Industrial attachment of landmark textile mills ltd.

INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
Landmark Textile Mills Ltd.

2
TABLE OF CONTENTS
Chapter No. Topics Contents Page no.
Chapter-I Project Description Name, Type, Year of
establishment, Address,
Sponsors, Product Mix,
Annual Production Capacity,
Project cost, History of the
project development,
Location, Different
departments, Physical
infrastructure, Remarks.
5-8
Chapter-II Manpower
Management
Organ gram /Man power of
administration, production &
maintenance, Management
system, Shift change,
Responsibilities of
production officers, Job
description of production
officer, Job description of
Asst. dyeing master,
Remarks.
9-12
Chapter-III Machine Description No. of machines, Origin,
Brand name, Machine
specification, Machinery
Layout Plan, Remarks.
13-20
Chapter-IV Raw Materials Types, Price, Source,
Remarks.
21-24
Chapter-V Production Planning
Sequence &
Operations
Production flow chart,
Dyeing parameters,
Description of Production
Process- Recipe, Dyeing
curve & Finishing m/c
settings, Daily production
report, Monthly average
production, Remarks.
25-47
Chapter-VI Quality Assurance Quality Policy, Quality
assurance procedure,
Inspection area, Problems
encountered in dyeing, List
of equipment, Quality
48-55

3
standard, Remarks.
Chapter-VII Maintenance Maintenance of machinery,
Routine, Manpower set up
for maintenance,
Maintenance procedure,
Maintenance tools and their
functions, Remarks.
56-62
Chapter-VIII Utility Services Utility facilities available,
Capacity and other technical
details, Source of utility,
Cost of different utility,
Remarks.
63-67
Chapter-IX Store and Inventory
Control
Scope of inventory control,
Frequency of inventory
update, Inventory system of-
Raw material, Spares,
Finished goods & others,
Remarks.
68-70
Chapter-X Cost Analysis No available data 71-72
Chapter-XI Marketing Activities Consumer of the product,
Country of export, Local
market, Marketing strategy,
Duties and responsibilities of
marketing officer, Remarks.
73-75
Chapter-XII Acrylic Yarn
Dyeing
Introduction, Machine
Description, Features of
dyeing machines, Features of
Acrylic yarn dyeing process,
Process flowchart, Process
description, Quality
standards, Drawbacks,
Buyers, Remarks.
76-82
Chapter-XIII Conclusion 83-84

4
CHAPTER – 1
PROJECT DESCRIPTION

5
Name of the Company : Landmark Fabrics Ltd.
Project Name : Landmark Textile Mills Ltd.
Type : Knit Composite Textile Industry.
Year of Establishment : 2000
Address :
Head Office : House#488/a, Road#32,
New DOHS Mohakhali,
Dhaka-1206,Bangladesh.
Ph: 88-02-8811679, 8814839
Fax: 88-02-8823999,8815868
E-mail: gbilmd@citechco.net
: lmdfab@bttb.net.bd
Factory : Boro Ashulia, Savar, Dhaka.
Ph:88-02-9289365-7,
Fax:88-02-9289364
E-mail:knitfty@dhaka.net
Sponsors : The industry is sponsored by Jamuna Bank Ltd.
Product Mix : 100% cotton
100% polyester(micro + coolmax)
100% viscose
CVC (chief value cotton)
P/C
Gray mélange
Nylon/Cotton
Annual Production Capacity: Knit Dyeing – 3000 ton ; Yarn Dyeing – 1400 ton
Project Cost : Initial investment is approximately 25 Crore Tk.
History of Project Development :
 The construction work of the factory was started
at 1999, after acquiring 20 bighas of high land at
Shadhurpara, Boro Ashulia, Savar, Dhaka.
 The construction work was completed at the
beginning of 2000. At the very beginning, the
project consisted only Knitting, Knit dyeing,
Garments section and Utility supply section.
 In 2001, Acrylic yarn dyeing and sweater
manufacturing unit was started.
 In 2002, production capacity of knit dyeing
section was increased with the addition of new Jet
dyeing m/c, Stenter m/c, Raising m/c.
 In 2004, Spray dyeing unit was started.

6
 Effluent treatment plant was under construction.
 Future plans to establish Acrylic Yarn
manufacturing unit, hospital, designing and
packaging unit.
Location :
Landmark
Complex
Ashulia
Bazar
Abdulla
hpur
Tongi

7
Different Departments :
To ensure smooth running of various activities, some departments are available
they are given bellow:
 KNITTING SECTION:
1.Knitting
2.Inspection
 KNIT DYEING SECTION:
1.Batch section
2.Store house for dyes & chemicals
3.Dye house
4.Dyeing & QC lab
5.Finishing
 GARMENTS SECTION:
1.Merchandising
2.Sample
3.Production
 MAINTENANCE:
1.Electrical
2.Mechanical
 ACCOUNTS & COMMERCIAL SECTION
 ADMIN SECTION
Physical Infrastructure :
Buildings- 2 ten storied buildings, 1 five storied building, 3 two storied buildings
and 1 dyeing shade. Buildings are made by concrete.
Total Area of Industry : 30 Bighas.
Remarks:
The company owns 30 bighas of high land property at Sadhurpara, Baro Ashulia,
Savar, Dhaka; which is 40 km from the heart of the capital city. Charming sights along
with natural beauty of rural areas with no hazards or air pollution attracts the foreign
buyers during their visits. The company has the desire to achieve recognition of the
project as the ‘Landmark Industrial Park’ and to set up within the park area industries and
health care center in near future. Plans include for Acrylic Yarn manufacturing unit,
Packaging unit, Designing unit and Hospital.

8
CHAPTER – II
MANPOWER MANAGEMENT

9
Organ gram of Production Unit:
.
Landmark Fabrics LTD.
BORO ASHULIA, SAVAR, DHAKA
Administration Knitting Dyeing Finishing Lab Batch Maintenance
General Manager
Manager
Asst.
Dyeing
Master
Mechanical
Engineer
Asst. Admin.
Officer
Production
Officer
In-charge In-
charge
In-
charge
Electrical
Engineer
Store
In-charge
Supervisor Supervisor Q.C.
Supervisor
Chemist Super-
visor
Mech. Fitter
&
Electrical
Super visor
Store Keeper Operator Operator Operator Assistant Heeler Asst.
Mechanic
Office Boy Helper Helper Helper Helper Electrician
Cleaner Cleaner Cleaner Asst.
Electrician
Management System:
 Buyer sample is send to G.M.
 Matching is done by lab in charge.
 Sample is prepared by asst. dyeing master.

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 Sample is send to the buyer for approval.
 Approved sample is returned and taken as std. sample for bulk production.
 Asst. dyeing master gives responsibilities to production officer.
 Then production officer, with the supervisors start bulk production.
 On line and off line quality check is done by lab in charge and asst. dyeing
master.
 After dyeing finishing in charge controls the finishing process with the
supervision of production officer.
 After finishing, the material is checked by asst. dyeing master.
 Finally G.M. checks the result with asst. dyeing master and decision is taken for
delivery.
Shift Change:
Two shifts (day and night): each of 12 hrs
Day shift 8 a.m. to 8 p.m.
Night shift 8 p.m. to 8 a.m.
Responsibilities of Production Officer:
 Over all supervision of production both dyeing & finishing.
 Batch preparation and pH check.
 Dyes and chemical requisition, issue and check.
 Write fabric loading and loading time from machine.
 Programme making, sample checking, color matching.
 Control the supervisors, operators, asst. operators and helpers of dyeing machine.
 And also other work when it is required by top level management.
Job Description:
Title: Asst. Dyeing Master
Dept/section: Dyeing and Finishing.
Report to: G.M.
Job Summary:
 After having the work order, prepares production plan.
 To execute and follow up the plan along with quality conformation.
 To face various difficulties of production and overcome them.
 Inspecting the material for conformation to buyer requiremnt.
Title: Asst. Production Officer
Dept/section: Dyeing and Finishing

11
Report to: Asst. Dyeing Master.
Job Summary:
 To execute the plan given by asst. dyeing master.
 Organizing personnel under him.
 Control the supervisors, operators, asst. operators and helpers of dyeing machine.
 Checking of shade match.
Remarks:
The manpower management system of Landmark Textile Mills Ltd. is well
arranged. Every officers & stuffs are responsible for their duty. But there are only three
textile engineers in the industry (General manager, Asst. dyeing master and Production
officer). It is not sufficient for smooth production. More technical people is required.

12
CHAPTER – III
MACHINE DESCRIPTION

13
Dyeing machinery:
In dyeing section of Landmark Fabrics Ltd, there are 7 Dyeing Machines, among
them 2 m/c’s are for sample dyeing and 5 m/c’s are for bulk production. Besides these, a
Salt Dozing m/c and an Air Turner m/c are available.
Machine no.- 01
Name of the m/c : Sample Jet Dyeing Machine
Brand Name : Thies.
Manufacturing Country : Germany.
Year of Manufacturing : 2001
M/C Specification :
M/C capacity : 20 kgs
No. of nozzle : 01
Maxm
Temp : 1350
C
Motor :
winch motor : 01
pump motor : 01
stirring motor : 01
Machine no.- 02
Name of the m/c : Bangla Winch Dyeing M/C.
Brand name : None
Manufacturing country : Bangladesh
M/C specification :
No. of nozzle : 02
Machine no.- 03
Name of the m/c : Jet Dyeing M/C
Brand name : Thies
Manufacturing country : Germany
Year of manufacturing : 2001
M/C specification :
No. of nozzle : 01
Motor :
winch motor : 01
pump motor : 01

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stirring motor : 01
Machine no.- 04
Name of the m/c : Jet Dyeing Machine .
Brand name : Thies.
Manufacturing country : Germany.
M/C specification :
No.of nozzle : 02
Motor :
winch motor : 02
pump motor : 01
stirring motor : 01
Machine no.- 05 & 06:
Brand name : Thies.
M/C specification :
No.of nozzle : 03
Motor :
winch motor : 03
pump motor : 01
stirring motor : 01
Machine no.-07:
Brand name : Thies.
M/C specification :
No.of nozzle : 04
Motor :
winch motor : 04
pump motor : 01
stirring motor : 01

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Salt Dozing Machine :
Brand name : Fong’s National Eng (Shenzhen Co.)
Manufacturing country : China
M/c capacity : kgs
Function of the m/c:
It is an additional m/c only used for the large m/c(capacity-1000kgs).When large
amount of salt are to be added, in that case salt are added by dosing system which are
maintained by this m/c.
Air Turner M/C:
Brand name : Dong Nam Industrial Co.
Manufacturing country : Korea
Function of the m/c : To turn the fabric
Finishing Machinery:
In finishing section of Landmark Fabrics Ltd, the machines which are available
are listed below:
1. Slitter m/c
2. Stenter m/c
3. Dewatering & Detwisting m/c
4. Gas Burnt Tensionless Dryer m/c
5. Tubular Compactor m/c
Slitter M/C:
Specification:
Brand name : BIANCO
Manufacturing Country : Italy
M/c speed : 60 meter/min
M/c width : 80 inch
Purpose of the m/c:
 To open the fabric from tubular form to open width form
 Fabric is cut according to the needle drop
Main parts:

16
 Turntable  Beater
 Rope Squeeze  Centering Unit
 De-twister  Slitting Unit
 Pulley Drive  Squeezing
Utilities used:
 Electricity(to drive the m/c only)
 Compressed air(to keep the tubular fabric to be cut in proper tension)
Stenter m/c:
Specification:
Brand name : Mahlo + Bruckner
Manufacturing country : Germany
Production/day : 12,000 Kg/day
Maximum steam pressure : 2 bar
Maximum air pressure : 10 bar
Purpose of the m/c:
 To make the fabric dry
 For heat setting in case of p/c & 100% polyester fabric
 Width control
Main parts:
 Heating Chamber(7)  Blower(14)
 Width Control Device  Biasing Unit
 Selvedge Trimming Device  Softener Applicator
 Selvedge Gumming Device  Folding Device
Heating system: Gas Burner
Gripping system of fabric edges: pinning
Utilities used:
 Electricity
 Gas
 Steam
Controlling points:
 Fabric speed
 Fabric width
 Temperature
 Overfeed %

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Dewatering & Detwisting m/c:
Specification:
Brand name : Santex group
Manufacturing country : Switzerland
Purpose of the m/c:
 To remove excess water of fabric by squeezing after pretreatment and
dyeing
 For the application of softener finish which make the fabric soft in hand
feel
 Wet-on-wet application is possible
 Shrinkage is controlled by overfeed mechanism
Main parts:
 De-twisting device(to deliver the fabric roll in untwisted form)
 Over feeding wheel(to control shrinkage)
 Stretcher(to control width)
 Squeeze roller(to remove water)
 Folding device(to delivery the fabric in folded form)
Utilities used:
 Electricity
 Compressed air(to form the tube fabric into balloon to ensure the delivered
fabric to be crease free)
Chemical used:
1. Softener (10g/l)
2. Acetic acid (1g/l)
Controlling points:
Over feed control Fabric speed
Pressure of squeeze R/r Width control
Gas Burnt Tensionless Dryer:
Specification:
Brand name : Santex Group

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Purpose of the m/c:
 To dry the fabric uniformly in tensionless state
 To control the shrinkage
Main parts:
 Heating chamber(2)  Folding device
 Blower()  Exhaust fan
 Teflon conveyor  Mesh
Heating system: Gas Burner
Utilities used:
 Gas
 Electricity
 Compressed air
Controlling points:
Speed control  Motor control
Temperature control  Net vibration
Exhaust fan control Heating chamber height
Tubular compactor:
Specification:
Brand name : Santex Group
Prodn
/day : 12,000 Kg/day
Purpose of the m/c:
 Used for tubular fabric as final finishing
 Amount of shrinkage is given to the fabric in compaction zone as
per buyer requirement
 Final finished width and GSM can be obtained as buyer
requirement
Main parts:
 Stretcher
 Steam heated roller

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 Blanket
 Teflon R/r
 Folding device
Utilities used:
 Electricity
 Steam
 Compressed air
Raising M/c:
This m/c is used only for raising finishing which imparts a hairy surface to the
fabric. A layer of fabric fibres lifting from the body of the fabric is achieved by passing it
over a no. of pile R/r and counter R/r. It is mostly applied on Terry fabric, Polar fabric
etc.
Specification:
Brand name : Yantu
Manufacturing country : Taiwan
Type of m/c : Gear type raising m/c
No. of pile R/r : 12
No. of counter R/r : 12
Roller width : 2000 mm
Avg. speed of m/c : 30 m/min
Remark:
Landmark Fabrics Ltd is a well-equipped industry. It contains machinery of well
known brands like Thies, Bruckner, Bianco, Santex, etc. The availability of these m/c’s
are helpful to increase the productivity of the industry. The arrangement of machines is
very beautiful and there is enough space for movement of the workers.

20
CHAPTER – IV
RAW MATERIAL

21
Raw material:
Landmark Fabrics Ltd is a knit composite textile industry. In the industry the raw
materials used for production are:
1.Grey Fabrics
2.Dyes
3.Chemicals
1. Grey Fabrics:
Following types of grey fabrics are processed
Single jersey Terry & French terry
Single jersey/lycra Polar
Interlock Eyelet & mini-eyelet
Rib Mesh (warp knitted fabric)
1X1rib/lycra waffel
Combined rib Collar & cuff
Lacoste Pique
Source 40% comes from the Knitting Department of Landmark Fabrics Ltd and
other 60% comes from outward as sub-contract.
Daily Fabric Production Capacity
Item Quantity
Single jersey, Pique 1000 kg/day
Lacoste, Interlock 3500 kg/day
Rib 3500 kg/day
Collar & cuff 6000 pcs
2. Dyes:
In Landmark Fabrics Ltd. the following types of dyes are used:
 Reactive dyes (cold brand & hot brand)
 Disperse dyes
The commercial name of the dyes with their prices are collected from the dye
stock report
Sl.
No
.
Names of the dyes Price in
Tk/kg
Sl.
No
Names of the dyes Price
in
Tk/kg
1 Kemazol black-B - 32 Drimarine Red CL-5B 800/-
2 Kemazol Turqu.BlueG2-HC - 33 Drimarine Blue CL-2RL 2250/-

22
3 Kemafix red 2B 750/- 34 Drimarine Navy CL-R 1100/-
4 Kemafix black GR 260/- 35 Drimarine Orange CL-3R 720/-
5 Kemafix yellow 4G 325/- 36 Drimarine Yellow CL-2R 825/-
6 Kemafix yellow FRL 390/- 37 Drimarine Yellow CL-3G 1000/-
7 Kemafix red-3BC 390/- 38 Drimarine Blue CL-BR 1100/-
8 Kemafix Blue F2R 430/- 39 Drimarine Turquise CL-B 750/-
9 Kemafix Orange 2RL 400/- 40 Dianix Black CCR 340/-
10 Kemafix N.Blue MER-150% 390/- 41 Dianix Navy CC 650/-
11 Kemafix Red HE-3B 385/- 42 Taicron Black SE-EXNT 300% 450/-
12 Kemactive Orange HER - 43 Taicron N.Blue SE- EXNT 300% 480/-
13 Kemactive Red HE-3B 385/- 44 Taicron Rabine SEBL-T 200% -
14 Solacion Red HE-3B 440/- 45 Taicron Scarlet EBT 200% -
15 Terasil Red WFS - 46 Taicron Yellow SE -4GT 200% 550/-
16 Terasil Yellow W6HG - 47 Taicron Orange E-BRT 200% 380/-
17 Terasil Red W4BS - 48 Taicron Red EE-BNT 200% 600/-
18 Terasil G.Yellow W3R - 49 Taicron Blue EBRT 200% 720/-
19 Terasil Blue 3RL - 50 Taicron T.Blue SE-2BT 200% 1100/-
20 Terasil Blue WBLS - 51 Taicron Blue SE-2BT 750/-
2I Remazol Brilliant Red 5B - 52 Taicron Black HWT 400/-
22 Foron D.Blue RD-2RE-300-6RN - 53 Taicron Scarlet-HWT 650/-
23 Foron D.rubin RD-GFL-200% - 54 Taicron Navy-HWT 650/-
24 Foron black RD-BRE-300-GRM - 55 Taicron Red-XFT 450/-
25 Foron brilliant orange ERL-200% - 56 Cibacron Yellow EN-2R 1700/-
26 Foron yellow RD-4GRL-300-6RN - 57 Cibacron Red FNR 1600/-
27 Foron yellow brown F2RL-300% - 58 Cibacron Blue FNR 2600/-
28 Foron blue SE-2R - 59 Cibacron Dk.Blue WR 1150/-
29 Foron turquise S-2B - 60 Cibacron Red EB-150% 1100/-
30 Foron scarlet RD-FRS-200% - 61 Best Acid Yellow BMR -
31 Foron black RD-3G-300% - 62 Best Milling red 2B -
Sources
Matex Grasim
Dyestar Ahmed Enterprise
3.Chemicals:

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In Landmark Fabrics Ltd., the following chemicals are used. The names of the
chemicals with their prices are collected from the dye stock report:
Sources
BASF Matex
Hightech-Oxichem Friends International
Global Colourchem Ltd.
Remarks:
Sl
no.
Names of the chemicals Price
in
Tk/kg
Sl
no.
Names of the chemicals Pric
e in
Tk/
kg
1 Caustic soda(Alkaline Medium) 26/- 33 TC Antistati kem
NPSZ(Antistatic Electricity
Agent)
-
2 Hydrozen per oxide(Bleaching Agent) 32/- 22 Powersoft-18(Silicon Softener) -
3 Acetic acid (Acid Medium) 65/- 23 Nalco 450(Boiler Chemical) -
4 Common salt(Exhausting Agent) 5/- 24 Protek SB-157(Boiler
Chemical)
-
5 Soda ash(Alkaline Medium) 18/- 25 Sindonerin MC(Silicon
Softener)
-
6 Rucostab LGE(Multi-Purpose Chemical as
alkali, stabilizer,sequestering agent)
120/- 26 Oxalic acid(Sequestering
Agent)
46/-
7 Verlon LGA(Multi-Purpose Chemical as
alkali, stabilizer,sequestering agent)
- 27 Adasil SM(Silicon Softener) 274/-
8 Bittex-0X(O.B.A Agent for Cotton ) 250/- 28 Ludox AM-400(Silicon
Softener)
-
9 Alvatex HOS(Stabilizer) 120/- 29 Adasil ME(Silicon Softener) 178/-
10 Lanapex HTS(Stabilizer) - 30 Gissapol-115(Wetting Agent) 160/-
11 Eulysin(Acid Buffer) 34.50 31 Felloson NOF(Oil Remover) 163/-
12 Multisoap SR(Soaping Agent) 120/- 32 Biopolish AL(Acid Enzyme) -
13 Ludox SPL(Oil &mineral Iron remover) - 33 Remapon-173(Anticreasing
Agent)
135/-
14 Mollan-130(Sequestering Agent) 140/- 34 Powersoft-CD34E(Silicon
Softener)
-
15 Alvatex 66-C(Fixing Agent) 135/- 35 Bickersoft CFL(Silicon
Softener)
-
16 Glauber salt(Exhausting Agent) 10.50 36 Welsoft-40(Silicon Softener) -
17 Alvasoft EG(Cationic Softener) 155/- 37 Belfasin 615(Cationic Softener) -
18 Hydrose (Reducing Agent) 80/- 38 Valzyme(Acid Enzyme) 330/-
19 Feran ice(Hydrophilic Softener) - 39 Setamol BL(Dispersimg Agent) 65/-
20 Tabanol FTR(Levelling Agent) - 40 Palagal FAH8(Leveling Agent) 138/-
21 Unitex EBF(O.B.A Agent for Polyester) - 41 Glycerine(Solvent) -

24
Landmark Fabrics Ltd is so careful about its raw materials. The raw materials are
always collected from those suppliers who supply the dyes & chemicals of higher quality.
CHAPTER-V
PRODUCTION PLANNING,
SEQUENCES & OPERATION

25
Production Flowchart:
Knitting
Inspection
Dyeing
Tubular Open Width
Stenter(Heat Setting)
Dewatering
Stenter
Gas Dryer
Compactor
Folding
Slitter(Drying)
Folding

26
Dyeing Parameters:
a. pH:
- During H2O2 bleaching pH 9.2 – 12
- During reactive dyeing pH 10.5 – 12.5
- During disperse dyeing pH 4.5 – 6.0
b. Temperature:
- For cotton scouring 1050
C
- For cotton cold wash 300
– 400
C
- For cotton hot wash 700
-800
C
- For cotton acid wash 450
C
- For cotton dyeing 980
C (For hot brand)
600
C (For cold brand)
- Polyester dyeing: 1350
C
- OBA application 980
C
c. Time:
Set Actual
- For scouring & bleaching 30 mins - For scouring & bleaching 90 mins
- For reactive dyeing 60-90 mins - For reactive dyeing 150 mins
- For disperse dyeing 60-90 mins - For disperse dyeing
d. M:L ratio:
- For reactive dyeing M:L ration maintained between 1 : 6 to 1 : 8
Dyeing Recipe:
1. 100% Cotton Fabric Dyed in Deep Shade with Hot Brand Color–
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS

27
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
Common Salt
Soda
3.04% Kem Orange HER
0.046% Kem Navy Blue HER
3.76% Kem Red HE7B
Multisoap SR
Acetic Acid
Alvatex 66C
Acetic Acid
Dyeing Curve:
105c x 30 min
B
A
80c
60c
Drain
A = 1) Gisapal 115
2) Felosun NOF

28
3) Remapon 173
4) Alvatex HOS
5) Caustic Soda
B = Hydrogen Per Oxide
98c
x 45c
5 min x
Gisapal115 Acetic Acid 5 min
Normal
80c Drain Temp Drain
98c x 60’
30’D
Soda
80
20’D 10’D c
Salt Dye
10’ Drain
10’ 10’
60c
40c
98c
Multisoap SR x Acetic Acid
5 min
Normal
Alvatex 66c 50c

29
Acetic Acid x
15 min
Drain
2. 100% Cotton Fabric Dyed in Light Shade with Hot Brand Color–
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
Mollan -130
Tabanol - FTR
Glouber Salt
Soda
0.136% Drimarine T. Blue CL - B
0.0162% Drimarine Yellow CL 2R
0.0066% Drimarine Blue CL – 2RL
Multisoap SR
Acetic Acid

30
Note – Since Turquise Blue color is being used, Dye dosing will be done first. Then
Glouber salt dosing will be done. If salt is added first oily substance is formed which
creates mark in the dyed fabric.
Dyeing Curve:
105c x 30 min
B
A
80c
60c
Drain
A = 1) Gisapal 115
2) Remapon 173
3) Alvatex HOS
4) Caustic Soda
45c
98c
Gisapal115 x Acetic Acid
5 min
Normal
85c x 40 min
A= Mollan 130 15’ D
B= Tabanol FTR Soda Ash
80c
15’ D 30’D
A&B Dye G.Salt 20’

31
15’ 20’
60c
Drain
40c
98c
5 min
Drain Normal
80c Temp Drain
3. 100% Cotton Fabric Dyed in Deep Shade with Cold Brand Color–
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
Common Salt
Soda
10.4% Kem Black GR
1.38% Kem Red 3BS
1.39% Kem Yellow FRL

32
Multisoap SR
Acetic Acid
Alvatex 66C
Acetic Acid
Dyeing Curve:
105c x 30 min
B
A
80c
60c
Drain
A = 1) Gisapal 115
2) Felosun NOF
3) Remapon 173
4) Alvatex HOS
5) Caustic Soda
98c
x 45c
5 min x
Gisapal115 Acetic Acid 5 min
Normal
30’D 15’D 20’D 65c x 60 min
Salt Dye Soda

33
10’ 10’ 20’ Drain
60c
40c
98c
5 min
Normal
Alvatex 66c 50c
Acetic Acid x
15 min
Drain
4. 100% Cotton Fabric Dyed in Light Shade with Cold Brand Color–
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
Mollan -130

34
Tabanol FTR
Glouber Salt
Soda
0.156% Kem Red 3BS
0.0018% Kem Blue F2R
Multisoap SR
Acetic Acid
Dyeing Curve:
105c x 30 min
B
A
80c
60c
Drain
A = 1) Gisapal 115
2) Remapon 173
3) Alvatex HOS
4) Caustic Soda
45c
98c
5 min
Normal

35
65 c x 45 min
10’ D 20’D 20’D 30’ D
1/4 Salt Dye 3/4 Salt Soda Ash
A&B
60 Drain
c 10’ 20’ 10’ 20’
A= Mollan -130 B= Tabanol -FTR
40c
98c
5 min
Drain Normal
80c Temp Drain
5. 100% Cotton Fabric With Optical Brightening Agent –
0.5% Gisapol 115
3.5% Caustic Soda
Rucostab LGE
H2O2
0.6% Bittox.ox (BYB)

36
Acetic Acid
Dyeing Curve:
A= Gisapal 115
105c x 15 min
B= Caustic Soda
A B
80c
Drain
105c x 70 min
B
80c
A
60c
Drain
A=Rucostab LGE B= Hydrogen Per Oxide
40c
98c
OBA x Acetic Acid
10 min
Normal

37
6. 100% PET Fabric Dyed in Deep Shade –
2% Soda
Gisapol 115
Felosun NOF
Hot Wash
Acetic Acid
Setamol BL
Palagal FA8
Eulysin -S
5% Tai Black HWT
2% Dainix Black CCR
1% Tai Orange HWT
4% Hydrose
3% Caustic Soda
1% Setamol BL
Hot Wash
Dyeing Curve:
A= Soda
90c B= Felosun NOF
A,B&C x C= Gisapol 115
20 min

38
80c Drain
135c x 60 min
Temp Gradient: upto 100c  1c/min
upto 135c  2c/min
Dye Drain
45c
A,B&C
40c 10’
A=Setamol BL B= Palagal FA8 C= Eulysin -S
A= Soda
90c B= Hydrose
A,B&C x C= Setamol BL
20 min
80c Drain
7. 100% PET Fabric With Optical Brightening Agent –
2% Soda
0.5% Felosun NOF
Hot Wash
Acetic Acid
Palagal FA8

39
Eulysin -S
0.6% Ultraphone BN
Dyeing Curve: 45c
x
90c Acetic Acid 10 min
A&B x
20 min
Normal Drain
80c Drain Temp
A= Soda B= Felosun NOF
135c x 35 min
Temp Gradient: 4.5c/ min
OBA
45c
A&B Drain
40c 20’
A= Palagal FA8 B= Eulysin -S
8. 100% Viscose Fabric With Optical Brightening Agent –
1% Multisoap SR
2% soda
2% H2O2
Alvatex HOS
Multisoap SR
0.25% Bittox.ox (BYB)

40
Acetic Acid
Dyeing Curve:
98 c x 10 min
98c A,B,C&D
Multisoap SR x
10 min
80c Drain 80c Drain
A= Soda C= Alvatex HOS
B= H2O2 D= Multisoap SR
40c
98c
OBA x Acetic Acid
10 min
Normal
9. 100% Viscose Fabric in Deep Shade with Cold Brand Color–
2% Soda
0.5% Felosun NOF
0.5% Gisapol 115
Hot Wash
Acetic Acid
Mollan -130
Tabanol FTR

41
Glouber Salt
Soda
7% Kem Black GR
0.83% Kem Red 3BS
Multisoap SR
Acetic Acid
Alvatex 66-C
Acetic Acid
Dyeing Curve:
98c 45c
A,B&C x 20 min Acetic Acid
80c Drain
Normal Drain
A= Soda B= Felosun NOF C= Gisapol 115 Temp
A= Mollan 130
B= Tabanol FTR
30’ D 30’D 30’ D 65c x 60 min
A&B Dye G.Salt Soda Ash
15’ 20’ 20’
60c
Drain
40c
98c
5 min

42
Normal
Alvatex 66c 50c
Acetic Acid x
15 min
Drain
10. C.V.C Fabric Dyed in Deep Shade–
Setamol BL
Palagal FA8
Eulysin -S
1.1% Terasil G. Yellow W3R
0.25% Megaperse Red RNA
Gisapol 115
Felosun NOF
Remapon 173
Alvatex HOS
Caustic Soda
H2O2
Gisapol 115
Acetic Acid
Common Salt
Soda

43
2.0% Kem Orange 2RL
0.11% Kem Red 3BS
0.1% Kem Yellow FRL
Multisoap SR
Acetic Acid
Alvatex 66 - C
Acetic Acid
Note-
1. For Deep shade the sequence is : PET Dyeing  Scouring  Cotton Dyeing
2. For Light Shade the sequence is : Scouring  PET Dyeing Cotton Dyeing
Dyeing Curve:
135c x 60 min
Temp Gradient: upto 100c  1c/min
upto 135c  2c/min
Dye Drain
45c
A,B&C
40c 10’
A=Setamol BL B= Palagal FA8 C= Eulysin -S
105c x 30 min
B
A
80c
60c
Drain

44
A = 1) Gisapal 115
2) Remapon 173
3) Alvatex HOS
4) Caustic Soda
45c
98c
5 min
Normal
30’D 15’D 20’D 65c x 60 min
Salt Dye Soda
10’ 10’ 20’ Drain
60c
40c
98c
5 min
Normal
Alvatex 66c 50c
Acetic Acid x
15 min
Drain

45
Finishing:
Dewatering M/C Setting 
Fabric type Fabric
speed(m/min)
Over feed%
Single jersey(Viscose) 80 30
Single jersey(cotton/lycra) 80 22
Single jersey(cotton) 80 10-11
1X1 Rib 80 11
Interlock 80 14-15
Terry 80 5-9
Gas Burnt Tensionless Dryer M/C Setting 
Compactor Setting 
Fabric Type Fabric
speed
(m/min)
Steam
pressure
(psi)
Compacting
pressure
(psi)
Temp
c
Overfeed%
Single jersey (cotton) 25 60 70 120-150 5-7
Single
jersey(cotton/lycra)
20 50 60 120-150 6-7
Single jersey
(viscose)
25 60 70 120-150 8
Fabric type Fabric speed
(m/min)
Temperature Over feed%
Single jersey(cotton) 6.5 140 15
Single jersey(cotton/lycra) 6.5 140 15
1x1 Rib 6 140 15
Interlock 5 140 15
Terry 5 140 15

46
1x1 Rib 25 60 70 120-150 3-4
Interlock 25 60 70 120-150 3-4
Terry 25 60 65 120-150 8
Stenter Setting 
FABRIC TYPE FABRIC
SPEED
(m/min)
TEMPERATURE
(0
C)
OVER FEED%
Single jersey (Cotton) 30-40 160 Upto 30
Rib/Interlock (cotton) 25-30 160 Upto 30
Single jersey (Viscose) 26 170 Upto 60
Mini-eyelet(Polyester) 20-25 185 Upto 4
Mesh (Polyester) 20-25 185 Upto 4
Daily Production Report:
The daily production report is recorded in the logbook and it contains following
information
Machine No. Quantity
Date Loading Time
Batch No. Unloading Time
Order No. Runtime
Fabric Type Shift
Color Remark
Monthly Average Production:
The monthly average production of dyeing unit of Landmark Textile Mills Ltd. is
250 tons.
Remarks:
The production process, followed by the Dye-house of Landmark Textile Mills
Ltd. is impressive. The processes are being carried out very quickly and accurately. Due

47
to the excellence of process, machineries and lab trials very few cases of re-dyeing is
performed.
CHAPTER – VI
QUALITY ASSURANCE SYSTEM

48
Quality Policy:
It is the policy of Landmark Textile Mills Ltd. to produce quality dyed knit
fabrics that meet the customer’s expectations & needs. To implement this policy the top
management of Landmark Textile Mills Ltd. is committed to provide adequate resources
in terms of good raw materials and trained personnel & continually improve / upgrade its
processes and systems. The quality control policy of Landmark Textile Mills Ltd. is
stated below-
 Leadership program from the top.
 In-process quality control during manufacturing operation.
 Evaluation programs in all areas of knitting, dyeing, cutting, sewing and finishing.
 Maintain chain of responsibility.
 Follow strict stuffing, auditing and reporting.
 Use inspection machines in required points.
 Maintain standard AQL.
 Sufficient lighting and sanitation.
 Final inspection prior to packaging.
 Meeting the appropriate expectations of clients.
Quality Assurance Procedure:
Landmark Textile Mills Ltd. assures the quality of their products in the following
three steps:
1. In laboratory.
2. In dyeing section
3. In finishing section
The quality assurance procedures are described below:
In laboratory:
 Swatch card from buyer according to their requirement is received.
 Recipe prediction for sample dyeing using CCMS.
 Sample dyeing until matching with the swatch card. Acceptable color difference
is less than 1.
 If matching is OK, then it is sent to the buyer for approval.
In dyeing section:
 After approval form the buyer, sample dyeing is done in dyeing m/c, in
dyeing shed & again matched with the approved sample.
 If result is OK, then balk production is commenced.

49
 During dyeing process, before the final acid wash, samples are taken and checked
for accurate shade matching.
 After dyeing sample is collected & matching is done.
 Rubbing and wash fastness tests are carried out.
In finishing section:
 Correctly dyed, after treated & matched fabrics are allowed for finishing.
 By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
 Then sampling is done several times to test GSM, Shrinkage & fastness properties.
 Finally fabric is inspected & prepared for delivery.
Inspection area:
 Shade match of fabric
 G.S.M.
 Fabric diameter
 Spirality
 Shrinkage (%)
 Length wise
 Width wise
 Wash fastness
 Rubbing fastness
 Faults
 Dyeing faults
 Knitting faults
 Finishing faults
Knitting Faults 
 Hole
 Slub
 Needle mark
 Stripe
 Missing yarn
 Contamination
Dyeing Faults 
 Uneven shade
 Running shade
 Fastness property
 Dye spots and marks
Finishing Faults 

50
 GSM variation
 Spirality
 Shrinkage control
 Marks
PROBLEMs ENCOUNTERED IN DYEING:
Uneven Dyeing 
1. It can be caused due to rapid addition of dyes and chemicals. For this purpose
the dosing of soda ash should be maintained properly.
2. Pressure difference.
3. Over loading in the m/c.
4. Yarn lot mixing.
5. Improper control of temperature.
6. Less amount of leveling agent.
7. Improper pretreatment.
Uneven Shade in Rope to Rope 
1. Improper rope length in each chamber.
2. Improper fabric flow speed in each nozzle.
Off Shade
1. Improper M: L ratio.
2. Lower amount of auxiliaries.
3. Improper mixing of dyestuffs.
Dye Spots 
This is most common fault caused by operator not correctly mixing and
thoroughly dissolving dyestuffs in the right amount of water.
Batch to Batch Shade Variation 
If any of parameters of dyeing are changed then it will produce problems in batch
to batch consistency. In order to avoid this defect the following steps should be followed-
1. Maintain the same liquor ratio.
2.Check that the fabric has the same dye affinity.
3. Use the same standard program procedures for each batch.
4. Making sure that the operators add the right bach of chemicals at the same time
& temperature in the process.
5. Check the water supply daily especially ph
, hardness & Na2CO3 content.

51
Crease Mark 
Crease marks are produced due to the lower concentration of anti creasing agent
and improper cooling rate (defective cooling gradient). This is encountered by increasing
the concentration of anti creasing agent and proper adjustment of cooling rate.
Running Marks 
Running marks are frequently related to the material construction and are caused
by poor opening of the fabric rope.
1. Reducing the machine load and running at a slightly higher nozzle pressure, or
using the next largest available nozzle size, may also help.
2. Either pre setting or pre relaxation of the fabric before dyeing can avoid this
problem.
3. Running and crack marks can also be a result of incorrect process procedures.
A higher fabric speed, combined with slower rates of rinse and cooling will often
correct the problem.
4. Care should be taken to check that bath draining temperatures are not very high
especially viscose blends are involved.
5. Shock cooling of static material will also cause crack marks.
Intensive Foaming 
In case of intensive foaming, which is caused when, the pumps try to pump a
mixture of air and water. This resets in the loss of nozzle pressure & floating of flake. If
the foaming is severe it is better to drop the bath & restart the process, after adding an
anti foaming agent to the new bath.
Patchy Dyeing 
It is caused, if dye solution is not correct and also scouring is improper.
Miscellaneous Problems 
Batch to batch processing may vary due to the improper calculation of dyes and
chemicals and improper strength of salt soda and H2O2 etc. Beside hardness of water and
caustic may lead to an improper shade.
Process of Shade Matching:

52
The required shade provided by the buyer is reproduced in the lab in lab dyeing
machine after the recipe prediction. The lab in-charge first uses the Computer Color
Matching System, to obtain the closest shade match recipe. Then he consults the shade
card and Pentone book to verify the obtained recipe. If he thinks that certain changes in
the recipe is necessary, he then alters the recipe according to his experience. This recipe
is used to dye a sample of 5 gm fabric in the lab dyeing machine with following
parameters.
a) Temperature and time 
Cold Brand Reactive Dye - 65 c temp; 60 min
Hot Brand Reactive Dye - 98 c temp; 60 min
Turquoise Color (Cotton) - 85 c temp; 60 min
Polyester - 130 c temp; 30 min
b) M:L ratio 
The samples are usually dyed using 1:15 ratio.
Pentone Book:
Pentone Textile Color Selector
Total shade – 1701
Color numbering system – 6 digit + suffix
First two digits  11 to 19 ( range of lightness)
Middle two digits  01 to 64 ( range of hue)
Last two digits  01 to 64 ( range of chroma)
List of Equipments:
1. Light Fastness Tester
Brand – Star
2. I.C.I. Pilling Box Tester
Brand – SDL
Operation Time – 6 hours
R.P.M. – 60
Total Revolution – 21600
Scale Range for Pilling – 1 to 5
Accepted Level – 4 to 5
3. Rubbing Fastness Tester 
Brand – SDL
Instrument Name – Crock meter
Measured Elements – Wet and Dry Rubbing Fastness
Number of Rubbing – 10
Scale Range – 1 to 5

53
Accepted Scale Range – For Wet 3 to 4 and For Dry 4
4. Single Yarn Strength Tester 
Measured Elements – Breaking Strength (in gram) and Breaking Elongation (in
percent and mm).
5.Yarn Twist Tester 
Test Method – Twist-Detwist
Yarn Length – 10 inch
6.Yarn Appearance Tester 
Brand – SDL
Grades Used – A, B, C & D
Grade Scale Applicability – For 24 to 36 Ne Yarn
7. Yarn Count Tester 
Number of Revolution – 80
Total Length of Yarn – 150 meters
Circumference – 1.875 meters
8. C.C.M.S.
Brand – Macbeth
Program Menu Normally Used ---
Formulation – Recipe prediction for given sample to reproduce the shade. Gives
10 best combination of trichomatic color match.
Quality – Gives color difference (i.e. E) and indicates the excess of a particular
depth of color. It also gives a remark whether the dyed sample is acceptable on the basis
of E and gives a pass or fail . Acceptable color difference is less than 1%.
9. Light Box 
Brand – Verivide
Origin – England
Lamp Option – TL-84 (tube light), D65 (normal daylight), UV (optical brightener),
F (fluorescent).
10. Tumble Dryer 
Brand – Miele
Lowest Material Loading – 1 kg
Time – 40 to 45 minutes
Temp - 120 c
11. Washing Machine 
Brand – Samsung
Option ---
Delicate – Polyester (wash-main; spin-600)
Speed – Cotton (wash-main; spin-900)
12. Data Color Sample Dyeing Machine 
Brand – SDL
Heat Source – Infrared
Wash Fastness Tests ---
Cotton - 40 c temp; 20 min
Dyeing ---

54
Cold Brand Reactive Dye - 65 c temp; 60 min
Hot Brand Reactive Dye - 98 c temp; 60 min
Turquoise (Cotton) - 85 c temp; 60 min
13. Solvent Sample Dyeing Machine 
Medium of Heat – Glycerin.
14. Dryer 
Temperature – Up to 240 c
Type – Electrically Operated
Quality Standard:
Landmark Textile Mills Ltd. follows ISO standards. The company received ISO
9001:2000 certification for its excellent maintenance of quality. Following quality
criteria’s are maintained strictly in Landmark Textile Mills Ltd.
 Shrinkage: Should not exceed  4.
 Wash Fastness:
Fastness to washing DIN EN ISO 20105 C 03: 60c : at least 4 -5.
Staining on Cotton, Polyester, Polyamide, Wool : at least 4.
 Rubbing Fastness:
Fastness to rubbing DIN EN ISO 105 X 12: Dry at least 4 & Wet
at least 3.
 Color Difference, E: Should not exceed 1.
Remarks:
Landmark Textile Mills Ltd. is always aware about the quality of their product.
The quality of the product is maintained as per requirement of the buyer. They
follow the quality standard: ISO 9001: 2000. Landmark Textile Mills Ltd. is well
equipped for checking the quality of the product. They send the quality report to the buyer
from time to time/ batch to batch.

56
Maintenance of Machinery:
Maintenance of machinery is very essential mechanical effort for achieving
smooth running of different machines. Maintenance is a process by which equipment
is looked after in such a way that trouble free services 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.
In Landmark Textile Mills Ltd. 2 types of maintenance are done:
1. Break down maintenance
2. Routine maintenance
1. Break down maintenance: Break down maintenance is done instantly when
problem arises in machine. In this case, repairs are made after the equipment is out of order
and it cannot perform its normal functions.
2. Routine maintenance: After a particular period of operation, the machines
are cleaned & reordered, that is routine or schedule maintenance. The maintenance
department does it once in a month. Schedule maintenance varies, time in time &
also depends on situation according to types of machines, because maintenance is
directly related to production.
Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also
done. Workers inform about the problem areas of the machines. Depending on
their information maintenance is done. Maintenance engineer analyze the records and
take steps according to requirement.
Routine:
Maintenance is a necessary task in any industry. But the degree and interval of
maintenance is dependent upon the age of the machineries. Landmark Textile Mills Ltd.
has relatively new machineries, which are very modern and state-of-the-art. Due to this
reason a relatively less amount of maintenance is needed to be carried out in Landmark
Textile Mills Ltd. Never-the-less, routine maintenance of the machineries of the dyeing
section is carried out once a week.
Maintenance
Routine Maintenance Break Down Maintenance
Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance

57
As the dyeing section remains closed in Friday, the routine maintenance is carried out in
Friday. As for break down maintenance (very few break down cases occur), proper steps
are taken to rectify the problem.
Manpower Setup for Maintenance:
Post Number of Employees
Mechanical Engineer 1
Electrical Engineer 2
Mechanical Fitter 1
Electrical Supervisor 1
Asst. Mechanic 2
Electrician 1
Asst. Electrician 2
Maintenance Procedure:
Maintenance: Mechanical
Machine: Dyeing Machines
Sl. No. Item needed to be checked & Serviced
1. Greasing of the winch bearing
2. Complete cleaning of machine
3. Cleaning of drain valves, replace seals if required
4. Checking of air supply filter, regulators, and auto drain seals
5. Cleaning of filter elements
6. Greasing of unloading roller bearings
7. Checking and cleaning (if required) of addition tank level indicator
8. Checking the oil level of pump bearing and refill if required
9. Checking the function of heat and cool modulating valves
10. Checking of all belts and belt tension
11. Check circulation, reel and other pumps
12. Checking of all door seals

58
Machine: Stenter Machine
1. Removal of gas burnt deposits from chains
2. Checking of gas burners
3. Cleaning of softener application unit
5. Checking and cleaning of steam pipe lines
4. Checking and cleaning of gas pipe lines
5. Grinding of fabric gripping pins
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet
8. Checking of motors
Machine: Dewatering Machine
1. Cleaning of softener application unit
2. Checking of rotating device of rotating trolley unit
3. Checking of pneumatic pressure valves
4. Checking and replacement (if necessary) of rubber pads of stretching unit
5. Checking of plaiting device
6. Checking of speed regulating unit

59
Machine: Tensionless Dryer
1. Checking of gas pipe lines
2. Checking of gas burners
3. Checking of belt conveyor system
6. Cleaning of ventilation duct
7. Cleaning of m/c cabinet
Machine: Compactor Machine
1. Checking of Steam pipe lines
2. Checking of pneumatic pressure valves
3. Checking of belt conveyor system
6. Checking and replacement (if necessary) of compacting shoe
7. Cleaning of compacting shoe
Machine: Raising Machine
1. Checking of Gearing system and replacement of faulty gears
2. Cleaning of fibre deposits from the pile and counter pile rollers

60
3. Grinding of pins of pile and counter pile rollers
4. Lubrication of gearing system
Machine: Boiler
1. Checking of gas pressure and gas supply line
2. Dosing of softening chemicals to supply water
3. Checking of all steam lines
4. Cleaning of burner tank (after six month interval)
5. Checking and replacement of valves
6. Cleaning of feed water tank
7. Checking and replacement of filters
8. Cleaning of sight glass
Maintenance Tools and Equipments:
Sl. No. Maintenance tools/equipments Functions
1. Adjustable wrench Used for setting nut & bolts
2. Pipe Spanner For pipe fitting
3.
Spanner
Fixed Spanner for nut & bolts
fitting
4.
Socket spanner
Handle system for nut & bolt
fitting
5. Hammer To apply load where required
6. Screw driver To release any screw
7. Punch Used to fit any worn out shaft
8. Lock opener To open the clip of bearing

61
9. Hack saw To cut any metallic thing
10. Outside calipers To measure outside dia
11. Inside calipers To measure inside dia
12. Slide calipers To measure very small dia
13. Vernier scale To measure very small dia
14. Chain ton To lift heavy load
15. Welding machine To join metallic parts
16. Grinding machine To make the smooth fabrics
17. Tester To test electric circuit
18. Pliers To grip anything & cut anything
19. Avometer/Voltmeter To measure voltage
20.
Steel tape
To measure length, width &
height
21. Chisel To cut any metal
22. File To smooth the rough surface
Remarks:
The maintenance department of Landmark Textile Mills Ltd. is well
equipped. It has sufficient maintenance manpower including mechanical and
electrical engineers. They perform maintenance tasks of the machines during
the holidays and vacations. Otherwise, they perform breakdown maintenance,
which as stated earlier is very rare in Landmark Textile Mills Ltd. To increase
the lifetime of the machineries and ensure the proper running of the machines,
the task of this department is very important.

62
CHAPTER- VIII
UTILITY SERVICES

63
Utility Services Available:
 Electricity
 Gas
 Water
 Steam
 Compressed air
Capacity & Other Technical Details:
Electricity -
The electricity is supplied form PDB from the national power grid. The
electricity supplied is of 11,000 volts which is transformed into 440 volts using a
transformer of ‘ENERGYPAC’. But two standby power generators are also kept to meet
the need of electricity if necessary.
Generator Specification
PARAMETER GENERATOR 1 GENERATOR 2
Company Musgrave Generators Ltd. Technol Power Generation
Origin England UK
Mfg. 2001 2003
Fuel Gas Driven Gas Driven
Power 500 KVA 720 KVA
Frame/Core HC.1544D1 HC.1634G1
KVA Base Rate 500 720
KW Base Rate 400 576
Hz. 50 50
RPM 1500 1500
Volts 400/230 380/220
Phase 3 3
PF 0.8 0.8
Rating Cont. Cont.
Ex. Volts 43 58
Ex. Amps 2.5 3.3
Ambient Temp. 40c 40c
Insulation Class Class H Class H
Total power is then distributed as per requirements of different section of
Landmark Textile Mills Ltd.
Gas -
Gas is mainly used for steam production. The gas is supplied by TITAS
GAS DISTRIBUTION CO.

64
Water-
Continuous supply of water for different section of Landmark Textile
Mills Ltd. must be ensured by pump. In total six (6) pumps are used for water pick up.
TYPE OF PUMP NOS. CAPACITY SETUP
Submersible 2 # 100% open
Pressure 2 100% open
Centrifugal 2 100% open
Steam-
Pure steam with required temperature must be produced to meet the
continuous demand of steam in different sections. There are two Fire tube type boilers
used for steam generation, to meet the requirement of different sections.
Specification of Boiler No. 1
 Company- BIB COCHRAN LTD.
 Origin- Scotland
 Product type- Thermax
 Year- 2003
 Capacity- 9 ton/hr
 Design pressure- 11 Bar
 Design temperature- 188c
 Supply voltage- 400 V/ 3 phase / 50 hz
Specification of Boiler No. 2
 Company- BIB COCHRAN LTD.
 Origin- Scotland
 Year- 2001
 Capacity- 5 ton/hr
 Design pressure- 11 Bar
 Design temperature- 188c
 Supply voltage- 400 V/ 3 phase / 50 hz
Compressed Air-
The requirement of compressed air is fulfilled by air compressor m/c. In
this m/c, natural gas is drawn by pipe through the filter above the compressor & the air is
compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to
reduce the temperature of compressed air. While doing so, the cold water becomes
slightly hot & it is transferred through outlet pipe to the overhead reservoir. There the
vapors are condensed and outlets drop by drop. Then the water is let to fall slowly
through the reservoir to the compressed air to obtain moist compressed air.

65
The moist compressed air is transferred to the dryer & a slight warm
compressed air is delivered to required sections of Landmark Textile Mills.
Specification of Compressor
COMPLETE UNIT
PED 97/23/EC
TSL - 2C , TSH - 50C
Fluid Grp. 2
Module A1 cat.11
ELECTRIC
220-230 V/ 50 Hz
1.28 KW
16 amp
REFRIGERANT
R 134A / 1, 35 Kg
PSL – 16 bar , PSH – 20 bar
TSL – (-10)C , TSH - 120C
COMPRESSED AIR
PS – 16 bar
TSL - 2C , TSH - 60C
REFRIGERANT VESSEL
VOL – 777 liter
PS – 20 bar , TS - 120C
Module A cat.1
COMPRESSED AIR VESSEL
VOL – 191 liter
PS – 16 bar , TS - 60C
Module A1 cat.11
REFRIGERANT TUBE
DN - 16 mm
PS – 16 bar , TS - 60C
Module art. 3(3)
COMPRESSED AIR TUBE
DN -
PS – TS -
Module

66
Source of Utility:
Electricity : PDB & Gas Generator
Steam : Boiler
Water : Pump
Compressed air : Compressor
Gas : TITAS GAS DISTRIBUTION CO.
Cost of Different Utility:
We could not collect the cost of different utility from the industry due to official
secrecy.
Remarks:
Utility services are the life-line of a production unit. In Landmark Textile Mills
Ltd. the capacity of the utility services is enough to meet the current demand. But as
further expansion of production units take place, the capacity of the utility service will
have to be increased.

67
CHAPTER – IX
STORES & INVENTORY CONTROL

68
Scope of Inventory Control:
1. Raw materials 
a) Dye store
b) Other chemicals
c) Gray fabric
2. Finished fabric
3. Spare parts
Frequency of Inventory Update:
1. Monthly inventory control
2. Annual inventory control
Inventory Control System for Raw Materials:
Dye store & other chemicals store 
 Both of these are received by the store in charge.
 First he sends these to quality in-charge for inspection. If they are found to be of
required quality then they are taken to store by the storekeeper.
 Store in-charge supplies these when required and records the date, type of material,
quantity and section in which supplied, in his register book.
Grey fabric store 
 Grey fabric is usually stored in another storeroom, which is separate from dyeing
shade.
 Grey fabric is first sent to the QC department for quality assurance and then taken to
the storeroom.
 Grey fabric is received by fabric store in-charge.
 He supplies the fabric as per requirement and records the date, type of material,
Inventory Control System for Finished fabric:
 Finished fabric from the compactor or stenter goes to inspection team. Here
inspection is done by a four points system.
 Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness
etc are tested from the lab before packaging.
 After finishing the fabric is kept in package before their transfer to the garments
department.
 It is controlled by the finishing in-charge who keeps a list of total finished product.
He also keeps a list of delivery products.

69
 He supplies the fabric as per requirement and records the date, type of material,
Inventory Control System for Spare Parts:
 Spare store officer keeps the spare parts in store and makes a list of spare parts.
 If the spare parts are little in stock he gives requisition to maintenance manager.
 Maintenance manager gives requisition to head office. Head office imports spare
parts or buys from local market as per requirement.
 As new spare parts arrive to store officer, he receives and catalogues them.
 He supplies the spare parts as per requirement and records the date, type of material,
Remark:
Landmark Textile Mills Ltd. has individual stores forraw materials, finished goods and
spareparts. The store of dyestuff and chemicals are not so clean. There is not enough
space to store the finished goods. It requiresincreasingthestorearea.

71
Due to official secrecy act we couldn’t collect any information related to cost analysis as
they were considered confidential and secret by the management of Landmark Textile
Mills Ltd.

72
CHAPTER – XI
MARKETING ACTIVITIES

73
Consumer of Products:
1. Textile Pressing Germany (TPG)
2. Ananda fashion (Indian buying house) – U.K.
3. Euro centra
4. Kauf hoff
5. Gulden Pfenning
6. Metro Sandra
Country of Export:
 Holland
 Germany
 Italy
 Finland
 USA
 Others
Local Market:
Landmark Textile Mills Ltd. is a 100% export oriented industry. But the dye-
house of Landmark Textile Mills Ltd. do take orders from several local companies on
sub-contract basis when they are free. These local companies are following.
 Belkuchi Knit
 Kist Design
 Beq Knit
 Waqfi Knit
Marketing Strategy:
Marketing strategy is a very important factor to sale the products to the buyer. If
the marketing strategy is not so developed, it will be very hard to reach the goal. In case
of garments marketing the dealings with the buyer is a very important factor.
In Landmark Textile Mills Ltd. mainly senior marketing officers, merchandiser &
higher officials deal with the buyer. There are some fixed buyers of the industry. These
buyers give their orders continuously all over the year. The marketing officers & the
merchandisers communicate with the buying houses to collect the orders.
By both side understanding the rate & the order quantity are fixed.

74
Duties & Responsibilities of Marketing Officer:
Dealing with the buyer & convincing the buyer is the main duty of marketing
officer. A marketing officer also has some other duties. The main duties &
responsibilities of a marketing officer are given bellow-
 To prepare cost sheet by dealing with the buyer.
 To take different steps by discussing with the high officials & merchandisers.
 To maintain a regular & good relationship between commercial officers &
merchandisers.
 To maintain communication with the buyers and buying houses.
 Communicate with better knowledge of the products.
Actually the responsibilities & duties of marketing officer begin from getting
order of buyer & ends after receiving payment by the buyer. So, he should be always
smart, energetic & sincere.
Remarks:
Landmark Textile Mills Ltd. has an energetic and motivated marketing &
merchandising team. They are always in communication with the buyers. The marketing
section also looks after the quality & quantity requirement of the buyers.

75
CHAPTER – XII
ACRYLIC YARN DYEING

76
Introduction:
Now-a-days yarn dyeing is being very much popular as a means of
producing raw material for woven and knitted stripe fabric and sweaters. Landmark
group has developed a project for Acrylic Yarn Dyeing to produce raw materials for
sweater production in the year 2001. It’s a large project with m/c capacity of 1600 kgs
and production per year is about 1400 tons. Here the Acrylic yarn is dyed in hank dyeing
system using cabinet type m/c.
Machine Description:
1. Batching or Bulking Unit:
Brand : Made locally
Machine No. : 01
2. Cabinet Dyeing M/C:
Brand : Fong’s International Engineering Ltd.
Origin : China
Machine No. : Total 9 (nine) sets
Model : Y-25, CY-100, CY-200, CY-450, CY-600, CY-800.
Capacity : 1600 kgs
3. Hydro Extractor M/C:
Brand : Tai Yat Industrial Extractor
Origin : Taiwan
Machine No. : 1
Capacity : 100 kg.
4. Hydro Extractor M/C:
Brand : United Machinery Manufactures Co. Ltd.
Origin : China
Machine No. : 2
Capacity : 200 kg each
5. Dyer:
Brand : Fong’s International Engineering Ltd.
Origin : China
Machine No. : 1
6. Packing M/C:
Brand : Power Pack
Machine No. : 1
Operating : Pneumatic Pressure Operated

77
Features of Dyeing Machines:
 Dyeing is done by overflow method.
 Yarn hank is kept on stick inside the cabinet.
 Temperature can’t exceed 98C i.e. atmospheric pressure m/c.
 Sampling device remains at every m/c where sample is separately joined before
dyeing commences. So it is possible to check shed without stopping the machine.
 Liquor circulation is done flowing three times up and three times down.
 All the machines have own control unit, which can be programme according to
necessity.
 Manual dozing system i.e. dozing is not computer controlled.
Features of Acrylic Yarn Dyeing Process:
 Bulking is necessary to assure better penetration of dye.
 Basic dye (here Tai – acrylic dye) is use for acrylic yarn.
 Dyeing is done in acidic condition (pH 4 - 5).
 Retarder and leveling agent is used to maintain dyeing accuracy.
 In this process retarder calculation is very important.
 There is a constrain in selecting dye%. It depends on the retarder calculation.
 Softener and washing chemical is used if required at the end of the dyeing
process.
 As dyeing is done above the Tg of Acrylic yarn, temperature gradient must be
maintained carefully. Special dyeing curve is followed very carefully with
specific temperature gradient.
 High migration is another special feature of this dyeing.
 M:L is maintained at 1:25.
Process Flowchart:
Batching

Dyeing

Hydro extraction

Drying

Packaging

78
Process Description:
Batching  Application of steam for 15 minutes to make the Acrylic yarn (hank
form) fluffy. This aids penetration of the dye molecules.
Dyeing 
 Chief ingredients in the recipe –
1. Basic Dye
2. Acetic Acid – To maintain pH of 4 – 5.5. Usually 0.7 gm/liter is used.
3. PAN – Retarder (Not used for deep shade as color may bleed e.g. black)
4. AN – Leveling agent. Usually 0.6% is used.
5. Taisoft SSK – Cationic Softener (Requires acidic medium). Usually 0.5%
is used.
Dyeing curve –
E
98c
95c 20-40 min
10’
93c 0.5c/min
92c
6’ 0.2c/min
91c 10’
90c 10’ 0.2c/min
10’
0.2c/min
C 0.2c/min Drain
B 70
A & c Without
C Gradient
30c
A = Acetic Acid C = Leveling Agent E = Cationic Softener
B = Retarder D = Basic Dye

79
Retarder Calculation –
S.F.  D.C. -  ( Amount of particular dye  f value)
Amount of retarder =
Saturation value of retarder
Here,
S.F. = Saturation value of Acrylic fibre. The fibre used in Landmark Yarn Dyeing
Ltd. has a S.F. value of 1.8. This value depends on the polymer composition of Acrylic
fibre.
D.C. = Dyeing constant of particular machine. The dyeing machines used in
Landmark Yarn Dyeing Ltd. has a D.C. value of 80% or 0.8.
f value = Saturation value of dyestuff. Individual dyestuff have separate f value.
This is provided by the dyestuff manufacturer.
Saturation value of retarder = The value of the used retarder i.e. PAN is 0.6.
Dye Percentage Constraint –
There is a constraint in selecting dye percentage. For example say a sample is
dyed with 0.04% Tai Red GTL, 0.0135% Tai Red 6BNT and 0.047% Tai Blue RGN. The
dyestuffs has f value of 0.58, 0.75, 0.33 respectively. Say, the amount of retarder used is
1.8 and the saturation value of retarder is 0.6.
Now,
 (Amount of particular dye  f value) + (Retarder amount  Saturation value of retarder)
= (0.04  0.58 + 0.0135  0.75 + 0.047  0.33) + (1.8  0.6)
= 1.46
The calculated value is less than 1.8 which is the saturation value of acrylic fibre. If this
value exceeds the saturation value of fibre, then the recipe is incorrect.
Hydro Extraction  For Acrylic yarn one passage is given.
Drying  Drying is done at 80c - 100c.
Topping  PAN is not used. Only 50% amount of AN is used with required dye
addition.
Stripping  The dyed Acrylic yarn can be stripped with treating the material
with NaClO3 and oxalic acid at 98 c for 15 minutes. Then the material is washed for 10
minutes.

80
Recipe for 100% Acrylic Yarn Dyed in Light Shade:
Ingredients Percentage Temperature &
Time
Acetic Acid 0.7 gm/litre
98c  30 min
PAN 1.5%
AN 1.6%
Tai G/Yellow 2GT 0.26%
Tai Red GRL 0.074%
Tai Blue RGN 0.12%
Taisoft SSK 6% 65c  15 min
Acetic Acid 0.05%
Recipe for 100% Acrylic Yarn Dyed in Deep Shade:
Ingredients Percentage Temperature &
Time
98c  40 min
AN 0.6%
Tai Black NSLT 2.00%
Tai Red GTL 0.05%
Tai Mela Green T 0.05%
Taisoft SSK 3% 65c  15 min
Acetic Acid 0.5%
Recipe for Acrylic/Cotton Blend Yarn Dyeing:
Ingredients Percentage Temperature & Time
98c  40 min
AN 0.6%
Tai Black NSLT 2.00%
Tai Red GTL 0.05%
Tai Mela Green T 0.05%
Mollan 130 0.5 gm/litre
65c  60 min
Glouber Salt 80 gm/litre
Soda 20 gm/litre
Kem Yellow FRL 0.93%
Kem Red XF3B 1.87%
Kem Black GR 7.2%
Cold Wash
Acetic Acid 0.5 gm/litre Room Temp  10 min
Mollan 130 0.5 gm/litre 98c  10 min

81
Hot Wash
Alvafix 66C 1.5% 50c  15 min
Taisoft SSK 3%
45c  15 minRayolan FRS 3%
Acetic Acid 0.5%
Quality Standard:
Landmark Yarn Dyeing Ltd. follows ISO:9001 2000 standardization for quality
product manufacturing.
Drawbacks:
 They are following very large temperature gradient curve, which may not be
necessary. So dyeing time can be reduced.
 Dozing is not done accurately as it is manual.
 Activities of yarn dyeing lab is not up to standard quality level.
Buyers:
 Cosmos Sweater
 Gulden Pfennig
 Look Fashion
Remarks:
Landmark Yarn Dyeing Ltd. has already achieved a well reputation in foreign
market and established own goodwill. They are planning to setup a acrylic yarn
manufacturing plant in Landmark complex very soon.

83
Landmark Textile Mills Ltd. is a well-planned versatile project. The
administrations, management, chain of command – all are well organized. They are
devoted to satisfy the customer with their activities.
Landmark Textile Mills Ltd. has following excellent features, which are worth
mentioning in this conclusion. These are,
 The dyeing process of Landmark Textile Mills Ltd. is very quick and accurate. It
is amazing that with only 3.5 ton machine capacity Landmark is capable of 10 ton
production daily. Furthermore very limited amount of re-dyeing is carried out in
Landmark, which proves the excellence of the dye-house.
 Landmark Textile Mills Ltd. has a very good labor management policy, which
enables the smooth running of the production line.
 The Dye-house is very clean with excellent working atmosphere due to plenty of
air circulation and planned layout.
Landmark Textile Mills Ltd. has following drawbacks,
 There is no water treatment plan in Landmark Textile Mills Ltd. The water
obtained from the pump is directly flowed to the dyeing machine without any
treatment.
 Due to shortage of textile engineers, night shifts some time continue production
without any production officer. As a result in some cases quality level drops.
College of Textile Technology has given us the chance to perform the industrial
attachment in Landmark Textile Mills Ltd. This attachment, acts as a bridge to minimize
the gap between theoretical and practical knowledge. Undoubtedly, this attachment
taught us more about textile technology, industrial management and production process.
Besides it gave us the first opportunity to work in an industry. I believe that, the
experience of this industrial attachment will help us in our future career as textile
technologist.

Industrial attachment of landmark textile mills ltd.

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