AN Industrial Visiting REPORT

ON

AMA SYNTEX LTD.

Prepared For :
MR. Sudipta Bain

Course Teacher

Department of Fashion Design and Technology

Uttara University

Prepared By :
MD. Rafeuzzaman

ID : 2201401055

Batch : 23rd

Semester : 6th

January 11th, 2022

Department of Fashion Design and Technology Uttara University

Uttara ,Dhaka
 LETTER OF TRANSMITTAL

January11th, 2022
MR. Sudipta Bain
Course Teacher
Department of Fashion Design and Technology
Uttara University

Subject : INDUSTRIAL VISITING REPORT ON AMA SYNTEX LTD.

Dear sir,

I am pleased to submit above subject report as asked by you. I have tried my best to make this report a
resourceful one.

If you need any clarification then please let me know.

Thanking You,
Sincerely,

MD : Rafeuzzaman
ID : 2201401055
Batch : 23rd
Semester : 6th
 ACKNOWLEDGEMENTS

At first, I would like to express my deepest gratitude to Almighty Allah for giving me the strength to
Complete the task within the schedule time.

I would like to offer my deep gratitude, compliments and heartfelt thanks to respectable teacher
MR.Sudipta Bain ,Assistant Professor & Coordinator , Department of Fashion Design and Technology ,
Uttara University , whose constant supervision and guidance enabled me to prepare this report. I am
indebted to him for his excellent support and guidance throughout the study.

My gratitude also goes to Mr.Akter Hossain , Assistant General Manager, Design and Merchandising
department , Ama Syntex Ltd ,for providing necessary help and guidance. I would like to also thanks the
management of Ama Syntex Ltd for giving me the factory visiting opportunity and providing me all kinds of
necessary support and guideline

I am ever grateful to all of my friends of Fashion Design Department of Uttara University , who helped and
guided me to complete this internship report.

Finally, a silent stream of gratitude is for my most adorned parents whose blessing is always with me in this
world.
 DECLARATION

I hereby declare that the work presented in the industrial visiting report has carried out by me and has not
been previously submitted to any other University / College / Organization for an academic qualification /
certificate / diploma or degree.

I further undertake to indemnify the University against any loss or damage arising from breach of the
foregoing obligation.

MD: Rafeuzzaman

ID: 2201401055

Batch: 23rd

Semester:6th

Department of Fashion Design and Technology

 EXECUTIVE SUMMARY

The Industrial Visiting is the most effective way for apparel merchandising student to achieve the
knowledge about the practical field of the garments manufacturing and merchandising. It brings an
opportunity to all the learners to enrich their academic knowledge by practicing with the experts of the
practical field of textile. It is my pleasure that I had an opportunity to visit at AMA Syntex Ltd , having all
state of the art facilities with incredible annual turnover last year.

Ama Syntax Ltd is 100 % export oriented garments factory in Bangladesh . This organization increasingly
reducing its rejection and rework rate in-process and final garments in order to ensure product quality and
delivery time as per buyer requirement and increase profitability. Ama Syntex Ltd will ensure sufficient
training and suitable work to increase productivity and skills of the employee. They have different types of
Knitting, Dyeing ,Cutting, Sewing, and Finishing machines supplied by mostly from China, Taiwan, Italy
,Spain, Belgium, UK, USA, France, Norway etc. All the chemicals and dyes used for dyeing and finishing
are well branded.

During the time of visiting a schedule of different sections is given by Mr. Konok (Manger ) of knitting and
dyeing division. The authority allowed me to gather practical knowledge from following section knitting
dyeing ,cutting ,sewing ,printing, finishing department .I am also allowed by the authority to observe WTP,
ETP & maintenance department of Ama Syntex Ltd .
 TABLE OF CONTENTS

Page

LETTER OF TRANSMITTAL..........................................................................................................................
DECLARATION ..............................................................................................................................................
ACKNOWLEDGEMENT ................................................................................................................................
EXECUTIVE SUMMARY ..............................................................................................................................

INTRDUCTION TO THE ORGINAZATION ........................................................................................... .....1

1.1 History of Ama Syntex Ltd. ............ ...................................................................................................... ...1

1.2 Vision and Mission of the Company .......................................................................................... ..............1
1.3 General Information of Ama Syntex Ltd...................................................................................... ..............2
1.4 Organization Structure................................................................................... .............................................3
1.5 Different Section of Ama Syntex Ltd ........................................................................ ..............................3
1.6 Organogram of Garments Section................................................. ...... .......................................................4
1.7 Buyer .......................................................................................................................................................... 5
1.8 Products........................................................................................................................................................5
1.9 Certifications................................................................................................................................................6
1.10 Social Compliance.................................................................................................................................... .6

KNITTING SECTION.......................................................................................................................................7

2.1 Organogram of Knitting Section..................................................................................................................7

2.2 Types of Knitted Fabrics..............................................................................................................................8
2.3 Knitted Fabrics Produced in Ama Syntex Ltd.............................................................................................9
2.4 Production parameters for knit fabric .........................................................................................................9
2.5 Process Flow Chart of Knitting............................................................... .................................................10
2.6 Classification of Knitting Machine............................................................................................................10
2.7 Parts of knitting Machine and Functions....................................................................................................13
2.8 Knitting Machine Profile ...........................................................................................................................15
2.9 Yarn count selection ..................................................................................................................................16
2.10 Different Types Knitted Fabric................................................................................................................18
2.11 Knit Fabric Faults....................................................................................................................................19

BATCH SECTION .........................................................................................................................................20

3.1 Batching.....................................................................................................................................................20
3.2 Objectives of Batching..............................................................................................................................20
3.3 Process sequence of Batch preparation....................................................................................................21
3.4 M/Cs in Batch Section..............................................................................................................................22

LAB SECTION .............................................................................................................................................23

4.1 Lab Dip.....................................................................................................................................................23

4.2 Organogram of Lab Section.....................................................................................................................23
4.3 Duties & Responsibilities of Production Manager...................................................................................24
4.4 Order Flow Chart of Lab Dip ..................................................................................................................24
4.5 Lab Dip Making Procedure.......................................................................................................................24
4.6 Flow chart of Lab Dip Submission............................................................................................................25
4.7 Stock Solution Preparation........................................................................................................................25
4.8 Selection of Stock Solution for Lab Recipe..............................................................................................25
4.9 Types of Test in Laboratory.......................................................................................................................25
4.10 Physical Test ...........................................................................................................................................26
4.11 Chemical Test...........................................................................................................................................26
4.12 Machine Used in Lab Section..................................................................................................................26

DYEING SECTION.......................................................................................................................................27

5.1 Organogram of Dyeing Section.................................................................................................................27

5.2 Process Flow Chart of Dyeing...................................................................................................................28
5.3 List of Machineries in Dyeing Section ......................................................................................................28
5.4 Raw Material for Dyeing............................................................................................................................29
5.5 Flow Chart of 100% Cotton Dyeing .........................................................................................................29
5.6 Flow Chart of 100% Polyester Dying .......................................................................................................30
5.7 Flow Chart of CVC Dyeing ......................................................................................................................35
5.8 Dyeing Faults.............................................................................................................................................36

DYEING FINISHING SECTION...................................................................................................................37

6.1 Process Flow Chart of Finishing................................................................................................................37
6.2 Objective of Finishing................................................................................................................................38
6.3 Finishing Effects........................................................................................................................................38
6.4 Finishing Machinery.......................................................................................................................... .......38
6.5 Function of the Slitting Machine...............................................................................................................38
6.6 Function of Squeezing/Dewatering Machine.............................................................................................39
6.7 Function of Stenter M/C.............................................................................................................................40
6.8 Functions of Compactor M/C.....................................................................................................................40
Conclusion ........................................ ................. ...........................................................................................42
1. INTRODUCTION TO THE ORGANIZATION

Ama Syntex Ltd started its journey in 2004 with stepped into the garment sector with its first Knit garment
named Ama Syntex Ltd. Now Ama Syntex Ltd has become one of the leading knit garments manufacturing
company. Ama Syntex Ltd is one of the most successful Garments manufacturers in Bangladesh; a country
with great potential in the field of garment manufacturing. Ama Syntex Ltd has acquired a versatile
production chain to cater flexible orders in shorter lead-time.

1.1 History of Ama Syntex Ltd

Ama Syntex Ltd. is a fully compliant Knit fabrics and garments manufacturing and exporting firm located in
South Jarun, Kashimpur, Gazipur-1712, Bangladesh. The product range includes basic and fashion T-shirt,
Polo shirt, Sweat-shirt, Jacket, All types of Fleece item (Polar Fleece, Micro-Fleece), Legging, Sports-wear,
Blanket, Soft Shell, ladies & kids-wear.

The factory is housed in appropriately designed buildings certified to be suitably used as garments
manufacturing unit. The building is equipped with necessary structural and fire safety measures required to
grow a healthy and fulfilling garments manufacturing environment.

1.2 Vision & Mission of the Company

Vision
The vision of Ama Syntex Ltd is to consistently challenge the standard, in producing top quality apparels
with complete satisfaction of our valued customers by. Adapting the latest fashion trends & industry needs.

1
Mission
The mission of Ama Syntex Ltd.is to constantly meet, exceed & deliver the right products with right quality
and on time deliveries.

1.3 General Information of Ama Syntex Ltd.

Factory Name Ama Syntex Ltd.

Nature of Business 100% export-oriented

Location South Jarun , Kashimpur , Gazipur

Knitting Capacity 8000 kg per day

Dyeing capacity 10000 kg per day

Sewing capacity 20076 pcs per day

Floor capacity 80000 square feet

Printing capacity 30000 pcs per day

Establishment 2004

Contact Person MD .Akter Hossain

Managing Director
Contact :+880 1714 ******
E-mail: [email protected]

2
1.4 Organization Structure

1.5 Different Section of Ama Syntex Ltd.

 Knitting Section
 Dyeing Section
 Printing Section
 Garments Section
3
1.6 Organogram of Ama Syntex Ltd

GM

DGM

FACTORY MANAGER

ADMINISTRATION MANAGER

PRODUCTION MANAGER

CUTTING MANAGER

QUALITY MANAGER

SHIFT IN-CHARGE

FLOOR IN-CHARGE

SUPERVISOR

LINE CHIEF

OPERATOR & HELPER

4
1.7 Buyer

1.8 Products

T-shirt ,polo ,hoody ,Sweat-Shirt ,Jacket ,Active wear and fancy items

5
1.9 Certifications

 Oeko-Tex
 BSCI
 Amfori
 Sedex

1.10 Social Compliance

Compliance, Safety Procedure & Employees Benefits: Without Social and environmental responsibilities,
business is unethical and not legal. That's why we invested a lot to keep the working environment safe and
secured. We give emphasis on reasonable access to safe drinking water, sanitary facilities, fire safety,
adequate lighting and proper ventilation.

6
2.KNITTING SECTION

Knitting is defined as the construction of fabric by interlocking loops of a single yarn with the help of
hooked needles. Knitting is the method of creating fabric by transforming continuous strands of yarn into a
series of interlocking loops, each raw of such loops hanging from the one immediately preceding it.

2.1 Organogram of Knitting Section

7
2.2 Types of Knitted Fabrics

Mainly two types of knitted fabrics are produced. They are as follow:

Warp knitted fabrics

In a warp knitted structure, each loop in the horizontal direction is made from different thread and the
number of thread used to produce such a fabric is at least equal to the numbers of loops in horizontal row.

Weft knitted fabrics

A horizontal row of loops can be made using one thread runs in horizontal direction. The fabric structure is
different from one from another. Weft knitted fabrics are widely use.

8
2.3 Knitted Fabrics Produced in Ama Syntex Ltd

The following types of fabrics are generally produced in K.A Fashions Ltd

Single Jersey

 Plain Single Jersey

 Single Jersey with Lycra
 Single Lacoste
 Double Lacoste
 Single Pique
 Double Pique
 Polo Pique
 French Terry
 Terry with Lycra
 Fleece
 Fleece with Lycra

Double Jersey

 Rib Fabric
 2x1 Rib
 2x2 Rib
 Lycra Rib

Interlock Fabric
 Palin Interlock
 Interlock with lycra

2.4 Production parameters for knit fabric

 Machine diameter
 Machine rpm (revolution per minute)
 No of feeders in use
 Machine gauge
 Count of yarn
 Required time (machine running time

9
2.5 Process Flow Chart of Knitting

Fabric manufacturing methods are divided into three types; they are as weaving, knitting and non- weaving.
Yarns use to produce different types of fabric. Knitted fabrics are one of them. Knitting technology is one of
the interesting methods for producing knitted fabrics. Knitted fabrics are produced as the following flow
chart.

Yarn in cone form

↓
Feeding the yarn cone in the creel
↓
Feeding the yarn in the feeder via trip tape positive arrangement and tension device
↓
Knitting
↓
Withdraw the rolled fabric and weighting
↓
Inspection
↓
Numbering

2.6 Classification of Knitting Machine

Knitting machines are use to produce knit fabric. Knitted fabrics are produced by the interlocking of one or
more yarns through a series of loops by the use of hooked needle. Knitted fabrics are differing from one to
another depending on their fabric design. Specific fabrics are produced from specific knitting machine.
Knitting machines are classified as follows:

10
Weft Knitting Machine

 Circular Knitting machine

 Flat knitting machine

Warp Knitting Machine

 Rachel Knitting Machine

 Tricot Knitting Machine

Single Jersey Circular knitting Machine

11
Double Jersey Circular knitting Machine (Rib)

Double Jersey Circular Knitting Machine (Interlock)

12
2.7 Parts of Knitting Machine and Functions

Serial No Parts Name Function

1 Needle To stretch the thread and making new loop

also pass the new lop through the old loop.

2 Sinker The main function is to hold the old loop and

help to formation of new loop.

3 Creel It is use to hold the yarn package.

4 Yarn guide The main function of this is to guide the yarn
in proper direction.

5 Knot catcher To hold the dust and other extra impurities

also knot. Only allow yarn pass through this.

6 Positive wheel To feed the specific amount of yarn keeping

proper tension and ensure even yarn feed.

7 Sensor To stop the yarn after breaking a single yarn

as result machine will stop.

8 Indicator light The function of this device is to identify the

feeder or wheel place where yarn break.

9 Ceramic yarn guide To guide the yarn properly to the feeder.

10 Yarn feeder To feed the yarn to the needle for loop
formation.

11 Sinker Bed This is use to hold/place the sinker.

12 Sinker Cam To make sinker path also give to and fro
motion properly.

13 Cylinder To hold and place the needle in right

position.

14 Base plate To hold and place the cylinder properly.

15 Needle Cam To make a path for needle for accelerating through
in the cylinder according to the
fabric construction..

13
16 Nozzle To pass the oil into the cylinder for better
movement also reduce friction.

17 Blower Fan Removing dust from the cylinder and feeder

wheel by air blowing.

18 VDQ pulley To control the GSM also change the stitch

length.

19 Take up roller To winding the fabric after producing in

even direction.

20 Tensioner Roller Maintain the tube fabric tension during

winding.

21 Lycra feeder To feed Lycra to the machine with proper

direction.

22 Toothed Belt To transfer the motion from the VDQ pulley

to the positive feeder.

23 Cylinder Brush To clean dust from the surface of the

cylinder.

24 Fabric detector/sensor To check any type of split in the fabric if it

is found in the machine then machine will stop.
25 Wastage oil pot To store additional and wastage oil.
26 To set the motion of take up properly.

27 Fabric spreader To make tension in width wise direction of

fabric during take up action.

28 Off switch To stop the machine.

29 Start switch To start the machine
30 Jog switch To rotate the machine slowly
31 Handle To make motion in the cylinder after
shade up to solve it.

32 Tension pulley To maintain the tension of toothed belt.

33 Air gun To clean the machine also use foe feed the
yarn after breakage.

14
2.8 Knitting Machine Profile

S/ L Brand Name Country of Machine Dia(inch) Type of No of Feeders Machine Qty

no Origin and Gauge Machine
1 Jiun Long Taiwan 38, 20 Single jersey 1 2
1
4
2 Ta Yu Taiwan 38, 20 Single 1 3
jersey 1
4
3 Ta Yu Taiwan 40, 20 Single 1 2
jersey 2
0
4 Lisky Taiwan 42, 24 Single 1 1
jersey 2
6
5 Lisky Taiwan 44, 24 Single 1 1
jersey 3
2
6 Zentex Singapo 30, 20 Single 9 4
re jersey 0
7 Jiun Long Taiwan 30, 20 Single 3 2
jersey 0
8 Jiun Long Taiwan 36, 20 Single 1 2
jersey 0
8
9 Jiun Long Taiwan 34, 20 Single 1 2
jersey 0
2
10 Fukahara Japan 22, 20 Single 8 1
jersey 8
11 Ta Yu Taiwan 24, 20 Single 7 2
jersey 2
12 Fukahara Japan 26, 24 Single 1 1
jersey 0
4
13 Fukahara Japan 22, 24 Single 7 2
jersey 0
15
 S/L no Brand Name Country of Machine Type of Machine No of Machine Qty
Origin Dia(inch) Feeders
and Gauge
1 Jiun Long Taiwan 32, 20 Double 9 1
jersey 6
2 Jiun Long Taiwan 32, 20 Double 9 3
jersey 6
3 Jiun Long Taiwan 42, 18 Double 1 1
jersey 2
6
4 Ta Yu Taiwan 34, 28 Auto stripe single 6 1
jersey 9

5 Pailung Taiwan 30, 24 Auto stripe single 4 1

jersey 2

2.9 Yarn count Selection

As we know VDQ pulley on the knitting machine controls GSM of fabric, but its raw material has direct
impact on GSM. Yarn counts and stitch length that are used to achieve required GSM are given below:

Single Jersey

Yarn count GSM Stitch length (mm)

20s 190 2.85

24s 175 2.94

26 s 160 2.95

28 s 160 2.70

2.80

2.65

30 s 130 3.20

140 2.75

16
Rib Fabric

Count GSM Stitch length (mm) Fabric

type

26 s 300 2.70 2x1

230 2.65 1x1

28 s 200 2.60 `1x1

200 2.75 2x1

30 s 200 2.50 1x1

200 2.60 1x1

34 s 300 2.75 1x1

250 2.60 1x1

Interlock fabr

Count GSM Stitch length (mm) Fabric type

40 s 190-200 2.90 1x1

210-220 3.70

34 s 300 3.75 1x1

17
2.10 Different Types Knitted Fabric

18
2.11 Knit Fabric Faults

Knit fabric is produced from loop formation. So it needs to be careful during production. Different types of
faults could be found in knit fabric, which could be the cause of fabric rejection. If we can find out the
defects of fabric during production, than we can take steps to remove it from the next knitting production
process. In practical following knitting faults could be found in the knit fabric. Some knitting faults are
given below .

 Holes / Cracks

 Loop / Drop stitches

 Cloth fall-out

 Snagging

 Tuck or Double stitches

 Bunching-up

 Vertical stripes

 Horizontal stripes

 Soil stripes

 Color fly

 Distorted stitches

19
3. BATCH SECTION
Batch section is a preparatory stage of dyeing .It is the receiving section of grey fabric and sending section
of grey fabric to the dyeing section which will dye .Batching section plays an important role for the
particular lot of a particular order .

3.1 Batching
Batching, a process monitored and supervised by the dyeing manager, is carried out in the batching
section. It involves preparing a batch for dyeing according to machine capacity (so that equal amounts of
fabric is passed through each nozzle of a dyeing machine), order and priority basis. Grey fabric from grey
fabric storage or knitting section is collected in order to dye a particular shade of color. Batching is the
receiving section of grey fabric and sending section of grey fabric to the dyeing section which will dye.

3.2 Objectives of Batching

 To make a batch from the same fabric material
 Prepare the fabric batch for dyeing according to the following criteria –
 Order sheet (received from buyer)
 Dyeing shade (light, medium, deep shade or white)
 Machine capacity
 Machine availability
 Type of fabric to process (100% cotton, CVC, PC, fleece, rib etc.)
 Weight the fabric correctly and accurately for creating a correct recipe and avoid dye and
chemical wastage along with shade mismatched shades
 Receive grey fabrics from grey storage or knitting section
 Make a batch plan manually, keeping in mind the process losses which would take place along
production route (e.g. dyeing process loss, cutting loss etc.)
 Prepare a batch card having necessary information about the batch, such as color to dyed, grey
fabric parameters, finishing parameters etc.
 Arrange the fabric for dyeing according to quantity, fiber type, fabric structure and shade
 Gradually reduce grey fabric inventory (which is replenished as production proceeds)
 Reduce idle time of a dyeing machine
 Keep the floor free from extra material
 Turn the fabric when required using a turning machine.

20
3.3 Process sequence of Batch Preparation

Taking batch card

↓
Make the priority as per dyeing plan
↓
Take one specific Batch card.
↓
Read the Batch Card for own understanding
↓
Check the availability of fabric
↓
Take required quantity of body fabric from warehouse.
↓
Make required no. of Rope maintaining equal length.
↓
Take collar/cuff as per size, keep the total weight.
↓
Distribute the collar /cuff or Rib in each rope equally unsure equal length
↓
Stitch the fabric
↓
Write down the weight against roll no. in the back side of the Batch Card.
↓
Write the total weight in Batch Card.
↓
Put signature & date.
↓
Fill up the production report form.
↓
Send for the Production

21
3.4 M/Cs in Batch Section
M/c no : 01
Machine Name : Turning m/c
Origin : Local
Capacity : 10 ton to 16 ton per day

Inspection m/c:
No. of m/c: 02
M/c name : Inspection m/c
Brand Name :
Origin:Local
Capacity:

22
4. LAB SECTION
Testing Lab provides assistance to the textile and apparel industry through the development of high
quality products, evaluation and/or development of specifications for an existing product, and/or
evaluation of the end use performance of a product. The lab also offers expert consultation to assist
industry members with analyzing product failures.

4.1 Lab dip

Lab dip is a process by which buyers supplied swatch is matched with the varying dyes percentage in the
laboratory with or without help of ―DATA COLOR‖ Lab dip plays an important role in shade matching & and
detaching the characteristics of the dyes and chemicals are to be used in the large scale of production so
this is an important task before bulk production

4.2 Organogram of Lab

Organogram
↓
Manager
↓
Lab In-charge
↓
Supervisor
↓
Senior technician
↓
Technician
↓
Operator
↓
Helper

23
4.3 Duties & Responsibilities of Production Manager

 To collect order sheet from merchandiser

 To talk with knitting master for necessary m/c set up
 To collect the production accessories for production
 To discuss with AGM about overall production if necessary

4.4 Flow Chart of Lab Dip

Buyer
↓

Merchandiser (Buying house)

↓
Merchandiser (Factory)
↓

Lab dip receiving (Lab)

↓

Input samples code no.

↓

Entry in lab register

4.5

24
4.6 Flow chart of Lab dip Submission
Lab preparation
↓
Checking light box or Spectrophotometer
↓
Lab dip submission
↓
Keep submission in register
↓
Re-submit if not pass
↓
Shade receive from buyer
↓
Transfer to dyeing floor with recipe

4.7 Stock Solution Preparation

In practice 1% stock solution is very common used in dying process. In Laboratory work, 1.0 gm solid (
100% concentration ) dyestuff / chemicals taken in a conical flax & poured 100 ml of warm water ( 450c)
to dissolve the reagent to make 1% stock solution.
In the case of liquid : Take 10 ml liquid in a beaker; making it 100 ml by pouring necessary amount of
water is prepared 10% solution

4.8 Selection of Stock Solution for Lab Recipe

Shade % Stock solution %

Above 5 % 2%
0.10%--5% 1%
Below 0.10% 0.10%
Glauber salt% 25%
Soda ash% 10%

4.9 Types of Test in Laboratory

There in two types of test done in laboratory

 Physical Test
 Chemical Test

25
4.10 Physical Test

 Yarn grade
 Gsm test
 Shrinkage test
 Spirality test
 Tensile test
 Abrasion resistance
 Pilling resistance

4.11 Chemical Test

 Calmly fastness properties

 Chemical solubility test
4.12 Machine Used in Lab Section

Sl Name of the Machine Nos Origin/Brand

1 Spectra Flash Sf 600 Plus Spectro Photo Meter(Data 1 set U.S.A

Color)

2 Infrared sample Dyeing Machine 2 set U.K

3 Color Fastness to washing 1 set Korea

4 Croc meter 1 set U.K

5 Light box 1 set U.K

6 Electric balance 1 set U.S.A

7 Washing machine 1 set Italy

8 Tumble Dryer 1 set Italy

9 Perspire meter 1 set U.K

10 Pilling Tester 1 set U.K

11 Rota Wash 1 set

26
5 DYEING SECTION
Dyeing means to color the whole fabric using different chemicals & dyestuff. Although dyeing is a
chemical operation, most of the simpler processes may be carried out on the small scale by sensible
people who have very little chemical knowledge, nevertheless, following a set of instruction in ignorance
of the reasons behind their formulation is unlikely to lead to the deeper understanding of textile coloration
that is needed by professional people in the coloration industry.

5.1 Organogram of Dyeing Section

27
5.2 Process Flow Chart of Dyeing
Grey fabric receive from knitting section
↓
Batching
↓
Select machine number
↓
Fabric loading
↓
Select production program
↓
Pretreatment
↓
Dyeing
↓
After treatment
↓
Fabric unloading

5.3 List of Machineries in Dyeing Section

28
5.4 Raw Material for Dyeing
Raw material used in the dyeing section is:
 Grey fabric
 Dyes
 Chemicals

Grey Fabric
Following types of grey fabric are dyed:
 Single jersey
 Single jersey with lycra
 Interlock
 Interlock with lycra
 ST Back Pique
 DT Back Pique
 Polo Pique
 Single lacoste, Double lacoste
 2T Fleece,2T Fleece with lycra, 3T Fleece, 3T Fleece with lycra
 1 X 1 Rib,1 X 1 Rib with lycra,2 X 1 Rib,2 X 1 Rib with lycra
 2 X 2 Rib,2 X 2 Rib with lycra
 CVC, PC

5.5 Flow Chart of 100% Cotton Dyeing

Select bleach fabric (5 gm)
↓
Recipe making
↓
Select dyes

↓
Dyeing

↓
Hot wash
↓
Neutralization
↓
Soaping
29
 ↓
Cold wash
↓
Drying
↓
Match with standard sample
(If Yes)
↓
Bulk production

5.6 Flow Chart of 100% Polyester Dying

Fabric Load
↓
Water Level – As Required
↓
Raise temp to 60 oC
↓
Add Feloson NOF
↓
Raise temp.to 90 oC & run time 10 min
↓
Drain
↓
Water Level – As Required

30
 ↓

Raise temp. to 45 oC
↓

Add Neutracid RBT (Non volatile Acid) & run time 10 min

Drain
↓

Water Level – As Required

Raise temp. to 450C

↓

Dye dosing for 10 min

Raise temp. to 130 oC & run for 45 min

↓

Drain
↓

Water
↓

Cooling at 700C & sample cheek if shade ok then bath drop

↓

Acetic wash at cold temp. for 10 min

Acetic Acid + Softener is added at 450C & run for 10 min

Cold Wash

↓
Fabric Unload

Page | 34
5.7 Flow Chart of CVC Dyeing

Take water in the machine bath at the required level.

↓
Then add Detergent, Sequestering agent, Anti-creasing agent, Dispersing agent. –Circulate the fabric for
5 mins at 50oC.
↓
Add acetic acid and circulate for 5 mins at 50oC.
↓
Add Glauber’s salt and circulate for 5 mins at 50oC.
↓
Check PH of the dye bath.
↓
Add Polyester dye solution by linear dosing and circulate the fabrics for 10 mins at 50oC.
↓
Add Cotton dye solution by linear dosing and circulate the fabrics for 10 mins at 50oC.
↓
Circulate the fabric and raise the temperature at 130oC.
↓
Continuing Circulate the fabric for 30 – 40 mins at a constant temperature at 130 oC.
Circulate the fabric and decrease the temperature to 70 oC.

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 Then Check the shade of the Polyester Part with the approved shade.
↓
Circulate the fabric and raise the temperature at 82 oC.
↓
Continuing Circulate the fabric for 30 – 40 mins at a constant temperature at 82 oC.
↓

Add Soda ash by Curve dosing and continue circulating the fabric for 30 – 40 mins at 82 oC.

5.8 Dyeing Fault

Circulate the fabric and decrease the temperature to 70 oC.

↓
Then Check the shade of Cotton Part with the approved
shade.
↓
Drain.
↓
Add Soaping Chemical and circulate for 10 mins at 95oC.
↓
Unload.

 Batch to batch variation

 Running shade
 Uneven dyeing
 Dye spots/ colored spots
 Patchy dyeing
 Crease marks
 Chemical spots

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6 DYEING FINISHING SECTION

After fabric unloading from dyeing machine. Every required quality is checked by the quality control. If all
requirements are ok .then fabric is received by the finishing section. Textile finishing, in a restricted sense, is
the term used for a series of processes to which all bleached, dyed, printed & certain grey fabrics are
subjected before they are put to market

6.1 Process Flow Chart of Finishing

Flow Chart of Textile Finishing(Open fabric )

Slitting
↓
Stentering
↓
Compacting
↓
Final inspection
↓
Packing
↓
Bailing
↓
Delivery
↓
De-watering
↓
Drying
↓
Compacting
↓
Final inspection
↓
Packing
↓
Bailing

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6.2 Objective of Finishing
Improving the appearance, luster, feel softness whiteness suppleness etc.
To improve attractiveness of the fabric.
To increase the life time or durability of the fabric.
To meet up specific requirement of the fabric for achieve the final goal

6.3 Finishing Effects

 Easy care
 Crease recovery
 Dimensional stability
 Good abrasion resistance
 Improved tear strength
 Good sew ability
 Soft or stiff handle
 Shine or luster

6.4 Finishing Machinery

In finishing section of Ama syntax the machines which are available are listed below
 Slitter m/c
 Stenter m/c
 Detwisting m/c
 Natural Gas Dryer m/c
 Compacting m/c
 Air Turning m/c
 Calendering m/c

6.5 Function of the Slitting Machine

 Used to remove excess water after pretreatment and dyeing
 To slit the tube fabric by the knife for opening of the fabric and ready for stentering
 Delivered fabric increase free state
 It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism

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6.6 Function of Squeezing/Dewatering Machine
 Reduce water from fabric
 Fabric open from rope form
 Dia/width control
 Twisting and spirality control by twisting wheel
 Apply chemical
 Softening agent
 Brightening agent

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6.7 Function of Stenter M/C
 Width control
 Curing of fabric
 GSM control
 Shrinkage control
 Spirality control
 Heat setting on cotton/ Lycra

5.8 Functions of Compactor M/C

Compactor machines are two types. They are-

 Tubular compactor
 Open compactor

Tubular compactor

Tubular compactor is used after hydro-extractor, de-watering and dryer. By the compactor
machine, compacting is done for control the shrinkage of the fabric. Here, different types of off
line quality of the fabric are measured.

Open compactor
Open Compactor is used for compacting the open form fabric. Here, slitting machine is used for open
the fabric from the tubular form

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Drying Machine
In textile finishing unit; dryer uses for dry the knit, woven fabrics and dyed yarn. But the drying process
and drying mechanism of yarn and fabrics is different from one to another. In dryer, drying and curing is
done as per required.
Drying
The main functions of a textile dryer is to dry the textile fabrics. Drying is defined as a process where the
liquid portion of the solution is evaporated from the fabric.
Curing
Curing can be defined as a process following addition of a finish to the textile fabrics, in which materials
are heated for a certain time in elevated temperature to effect a chemical reaction. This curing operation is
most common in finishing of the printed goods.

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Conclusion

I have completed my industrial visiting report successfully by the grace of almighty Allah. Industrial
attachment provides the learning scope to enhance the curiosity of knowledge to entered into the practical
life. Ama Syntex Ltd. is a well know factory in the textile field of Bangladesh. The administrative,
management, chain of command all are the well- organized. They are well equipped with all of the modern
machineries and the working environment is excellent. The relation between top management to bottom
level is so nice & devoted to satisfy the customer demand by their activities.

This factory does not compromise in case of quality. Besides, they also use the good quality yarn, dyes and
chemicals in their production process. Due to this, it has earned a very good reputation in foreign market
for its quality product over many other export oriented textile mills. It has very well educated and
technically experienced manpower to get rid of any defect in production process. It has also a good
organizational hierarchy. At last, I can say industrial attachment prepares the students for the expected
destiny of practical life.

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