Industrial Attachment On Aboni Textiles Ltd.

Department of Textile Engineering
Faculty of Engineering
Course Title: Industrial Attachment
Course Code: TE 410
A report on Aboni Textiles Ltd.

(A Concern of Babylon Group)
Submitted by:
Name
ID
Md. Tariqur Rahman

Moshfiqur Rahman
131-23-3333
131-23-3437
Supervised by:
Dr. Engr. Md. Saifur Rahman
Professor
Department Of Textile Engineering
(A report submitted in partial fulfillment of the requirements for the degree of Bachelor
of Science in Textile Engineering)
Semester- Fall Year- 2016

Daffodil International University
Letter of Approval
The internship report on Aboni Textiles Ltd. is prepared by Md. Tariqur Rahman of
bearing ID: 131-23-3333 and Mushfiqur Rahman of bearing ID: 131-23-3437. This report
is submitted in partial fulfillment of the requirements for the degree of BACHELOR OF
SCIENCE IN TEXTILE ENGINEERING. The whole report is prepared under my
supervision and guidelines. During the internship the student was found sincere, punctual and
hard working. I wish him every success in life.
Dr. Engr. Md.Saifur Rahman

Professor
Department of Textile Engineering
Faculty of Engineering
Page i
Declaration
We hereby declare that, this internship has been done by us under the supervision of
Professor Dr. Engr. Md. Saifur Rahman, Professor, Department of Textile Engineering,
Faculty of Engineering, Daffodil international University. We also declare that, neither this
report nor any part of this has been submitted elsewhere for award of any degree or diploma.
Md. Tariqur Rahman

ID: 131 -23-3333
Department of TE
Mushfiqur Rahman
ID: 131 -23-3437
Department of TE
Page | ii
Dedication
At first we have to thank almighty ALLAH to make us enable to finish our study and also
give us the opportunity to reach a healthy destination of our life.
We pray to ALLAH, gives us forgiveness and helps us to fight through the complexity of
our lives with right path.
We dedicate this report to our honorable and respectable PARENTS.
Page | iii
Acknowledgement
All pleasure goes to the Almighty Allah to give us strength and ability to complete our two
months long industrial attachment at Aboni Textiles Ltd. It was a great opportunity for us to
complete the industrial attachment with the assistance of persons employed in Industry name.
We feel grateful to our academic supervisor Dr. Engr. Md. Saifur Rahman, Professor,
Department of Textile Engineering, Faculty of Engineering, Daffodil international University
as well as to Name of your industry supervisor, our factory supervisor for their continuously
guiding us about the development and preparation of this training report. They have enriched
us with sharing necessary theoretical and practical ideas and supervised us to complete this
report on time.
We would like to express our thanks to Prof. Dr. Md. Mahbubul Haque, Head, Department
of Textile Engineering, Faculty of Engineering, and Daffodil international University for his
kind help to finish our training report. We would like to express our thanks to Prof. Dr. Md.
Zulhash Uddin, Dean, BUTex for providing us necessary information to complete the
report.
We are also grateful to the supervisors, technicians, operators and all other staffs of Aboni
Textiles Ltd. , who were most cordial and helpful to us during the tenure of internship.
Finally, we would like to express a sense of gratitude to our beloved parents and friends for
their mental support, strength and assistance throughout writing the training report.
Page | iv
Executive Summary
This report is about Aboni Textiles Ltd.. By achieving practical knowledge from the
industrial attachment is possible to apply the theoretical knowledge in the technical field. For
any technical education practical experience is almost equally necessary in association with
the theoretical knowledge. The industrial attachment is the most effective process of
achieving the practical experiences. It provides us sufficient practical knowledge about
production management, productivity, and evaluation, industrial management, planning and
controlling utilities and maintenance of machineries and their operation techniques. Aboni
Textiles Ltd. is a modern textile industry based on knit garments production. Our approach
was to know and work with all parameters of each section and practice with technical
persons. As our academic advance study was in Textile Wet Processing. Our emphasis was in
understanding and learning oif Fabric, Fiber and Dyeing. Industrial Attachment is an essential
part of 4 years B. Sc in Textile Engineering course of Daffodil International University. We
had the opportunity to perform the Industrial Attachment with Aboni Textiles Ltd. during 2
months long. We studied about Man, Machine, Material and Planning, Grey Fabric
Inspection, Finished Fabric Inspection. According to our studies in the whole chain of factory
we have prepared the following report and like to present our internship report B. Sc in
Textile Engineering is combination of the theoretical knowledge and practical experiences.
The main objective of this training is to comprehend our theoretical knowledge with the
practical knowledge. It is enable us to orient ourselves with the practical environment which
is our place of future work.
Page | v
Table of Contents
Chapters
Contents
Letter of approval
Declaration
Dedication
Acknowledgement
Executive Summery
Table of contents
Chapter-1
Information about Factory
Chapter-2
Details of Attachment
Page No.
i
ii
iii
iv
v
vi
1-06
Knitting section
7-18
Dyeing laboratory section
19-27
Batching section
28-30
Dyeing section
31-40
Finishing section
41-46
Q.C. Section
45-49
Utilities
48-51
Effluent Treatment Plant
52-57
Maintenance
58-61
Chapter-3
Impact of Internship
62
Chapter-4
Conclusion
63
Page | vi
Chapter-1
Information about Factory
Babylon Group started its journey in 1986 with Babylon Garments Limited with a humble
setup. Relentless efforts and a constant persuasion of quality resulted in the groups
expansion to 18 different concerns. All the units function independently but operate under the
direct supervision of the group head quarter.
Babylon has strong footing in both knit and woven products. Several units of the group are
dedicated to produce finest quality products for buyers around the globe. The group is self
reliant and is involved in woven wear manufacturing, knit wear manufacturing, washing
plant, printing house, knitting unit, dyeing and finishing of knitted fabrics, embroidery, trims
manufacturing, paper converting and packaging, apparel trading etc. It also has fashion wear
retailing
outlets
to
satisfy
the
growing
local
demand.
The company currently employs over 11,500 skilled employees and had a turnover of about
$127.00 million in the year 2011. In all the different production with the workers have to go
through a process of continuous and rigorous training to maintain a high standard of
production set by the management. The group also caters this driving force by ensuring
facilities that exceed the minimum set by international regulators. It maintains medical and
day care services, scholarship programs and other benevolent initiatives for the employees
and their family members. As part of their commitment towards the society, the group has
established a medical service station open for all. Babylon distributes relief materials
including cash to the victims in any part of the country during natural adversities.
Buyers have been the soul partners of Babylon. Many of the brands that rule the global
fashion industry have relied on Babylon to manufacture their products. Some of the
prominent names include KOHLs, J C Penney, Tesco, Mothers Work, JONES, CHARMING
SHOPPES Inc., Walmart, Sears, Inditex, HAGGAR, K-MART, PVH, Arcadia Group PLC,
Dimensions, New Look, CELIO, JULES, MONOPRIX, H & M (Hennes & Mauritz), ZARA
and many more. With the growing number of renowned names to work with Babylon looks
forward to explore new frontiers with the promise of quality and excellence. The Aboni
Textiles Ltd. was established on April 2001.
Page 1
Address of Factory
Plot# 169-171
TETULJHORA UNION,
HEMAYETPUR, SAVAR, DHAKA
Address of Head office
2/B-1, DARUSSALAM ROAD,
MIRPUR-1, DHAKA, 1216
Page | 2
Organ gram
General Manager
Assistant General
Manager
Knitting
Dyeing
Knitting
Manager
Assistant
Manager
Dyeing Lab
Finishing
Jnr.
Manager
Jnr.
Manager
Q.C.
Deputy
Manager
Jnr.
Manager
Senior Officer
Junior Officer
Senior Supervisor
Supervisor
Operator
Helper
Page | 3
Site Location of Aboni Textiles Ltd.
Member of Certificates
1. ISO
2. BGMEA
3. WTO
Different Sections of the Company

1.
2.
3.
4.
5.
6.
7.
Babylon Garments Ltd.

Aboni Textiles Ltd.
Babylon Washing Ltd.
Aboni Knitwear Ltd.
Junipeer Embroideries Ltd.
Babylon Printing Ltd.
Babylon Trims and Accessories Ltd.
Page | 4
Different Buyers of the Company

1.
2.
3.
4.
5.
6.
7.
8.
TESCO
DAVID HOWARD
CELIO
HM
BELLA
OEKO TEX
TRENDZ
MANGO
Name of The Products Exported

1.
2.
3.
4.
5.
6.
7.
8.
9.
Shirt
Pant
T-Shirt
Polo Shirt
Ladies Pant
Tank-top
Casual Shirt
Denim Shirt
Denim Pant
Page | 5
Pictorial View of the Factory
Page | 6
Chapter-2
Details of Attachment
KNITTING SECTION
Introduction
ABONI TEXTILE LTD. Knitting section is self sufficient to produce the fabric for fulfill the
requirements of garments. Overall 73 machine stands in the section including 50 knitting m/c,
13 Flat knitting m/c and 3 inspection m/c. Three shifts working hour here and occupancy here
about 220. The capacity to produce fabric in this knitting section is about 3 tons per shift.
This knitting section has enough space both in height and width for a hygienic environment.
Knitting is the interlocking series of loops by one or more yarn with the help of sinker, needle
and cam. The lengthwise loops are called Course and widthwise loops are called Wales. The
VDQ mechanism determines the stitch length or loop length and GSM. GAUGE corresponds
to the number of needle per inch in knitting machine.
Section Layout
Page | 7
M/C Specification
Types And
Number Of m/c
Single
Jersey
m/c (20)
Rib
m/c (30)
Interlock
m/c (2)
Flat
Knitting
m/c (18)
Fabric
Inspection
m/c (3)
Name
PAI LUNG M/C
JIUNN LONG M/C
MAYER CIE
M/C
PAI LUNG M/C
FUKAHAMA M/C
JIUNN LONG M/C
Origin
Cylinder
Diameter
TAIWAN
23,
28,
38.
TAIWAN
26, 30,
34, 36,
40, 42
FUKAHAMA M/C
TAIWAN
32
18
KEVO HENG
TAIWAN
14
EUZU CLOTH
INSPECTION M/C
THAILAND
24,
32,
GAUGE
26,
34, 18, 22, 24, 26.
32,
38,
18, 22.
Types Of Yarn Used Used In Knittin
a.
b.
c.
d.
e.
f.
g.
h.
i.
100% Cotton Combed Yarn (32 Ne, 32/1, 30/1)

100% Cotton Carded Yarn (30/1, 26/s)
100% Organic Cotton (28/1, 34/s)
10% Grey Mlange Yarn (34/s, 26/1)
100% Cotton Slab Yarn (28 Ne)
CVC Carded Yarn (Ne 28)
Polyester 20% Cotton 80% (32/1)
Lycra (40,30 denier)
100% Organic GOTS.
Page | 8
Description Of Knitting
Yarn package set up in creel
Production wise needle, cam and sinker setting by maintenance
VDQ pulley setting for required stitch length and GSM
The yarn pass trough guide to tension bar to feeder through needle
Machine is now to start
Production of fabric is ready now
The fabric is collect by the take up roller

Fabric Inspection
Store
Different Brands Of Lycra

Only Chinese brand of Lycra used here.
Count varies from 25-40 deniers.
Sources Of Yarn Used

a. B.S.B.
b. OMAX
Page | 9
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
RSWM
Y/P
V-MAN
SQUARE
ON
ISRAQ
MATAM
AMAN
M.S.A.
HASSAIN DYEING
ACATI
PTHM
BADSHAH
p.
NAHAR
End Product
a.
b.
c.
d.
e.
f.
g.
h.
i.
Single Jersey
Rib
Pique
Stripe
Loop Back
Single Locoest
Double Locoest
Flat Knit
Fleece
Page | 10
Production Calculation
Machine No.-29
11 Rib (Color Stripe)
Given, Count= 30
We Know,
Ne Tex =590.5
So, Tex =
590.5
32
=18.453
CPI= 34
Gauge= 18
RPM= 16
Feeder= 84
M/C diameter= 42
Efficiency= 95%
Loop Length (mm)= 2.4
Now,
Production In Length/shift =
RPMNo.of Feeder608efficiency
168460895
3436100
CPI36
yards/shift
yards/shift
=500.71 yards/shift
Production in weight per shift =

RPMNo.of feeder3.1426Cylinder dia(inch)GaugeLoop length(mm)tex608efficiency
100010001000
168442182.418.45608.95
1000000000
kg/shift
= 20.519 kg/shift
For Rib fabric= Weight2

= 41.04 kg/shift
Page | 11
Production Parameters
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Cylinder RPM
M/C Gauge
No. of feeder
Stitch length
Yarn Count
M/C efficiency
CPI
Types of fabric production
Quality of Yarn
Worker skill
VDQ mechanism
Knitting Faults
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
Hole
Needle line
Missing yarn
Stain
Lycra missing
Crease mark
Softener spots
Bowing
Slab
Dirt stain
Drop stitch
Pin hole
Wrong Design
Grease spot
Page | 12
Quality Assurance System In Knitting

4-Points System
Size Of Defect
Penalty
3 inches or less
1 point
Over 3 but not over 6
2 points
3 points

Over 9 inches
4 points
Total point found 36 100

Actual roll length(yds) Actualwidth(inch)
=Points/100 sq Yards
Knitting Cost Of Different Fabric

Style= Single Jersey
GSM= 200
Grey fabric costing for 1 Kg = (cost of yarn+ knitting charge + carrying charge) per kg
Given,
1 Kg Cotton Combed Yarn= 265.2 Taka
Knitting charge= 12 Tk./Kg
Carrying cost= 5 Tk./Kg
So, Total cost of grey fabric per Kg = (265.2+12+5) Tk.
=282.2 Tk.
Page | 13
Pictorial View Of Knitting Section
Page | 14
Page | 15
Page | 16
Textile Dyeing Lab

Introduction
The dyeing lab can test and measure all the result of Fabric, Dyeing, Finishing, Washing and
Garments requirement. The lab is usually combined with dyeing and washing procedure with
workforce. The lab is separated in two parts; one is official and other part is working area.
The sample dyeing procedure works here not actual but the shade matching or initial dye
conc. measurement did here and the appropriate shade of color for the cotton or polyester
creating here. This lab includes different types of dyes, auxiliaries and chemicals which are
essential for complete the task. Different types of m/c are here like; Sample Dyeing m/c,
Washing m/c, Woven, pH shaker, Rubbing m/c, Data Color, Light box etc. Generally Data
Color gives the recipe by scanning with Spectrophotometer through Computer. Then sample
dyeing procedure done with required programmed. Then shade match with the Light box
visually or in Spectrophotometer; if mach then ok for sample dyeing in dyeing floor or if not
ok then manual arrange the color concentration or again sent to Data Color. The lab works
maintain Lab Head In charge.
Section Layout
Page | 17
M/C Specification
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
Manual twist Tester India

Yarn Appearance Tester India
Yarn Count Tester India
Rubbing m/c 1
Pilling Tester 1
Incubator 1
Tumble Dryer 1
Dryer Bangladesh -1
Washing m/c 3
Lab dyeing m/c (ECO DYER) 2
Rapid Lab dyeing m/c (ASIAN STAR) 2
Balancing m/c 1
Oven England 1
pH meter -2
pH shaker -1
Modern Pipette -2
Data Color
Verified Light Box
Different Light Source In Light Box

a.
b.
c.
d.
e.
D65
Tungsten Light
P15
TL83
UV
Page | 18
Description Of Dyeing Lab

Pantone Code or Swatch received
Place Swatch on Spectrophotometer and collect the dye concentration by Data Color
Cut the required scoured fabric in piece of 5 gm.
Mix the water and dye concentration and auxiliaries if need then immersed the fabric into the
little bath and close the top of the bath
Then programmed set for Polyester, Cotton or types of fabric or types of color like
Turquoise, Dark/Black or General Shade
For adding Salt, Soda Or Acid when required in which step of the programmed
Time and temperature fixed in programmed; after done the procedure sample out from the
m/c
Then hot wash, soap wash and rise done
Dry the sample
Then shade match visually with Light Box or by Spectrophotometer
If OK then approved
If NOT OK then Topping or re-procedure
Page | 19
Collection Of Lab Dip Samples
Page | 20
Different Tests Of Fabric
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Twist
Rubbing (Dry and Wet)
Color Fastness To Water
Perspiration (Acid Or Alkaline)
Phenol Yellowing Test
Dimensional Stability Test ( Length And Width)
Average pH
Color Fastness To Wash
Fabric Weight
Yarn Count Test
Yarn Twist Test
Yarn Appearance Test

m. Resistance to light
Pictorial View Of Dyeing Lab
Page | 21
Page | 22
Page | 23
Batching Section
Introduction
This section stands just beside the dyeing floor and consist of two air tuning m/c. In here no
fabric inspection is needed because of knitting section is also own of the company. So the
fabric received from the knitting section and lot wise and m/c capacity, order and color wise
separate the required fabric.
Batching Criteria
To prepare the batch of fabric for dyeing

a.
b.
c.
d.
e.
f.
g.
h.
Order Sheet (Received from Buyer)

Color Shade (white, light or Dark)
M/C Capacity
M/C available
Types of fabric (100% Cotton, CVC, PC etc.)
Emergency
Send the grey fabric with batch card
Keep records every previous dyeing
Batch Distribution and Management

Primarily batching is done by dyeing manager taking the above criteria under consideration.
Batch section in-charge receives the plan from dyeing manager. Sometimes planning is
adjusted according to m/c condition or emergency.
Page | 24
Pictorial View Of Batching Section
Page | 25
Dyeing
Introduction
In Dyeing section of this company is fully planned and well equipped of m/c for environment
friendly and suitable situation for workforce. The dyeing m/c is vertically integrated in two
columns and intersection with a way. The height of the dyeing floor is about two and half
floor with covered by insulator shed for reducing the temperature of the floor. Dyeing m/cs
are also covered by insulator, window of this floor is huge and m/c wise floor space is also
huge for being maintain the quality of the job environment. Some heat releasing system of
fan or pipe line also stands here. Three dyeing managers control the floor.
This section includes dyeing, finishing and quality control department. All the waste water of
dyeing and washing are treated in ETP of their own to save our environment and society.
Section Layout
Page | 26
M/C Specification
M/C Name
Origin
Capacity
No. of m/c
SCALVOS
Greece
180 Kg, 360 Kg, 540Kg,

50 Kg, 1 ton
LONGCLOSE
Korea\
400 Kg
DILMENLER
Turkey
600 Kg, 1000 Kg, 450 Kg,

15 Kg
BENERS
Turkey
25 Kg, 150 Kg, 750 Kg
Bangla m/c
Bangladesh
15 Kg, 30 Kg
Dyeing Cost Of Different Color

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
Chocolate - 111.91 Taka/kg

Olive 17-210 62.11 Taka/kg
Blue light 70.91 Taka/kg
Russet Brown 68.76 Taka/kg
Antelope 51.70 Taka/kg
Ecru (11-0602 TPX) 17.81 Taka/kg
LT Pink 39.45 Taka/kg
Khaki Green 42.88 Taka/kg
Heather Gretna 63.37 Taka/kg
Black 58.97 Taka/kg
White 10.70 Taka/kg
Turquoise 23.54 Taka/kg
Fig 70 Taka/kg
Fluorescent White 110.55 Taka/kg
Page | 27
Flowchart Of Different Dyeing Process

Fabric: Polyester Cotton Blend (S/J)
Color: Blue Light
Demineralization (Temp.-80C, Time-20 min)
Leveling Agent (Desired pH=4.25)

Disperse Dye add to the Solution (Temp.-135C, Time-)
Scouring with Bleaching Agent (Temp.-80C, Time-20 min)
Wash
Acetic Acid (55C, 5 min)
Peroxide Killer (55C, 10 min)
Enzyme Wash (55C, 45 min)
Leveling Agent (30 min)
Glabrous Salt (30 min)

Reactive Color Dosing (30 Min)
Soda Ash Dosing (45 min)
Acetic Acid (55 C, 10 min)
Detergent Wash
Softener
Page | 28
Fabric: Cotton (S/J)

Color: Black
Demineralization
(60 C, 10 min)
Scouring
(60 C, 30 min)
Hot Wash
(90 C, 5 min)
Acetic Acid
(55 C, 20 min)
Enzyme Wash
(55 C, 45 min)
Cross color ADM
(80 C, 5 min)
Glaubers Salt
(Dosing 30 min)
Color Dosing (30 min)
Soda Dosing (20 min)
Caustic Soda Flax (30 min)
Acetic Acid
Hot Wash 2 times (60 C, 10 min)
Fixer
Softener
Page | 29
Fabric: S/J
Color: White
Demineralization (105 C, 45 min)
\Scouring and Bleaching
Wash
Acetic Acid Wash
Softener
Total Production
For the Month of October 2016
Production Date- 18/10/2016
Total production required = 1, 40,019 Ton
Average Production per day =8,574 ton
Today = 11,994 ton
Page | 30
Recipe Sheet Of different dyeing process
Page | 31
Page | 32
Page | 33
Page | 34
Production Parameters
a.
b.
c.
d.
e.
f.
g.
h.
Reel speed
Types of Fabric
Types of dying process
M/C fitness
Fabric load capacity
Types of dyes and chemical used
Operator efficiency
Lab fastness
Dyeing Faults
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Machine fitness problem

Maintenance
Operating
Tangle
Shade variation
Uneven dyeing
Soda spot
Color spot
Yellow spot
Red contamination
Slabs
Page | 35
Pictorial view of dyeing Section
Page | 36
Page | 37
Finishing Section
Introduction
In Finishing section of this company is fully planned and well equipped of m/c for
environment friendly and suitable situation for workforce. The Finishing m/c are vertically
integrated in two columns and intersection with a way. The height of the dyeing floor is about
two and half floor with covered by insulator shed for reducing the temperature of the floor. D
Finishing m/c are also covered by insulator, window of this floor is huge and m/c wise floor
space is also huge for being maintain the quality of the job environment. Some heat releasing
system of fan or pipe line also stands here. Three Finishing managers control the floor.
This section includes dyeing, finishing and quality control department. All the waste water of
dyeing and washing are treated in ETP of their own to save our environment and society.
Machine Specification
a.
b.
c.
d.
e.
f.
g.
CORINO Slitting m/c -2

SANTEX Dewatering Machine
SANTEX Dryer (Two chamber)
SANTEX Dyer (Three chamber)
SANTEX Tube Compactor
STENTER
SANTEX Open Compactor
Machine Arrangement In Finishing Section
For Tube Fabric

Dewatering m/c
Dryer
Tube Compactor
Page | 38
For Open Fabric

Slitting m/c
Stenter m/c
Open Compactor m/c
Description Of Finishing
All the process of finishing open or tube fabrics are maintaining the quality of the fabric.
Some very important properties of fabric controlled in this section are
a.
b.
c.
d.
e.
Diameter control
Shrink control
Shade control
GSM control
Spirality/ Twist control
Without White colored fabric others all color of fabric softener added in dewatering m/c for
tube fabric and in Stenter m/c for open fabric in this section and all the machining process
control the above system of the fabric.
Pictorial View of Finishing Section

Page | 39
Page | 40
Page | 41
Page | 42
Quality Control
Introduction
In Q.C. section of this company is fully planned and well equipped of m/c for environment
friendly and suitable situation for workforce. The Q.C. m/c are well integrated. The height of
the dyeing floor is about two and half floor with covered by insulator shed for reducing the
temperature of the floor. Window of this floor is huge and m/c wise floor space is also huge
for being maintain the quality of the job environment. Q.C. manager control the floor.
This section includes quality control department and finished goods.
M/C Specification
1. Fabric Inspection m/c 5
2. Washing m/c -3
3. Light box -1
Different Test Required In This Section

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Washing fastness
Rubbing fastness
Dimensional stability
Perspiration test
pH test
Pilling test
GSM
Twist measurement
Diameter
Shrinkage test
Shade check
Final Inspection
a.
b.
c.
d.
e.
Yellow spot
Grease spot
Stripe
Contamination
Crease mark
Page | 43
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
s.
t.
u.
v.
Thick and Thin Yarn

Knitting Hole
Back sewing hole
Red Contamination
Yellow contamination
Oil spot
Print problem
Needle line
Needle drop
Slab
Uneven Dyeing
Compactor problem
More twist
More shrink
Less or more dia
GSM failure
Shade failure
Quality Assurance System

4-Points System
Size Of Defect
Penalty
3 inches or less
1 point
2 points
3 points

Over 9 inches
4 points
Total point found 36 100

Actual roll length(yds) Actualwidth(inch)
=Points/100 sq Yards
Page | 44
If the produced fabric follows the 4 point method and passed the testing
result to fulfill the buyer requirement then the fabric is approved for
finished goods.
Pictorial View Of Q.C.
Page | 45
Page | 46
Utilities Section
This section is included or divided into three parts, which are-
1.
2.
3.
4.
Water Treatment Plant

Generator
Air Compressor
Boiler
Water Treatment Plant

Water Plant
Normal Filter Tank
Resin Filter Tank
Supply
Resin = Remove iron and heavy particles from water.
Salt = Clean the resin (using 980 Kg salt per 12 hours)
Total Water Production per Shift or 12 hours
= 552 m3 + 708 m3
= 1260 m3
= 12601000 L
=1260000 L
No. of Water Plant = 3
No. of Pump = 6
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Generator
No. Of Gas Engine Generator = 2
Model a. G3516
b. G3517
Capacity = 1 MW/engine
Total = 2 MW
No. OF Diesel Engine Generator =1
Model = MDEC1250
Capacity = 1 MW
No. Of small Engine Generator = 2
Capacity = 150 MW/engine
Total = 300 MW
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Boiler
No. of Boiler = 2
Brand Name = COCHRAN
Origin = Scotland
Capacity =
1. 5 ton/hour
2. \7.5 ton/hour
Total Production of steam
= (5+7.5) ton/hour
= 12.5 ton/hour
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Air Compressor
No. of air compressor = 5

No. of air dryer = 5
Origin = Belgium
Page | 52
Effluent Treatment Plant

Introduction
In this factory ETP treated the waste water of dyeing and washing plant. The ETP section is
situated at side by side of knitting section and also attached with the garments section. Its
height is almost three stored building. This section includes ETP lab, electrical and
mechanical works and also does the task of maintenance task. This section is able to purify
the waste water from dyeing and washing.
A major source of liquid discharge is a River little far from factory.
Process Sequence
Collection Tank
(Dyeing and Washing water)
Equalization tank
(Adding HCL to maintain pH)
Biological tank
(Feeding Bacteria)
Secondary Clarifier
(Store dirt and dust)
Electro Coagulation tank
Electro Skip
(440 Volt and Heat, Broke water particle to collect dust 94%)
Flash mixer
(Polyelectrolyte anionic)
HRSCC tank
Sludge thickener
(Excess dust with water)
Sand Filter
(For water)
Press filter
(For dust)
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Characteristics of waste water

1.
2.
3.
4.
5.
6.
7.
8.
9.
Colorful water
Odor of water
pH range is high or low
Water includes Salt
Water includes Soda
Water includes Acid
Water includes Softener
Water includes Fibrous dust
Water includes hazardous chemical
Chemicals Used In ETP And Their Function

1. HCL: To control pH
2.
3.
4.
5.
6.
7.
Blower: Mixing all color in one color and reduce the temperature.
Bacteria: Destroy color 30-40%, DO increase, Chemical concentration reduce.
Electro Skip: Individualize the water and dust particle.
Polyelectrolyte: Combine dust particle each other.
Dust tank: Collect only dust in a filter box.
Sand filter: Purify the treated water finally for environment.
Final Treated Quality of Water

a.
b.
c.
d.
e.
f.
g.
Colorless
Odorless
Maintained pH about 6.5 to 7.5
Removing or neutral the water from chemical
No hazard create in nature
Environment friendly.
100% purified water
Total Capacity of purifying water = 20, 00, 000 Liter/Day
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MAINTANANCE
Introduction
Machine, Building and other facilities are subjected to deterioration due to their use and
exposure to environmental condition process of deterioration, if unchecked culminates in
rendering these service facilities unserviceable and bring them to standstill. In Industry has no
choice out to attend them from time to repair and recondition them so as to elongate their life
to the extent it is economically and physically possible to do so.
Types Of Maintenance
Maintenance
Preventive Maintenance
Electrical
Mechanical
Breakdown Maintenance
Electrical
Mechanical
Page | 58
Maintenance Tools And Their Function

1. Combination tools / spanner
2.
Function: Tightening and loosing of nuts and bolts.
3. Socket ratchet set
Function: Tightening of nuts and bolts.
4. Slide range
5. Monkey pliers
6. Pipe threat cutting tools
Function: To cut the threat in pipe.
7. Bearing puller
Function: To assist the bearing from shaft.
8. Pipe range
Function: Tightening and loosing the pipe joints.
9. Pipe cutting tools
Function: For pipe cutting
10. Hole punch
Function: punching the hole
11. Divider
Function: For circle making for wood and pipe.
12. Easy opener
Function: To open the broken head bolt
13. External threat die
Function: For External threat cutting
14. Heavy scissors
Function: Cutting of gasket and steel sheet.
15. Pipe threat cutting tools
Function: To cut the threat in pipe.
16. Drill machine and drill bit
Function: For drilling
17. Grease gun
Function: For greasing of moving parts of the machine.
18. Grinding machine
Function: For grinding and cutting of machine
19. Welding machine
Function: For welding and cutting
20. Spirit leveler
Function: For perfect Leveling.
21. File
Function: For smoothing the surface.
22. Hammer
Function: For scaling and right angling
23. Circle tools
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Function: Circle opening and closing

24. Hacksaw blade
Function: For metal cutting
25. Handsaw
Function: For wood cutting
26. Grinding stone
Function: For smooth finishing
27. Grinding paste
Function: For easy cutting of metal.
Pictorial View Of Maintenance Tools
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Chapter-3
Impact Of Internship
Knitting Section
We know about yarn, Machine set up for individual fabric production.
We know about Knit fabric manufacturing and their fault.
Batching Section
We know about batching criteria and management.
Dyeing Lab
We know about recipe formulation.
We know about shade matching.
We know about different kind of test procedure.
We have known about Lab Dip.
Dyeing Section
We have known about sample dyeing procedure.
We have known about bulk dyeing method for different fabric and different color.
We have known about overall procedure for dyeing method.
Finishing Section
We have known about different machine mechanism.
We have known about the problem of fabric can be control.
We have known about how finish a good quality of fabric which fulfill the buyers
requirement.
Q.C. Section
We have known about the final inspection of the finished fabric.
We have known about the fabric quality.
We have known about the store the finished fabric
ETP
We know why ETP use in industry.
We know procedure of ETP.
How we benefit from ETP.
Functions of ETP.
Compliance
To know about their compliance system
We know about medical facilities
Page | 62
Chapter-4
Conclusion
After all we want to say that Aboni Textile was really a very nice and helpful textile industry.
We have learned many things about knitting, dyeing, finishing and quality control. The
operators were very friendly and helpful. We have learned how to operate the machine and
total working procedure from them. We were very responsible about factorys rules and
regulation. We always obeyed their instruction during the attachment period. We entered into
the factory within just time and came out in just time. We learned details theoretically about
textile in classroom but practically we applied our knowledge during attachment period. We
think this knowledge will help us in our future period to meet with different people and lead
the operator.
Page | 63

Industrial Attachment On Aboni Textiles Ltd.

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Industrial Attachment On Aboni Textiles Ltd.

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Department of Textile Engineering

A report on Aboni Textiles Ltd.

Md. Tariqur Rahman

of Science in Textile Engineering)

Semester- Fall Year- 2016

Dr. Engr. Md.Saifur Rahman

Md. Tariqur Rahman

Information about Factory

Dyeing laboratory section

Effluent Treatment Plant

Site Location of Aboni Textiles Ltd.

Different Sections of the Company

Babylon Garments Ltd.

Different Buyers of the Company

Name of The Products Exported

Pictorial View of the Factory

Types Of Yarn Used Used In Knittin

100% Cotton Combed Yarn (32 Ne, 32/1, 30/1)

Production wise needle, cam and sinker setting by maintenance

VDQ pulley setting for required stitch length and GSM

Machine is now to start

Production of fabric is ready now

The fabric is collect by the take up roller

Different Brands Of Lycra

Sources Of Yarn Used

Production in weight per shift =

For Rib fabric= Weight2

Quality Assurance System In Knitting

Over 3 but not over 6

Over 6 but not over 9

Total point found 36 100

Knitting Cost Of Different Fabric

Pictorial View Of Knitting Section

Textile Dyeing Lab

Manual twist Tester India

Different Light Source In Light Box

Description Of Dyeing Lab

If NOT OK then Topping or re-procedure

Collection Of Lab Dip Samples

Different Tests Of Fabric

Yarn Appearance Test

Pictorial View Of Dyeing Lab

To prepare the batch of fabric for dyeing

Order Sheet (Received from Buyer)

Batch Distribution and Management

Pictorial View Of Batching Section

180 Kg, 360 Kg, 540Kg,

600 Kg, 1000 Kg, 450 Kg,

25 Kg, 150 Kg, 750 Kg

Dyeing Cost Of Different Color

Chocolate - 111.91 Taka/kg

Flowchart Of Different Dyeing Process

Demineralization (Temp.-80C, Time-20 min)

Leveling Agent (Desired pH=4.25)

Peroxide Killer (55C, 10 min)

Enzyme Wash (55C, 45 min)

Leveling Agent (30 min)

Glabrous Salt (30 min)

Fabric: Cotton (S/J)

Soda Dosing (20 min)

Caustic Soda Flax (30 min)

Hot Wash 2 times (60 C, 10 min)

\Scouring and Bleaching

Acetic Acid Wash

Recipe Sheet Of different dyeing process

Machine fitness problem

Pictorial view of dyeing Section