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Chapter 01: Introduction about establishment:

1.1: About Brandix casualwear:
Brandix Lanka Limited was founded in 1972 and is based in Colombo, Sri Lanka. The
company was formerly known as Lux Shirts (Pvt.) Ltd. The company has manufacturing
locations in Sri Lanka, India, and Bangladesh. Vision of the Brandix casualwear is To be
the inspired solution for branded clothing. Brandix has been become the pioneer in Sri
Lanka's apparel sector.
Brandix Lanka limited is a well-known garment manufacturing company which has South
Asias largest apparel group, providing integrated solutions covering the entire value chain,
from product design, development, manufacturing and raw-material supply. Because of
that reason, clients are being provided best what clients can be satisfied. They are doing the
best for their customers, so they have been given lot of orders from foreign branded
company. Because of that reason Brandix is one of the largest exporter of apparel in Sri
Lanka. As the holding company of the Brandix Group of companies, it is engaged in
developing, manufacturing and marketing end-to-end apparel solutions to global fashion
super brands.
Brandix is supplying garments on behalf of world super brands such as Victoria's Secret,
Gap, Next, Marks and Spencer, Liz Claiborne, Abercrombie and Fitch etc.Brandix Lanka
Limited operates as a subsidiary of Phoenix Ventures Ltd. Although it was a single
manufacturing facility in 1972 now it has 34 plants island wide and supports the Group and
employs over 35,000 people directly.
Brandix Lanka Ltd was founded in 2002 and pioneered the concept of holistic apparel
solutions from a unique, customer-centric structure.The company specializes in casual
bottoms, intimate and active wear, woven and knitted fabrics and a host of apparel industry
accessories. Producing their own fabric, threads, buttons and hangers give them their most
tactical edge in textiles and reinforce our core strengths of advanced research and
development, outstanding design, fabric printing, washing, dyeing, wet processing,
finishing, and relentless quality control services with fastest turnaround times. Embedding
and integrating these services into seamless verticality is the value chain the Brandix
Lanka offered to their clients.

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Brandix Casualwear forms the
core of the Group, its flagship
unit where 'inspired solutions' are
conceptualized

in

holistic

service to its customers. The

company is supplying woven
bottoms, basic pants, cargo pants,
5-pocket jeans, shorts and skirts;
the quintessence of our product
portfolio, to the world's top
Figure 1.1: Brandix casualwear, Ekala

brands. Its seven production

facilities include a state-of-the-

art, fully automated denim facility which is the first of its kind in Sri Lanka.
Brandix casual ware adding another milestone for their successful movement, Brandix
commissioned its Green Factory in April 2008. It is not only for the country but the world
too, setting a new benchmark as the first one of its kind in the country. The 130,000 square
foot Brandix Casualwear plant at Seeduwa exceeds stipulated Green Factory standards for
energy consumption, water conservation, solid waste management and carbon emissions.
The complete conversion supports initiatives for supply chains to achieve carbon
neutrality, and reduces the facility's carbon footprint by as much as 64%, achieving a 46%
saving in energy a 63% cut in water consumption and zero solid waste to landfill. The new,
sophisticated air-conditioning systems and ducting have greatly increased efficiency with
special prismatic material in skylights letting in solar light but not solar heat.

1.2: Achievements of the company:

GOTS (Global Organic Textile Standard)
On-site inspection and certification of processors, manufacturers and traders performed by
independent specially accredited bodies is the basis of the GOTS monitoring system in
order to provide a credible assurance of the integrity of GOTS-certified textiles.( Six
Casualwear facilities in Sri Lanka have received

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LEED Certification
Brandix is proud to receive the recent global recognition for its Eco Centre in Seeduwa for
Brandix Casualwear. The plant received Platinum rating in August 2008 under the
Leadership in Energy and Environmental Design (LEED) Green Building Rating System
WRAP (Worldwide Responsible Apparel Production)
WRAP (Worldwide Responsible Apparel Production) is the most recognized compliance
standard in the United States for the apparel industry.
GOTS (Global Organic Textile Standard)
On-site inspection and certification of processors, manufacturers and traders performed by
independent specially accredited bodies is the basis of the GOTS monitoring system in
order to provide a credible assurance of the integrity of GOTS-certified textiles.( Six
Casualwear facilities in Sri Lanka have received)

1.3: Innovation Center at Brandix Casualware:

In Ekala factory there are two main departments who are responsible for technical issues.
They are Maintenance department and the innovation center. Maintenance department is
responsible for all the regular maintenances of the machining and the other technical
system in the company. The innovation center is the place which produce new machines to
the production lines according to the. After starting innovation center there are around 450
machines it had produced. The main target of the innovation center is 40% automate the
production lines. To achieve this target they are produce machine which are completely
different one another. During training period, that kind of projects had to be done.
Producing these machines is for minimize the time wastage and increase the production
rate.

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Chapter 02: Technical experiences obtained during training
2.1: Experiences obtained related to workshop activities:
2.1.1: Activities carried out: Welding
Arc welding
To operate an arc welder, the earth (ground
wire) must be attached to the material to be
welded. The other cable runs to the handpiece, in which the welding electrode is
clamped.When the electrode touches the
work, electrical current flows from the
Figure 2.1: Arc welder

welder though the rod and work-piece

back to the welding machine.

If the current flow is established and then the electrode quickly pulled back a little from
the work-piece, a very high temperature arc forms between the end of the rod and the
work-piece. This melts the welding rod (becomes filler material)and the materials being
welded.

The
Figure 2.2: Arc welding
Figure 2.3; Establishing arc
welding electrode (the stick or rod) has an inner core of metal similar to the material that is
being welded. This core also has a diameter that is proportional to the material as the workpiece gets thicker. The inner of the rod is surrounded by a welding flux. When the molten
material solidifies, the flux forms a spate layer on top that can later be knock away with the
chipping hammer. The flux on welding rods serves these functions : Provides a gas shield,
Gives steady arc by providing current bridge, cleans and slows the cooling of the weld,
introduces appropriate alloys into the weld.
Specific electrodes available for welding :
Mild steel
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Cast iron

Stainless steel

Copper, bronze, brass, etc.

High tensile steels

Safety precautions:
Always wear an appropriate welding visor, helmet, clothing that covers arms and legs,

and gloves
Wear goggles when hipping slag or wire-brushing welds
Keep all electrical cables in good conditions
Make sure contact cannot be made with hot items
Keep inflammable items well away
Ensure there is plenty ventilation

Gas welding
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas) and oxyfuel cutting are processes that use fuel gases and oxygen to weld and cut metals,
respectively. Oxy-fuel is one of the oldest welding processes and still widely used for
welding pipes and tubes, as well as repair work. It is also frequently well-suited, and
favored, for fabricating some types of metal-based artwork
In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when
two pieces are heated to a temperature that produces a shared pool of molten metal. The
molten pool is generally supplied with additional metal called filler. Filler material depends
upon the metals to be welded.
The apparatus used in gas welding consists basically of an oxygen source and a fuel gas
source (usually cylinders), two pressure regulators and two flexible hoses (one of each for
each cylinder), and a torch. A welding torch head is used to weld metals.
It can be identified by having only one or two pipes running to the nozzle and no oxygenblast trigger and two valve knobs at the bottom of the handle letting the operator adjust the
oxygen flow and fuel flow.
The flame is applied to the base metal and held
until a small puddle of molten metal is formed.
The puddle is moved along the path where the
weld bead is desired. Usually, more metal is
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added to the puddle as it is moved along by means of dipping metal from a welding rod or
filler rod into the molten metal puddle. The metal puddle will travel towards where the
metal is the hottest. This is accomplished through torch manipulation by the welder.
Oxyacetylene welding/cutting is not difficult, but there are a good number of subtle safety
points that should be learned such as:

More than 1/7 the capacity of the cylinder should not be used per hour. This causes the
acetone inside the acetylene cylinder to

Figure 2.4: Welding torches

come out of the cylinder and contaminate

the hose and possibly the torch.

Acetylene is dangerous above 1 atm pressure. It is unstable and explosively

decomposes.
Proper ventilation when welding will help to avoid large chemical exposure.

TIG Welding
Gas tungsten arc welding (GTAW), also known
as tungsten inert gas (TIG) welding, is an arc
welding process that uses a non-consumable
tungsten electrode to produce the weld. The
weld area is protected from atmospheric
contamination by an inert shielding gas (argon
or helium), and a filler metal is normally used.
Figure 2.5: Welding circuit
GTAW is most commonly used to weld thin
sections of stainless steel and non-ferrous
metals such as aluminum, magnesium, and
copper alloys. The process grants the
operator greater control over the weld than
competing processes such as shielded metal
arc welding and gas metal arc welding,
allowing for stronger, higher quality

Figure 2.6: TIG welding

welds. However, GTAW is comparatively more complex and difficult to master, and
furthermore, it is significantly slower than most other welding techniques.
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The electrode used in GTAW is made of tungsten or a tungsten alloy, because tungsten has
the highest melting temperature among pure metals, at 3,422 C (6,192 F). As a result, the
electrode is not consumed during welding, though some erosion (called burn-off) can
occur. Manual gas tungsten arc welding is often considered the most difficult of all the
welding processes commonly used in industry. Because the welder must maintain a short
arc length, great care and skill are required to prevent contact between the electrode and
the workpiece

2.1.2: Activities carried out: Drilling and tapping

Drilling
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular crosssection in solid materials. The drill bit is a rotary end cutting tool, often multipoint. The bit
is pressed against the workpiece and rotated at rates from hundreds to thousands of
revolutions per minute. This forces the cutting edge against the workpiece, cutting off
chips from the hole as it is drilled. Drilled holes are characterized by their sharp edge on
the entrance side and the presence of burrs on the exit side (unless they have been
removed). Also, the inside of the hole usually has helical feed marks.
Drilling may affect the mechanical properties of the workpiece by creating low residual
stresses around the hole opening and a very thin layer of highly stressed and disturbed
material on the newly formed surface. For fluted drill bits, any chips are removed via the
flutes.
Twist drill bits:
The twist drill bit is the type produced in largest quantity today. It comprises a cutting point
at the tip of a cylindrical shaft with helical flutes; the flutes act as an Archimedean screw
and lift swarf out of the hole.

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Twist drill bits range in diameter from 0.002 to
3.5 in (0.051 to 88.900 mm) and can be as long
as 25.5 in (650 mm). The most common twist
drill bit (sold in general hardware stores) has a
point angle of 118 degrees, acceptable for use
in wood, metal, plastic, and most other
Figure 2.7: Twist drill bit

materials, although it does not perform as

well as using the optimum angle for each material. In most materials it does not tend to
wander or dig in.
A more aggressive angle, such as 90 degrees, is suited for very soft plastics and other
materials; it would wear rapidly in hard materials. Such a bit is generally self-starting and
can cut very quickly. A shallower angle, such as 150 degrees, is suited for drilling steels
and other tougher materials.
Drill bits with no point angle are used in situations where a blind, flat-bottomed hole is
required. These bits are very sensitive to changes in lip angle, and even a slight change can
result in an inappropriately fast cutting drill bit that will suffer premature wear. Long series
drill bits are unusually long twist drill bits. However, they are not the best tool for routinely
drilling deep holes, as they require frequent withdrawal to clear the flutes of swarf and to
prevent breakage of the bit. Instead, gun drill bits are preferred for deep hole drilling.
Drill press:
A drill press (also known as a pedestal drill, pillar drill, or bench drill) is a fixed style of
drill that may be mounted on a stand or bolted to the
floor or workbench. Portable models with a
magnetic base grip the steel workpieces they drill. A
drill press consists of a base, column (or pillar),
table, spindle (or quill), and drill head, usually
driven by an induction motor.
Figure 2.8: Drill Press

The head has a set of handles (usually 3) radiating from a central

hub that, when turned, move the spindle and chuck vertically, parallel to the axis of the
column. The table can be adjusted vertically and is generally moved by a rack and pinion.

A drill press has a number of advantages over a hand-held drill:

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Less effort is required to apply the drill to the workpiece. The movement of the
chuck

and spindle is by a lever working on a rack and pinion, which gives the

operator considerable mechanical advantage

The table allows a vise or clamp to be used to position and restrain the work,

making the operation much more secure

The angle of the spindle is fixed relative to the table, allowing holes to be drilled

accurately and consistently

Drill presses are almost always equipped with more powerful motors compared to
hand-held drills. This enables larger drill bits to be used and also speeds up drilling
with smaller bits.

Taps and dies

Taps and dies are cutting tools used to create
screw threads, which is called threading. A
tap is used to cut the female portion of the
mating pair (e.g., a nut). A die is used to cut
the male portion of the mating pair (e.g., a
bolt). The process of cutting threads using a
tap is called tapping, whereas the process
using a die is called threading. Both tools can
be used to clean up a thread, which is called
Fig 2.9: Various taps

chasing.

The three taps types are commonly used by most machinists:

1-Bottoming tap or plug tap
This tap has a continuous cutting edge with almost no taper .A bottoming tap is usually
used to cut threads in a hole that has already been partially threaded using one of the more
tapered types of tap; the tapered end of a bottoming tap is too short to successfully start
into an unthreaded hole.
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2-Intermediate tap, second tap or plug tap :
This tap has tapered cutting edges, which assist in aligning and starting the tap into an
untapped hole. The number of tapered threads typically ranges from 3 to 5.Plug taps are the
most commonly used type of tap.
3-Taper tap :
Has a more pronounced taper to the cutting edges. This has a very gradual cutting action
that is less aggressive than that of the plug tap.
Tapping may either be achieved by hand tapping by using a set of taps first tap, second tap
& final (finish) tap or using a machine to do the tapping, such as a lathe, radial drilling
machine, pillar type drill machine, vertical milling machines. Machine tapping is faster,
and generally more accurate because human error is eliminated.
Common reasons for tap breakage are:

Tap-related problems:
Wearing of tap cannot be easily quantified (use of worn-out taps)
Use of tap with improper tap geometry for a particular application.
Use of non-standard or inferior quality taps.
Clogging with chips.
Mismatch of machines feed and tap feed may cause the tap to break in tension or

compressions.
Misalignment between tap and hole.
Use of improper and/or insufficient cutting lubricant.
Improper or zero float for use with screw machines (recommended feed .1 slower to

establish float for 40 tpi or higher and .15 slower for 40 tpi or finer)
Improper spindle speed.

In order to overcome these problems, special tool holders are required to minimize the
chances of tap breakage during tapping. Various tool holders may be used for tapping
depending on the requirements of the user.
2.1.3: Activities carried out: Grinding and finishing
Grinding
Grinding is considered to be a finishing process or finishing operation having many
different applications in the machine tool industry. Grinding covers a wide range of
finishing and machining tasks as follows.

Abrade hard materials

Improve surface finish

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Tighten the tolerance on cylindrical or flat surfaces by removing a small amount of

material
Reshaping cutting tools
Surface grinding of mold sections

For material removal, the method used in grinding is called abrasion.in other words, in
grinding, an abrasive material rubs against the metal part and clears or removes tiny pieces
of material. Grinding is necessary for the following reasons:

The material is too hard to be machined economically.

If the surface is adequately supported, grinding can produce flatness tolerances of

less than 0.0025mm on a 127 x 127 mm steel surface.

Machine removes excessive material.
Grinding should be used when size tolerance specifications are beyond the

capability of turning.
It is also applied if the requirements of surface finish are too tight for hard turning.

Grinding can be various types, like as follows:

Surface grinding
Centered grinding
Center less grinding
Contour grinding

Surface grinding: This is perhaps the most fundamental of operation. Surface grinding is
the process of providing precision ground surface either to a critical size or for the surface
finish.
Centered grinding: In this type of grinding, the grinding is performed at the center. There
are two types of centered grinding. OD and ID grinding.
Contour grinding: In case of contour grinding, the chopping function is used to grind the
side face of a work piece.
Grinding wheels

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Fig 2.10: Grinding wheels

Fig 2.11: Wheel specifications

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ANSI Standard Marking System
1.
2.
3.
4.

Type of grain material an abrasive wheel uses

The grit (or size) of the abrasive particles in the wheel.
The overall hardness of the wheel.
The type of bonding material used.

This is the syntax for the ANSI marking system:

[Grain material] [Grit] [Hardness] - [Bond Material]
Example: C24S-BF is a name for a common type os masonry grinding wheel.

C - Wheels grain material is silicon Carbide

24 - Grit of the wheel on the coarse side
S - Medium/Hard
BR Bonding material is Resinoid Reinforced

Grain Material
Grit
A=Aluminum Oxide
16=Very Coarse
Soft
C=Silicon Carbide
30=Coarse
CG=Ceramic
60=Medium
ZA=Zirconia Aluminum
80=Fine
ZAC=Zirconia Silicon Carbide
120=Very Fine
Hard

Hardness
A=Extremely
P=Soft
S=Medium/Hard
T=Hard
Z=Extremely

The abrasive grains in cutting and grinding wheels have to be held together by some kind
of material, a bonding material. There are several varieties of bonding materials and
bonding methods, including fiberglass mesh reinforcement.

2.1.4: Activities carried out: Lathe machine

A lathe is a machine tool which rotates the work piece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with
tools that are applied to the work piece to create an object which has symmetry about an
axis of rotation.
A lathe may or may not have legs which sit on the floor and elevate the lathe bed to a
working height. At one end of the bed (almost always the left, as the operator faces the
lathe) is a headstock. The headstock contains high-precision spinning bearings. Rotating
within the bearings is a horizontal axle, with an axis parallel to the bed, called the spindle.
Spindles are powered, and impart motion to the workpiece.

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In most modern lathes the spindle is
driven by an integral electric motor, often
either in the headstock, to the left of the
headstock, or beneath the headstock,
concealed in the stand.
In addition to the spindle and its bearings,
the headstock often contains parts to
convert the motor speed into various
spindle speeds.
Fig 2.12: Lathe machine parts
Metalworking lathes have a carriage (comprising a saddle and apron) topped with a crossslide, which is a flat piece that sits crosswise on the bed, and can be cranked at right angles
to the bed. Sitting atop the cross slide is usually another slide called a compound rest,
which provides 2 additional axes of motion, rotary and linear. Atop that sits a toolpost,
which holds a cutting tool which removes material from the workpiece. There may or may
not be a lead screw, which moves the cross-slide along the bed.
A workpiece may be bolted or screwed to a faceplate, a large, flat disk that mounts to the
spindle. Faceplate dogs may be used to secure the work to the faceplate or the workpiece
may be mounted on a mandrel, or circular work clamped in a three- or four-jaw chuck
which mount directly to the spindle. In precision work cylindrical workpieces are usually
held in a collet inserted into the spindle and secured either by a draw-bar, or by a collet
closing cap on the spindle. Suitable collets may also be used to mount square or hexagonal
workpieces.
A soft dead center is used in the headstock spindle as the work rotates with the center.
Because the center is soft it can be trued in place before use. The included angle is 60.
Traditionally, a hard dead center is used together with suitable lubricant in the tailstock to
support the workpiece.
A circular metal plate with even spaced holes around the periphery, mounted to the spindle,
is called an "index plate". It can be used to rotate the spindle to a precise angle, then lock it
in place, facilitating repeated auxiliary operations done to the workpiece. Other
accessories, including items such as taper turning attachments, knurling tools, vertical

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slides, fixed and traveling steadies, etc., increase the versatility of a lathe and the range of
work it may perform.
When a workpiece is fixed between the headstock and the tail-stock, it is said to be
"between centers". When a workpiece is supported at both ends, it is more stable, and more
force may be applied to the workpiece, via tools, at a right angle to the axis of rotation,
without fear that the workpiece may break loose.
When a workpiece is fixed only to the spindle at the headstock end, the work is said to be
"face work". When a workpiece is supported in this manner, less force may be applied to
the workpiece, via tools, at a right angle to the axis of rotation, lest the workpiece rip free.
Thus, most work must be done axially, towards the headstock, or at right angles, but gently.

2.1.5: Activities carried out: Milling machine

Milling is the machining process of using

rotary cutters to remove material from a
workpiece feeding in a direction at an angle
with the axis of the tool. It covers a wide
variety of different operations and machines, on
scales from small individual parts to large,
heavy-duty gang milling operations. It is one of
the most commonly used processes in industry
and machine shops today for machining parts
to precise sizes and shapes.
The milling cutter is a rotary cutting tool, often
with multiple cutting points
Fig 2.13: Milling machine
As the milling cutter enters the workpiece, the cutting edges (flutes or teeth) of the tool
repeatedly cut into and exit from the material, shaving off chips (swarf) from the
workpiece with each pass.
Milling machines are basically classified as vertical or horizontal. These machines are also
classified as knee-type, ram-type, manufacturing or bed type and planer-type.
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Milling cutters are usually made of high-speed steel and are available in a great variety of
shapes and sizes for various purposes. The teeth of milling cutters may be made for righthand or left hand rotation and with either right-hand or left-hand helix.

Milling types:

Fig 2.14: Milling cutter

End milling:
End mills are those tools which have cutting teeth at one end, as well as on the sides. They
are usually made from high speed steel or cemented carbide, and have one or more flutes.
They are the most common tool used in a vertical mill.
Side-and-face cutter:
The side-and-face cutter is designed with cutting teeth on its side as well as its
circumference. They are made in varying diameters and widths depending on the
application. The teeth on the side allow the cutter to make unbalanced cuts without
deflecting the cutter as would happen with a slitting saw or slot cutter (no side teeth).
Slot Mill:
Slot drills are center-cutting end mills, generally two- (sometimes three- or four-) fluted
cutters that are capable of drilling straight down into the material and then moving laterally
to cut a slot. Slot drills are so named for their use in cutting keyway slots. The term slot
drill is usually assumed to mean a two-fluted, flat-bottomed end mill if no other
information is given.
Ball nose cutter:
Ball nose cutters are similar to slot drills, but the end of the cutters are hemispherical.
They are ideal for machining 3-dimensional contoured shapes in machining centers, for
example in moulds and dies. They are also used to add a radius between perpendicular
faces to reduce stress concentrations.
Arbors:
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Milling machine arbors are made in various lengths and in standard diameters of 7/8, 1/2 ,
Fig 2.15: Arbor
1/4, 1 and1 inch. The shank is made to fit the taper hole in the spindle while the other
end is threaded.
Milling cutters that contain their own straight or tapered threaded portion to provide
alignment and support for tool shanks are mounted to the spindle with collets, spindle
adapters, and quick-change tooling which adapt the cutter shank to the spindle.
Collets:
A collet is a form of a sleeve bushing for reducing the size of the hole in the milling
machine spindle so that the small shank tools can be fitted into large spindle recesses

Figure 2.16: Collets

Spindle Adapters:
A spindle adapter is a form of a collet having a standardized spindle end. They are
available in a wide variety of sizes to accept cutters that cannot be mounted on arbors.

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2.2: Experiences obtained in automation field:

Fig 2.17: Adapters
2.2.1: Pneumatics:
Pneumatics basically is operating a machine or a tool using compressed air and the air
pressure is significant. Some of the advantages of using a Pneumatic system:

High effectiveness

There is an unlimited supply of air in our atmosphere to produce compressed air.

Moreover, the use of compressed air is not restricted by distance, as it can easily be
transported through pipes

High durability and reliability

Pneumatic components are extremely durable and can not be damaged easily. Compared to
electromotive components, pneumatic components are more durable and reliable.

Simple design

The designs of pneumatic components are relatively simple. They are thus more suitable
for use in simple automatic control systems.

High adaptability to harsh environment

Compared to the elements of other systems, compressed air is less affected by high
temperature, dust, corrosion, etc.

Safety

Pneumatic systems are safer than electromotive systems because they can work in
inflammable environment without causing fire or explosion.

Easy selection of speed and pressure

The pressure and the volume of air can easily be adjusted by a pressure regulator.

Environmental friendly

The operation of pneumatic systems do not produce pollutants. Therefore, pneumatic

systems can work in environments that demand high level of cleanliness.

Economical

As pneumatic components are not expensive, the costs of pneumatic systems are quite low.
The cost of repair is significantly lower than that of other systems.
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Although pneumatic systems possess a lot of advantages, they are also subject to many
limitations. Some of them are:

Relatively low accuracy

As pneumatic systems are powered by the force provided by compressed air, their
operation is subject to the volume of the compressed air. As the volume of air may change
when compressed or heated.

Low loading

As the cylinders of pneumatic components are not very large, a pneumatic system cannot
drive loads that are too heavy.

Processing required before use

Compressed air must be processed before use to ensure the absence of water vapour or
dust. Otherwise, the moving parts of the pneumatic components may wear out quickly due
to friction.

Uneven moving speed

As air can easily be compressed, the moving speeds of the pistons are relatively uneven.

Noise

Noise will be produced when compressed air is released from the pneumatic components.

2.2.1.1: Main pneumatic components:

Pneumatic components can be divided into two categories:
1. Components that produce and transport compressed air.
2. Components that consume compressed air.
All main pneumatic components can be represented by simple pneumatic symbols. Each
symbol shows only the function of the component it represents, but not its structure.
Pneumatic symbols can be combined to form pneumatic diagrams. A pneumatic diagram
describes the relations between each pneumatic component, that is, the design of the
system.
Components that produce and transport compressed air:
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Examples of components that produce and transport compressed air include compressors
and pressure regulating components.
Compressor:
Compressors are similar to pumps: both increase the
pressure on a fluid and both can transport the fluid
through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas. A
compressor can compress air to the required pressures.
It can convert the mechanical energy from motors and
engines into the potential energy in compressed air. A
Fig 2.18: Pneumatic compressor

single central compressor can supply various

pneumatic components with compressed air, which is

transported through pipes from the cylinder to the pneumatic components. Compressors
can be divided into two classes: reciprocating and rotary.
A reciprocating compressor or piston compressor is
a positive-displacement compressor that uses pistons
driven by a crankshaft to deliver gases at high
pressure. So it is used to provide compressed air for
the automation applications. The main advantages of
the reciprocating compressor are that it can achieve
high pressure ratio. The intake air enters the suction
Fig 2.19: reciprocating
compressor

manifold, and then flows into the compression cylinder

where it gets compressed by a piston driven in a

reciprocating motion via a crankshaft.

After that compressed air is discharged. This type of compressor are used for oil refineries,
gas Dynamic Displacement pipelines, chemical plants, natural gas processing plants and
refrigeration plants.
The rotary vane compressor employs a series of rotating vanes or blades, which are
installed equidistant around the periphery of a slotted rotor. The rotor is mounted
eccentrically in a steel cylinder so that the rotor nearly touches the cylinder wall on one
side, the two being separated only by an oil film at this point. Directly opposite this point
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the clearance between the rotor and the cylinder wall is maximum. Heads or end plates are
installed on the ends of the cylinder to seal the cylinder and to secure the rotor shaft.
The vanes move back and forth radially in the rotor slots as they follow the contour of the
cylinder wall when the rotor is rotating. The vanes are held firmly against the cylinder wall
by action of the centrifugal force developed by the rotating rotor. In some instances the
blades are spring loaded to obtain a more positive seal against the cylinder wall.
The suction vapor drawn into the cylinder through suction ports in the cylinder wall is
entrapped between adjacent rotating vanes. The vapor is compressed as the vanes rotate
from the point of maximum rotor clearance to the point of minimum rotor clearance. The
compressed vapor is discharged from the cylinder through ports located in the cylinder
wall near the point of minimum rotor clearance.

Fig 2.20: vane type rotary compressor

The rotary vane compressor does not have a sump to contain the oil reserve. The oil is
therefore extracted from the discharge gas by means of an oil separator (described later in
the series) and continually delivered in a controlled manner to the internal surface of the
rotor housing to perform essential lubrication. Some models are now constructed within a
body that has an oil reservoir adjacent to the compressor to simplify oil management and to
improve the security of lubrication.

20 | P a g e

Pressure regulating component:

Pressure regulating components are formed by various components, each of which has its
own pneumatic symbol. Individual functions are filtering, regulating and lubricating. This
is achieved though the service unit or Filter Regulator Lubricating (FRL) which is
connected upstream of the pneumatic systems. Filter regulator lubricator are being used in
both hydraulic and pneumatic system in
order

to

minimize

dust

particle,

moisture, abrasive materials from the

system. The air quality is measured in
classes

according

to

ISO

8573-1

standard .It considers the three types of

contaminants
Fig 2.21: Service unit

that

could

affect

pneumatic equipment life:

Quantity of water particles dissolved in the air, Quantity of oil particles dissolved in the air,
and Quantity of solid particles in the air.
Basic components of FRL unit are pressure regulator, pressure gauge, dust filter,
condensate drain, lubricator.
(i) Filter can remove impurities from compressed air before it is fed to the pneumatic
components.
(ii) Pressure regulator to stabilise the pressure and regulate the operation of pneumatic
components
(iii) Lubricator To provide lubrication for pneumatic components

Components that consume compressed air:

Examples of components that consume compressed air include cylinders (execution
components), directional control valves and assistant valves.

21 | P a g e

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Cylinders (execution components):
Pneumatic execution components provide rectilinear or rotary movement. Examples of
pneumatic execution components include cylinder pistons, pneumatic motors, etc.
Rectilinear motion is produced by cylinder pistons, while pneumatic motors provide
continuous rotations. There are many kinds of cylinders, such as single acting cylinders
and double acting cylinders.
Single acting cylinders:
Single acting cylinder is a linear actuator which produces work in only one direction.
Therefore piston is returned to the initial position by a spring. Single acting cylinders are
used in applications such as clamping, stamping, ejecting, lifting, feeding etc.

Fig 2.22: Cross section of Single acting cylinder

Double acting cylinders:
Double-acting cylinders are cylinders which producing work in two directions. They have
two ports to allow air in, one for outstroke and one for in stroke. Stroke length for this
design is not limited. However the piston rod is more vulnerable to buckling and bending.
Major difference between single acting and double acting, there is not spring in double
acting cylinder to return the piston. Because machine can brake under fatigue failure end
cushioning are used to take a smooth movement without a shocked movement of the
cylinder mounted parts.

Fig 2.23: Cross section of a double acting cylinder

22 | P a g e

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Gripper:
A pneumatic gripper is a specific type of pneumatic actuator that typically involves either
parallel or angular motion of surfaces. The gripper can be used as part of a "pick and
place" system that will allow a component to be
picked up and placed somewhere else as part of a
manufacturing system. Some grippers act directly
on the object they are gripping based on the force
of the air pressure supplied to the gripper, while
others will use a mechanism such as a gear or
toggle to leverage the amount of force applied to
the object being gripped. Grippers are frequently
Fig 2.24: Grippers

added to industrial robots in order to allow the

robot to interact with other objects.

Directional control valve:
Directional control valves ensure the flow of air between air ports by opening, closing and
switching their internal connections. Their classification is determined by the number of
ports, the number of switching positions, the normal position of the valve and its method of
operation. Common types of directional control valves include 2/2, 3/2, 5/2, etc. The first
number represents the number of ports; the second number represents the number of
positions.
2/2 Directional control valve:
The structure of a 2/2 directional control valve is very simple. It uses the thrust from the
spring to open and close the valve. The control valve can be driven manually or
mechanically, and restored to its original position by the spring.
Flow Path Open

Flow Path Close

Fig 2.25: 2/2 Directional control valve

3/2 Directional control valve
23 | P a g e

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A 3/2 directional control valve can be used to control a single acting cylinder. The open
valves in the middle will close until P and A are connected together. Then another valve
will open the sealed base between A and R (Ex). The valves can be driven manually,
mechanically, electrically or pneumatically. 3/2 directional control valves can further be
divided into two classes: Normally open type (N.O.) and normally closed type (N.C.)

Fig 2.26: 2/2 Directional control valve

5/2 Directional control valve

When a pressure pulse is input into the pressure control port P, the spool will move to the
left, connecting inlet P and work passage B. Work passage A will then make a release
of air through R1 and R2. The directional valves will remain in this operational position
until signals of the contrary are received. Therefore, this type of directional control valves
is said to have the function of memory.

Fig 2.27: 5/2 Directional control valve

Pushing connectors in Pneumatics:
24 | P a g e

`
In

Pneumatic

connectors

are

systems,

Pushing

used

connect

to

Pneumatic tubes together or with some

another device. There are many type of
them in many sizes. Normally they
include lock claws to fit the tubes with
the connectors, until press the release
sleeve. So it shouldnt be Never
touched the release sleeve of one-touch
Fig 2.28: Parts of a pushing connector

fittings when they are pressurized. It

may cause tube separation, resulting

in potentially dangerous situations. There are many type of pushing connectors in the
industry as can be used in various purposes.

Male connector

Female connector

Union straight

Union straight reducer

reducer

Union Tee

Union Y

Triple Branch

Union Elbow

Union Tee Reducer

Fig 2.29: Types of pushing connectors

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Branch Tee

Union Elbow

Union Y reducer

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2.2.2: Components used in industrial automation:
2.2.2.1: PLC (Programmable logic Controller):
Mechatronics is the latest trend in technology which is an integration of mechanical,
electronics and computer engineering. Automation technology is the technical part of the
Mechatronics.
Industrial automation consist of five basic components:

Actuators (Pneumatic, Hydraulic, Electrical)

Sensors (Binary, Analog.)
Processors (PLC,IPC, microcontrollers, Relays)
Network (Digital cables, Ethernet, profiBUS)
Software (Human-Machine interface, Controller programming)

Advantages of using PLCs as processors in automated system:

Greater flexibility and reliability.

Easy debugging as error detection programs are available.

Low power consumption and space requirement.

Less maintenance due to no moving parts.

No special programming skills required by maintenance personnel.

Types of PLCs: Depending on the way of connecting input and output modules to the
central control unit.

Fig 2.30: Modular PLC

Fig 2.31: Compact PLC

The PLC operates internally in a way very similar to computers:

26 | P a g e

The states of the input devices are continuously monitored and copied from the

input module into input RAM memory area.

The CPU then executes the control program stored in the program stored in the

program memory area.

Depending on the program and the states of the inputs, the output states of the

relevant output devices are then written into the output RAM memory area.
At the end of each execution cycle, data in output RAM area are then copied to the

output RAM area are then copied to the output modules.

After each execution new cycle begins.
Programming of a PLC:

Control programs must be systematically designed, well-structured and fully and fully
documented in order to be as; error free, low-maintenance, cost effective as possible.
Some of the Programming languages:
1. Ladder diagram (LD): A graphic programming language derived from the circuit
diagram of directly wired relay controls.

2. Function Block Diagram (FBD): This originates from the logic diagram for the
design of electronic circuits.

3. Instruction list (IL):

characterized by a
27 | P a g e

An assembler type language

simple machine model.

Industrial and commercial environments are being widely used PLC in present time. PLC
can be found in almost any manufacturing facility. There are several manufacturers of
PLCs. Each brands have unique programing method, but basically all PLCs hardware
structures and programming concepts are very similar .There are lot of different PLC
brands, famous brands can be mentioned as following

Allen Bradley PLC

GE Fanuc PLC

Horner electric PLC

Siemens PLC

Array PLC

Every PLC consist of following component

Central processing unit (CPU)

Memory

Inputs Output modules

Power supply

Programming Terminal

Connection between above mentioned components can be demonstrated using following

figure.

28 | P a g e

Fig 2.32: Connection among PLC components

Central processing unit of PLC:
PLC has a central processing unit like other computerized devices. It is the brain of the
PLC It is controlled by operating system software The operating system program is a
supervisory programs that are loaded and stored permanently in the PLCs memory by
PLC programmer .CPU does following operations

Updating inputs outputs ,using inputs status it energizes or de energizes its output

Performing logic and arithmetic operations

Communicating with memory ,Programed data are stored in memory .So CPU can
read or change the content of memory locations

29 | P a g e

Scanning application program

Communicating with a programing terminal

Memory:
Memory
is
the
component

that

most

Fig 2.33: Central processing unit

stores

important
information,

programs, and data in a PLC. There are two process that are being done using memory
.The process of putting new information into a memory location is called writing. The
process of retrieving information from a memory location is called reading.
There two common types of memory used in PLCs: Read Only Memory (ROM) and
Random Access Memory (RAM). A ROM location can be read, but it cannot be written.
ROM is used to store programs and data that should not be altered. Because of that reason
the PLCs operating programs are stored in ROM.
A RAM location can be read or written. Therefore the information stored in a RAM
location can changed. Ladder logic programs are stored in RAM, programing langue may
be different with the PLC brands. When a new ladder logic program is loaded into a PLCs
memory, the old program that was stored in the same locations is over-written and
essentially erased. The memory capacities of PLCs can vary. Memory capacities are often
expressed in terms of kilo-bytes (K). One byte is a group of 8 bits. One bit is a memory
location that may store one binary number that has the value of either 1 or 0. (Binary
numbers are addressed in Module 2). 1K memory means that there are 1024 bytes of
RAM. 16K memory means there are 16384 bytes of RAM.
Input modules and output modules:
A PLC takes information from inputs and makes decisions to energize or de-energize
outputs. The decisions are made based on the statuses of inputs and outputs and the ladder
logic program that is being executed. The input signal can be given to the PLC by using
pushbuttons, limit switches, relay contacts, photo sensors, proximity switches, temperature
sensors, and the like. These input devices can be AC (alternating current) or DC (direct
current). The input voltages can be high or low. The input signals can be digital or analog.
30 | P a g e

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Differing inputs require different input modules. An input module provides an interface
between input devices and a PLCs CPU, which uses only a low DC voltage.
The input modules function is to convert the input signals to DC voltages that are
acceptable to the CPU. Standard discrete input modules include 24 V AC, 48 V AC, 120 V
AC, 220 V AC, 24 V DC, 48 V DC, 120 V DC, 220 V DC, and transistor-transistor logic
(TTL) level.
The devices controlled by a PLC include relays, alarms, solenoids, fans, lights, and motor
starters. These devices may require different levels of AC or DC voltages. Since the signals
processed in a PLC are low DC voltages, it is the function of the output module to convert
PLC control signals to the voltages required by the controlled circuits or devices. Standard
discrete output modules include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V
DC, 120 V DC, 220 V DC, and TTL level.
Power supply:
Standard commercial AC power lines are being used to power the PLC. But many PLC
components are utilizing 5V or another low voltage of DC power. Those components are
CPU and memory. The PLC power supply converts AC power into DC power to support
those components of the PLC.
Programming Terminal:
A PLC requires a programming terminal and programming software for operation. The
programming terminal is used for programming the PLC and monitoring the PLCs
operation. It may also download a ladder logic program (the sending of a program from the
programming terminal to the PLC) or upload a ladder logic program (the sending of a
program from the PLC to the programming terminal).
Programing device:
Generally personal computers are used to program the PLC. Working software allows users
to modify, store, troubleshoot the program. Personal computers communicate with PLC
using processor via a serial or parallel data communications link
Hand-held unit are often used for modifying, troubleshooting or transferring programs to
multiple machines on the factory floor.

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2.2.2.2: Relays:
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such as solidstate relays. Relays are used where it is necessary to control a circuit by a low-power
signal, or where several circuits must be controlled by one signal. There are many
functions which are being used relays, those things can be mentioned as following

Relays are used where it is necessary to control a circuit by

a low-power signal .Moreover it can be used to take

Fig 2.34: Relay

different voltages level

where several circuits must be controlled by one signal ,it is

called multiple switching process

Relays are used to take different control path (separation of

different load circuits for multi pole relays )

It is used for logic function and interlocking

Easy maintenance is main advantage of relays. Relays are mainly made for two basic
operations. One is low voltage application and the other is high voltage. For low voltage
applications, more preference will be given to reduce the noise of the whole circuit. For
high voltage applications, they are mainly designed to reduce a phenomenon called arcing.
There are many applications for relays: laboratory instrument, telecommunication systems,
computer interfaces, domestic appliances, air conditioning and

heating ,automotive

electrics, traffic control ,light control ,electric power control ,control of motor and
solenoid. Relays act considerable part in control and automation engineering field. There
are only four main parts in a relay. They have been mentioned below

Electromagnet
Movable Armature
Switch point contacts
Spring

32 | P a g e

Fig 2.35: Relay working principle

When a voltage is applied to the relay coil, then it causes to create a electromagnet field
.That created electromagnet field causes to attract the armature to the coil core .then
armatures the relay contacts, either closing or opening them, it is depending on the design
of the relay. After that return spring return the armature to the initial position when the
current to the coil is interrupted .That return force is mainly provided by two factors. They
are the spring and also gravity.
2.2.2.3: Timers:
A timer is a specialized type of clock for measuring time intervals. In automation industry
timers are being used to preform different tasks, it is depending on the application. There
are two types of timers, a timer which counts upwards from
zero for measuring elapsed time is often called a stopwatch, a
device which counts down from a specified time interval is
more usually called a timer. Some timers sound an audible
indication that the time interval has expired. Time switches
that timing mechanisms which activate a switch, are
sometimes called timers.
Timers and time switches may be free-standing or
Fig 2.36: Multi range
Timer

incorporated into appliances and machines. Their operating

mechanism may be mechanical, electromechanical or purely

electronic (counting cycles of an electronic oscillator). Timing functionality can also be

provided by software, typically in a computer. Basically there are four types of timers that
can be found in automation industry .they are mentioned below

Mechanical timers
Electromechanical timers
Electronic timers
Computer timers
Mechanical timers:

Mechanically operated timers are called Mechanical timers, they use mechanical
clockwork to measure time. Mechanical timers are typically set by turning a dial to the
time interval desired turning the dial stores energy in a mainspring to run the mechanism.
33 | P a g e

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They function similarly to a mechanical alarm clock, the energy in the mainspring causes a
balance wheel to rotate back and forth.
Electromechanical timers:
Short-period bimetallic electromechanical timers use a thermal mechanism, with a metal
finger made of strips of two metals with different rates of thermal expansion sandwiched
together steel and bronze are commonly used materials. An electric current flowing
through this finger causes heating of the metals, one side expands less than the other, and
an electrical contact on the end of the finger moves away from or towards an electrical
switch contact.
Electronic timers:
Electronic timers are essentially quartz clocks with special electronics, and can achieve
higher precision than mechanical timers. Electronic timers have digital electronics, but
may have an analog or digital display. Integrated circuits have made digital logic so
inexpensive that an electronic timer is now less expensive than many mechanical and
electromechanical timers, because of that reason electronic switches are being used for
many application in automation industry. .
Many timers are now implemented in software. Modern controllers use a programmable
logic controller rather than a box full of electromechanical parts. The logic is usually
designed as if it were relays, using a special computer language called ladder logic. In
PLCs, timers are usually simulated by the software built into the controller. Each timer is
just an entry in a table maintained by the software. So electronic timer most useful device
that have been invented mainly for use of automation industry
2.2.2.4: sensors:
A sensor is a converter that measures a physical quantity and converts it into a signal which
can be read by an observer or by an (today mostly electronic) instrument. There are three
color wires in a common sensor and the brown and blue wires are for power supply. The
black wire is for the output signal. When we use sensors with normal electrical equipment,
the sensor output should not connect to the equipment directly, the high current can
damage to the sensor. It should be connect through a relay. But when the sensors use with
the PLC the sensor output can directly connect to the PLC. Some sensors give the (+)
outputs which are called PNP type and some sensors give the (-) outputs which are called
NPN type.. Some are normally close and some sensors are normally open.

34 | P a g e

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There are some four wire sensors as normally open and close together. Relays can be used
convert normally closed into normally open.

Fig 2.37: NPN and PNP outputs

There are different type of sensors those sensors are mentioned below

Proximity sensor
Temperature sensor
IR sensor
UV sensor
Touch sensor

A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact. There are several types of proximity sensors due to the sensing target:
Capacitive, photoelectric, inductive etc.
Capacitive Sensors:
Capacitive sensors detect anything (metal or
non-metal) that is conductive or has a
dielectric different from that of air.
Capacitive sensors are constructed from
many different media, such as copper,
Indium tin oxide (ITO) and printed ink. Size
and spacing of the capacitive sensor are both
very important to the sensor's performance.

Fig 2.38: Method in Capacitive Sensors

Photoelectric Sensors:
35 | P a g e

A photoelectric sensor, or photo eye, is a device used to

detect the distance, absence, or presence of an object by
using a light transmitter, often infrared, and a photoelectric
receiver. They are used extensively in industrial
manufacturing. There are three different functional types:
opposed (through beam), retro-reflective, and proximitysensing (diffused). There are three different functional
types: opposed (through beam), retro-reflective, and
proximity-sensing (diffused).
Fig 2.39: Photoelectric
sensors
Inductive sensors:
An inductive sensor is an electronic proximity sensor, which detects only metallic objects
without touching them. The sensor consists of an induction loop. Electric current generates
a magnetic field, which collapses generating a current that falls asymptotically toward zero
from its initial level when the input
electricity ceases. The inductance of the loop
changes according to the material inside it
and since metals are much more effective
inductors than other materials the presence of
metal increases the current flowing through
the loop. This change can be detected by
sensing circuitry, which can signal to some
other device whenever metal is detected.
Fig 2.40: An inductive sensor
Ultrasonic sensor:
Ultrasonic sensors (also known as transceivers when they both send and receive, but more
generally called transducers) work on a principle similar to radar or sonar which evaluate
attributes of a target by interpreting the echoes from radio or sound waves respectively.
Ultrasonic sensors generate high frequency sound waves and evaluate the echo which is
received back by the sensor. Sensors calculate the time interval between sending the signal
and receiving the echo to determine the distance to an object. This technology can be used
for measuring wind speed and direction (anemometer), tank or channel level, and speed
through air or water. To measure tank or channel level, the sensor measures the distance to
the surface of the fluid.
2.3: Air Conditioning and Ventilation System installed
36 | P a g e

`
Air conditioning is the process of altering the properties of air to more favorable
conditions. This type of system is designed to change the air temperature and humidity
within an area. The cooling is done by using a simple refrigeration cycle. Brandix
Company also have Air conditioning systems to have more confortable conditions to the
workers and customers also.
The Air Conditioning and Ventilation System installed at Brandix casualwear (pvt) Ltd. At
Ekala consist of the following:
Air cooled water system serves the product development area ground and mezzanine floors
and the cutting section.
The Mechanical ventilation system serves the raw material stores area.
The Chilled water Air Conditioning system consists of (03) Nos. Carrier Air cooled
chillers, (11)Nos. Carrier Air handling units( AHU rooms) complete with spiral ducted type
air distribution system. Mechanical ventilation system is completed with (10) Nos. fans for
cutting section.
A/C system commissioned and put to beneficial use on 11.07.2005
All the system has installed by the Built Mech Services (Pvt) Ltd., Narahenpita, Colombo
05.And all the maintenance are doing by Maintenance & Service Division of that company.

Table 2.1: Temperature Maintaining at Occupancy Areas.

Area
Temp.(C)
Cutting Section
1) Cutting Area
24
2) Office Cubicles
23
3) Medical Center
24
Product Development
4) Ground level
5) Mezzanine Level

There are several types of Air Conditioning systems.

Window Air conditioning

Split Air Conditioning
Package Air Conditioning

37 | P a g e

23
24

`
2.3.1: Package Air Conditioning
These types of Air Conditionings are used to cool more than two rooms or a large space.
There are two types because of the cooling method of Condenser:

Air cooled A/C system

Water cooled A/C system

In the Air cooled condenser packages, the condenser is cooled by the atmospheric air. This
is the most common method used in Brandix Casualwear, Ekala. There is an outdoor unit
that comprises of the important components like compressors, condenser, and in some
cases the expansion valve also. The outdoor unit is kept on an open place where the free air
flow is available.
Air handling Units (AHU)
An Air handling unit or an air handler is a device used to condition and circulate, air as a
part of heating, ventilating and air conditioning system (HVAC). HVAC is the technology
of indoor and vehicular environmental comfort. AHUs are usually large metal boxes with
blowers, heating or cooling elements, filter racks or chambers, sound attenuators and
dampers. AHU connects to the duct system to distribute the conditioned air through the
building and returns it to the AHU. Sometime returning air was admitted from the room
space. In Brandix cacualwear also used this method. A/C system at Brandix, Ekala doesnt
have ducts to return air to the AHU. Air is sucked from the spaces near by the AHU room.

Figure 2.41: HVAC ducts

An Air handling unit located at cutting section at Brandix has following specifications.
Table 2.2: Air Handling Units
Location
Designation
Make
Model No:
Serial No:
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Cutting section
AHU-1
Carrier
39G1722
MAH 05501539

`
Motor (K.W.)
Rated Voltage (V)
Rated Current (A)
Running Current (A)
Air flow rate (CFM)
Supply air Temperature (0C)
Return air Temperature (0C)

11
400
21.3
14
15,000
13
26

Chiller
A chiller is a machine that removes heat from liquid (Called Chilled water). Chilled water
is some type of cooled water. Chilled water is circulated through a heat exchanger. In the
Brandix at Ekala some Carrier brand air cooled chillers are used.
Where chiller capacities greater than 200
tons (703kW) are required, or where standby capability is desired, chillers may be
installed in parallel. Units should be equal
size to ensure balanced fluid flows.
Where a large temperature drop (>250F) is
desired,
series.3m

chillers

may

separation

be

installed

between

units

in
is

required for air flow, and a some distance

(1.8
Figure 2.42: Air cooled chiller

m)

is

required

from

units

to

obstructions.

Carrier Air cooled chillers used for Production development and cutting section in Brandix
have following specification.
Model No

: 30GBN-150

Serial No

Entering water temp. (Deg F)

: 58.7

Leaving water temp. (Deg F)

: 44.2

39 | P a g e

MCH 05130591

`
Running Capacity

: 66%

Saturated condensing temp. (Deg F)

: 95.2

Discharge pressure (Psig)

: 187.4

Suction Pressure (Psig)

: 65

Total Current (A)

: 111

Supply Voltage (V)

: 387

Water pumps used to circulate chilled water in Brandix have following specifications.
Make

: Monoflo-Din Master

Model No

: DMT-80-320

Serial No

: 326

Full load amps

: 21.5A

Inlet pressure

: 0 Psi

Outlet pressure

: 16Ps

Figure 2.43: Chilled water pumps

2.4: Introduction about projects done:
During training period I was able to participate and handle several projects. Meanwhile I
was able to help in their other projects as well. By involving their project I could
understand lot of things about manufacturing. Although I was there to train about control
and automation, I was able to take idea about not only automation but also machining and
electronic. In here I can mention major three projects that I could involve.
Mini loop cutter machine
Button wrapping machine
40 | P a g e

Buzzer controller
Garment surface grinder

2.4.1: Mini loop cutter machine:

Mini loop cutter construction was a most important project for beginner of automation
engineering which given during training at Brandix innovation center. Because of that
project lot of information about automation equipment could be known. Machine was
designed to cut loops of the trousers after taking initial commands. There are changeable
knife up time and loop length in the program. Some electronic components were also used
for the construction such as relays, Winston Bridge, capacitors, resistors, transformer etc.
This is fully automated and controlled by an
Array (ACD-12MCDC). Here the output rate
is greater than the human labor. So it is used
as a efficient and effective machine. First the
outer bodies of the loop cutters are fabricated
in the workshop. I could help to made some
parts also. Then we did the wiring for it. First
a step down transformer was used to reduce
230V into 24V and a bridge rectifier was
Figure 2.44: Mini loop cutter

used to convers 24VAC into DC. A

capacitor was also used to make the current smoothed.

A photoelectric sensor is used to indicate whether that the loop is present and then the loop
is held over by the rotating wheel which came down. The wheel which hold the loop and
the cutting blade are controlled by two solenoids.
During this project time lot of work shop experiences were taken such as drilling, milling,
polishing, lathing etc. When wiring the machine some action about electronic devices were
observed.
Table 7.1 Input and output of the mini loop cutter
Input
I0

photo electric Sensor [Detect loop lie

on the bed ]

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Output
Q1

Solenoid 1[Wheel down]

`
I1
I2

Push button [Emergency stop]

Proximity sensor[Detect joint in loop]

Q2
Q3

Solenoid 2[Cutting blade up and down]

Stepper motor driver

Figure 2.45: Solid work design of the Mini loop cutter

Figure 2.46: Electrical wiring of the mini loop cutter machine

We used the APB software for programming the ARRAY (ACD-12MCDC) PLC. The
Array plc, we used had 8 inputs and 4 transistor type outputs. This was a very challenging

42 | P a g e

`
project since we did not have experience or knowledge about PLC programming. The
simulation option within the APB software helped us a great deal.
Figure 2.47: Programming of an Array for Mini loop cutters
2.4.2: Garment Surface Grinder
Garment surface grinder is a machine used to have a finishing of clothes. Using these
machines shining or grounded surfaces can be obtained. One of this type machines was
repaired in the Innovation center at Brandix Casualwear, Ekala. Then another two
machines of this type were produced. At the first a
list of the amounts of all the required materials and
dimensions has to be taken. Then the existing
machine was designed by using Solidworks.
All the parts required for these two machines were
fabricated in the workshop at Innovation center
and new panel board has to be designed more
much suitable than existing one.
The panel board was designed by including 2metal detective sensors, 4-Relays (24 VDC), a 24
VDC Timer, a contractor and a power supply unit.
Figure 2.48: Garment surface
grinder

A motor, piston and a foot paddle also added.

Figure 2.49: Panel Board Circuit design of Surface Grinder

A LC1-D series
AC contactor is
used

for

the

Garment surface
grinder.
Contactor

is

type of relay that

can handle the
high
required
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power
to

`
control an electric motor or other load directly. But they are not generally called relays. A
contactor is controlled by a circuit which has a much lower power level than the switched
circuit. Unlike general-purpose relays, contactors are designed to be directly connected to
high-current load devices. Relays tend to be of lower capacity and are usually designed for
both normally closed and normally open applications. Devices switching more than 15
amperes or in circuits rated more than a few kilowatts are usually called contactors.
Contactors are usually normally open. So that power to the load is shut off when the coil
inside in the contactor is de energized. Contactors are normally used to control electrical
motors, lighting, heating, capacitor banks and thermal evaporators also.

Figure 2.50: LC1-D series contactor

Chapter 03: Management experience obtained during training:

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`
Brandix Lanka is an internationally popular garment manufacturing company which is
having many ISO standards. Therefore they have very good management system to
maintain high quality garments and control such a big amount of labors. Therefore it is also
a best place to acquire management training. They always work for a plan which has been
taken management of the company. 5S management technics is being used inside the
company in order to achieve their goals
3.1: Bill of Material (BOM):
A bill of Material (BOM) is a list of raw materials, sub-assemblies, intermediate
assemblies, sub-components, components, parts and the quantities of each needed to
manufacture an end product. A BOM can define products as they are designed (engineering
bill of material), as they are ordered (sales bill of materials). The different types of BOMs
depend on the business need and use for which they are intended.BOM are hierarchical in
nature with the top level representing the finished product which may be a sub-assembly or
a completed item.BOMs that describe the sub-assemblies are referred to as modular
BOMs.
A BOM can be displayed in the following formats:

A single-level BOM that displays the assembly or sub-assembly with only one level
of children. Thus it displays the components directly needed to make the assembly

No
1.
2.
3.
4.
5
6.
7

or sub-assembly.
An indented BOM that displays the highest-level item closet to the left margin and

components used in that item indented more to the right.

Modular (Planning) BOM
Table 3.1: Table of Bill of Materials
Component
Description
MS plate
6mm (thickness)
Anti-corrosive paint
Metal primer-Zinc Phosphate
Metal filler
Apology
Hex bolt
GI 6mm*15mm
Hex nut
GI 6mm
Three core wire
Plug top
13A

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Unit
nos
liters
grams
nos
nos
meters
nos

Quantity
01
03
50
08
08
03
01

3.2: Labor hours planning:

It is important to convert resources of produced good effectively (economically and
efficiently).productivity is a measure of this transformation. Increase in productivity is a
basic proposition for continuous economic growth in the modern word.
Among various kinds of productivity labor productivity is usually considered of the utmost
importance. In manufacturing industry a criterion called efficiency is often used.
Efficiency is the capacity of performing a given task within a specified standard time.
Raising the efficiency depends upon two factors:
I.

II.

Subjective factors
Workers qualities capability: Skills, Technical ability etc.
Workers quantitative capability: Working effort, Increase of working hours.
Objective factors
Factory automation, enhancing the work environments.

So for both productivity and efficiency of labor to be increased proper allocation of tasks
and targets is important.
No
01
02
03

Table 3.2: Table for calculate time consumption

Component/ Task
Quantity(nos) Time/ unit (min)

Time(min)

Total time
Approximate working days required of one laborer
3.3: 5S managing concepts:
5S is the name of a workplace organization method that uses a list of five Japanese words:
seiri, seiton, seiso, seiketsu, and shitsuke. Transliterated or translated into English, they all
start with the letter "S". The list describes how to organize a work space for efficiency and
effectiveness by identifying and storing the items used, maintaining the area and items, and
sustaining the new order. It is a better way to manage not only a company but also life.

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Fig 3.1: 5S concept

Sorting (Seiri):
Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and
so forth in the plant and work area. Keep only essential items and eliminate what is not
required, prioritizing things per requirements and keeping them
Straightening or setting in order (Seiton):
There should be a place for everything and everything should be in its place. The place for
each item should be clearly labeled or demarcated. Items should be arranged in a manner
that promotes efficient work flow, with equipment used most often being the most easily
accessible.
Sweeping or shining or cleanliness / systematic cleaning (Seiso):
Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of
each shift, clean the work area and be sure everything is restored to its place. This makes it
easy to know what goes where and ensures that everything is where it belongs.
Standardizing (Seiketsu):
Work practices should be consistent and standardized. All work stations for a particular job
should be identical. All employees doing the same job should be able to work in any
station with the same tools that are in the same location in every station
Sustaining the discipline or self-discipline (Shitsuke):
Maintain and review standards. Once the previous 4 S's have been established, they
become the new way to operate. Maintain focus on this new way and do not allow a
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`
gradual decline back to the old ways. While thinking about the new way, also be thinking
about yet better ways.

Fig 3.2: Brandix workshop arranged using 5S

Brandix innovation center is a place where lots of technical innovations are done therefore
inside the workshop.

Fig 3.3: Safety equipment

Some guidelines for safety have been mentioned below

Use the technical methods in the works.

Safety shoes, gloves, goggles, have to be worn when necessary.

Keeping the workshops clean in an orderly manner.

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Maintaining a well-equipped First aid box at workshop.

Provide a better working environment to the workers.

Provide warnings, notices and special instructions wherever necessary.

Use necessary equipment when it is required.

When considering about fire safety In Brandix casualwear there is a very sensitive fire
alarm system when any fire is occurred. When the alarms are ringed everyone has to run to
their positions. There are some firemen to check if all the workers come to safe places.
Most of the time they do trials to train the employs for the real situation.

Fig 3.4: Fire exhauster chart

3.4: The Human Resources Management (HRM):

The Human Resources Management (HRM) function includes a variety of activities, and
key among them is deciding what staffing they need or hire employees to fill these needs,
recruiting and training the best employees, ensuring they are high performers, dealing with
performance issues, and ensuring your personnel and management practices conform to
various regulations. Activities also include managing the approach to employee benefits
and compensation, employee records and personnel policies.
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`
They should always ensure that employees are aware of personnel policies which conform
to current regulations. Human Resource Management is a planned approach to managing
people effectively for performance. HRM planning is the process by which managers
ensure that they have the right number and right kinds of people in the right places, and at
the right times, who are capable of effectively and efficiently performing assigned tasks.
From this we can get long time benefits. Human resource planning must be integrated
within the organizations strategic plans.

3.4: Training & development

Brandix is Sri Lankas largest apparel exporter employing over 40,000 Associates directly,
while generating indirect employment to an equivalent number. The Group is supported by
over 38 integrated manufacturing facilities in Sri Lanka, India and Bangladesh.. So they
have understood the importance of acquiring a talent pool with the desired skill sets to
keep us at the forefront of their industry. In the fast changing industry of apparel, expertise
and aptitudes must necessarily be in a state of flux to stay at the cutting edge. To this end,
Brandix Training and Development constantly develops its broad purview of skills and
talent development programs at various levels. Most training is directed at upgrading and
improving an employees abilities or skills.
Developmental program is a process designed to develop skills necessary for future work
activities. Newly joined staff must be told the length of their probationary period, which
varies with the requirements of each grade. If there are indications that staff is not suitable
for confirmation, they must be counseled and then warned in writing if the problem
persists. Confirmation is the step whereby a member of staff on probation is found suitable
for the job and employed on permanent and personable terms.

3.5: Water management:

Water

purification

process

of

undesirable
biological

is

the

removing
chemicals,
contaminants,

suspended solids and gases

from
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contaminated

water.

`
There is a water management plant which supply water for each and every tasks for the
factory. Three tube wells are being used to supply water. There is a specified team to serve
water managing. Tube well provided water they purify using standard method of
chlorination.
They send chemical added water for filtering through a bended pipe system which can
decrease head of the water. It is done to minimize the water pressure for better filtering.
After filtering the water it sends to a tank. They have installed firing treatment line also to
Fig 3.5: Water supply system in Brandix, Ekala

the plant. In this water supply plant they

have used continuously timed chemical

adding units to add chlorine and other chemical, pressure meters to detect pressures in
some important places, submersible water pumps to pump tube well water to the plant.
Every one of Brandix associates has grasped a sense of ownership of their comprehensive
policy on waste management. Inclusive systems continuously monitor and improve
compliance with the Group's numerous certifications and standards. They have a very good
waste water management system. Industrial Wastewater is characterized by its large
volume, high temperature, high concentration of biodegradable organic matter and
suspended solids, high alkalinity or acidity and by variations of flow.

Characteristics of wastewaters are measured in terms of Chemical Oxygen Demand

(COD),

Biochemical

Oxygen

Demand

(BOD)

and

volatile

suspended

solids

(VSS).Generally, pollutants take long time, may be thousands years, to be degraded

naturally. Hence, those must be treated synthetically. Therefore, Industrial Wastewater
treatment is an essential process. With the rising cost of land treatment, depletion of
space, and concern over contamination of ground water, advanced technologies will have
to take on a more significant role in treating industrial wastewater.

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Chapter 04:

Fig 3.6: Waste water management in Brandix

Summary and

Conclusion :
4.1: Summary:
I selected Brandix Casualwear LTD, Ekala as my training institute, since Brandix is a
well-known garment manufacturing company which has South Asias largest apparel
group. Also Ekala factory has a Maintenance department and the innovation center.
During the training period of three months I was able to get experience about some
fabricating methods including: Lathe machine, Milling machine, Different types of saws,
and welding, grinding also.
This exposure helped in understanding how a machine should be operated and maintained
and how to choose the proper way of doing a task using a machine together with the
knowledge of different types of tools required.
Also at the work shop I experienced the way of handling the technicians and other workers,
how they allocate other resources like materials and machines by managing the optimum
minimum cost. Arrangement of machines and stores in the shop floor also was an
important issue at the work shop.
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4.2: Conclusion:
As a mechanical and Manufacturing Engineering undergraduate of Faculty of Engineering,
for the three months of industrial training I selected Brandix Casualwear LTD, Ekala as
my training place. I selected this particular company as it consists of a work shop and it
gives knowledge n industrial automation including pneumatics, electro pneumatics, PLC
(Programmable Logic Controller) etc.
Brandix Casualwear LTD has its design center and the work shop at Ekala. During my
training period of three months, I could work at the work shop where fabrication works
took place of the automated systems. So I could experience the work shop activities which
I believe to be an essential requirement for a Mechanical and Manufacturing Engineer,
when working in the field.
So it is a pleasure to mention that I could gather a lot of information to my knowledge of
which I presented a brief description in this report during a period of three months at
Brandix Casualwear LTD with the appreciable assistance of engineering professionals and
other staff of both work shop and head office.

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Contents
Chapter 01: Introduction about establishment:......................................................................1
1.1: About Brandix casualwear:........................................................................................1
1.2: Achievements of the company:...................................................................................2
1.3: Innovation Center at Brandix Casualware:................................................................3
Chapter 02: Technical experiences obtained during training.................................................4
2.1: Experiences obtained related to workshop activities:.................................................4
2.1.1: Activities carried out: Welding.............................................................................4
2.1.2: Activities carried out: Drilling and tapping..........................................................7
2.1.3: Activities carried out: Grinding and finishing....................................................10
2.1.4: Activities carried out: Lathe machine................................................................13
2.1.5: Activities carried out: Milling machine.............................................................14
2.2: Experiences obtained in automation field:................................................................18
2.2.1: Pneumatics:........................................................................................................18
2.2.2: Components used in industrial automation:.......................................................27
Mechanical timers:...............................................................................................................35
Electromechanical timers:....................................................................................................35
Electronic timers:.................................................................................................................35
2.3: Air Conditioning and Ventilation System installed...................................................38
2.3.1: Package Air Conditioning..................................................................................39
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`
2.4: Introduction about projects done:..............................................................................42
2.4.1: Mini loop cutter machine:..................................................................................42
2.4.2: Garment Surface Grinder...................................................................................45
Chapter 03: Management experience obtained during training:..........................................47
3.1: Bill of Material (BOM):............................................................................................47
3.2: Labor hours planning:...............................................................................................48
Approximate working days required of one laborer............................................................49
3.3: 5S managing concepts:..............................................................................................49
3.4: The Human Resources Management (HRM):...........................................................52
3.4: Training & development...........................................................................................53
3.5: Water management:...................................................................................................53
Chapter 04: Summary and Conclusion :..............................................................................55
4.1: Summary:..................................................................................................................55
4.2: Conclusion:................................................................................................................56

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