondary clearer 02
Out
Ph 6 - 8
De-colorant
dosing here
Aeration for proper
oxygenation

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