Industrial Attachment of Shohagpur Textile Mills Ltd.

INDUSTRIAL ATTACHMENT
National Institute of Textile Engineering & Research

(NITER)
Nayarhat, Savar, Dhaka
REPORT ON
Duration (10.12.2017 to 10.02.2018)
WITH
Shohagpur Textile Mills Ltd.
Lakkhon Khola Bondor, Godnail, Narayanganj, Bangladesh.
Supervising Teacher
Sadikur Rahman
Lecturer
Department of Yarn Manufacturing Engineering
National Institute of Textile Engineering & Research (NITER)
Nayarhat,Savar,Dhaka
Submitted By :
NAME STUDENT ID SESSION

Md. Rakibul Islam 140401-065 2013-14
Subir Kar 140401-081 2013-14
Shuvo Sarkar 140401-116 2013-14
National Institute of Textile Engineering & Research (NITER) | 1

I. Acknowledgement
We are thankful to the Almighty for enabling us to complete the industrial training successfully. We
would like to express our deepest appreciation to all those who gave us the chance to complete this
industrial training.
Our industrial training was carried out at Shohagpur Textile Mills Ltd. a concern of Purbani Group,
located at Lakhhon Khola Bondor, Godnail, Narayangonj, Bangladessh. We express our thanks to
the authorities of Purbani Group of Industries for giving us the official permission for industrial
training.
A special appreciation to Major Md. Mahbubur Rahman (Retd), Deputy General Manager,
Shohagpur Textile Mills Ltd, who gave us the permission to access all required equipment and
necessary materials to complete the industrial training.
A special gratitude to our respected supervisor Md Ali Reza, Production Manager (U-2),
Shohagpur Textile Mills Ltd. for his support, cooperation and constant supervision during the
industrial training at Shohagpur Textile Mills Ltd.
We would like to thank Prof. Dr. Mizanur Rahman, Principal, National Institute of Textile
Engineering & Research (NITER) for giving us guidance and official permission for
internship at Shohagpur Textile Mills Ltd.
A special gratitude to our respected academic supervisor Sadikur Rahman, Lecturer, Dept.
Of Yarn Manufacturing, National Institute of Textile Engineering & Research (NITER).
for his successive instruction, cooperation and constant supervision during industrial training
We would also like to applaud other teachers of our department for providing the base of our
textile engineering knowledge.
Last but not the least we express our special thanks to all the staffs and officers of Shohagpur Textile
Mills Ltd for their co-operation, love, services& support which they offered during our training
period.

II. Executive Summary /Introduction
Industrial Training refers to work experience obtained during the program of study that is relevant
to professional development prior to graduation. The main objectives of Industrial Training are:
 To experience what it is like to work in a professional organization,

 To increase technical, interpersonal and communication skills, both oral and written,
 To gain a first-hand experience working as an engineering student,
 To apply the technical knowledge and engineering methods to a real-life situation,
 To work with other engineering professionals,
 To observe interactions of engineers with other professional groups.
We got an opportunity to complete 02 months long industrial training in Shohagpur Textile Mills
Ltd. (STML), a concern of Purbani Group. Our industrial training started in Dec 10, 2017 and ended
in Feb 10, 2017. As there were different departments in factory, our 02 months long program was
sub-divided as per following to get us acquainted with all of them-
 2.5 weeks in Maintenance Department.

 2 weeks in Production Department.
 2.5 weeks in Quality Control Department.
 0.5 week in Utility and Electrical Department.
 0.5 week in Administration Department.

III. Table of Contents
CONTENTS PAGE
Chapter 01: Description of Organization 08-10

Part 1.1: History of Purbani Group 07
Part 1.2: Purbani Group Subsidiaries 07
Part 1.3: Information about Shohagpur Textile Mills Ltd. 07
Part 1.4: Overview on Shohagpur Textile Mills Ltd. 08
Part 1.5: Different Departments of Shohagpur Textile Mills Ltd. 08
Part 1.6: Location of the Factory 09
Chapter 02: Man Power Management 11-16

Part 2.1: Organogram of STML 10
Part 2.2: STML Manpower setup 11
Part 2.3: Job responsibilities of officers 14
Chapter 03: Material Management 17-18

Part 3.1: Sources and different types of raw material 16
Part 3.2: Bale Information 16
Part 3.3: Contaminations of raw cotton 17
Chapter 04: Machine Description & Production Planning Sequence &

Operation 19-56
Part 4.1: Process flow charts of ring spinning yarn production 19

Part 4.2: Machines sequence & descriptions of blow room 20
Part 4.2.1: Flowchart of blow room machines of unit-1 20
Part 4.2.2: Machine descriptions of blow room of unit-1 21
Part 4.2.4: Machine descriptions of blow room of unit-2 24

Part 4.2.6: Machine description of blow room machine of unit-3 28
Part 4.3: Carding machine 33
Part 4.3.1: Carding machine specification & description of Unit-1 34
Part 4.3.2: Carding machine specification & description of Unit-2 35
Part 4.3.3: Carding machine specification & description of Unit-3(Line-1) 36
Part 4.4: Breaker Draw Frame 37
Part 4.4.1: BDF machine specification and description Unit-1 38
Part 4.4.2: BDF machine specification and description Unit-2 38
Part 4.5: Finisher draw frame 41
Part 4.5.1: FDF machine specification and description Unit-1 42
Part 4.5.2: FDF machine specification and description Unit-2 43
Part 4.5.3: FDF machine specification and description Unit-3 (Line-1) 44
Part 4.5.4: FDF machine specification and description Unit-3 (Line-2) 45
Part 4.6: Simplex 45
Part 4.6.1: Simplex machine specification and description Unit-1 46
Part 4.6.2: Simplex machine specification and description Unit-2 47
Part 4.6.3: Simplex machine specification and description Unit-3 (Line-1) 47
Part 4.6.4: Simplex machine specification and description Unit-3 (Line-2) 48
Part 4.7: Ring frame 49
Part 4.7.1: Ring Frame machine specification and description Unit-1 49
Part 4.7.2: Ring Frame machine specification and description Unit-2 49
Part 4.7.3: Ring Frame machine specification and description Unit-3(line-1) 50
Part 4.7.4: Ring Frame machine specification and description Unit-3(line-2) 51
Part 4.8: Auto Cone Winding section 51
Part 4.8.1: Auto Cone Winding specification and description Unit-1 51
Part 4.8.2: Auto Cone Winding specification and description Unit-2 52
Part 4.8.3: Auto Cone Winding specification and description Unit-3(line-1) 53
Part 4.8.4: Auto Cone Winding specification and description Unit-3(line-2) 53
Part 4.9: Heat setting 54

Part 4.10: Packaging section 55
Chapter 05: Quality Control 57-63

Part 5.1: Quality control system 57
Part 5.2: Plan of quality department 57
Part 5.3: List of testing equipment and their manufacturer and model no 58
Part 5.4: Machine description 58
Chapter 06: Maintenance 64-71

Part 6.1: Maintenance 64
Part 6.2: Maintenance of machineries 64
Part 6.3: Machineries used for maintenance 65
Part 6.4: Maintenance points 66
Part 6.5: Machine maintenance schedule 67
Part 6.5.1: Maintenance for Blowroom 68
Part 6.5.2: Maintenance for carding 68
Part 6.5.3: Maintenance for Drawframe 68
Part 6.5.4: Maintenance for simplex 69
Part 6.5.5: Maintenance for ring frame 70
Part 6.5.6: Maintenance for auto cone winding 71
Chapter 07: Utility Services 72-78

Part 7.1: Generator 72
Part 7.2: Cooling tower 77
Part 7.3: AC Plant 77
Part 7.4: Compressor 78
Chapter 08: Store & Inventory Control 79-81

Part 8.1: Inventory control 79
Part 8.2: Sections of store 79
Part 8.3: Inventory procedure 81

Chapter 09: Marketing Activities and Cost Analysis 82-83
Part 9.1: Consumers of product 82
Part 9.2: Exporting country 82
Part 9.3: Importing country 82
Part 9.4: Local market 82
Part 9.5: Cost analysis 83
Part 9.6: Marketing strategy 83
Chapter 10: Administration, Account, HRD and First aid 84-86

Part 10.1: Administration 83
Part 10.2: Accounts 83
Part 10.3: HRD department 84
Part 10.4: First aid 86
Chapter 11: Impact of the Internship 87
Chapter 12: Conclusion 88

CHAPTER ONE
DESCRIPTION OF ORGANIZATION
1.1: History of Purbani Group:
PURBANI is one of the largest & oldest established 100% export oriented Textile conglomerates in
Bangladesh since 1973 and doing business for more than 4 decades with eminence. The group’s first
venture was M/S Purbani traders in 1973. Since 1973, however, the Purbani group has grown into
a leading group of companies in Bangladesh by virtue of its dynamic It is a vertically integrated
textile manufacturing company and title holder of 12 business groups involve in Spinning, Yarn
Dyeing, Fabrics Manufacturing & Dyeing and Ready Made Garments .
The Group includes a number of textile mills that employ approximately 5000 work forces. A
significant contribution to the country’s reduction of unemployment problem.
At present Purbani Group has established itself as a renowned textile manufacturer in the country.
The Group has earned a good reputation among the countries that are involved in the business.
The group is striving very hard to reach its goal that is to be one of the largest textile
manufacturing companies globally.
1.2: Purbani Group Subsidiaries:
 Karim Spinning Mills Ltd.

 Shohagpur Spinning Mills Ltd.
 Purbani Rotor Spinning Ltd.
 Purbani Synthetic Spinning Ltd
 Purbani Fabrics Ltd.
 Purbani Yarn Dyeing Ltd.
 Karim Textile Ltd.
 Purbani Fashion Ltd.
 Purbani Agro Processing Ltd.
 Purbani Fisheries.
 Purbani Traders.
1.3: Information about Shohagpur Textile Mills Ltd.:
Name of the Factory Shohagpur Textile Mills Ltd.
Chairman Abdul Hai Sarker
Managing Director Shafiqul I. Sarker (Sohel)
Deputy General Manager Major Md. Mahbubur Rahman (Retd)

Type Yarn Manufacturing Industry (Ring Spinning)
Head Office Sena Kalyan Bhaban (15th floor),

195 Motijheel C/A, Dhaka.
Factory Location Lakkhon khola Bondor, Godnail, Narayanganj
1.4: Overview on Shohagpur Textile Mills Ltd.:
Nature of the company Private Limited Company.
Number of spindles installed 44000
Product Mix Mélange Yarn, 100% Cotton Mélange, Neps,

Viscose, Inject, Siro, Snow and other Fancy
Yarn
Count Range 20-40 Ne
Production capacity 25 Ton/Day
Establishment 1984
Manpower 1400
Male Employee 650
Female Employee 750
Power Supply Gas generator
1.5: Different Departments of Shohagpur Textile Mills Ltd.:

 Production Department.
 Quality Control.
 Maintenance Department.
 Utility Department
 Store Department
 Administration Department
 Marketing and Sales Department
 Commercial Department.

1.6: Location of the Factory:

INDUETRIAL ATTACHMENT
CHAPTER TWO
Man power Management

2.1: Organogram of STML:
An organizational chart (often called organization chart, org chart, organigram or organogram) is a
diagram that shows the structure of an organization and the relationships and relative ranks of its
parts and positions/jobs. The organogram of Shohagpur Textile Mills Ltd. is given below:

2.2: STML Manpower setup:
Quality control department:
Designation Current
manpower
Assistant general manager 1
Assistant manager 1
Quality control officer 1
Lab assistant 5
Lab boy/girl 2
Total 10
Maintenance Department:
Designation Current
manpower
Assistant general manager 1
Maintenance officer 5
Assistant Maintenance officer 16
Head fitter 10
Senior fitter 7
Assistant fitter 25
Helper 50
Total 114

Production department (Unit- 1,2, 3):
Designation Current
manpower
DGM(production) 1 (Unit-1,2,3)
Sr. Assistant General Manager 2 (Unit-1,3 & 2)
Production manager 3
Senior production officer 0
Production officer 8
Assistant production officer 15
Management information system officer 1
Production clerk 3
Supervisor 12
Worker 1100
Total 1145
Administration Department:
Designation Current manpower
Manager (admin) 1
Asst. Manager 1
Admin officer 5
Accounts officer 1
Executive security 1
Security inspector 2
Security guard 32
Pc operator 1
Imam 1
Driver 5
Total 50

Utility Department:
Generator &Maintenance Designation Current manpower
Manager 1
Engineer 4
Electrical Sub. Assistant engineer 10
Operator + helper 3
Electrician 10
Helper + Loop cleaner 4
Head fitter 1
Work Shop
Helper 10
Sub. Assistant engineer 1
AC
H. fitter + Fitter 1+1
Heat setting Op + Helper 2+2
Store Department:
Designation Current manpower
Manager 1
Store officer 2
Assistant Store officer 1
Store keeper 6
Total 10

2.3: Job responsibilities of officers:
a) Maintenance manager:
Job responsibilities:
 To ensure all machine safety devices.
 Machine maintenance schedule development.
b) Assistant Quality manager, Quality Control Officer:

 To maintain the quality and process parameters of the yarn production process.
 To plan and monitor the daily activities of quality department.
 To ensure the proper training and motivation of QCA officers and supervisors, lab
assistances etc. up to date to G.M. regularly about the production process as well as the yarn
quality.
c) Senior production officer and Production officer:

 To achieve the target production and ensuring the production from blow room to finishing
 To cheek process parameters lot wise and count wise from blow room to finishing against
standard value.
 To control count mixing, lot mixing of sliver, roving yarn and mixing / Bale management of
raw cotton.
 To control unusable wastage in every stage from blow room to finishing.
 To take the charge from the outgoing shift and hand over the charge to the incoming shift.
 To allow leave of workers & subordinate supervising staffs in systematic way.
 To supervise performance evaluation.
 To maintain doff ticket and control of doffing time in ring section.
 To check attendance.

d) Maintenance engineer:
 Operation and maintenance.
 Monthly maintenance schedule.
 Local and foreign indents.
e) Maintenance officer:
 Maintenance of boiler, AC plant etc.
 Operating and controlling.
 Machine selection and installation.
 Humidity setting.
f) Admin manager:
 To recruit labor by ensuring that there is no any child or forced labor.
 Punishment and appeal, harassment and abuse – to deal with these matters.
 To keep payroll and attendance record.
 To manage overtime, working hour, wages, breaks, leave, benefits etc.
g) Manager of store:
 Total storage management of raw material, yarn, chemical etc.
 Waste management.
h) Admin officer:
 Responsible person for overall Implementation, review, reporting and corrective action.
 Internal audit and HR management.

CHAPTER THREE
Material Management
3.1 Sources and different types of raw material: (Fibres)

There are different types of fibres used to produce yarns of various qualities. Those fibres are coming
from different origin and region. Some fibres types and their origin are given below:
Cotton
Brand Name Origin Staple Length Average MIC
CIS Uzbekistan, Russia 36.5mm 4.6
Zambia Africa 29-30mm 4.3
Sankar-6 India 28.5mm 4.0
Benin Benin 27-32mm 4.5
Burkina Burkina 27-32mm 3.5-4.8
Tanzania Tanzania 28.2mm 4.3
Azerbaijan Azerbaijan 27-30 mm 4.4
Viscoses
Origin Staple Length Average denier
India(Black Viscose) 38mm 1.4
3.2: Bale Information :
Binding material used for bales Steel wire

Bale size Height: 59 cm, Length: 95 cm, Width: 80 cm
Bale weight 230 kg
Tare weight 2.6 kg
Bale loading & unloading system It is done by HELI
Bales used in per lay down 47 bales
Bales consumption/day 94 bales

3.3: Contaminations of raw cotton:

Dirty cotton Piece of plastic
White cloth piece Black cotton
White thread Broken seeds
Colored cloth piece Wooden piece
Colored thread
Leaf
Feather
Other raw materials:

 Coloured Cotton
 Bleached Cotton
 Polyethylene bag

CHAPTER FOUR
Machine Description & Production Planning Sequence & Operation
4.1: Process flow charts of ring spinning yarn production:
The flow chart of carded yarn is here.
Blow -room
Carding
Breaker Draw Frame
Finisher Draw Frame
Simplex
Ring Frame
Auto Cone Winding
Yarn Conditioning
Packaging

4.2: Machines sequence & descriptions of blow room:
4.2.1: Flowchart of blow room machines of unit-1:
Bale Opener
MAXI-FLO
Multi -Mixer
CLEANOMAT
Dust X
- SP FPDX
DJjbglkjglkj
U
FD-S

4.2.2: Machine descriptions of blow room of unit-1:
Automatic Bale Plucker:
Manufacturing Trützschler
Company
No. of M/C 01
Model BO 1600
Manufacturing 2001
Year
Country of Origin Germany
Production 1200 kg/hr
Material used Cotton
Function To open fibre
Fig: Automatic Bale Plucker
MAXI-FLO:
Company
No. of M/C 01
Model MFC
Manufacturing 2001
Year
Production up to 820 kg/hr
capacity
No of beater 2
Function Opening & Beating,
to remove seed etc.
Fig: MAXI-FLO

MPM:
Company
No. of M/C 01
Model MPM-10/1600
Manufacturing Year 2001
Storage capacity 300 kg

No of Blending 06
chamber
Function Homogenous
mixing
Fig: MPM
CLEANOMAT ( CVT1) :
Company
Fig: CLEANOMAT No. of M/C 02
Model BS 987/1600
No. of Beater 01
Function Opening,beating,
cleaning & refining.

Dust X:
Company
No. of M/C 01
Model DX
Installed power 0.8 KW

Function Remove the Dust
Fig: DX

Bale Opener
MBO
ERM
Kirschner Beater
Scutcher
4.2.4: Machine descriptions of blow room of unit-2:
a) Bale Opener:
Manufacturing Perfect
Company
Fig: Bale Opener
No. of M/C 03
Model PB-1200
Manufacturing 2011
Year
Country of India
Origin
Function Opening &
Beating and feed
fibres to other
machines.

b) MBO (Mixing Bale Opener):
Manufacturing Lakshmi Rieter

Company
No. of M/C 02
Model N/A
Manufacturing 2007
Year
Country of India
Origin
Function Mixing different

fibers properly.
c) ERM:

Company
No. of M/C 06
Model N/A
Country of Origin India
Function Separate the wastage

and mix the fibre.
Fig: ERM

d) Kirschner Beater:

Company
No. of M/C 06
Model N/A
Manufacturing 2007
Year
Country of India
Origin
Function To comb and extract the

lighter impurities from
cotton.
Fig: Kirschner Beater
Scutcher:

Company
Model N/A
Manufacturing 2000
Year
Country of Origin India
Function To make a lap

sheet and wind on
roller
Fig: Scutcher

Unifloc
Semi-condenser
Uni Clean
Carding
Multimixer
Codenser
CVT-1
CVT-3
MBO
DX
Line-1
Uni - Blend
Line-2
BO Uni-Store 1 Uni-Store 2 Condenser
MBO
Condenser
 Cotton Processing Line Carding
 Viscose Processing line
Fig: Flow chart of Blowroom of Unit-3

Machine Specification & Description of Blowroom-3:
a) Unifloc:
Manufacturing RIETER
Company
Model A11
Country of Origin Switzerland
Production rate 1200 kg/hr
Function To open, clean &

blend or mix the fibre.
Fig: Uni floc
b) Uni-Clean:
Company
Model B12
Beater roller rpm 780 RPM
Function To beat, clean and

remove the wastage.
Fig: Uni clean

c) Multi-mixer (Cleanomat):
Company
Model MCM6 / 1200
No. of Chamber 6
Function To open & mix the

fibre.
Fig: MCM
d) CVT 3 :
Company
Model CVT3(097)
No. of Beater 3
Function To more beat & clean

the fibre .
Fig: CVT3

e) Dust X :
Company
Model DX
Function To remove short fiber

and dust .
Fig: DX
f) BO (Viscose) :
Company
Model BO-1200
Manufacturing 1999
Year
Function To open, clean the

viscose fibre.
Fig: BO

h) Uniblend (Viscose) :
Manufacturing Rieter
Company
No of Machine 02
Model A79
No. of feed roller / 01

machine
No. of opening roller / 01
machine
Function To blend the fibers
properly .
i) Condenser :
Company
Model A21
Manufacturing 2016
Year
Function to control the width

of the fiber strand.
Fig: Condenser

j) Uni-Blend :
Company
Model A81
No of Chamber 03
Chamber in which 01 & 03

cotton Stored
Chamber in which 02
Viscose Stored
Function To store the processed
Cotton and Viscose.
After all supply the
cotton-viscose mixer to
Fig: Uni-Blend the MBO in proper
ratio.
k) MBO :
Company
Model B34
Manufacturing 2016
Year
Function To blend the

different fibers in
given ratio.
Fig: MBO

Accessories of blow room:
Item Name Quantity
Bale Trolley 8
Wastage Carrier 06
Trolley
Bale Cutter 5
Bale Cleaner 6
4.3: Carding Machine:
Carding is defined as the reduction of an entangled mass of fibers to a filmy web working between
two closely spaced, relatively moving surface clothed with sharp wire points. The carding is the
heart of spinning and well card is half of spun demonstrate the immense significance of carding for
the final result of the spinning operation. The importance of carding is still greater where new
spinning systems are concerned.
The Objectives of Carding are:
 Neps removal,
 Fibre individualization and slightly straightening including parallelization,  Web
formation,
 Cleaning of heavy particles by stripping and carding action.

4.3.1: Carding machine specification and description:
Carding machine specification and description of Unit-1 of STML:
Trützschler DK-903:
Model DK-903
No. of M/C 05
Country of origin Germany

Production 45 kg/hr
Manufacturing Trützschler GmbH &
company Co. KG.
Fig: Trützschler DK-903
Trützschler TC-03:
Model TC-03
No. of M/C 01
Manufacturing 2016
Year
Country of Germany
origin
Production 85 kg/hr
Manufacturing Trützschler GmbH

company & Co. KG.
Fig: Trützschler TC-03

Parameters of carding machines:
Technical data & settings DK-903 TC-03
No. of machines 05 01
Feed roller diameter 127 mm 100 mm
Taker in diameter 254 mm 172.5 mm
Taker in speed 930-2200 rpm 1162 -2392 rpm
Taker in PPSI 120, 10° 1) 34, 10º
2) 163, 10º
3) 210, 10º
Cylinder diameter 1290 mm 1287 mm

Cylinder speed 600-900 rpm 500 rpm
Cylinder PPSI 950, 40º 950, 40º
No of flats 104 84
No. of flats in carding action 33 38
Flat speed 342 mm/min 320 mm/min

Flat PPSI 520-550, 5º 525-600, 5º
Doffer diameter 510 mm 700 mm
Doffer speed Depends on delivery Depends on delivery
Doffer PPSI 367, 30º 483, 30º
Carding machine specification and description of Unit-2 of STML:
Model D1/3
No. of M/C 14
Country of origin India
Production 45 kg/hr
Manufacturing company Lakshmi

Carding machine specification and description of Unit-3 (line-1) of STML:
Model DK-903
No. of M/C 05
Manufacturing 2001
Year
Production 45 kg/hr
company
Model DK-803
No. of M/C 05
Production 45 kg/hr
Manufacturing company Trützschler

 Carding machine specification and description of Unit-3 (Line-2) of STML:
RIETER C70L:
Model C70L
No. of M/C 05
Country of origin Switzerland
Production 75 kg/hr
company
Fig: RIETER C70L
4.4: Breaker Draw Frame:
The carded sliver is fed in the Breaker Draw Frame. In STML 8 (eight) card sliver cans are fed in
each Breaker Draw frame. More no. of doublings give more removal of irregularity. If the number
of doubling increases, the number of drafting also increased. But more draft leads more unevenness
in the drawn sliver. So optimum doubling should be maintained.
Objectives of Breaker Draw Frame:

 To parallelize and straighten the fibers in card sliver along the sliver axis.
 To reduce the weight variation.
 To reduce hook formation.
 To lay the sliver in can with uniform coils forming a clear center hole.
 Micro dust removal.

 Specification and machine description of Breaker Draw Frame of Unit-1:
a) Trützschler HS - 1000:-
Model HS - 1000
No. of M/C 02
Manufacturing 2001
Year
company
Fig: Trützschler HS - 1000
 Specification and machine description of Breaker Draw Frame of Unit-2
Trützschler HS - 1000:-
Model HS - 1000
No. of M/C 02
company
Fig: Trützschler HS - 1000

a) Rieter RSB-D45 :-
Model RSB-D45
No. of M/C 02
Manufacturing 2016
Year
Production 3000m
Capacity
company
Fig: Rieter RSB-D45
b) Lakshmi LDO/6 :-
Model LDO/6
No. of M/C 01
Manufacturing 1999
Year
Production 4000m
Capacity
Manufacturing Lakshmi
company
Laxmi LDO/6

 Specification and machine description of Breaker Draw Frame of Unit-3 (Line – 1) :-
a) Trützschler HS – 1000:-
Model HS - 1000
No. of M/C 01
Manufacturing 2001
Year
Country of Germany
origin
company
Fig: Trützschler HS – 1000
b) RIETER SB-D45 :
Model RSB-D45
No. of M/C 01
Manufacturing 2016
Year
company
Fig: Rieter SB-D45

 Specification and machine description of Breaker Draw Frame of Unit-3 (Line – 2) :-
a) Toyota DX7A :-
Model DX7A
No. of M/C 02
Manufacturing 1999
Year
Country of origin Japan
No. of Head 2 per machine
No. of 8
Doubling/Head
Capacity 3000m
Manufacturing Toyota
company
Toyota DX7A

Parameters of breaker draw frame:
Technical Data and settings RSB-D45
Drafting system 4 over 3
No. of head 2
Roller weighting system Spring loaded

Cot roller shore hardness 83º (Carded)
Bottom roller diameter Front roller-35 mm
Middle roller-35 mm
Back roller- 35 mm
Top roller diameter Front roller - 38 mm

Middle roller - 34 mm
2nd Middle roller – 34 mm
Back roller- 38 mm
Bottom roller gauge Front zone - 40 mm
Back zone - 45 mm
Delivery speed 550 m/min

Sliver length/can 6000m
Trumpet size 3.8/4.2 mm
Present of auto leveler No

No of doubling 08

4.5: Finisher draw frame:

This machine is used both for card and combed yarn. The card and combed sliver both are fed to the
finisher draw frame. If any fault is occurred in this process it cannot be removing in the further
process. The main deference of finisher draw frame to breaker draw frame is the auto leveller. If
sliver mass variation is occurred, then it averages out the mass variation. The auto leveller can
remove maximum about ±25% variation.
 Specification & machine description of FDF of Unit-1:
RSB-D45:
Model RSB-D45
No. of M/C 02
Manufacturing 2016
Year
Country of Switzerland
origin
Capacity 4000m
Delivery speed 700m/min
 Specification & machine description of FDF of Unit-2:
a) Rieter RSB-D45:-
Model RSB-D45
No. of M/C 02
Manufacturing 2016
Year
Capacity 3500m
Delivery Speed 600m/min
company

b) Toyota : (Double Headed):
Model DX7A
No. of M/C 01
Manufacturing 1999
Year
No of Head 2

Capacity 3500m
company
 Specification & Machine Description of FDF of Unit-3 (Line-1):
Rieter RSB-D45:-
Model RSB-D45
No. of M/C 02
Manufacturing 2016
Year
Capacity 3500m
company

 Specification & Machine Description of FDF of Unit-3 (Line-2):
Toyota DX7A-LT (Double Headed):
Model DX7A-LT
No. of M/C 02
Manufacturing 2000
Year
No. of Head 2 per machine
No. of 8
Doubling/Head
Capacity 4000m
company
4.6: Simplex:
The finisher draw frame slivers are fed to the simplex. The sliver is extended and small amount of
twist is inserted. This twist only helps to hold the fiber during winding of roving and unwinding of
slivers.
Objectives of Simplex Machine:

 To draft the sliver to reduce weight per unit length.
 To insert small amount of twist to strengthen the roving to prevent breakage during next
processing.
 To make conical or tapper shape of the bobbin.
 To wind twisted strand on the bobbin.

 Specification and Description of Simplex Machine of Unit 1:
Toyota FL100:
Model FL100
No. of M/C 03
Manufacturing 2001
Year
Production 2200 m/ Bobbin

Capacity
company
Technical Data of FL100:
No of machine 03
No. of flyer 120
Spindle gauge 220 mm
Roving hank 0.80
Roving TPI 1.19
Total draft 8.2
Auto stop motion Yes
Problem indicating lamp system Yes
Top apron size 37×40×1.1 mm

Bottom apron size 38.8×40×1.1 mm
Top clearer cloth size 680 (l)×3(t)×40(w) mm
Bottom clearer cloth size 510(l)×160(w)×3(t) mm
Flyer speed 600-1500 rpm

Top roller + cradle hardness 83º

 Specification and Description of Simplex Machine of Unit 2:
a) TONG HE- TH496:-
Model TH496
No. of M/C 04
Manufacturing 2016
Year
Country of origin China
Production 2200 m/Bobbin

Capacity
No. of Flyer 130 spindles/machine
Flyer Speed 1100 m/min
Manufacturing TONG HE
company
b) Lakshmi LR 9/AX :-
Model LR 9/AX
No. of M/C 01
Manufacturing 2012
Year
Country of China
origin
Capacity
No. of Flyer 120
spindles/machine
company

 Specification and Description of Simplex Machine of Unit 3(Line 1):-
Laksmi LF 4200/A:
Model LF 4200/A
No. of M/C 03
Manufacturing 2017
Year
Country of India
origin
Capacity
No. of Flyer 140 Flyers/machine
Manufacturing Laksmi
company
Technical Data of Laksmi LF4200/A:
No of machine 03
No. of flyer 140
Spindle gauge 220 mm

Bobbin Dia 112 mm
Roving hank 0.80
Roving TPI 1.250
Total draft 8.2
Efficiency 81.7%
Auto stop motion Yes

Problem indicating lamp system Yes
Flyer speed 900-1300 rpm
Top roller + cradle hardness 83º

 Specification and Description of Simplex Machine of Unit 3(Line 2) :-
Toyota FL100:-
Model FL100
No. of M/C 03
Manufacturing 2001
Year
Production 2200 m/
Capacity Bobbin
No. of Roving 120
Production 4000 kg/day
Flyer speed 1000m/min
company
4.7: Ring frame:

The roving is fed into the ring frame to produce yarn. The necessary amount of draft is also needed.
The twist is inserted to improve the strength but excessive twist may decrease the strength. The
traveller is mainly inserted for imparting the twist.
Objective of a Ring Frame Machine: -
 To produce required count of yarn from the supplied roving by the drafting.
 To insert sufficient amount of twist to the yarn.
 To wind the yarn onto the bobbin.
 To build the yarn package properly.

 Machine specification & description of Ring Frame of Unit – 1:
Rieter G32 V3:-
Model G32 V3
Manufacturing 2016
year
No. of M/C 09

Country of Switzerland
origin
company
 Machine specification & description of Ring Frame of Unit – 2
Model AD - 2
Manufacturing 2013
year
No. of M/C 27

Country of India
origin
company

 Machine specification & description of Ring Frame of Unit – 3 (line-1)
Model AD - 2
Manufacturing 2013
year
No. of M/C 14

Country of India
origin
Auto doffer Present
company
 Machine specification & description of Ring Frame of Unit – 3 (line-2)
Model AD - 2
Manufacturing 2013
year
No. of M/C 11
Country of India
origin
Auto doffer Connected in 3 machine
company

4.8: Auto Cone Winding section:

The Auto cone winding machine is used to make the yarn cone package from ring cops. During
winding, a yarn clearer device is placed onto each drum head of the auto coner machine which
detects the faulty parts of yarn. Then the faulty part is cut& a splicer joins it. Quantum-3 is used as
yarn clearer.
Objectives of Autocone Winding Machine:
 To prepare a big package from ring bobbin.

 To remove spinning faults.
 To improve the quality of yarn.
 To wax the yarn.
 Specification and machine description of Autocone Winding machine of Unit-1:

Autoconer 6:
Model Autoconer-6
No. of M/C 04
Manufacturing year 2017
Production 62 kg/hr
Electric Clearer USTER Quantum 3
Manufacturing Schlafhorst
company
Fig: Auto Cone Winding
 Specification and machine description of Autocone Winding machine of Unit-2:
a) Autoconer 6:
Model Autoconer-6
No. of M/C 04
Production 62 kg/hr
Electric Clearer USTER Quantum 3
company

b) Autoconer X5
Model Autoconer X5
No. of M/C 01
Production 50 kg/hr
Electric Clearer USTER Quantum
company
c) Autoconer
Model Autoconer
No. of M/C 01
Production 35 kg/hr
company
 Specification and machine description of Autocone Winding machine of Unit-3(Line-1):
Autoconer 338:
Model Autoconer 338
No. of M/C 05
Production 40 kg/hr
Electric Clearer USTER Quantam
company

 Specification and machine description of Autocone Winding machine of Unit-3(Line-1):
Autoconer 6:
Model Autoconer 6
No. of M/C 04
Production 62 kg/hr
Electric Clearer USTER Quantam 3
company
Process parameters of winding machine:
Winding heads 60
Drum diameter 100 mm
Tensioning device Tensor Disc
Yarn speed 1350m/min

Splicing system Pneumatic
Finished package wt. 1.9kg

Electronic clearer USTER Quantum-3
Magazine 9 bobbin feed

Cutter Ceramic
Traverse length 132 mm

Drum type Pac21(Ø100) 2.3 w

USTER® QUANTUM 3:
The USTER® QUANTUM 3 is a yarn clearing and monitoring system for winding machines
consisting of:
1. Central Clearing Unit 6 (CCU6). One control unit per winder. All settings and operational check
of
each position are made from the Central Clearing Unit.
- Standalone on all winders except Saurer. Schlafhorst Autoconer 6, Autoconer 5, X5
- Integrated with winder Informator on Saurer. Schlafhorst Autoconer 6, Autoconer 5, X5,
as well as Savio Polar and Savio Polar Multi-cone
2. Intelligent clearer measuring heads (IMH) for each winding position.
3. Interface to the winding positions and connecting cables.
The USTER QUANTUM 3 measures yarn quality parameters, including CV, imperfections and
hairiness, using the Q Data feature, correlated with USTER TESTER data. The USTER QUANTUM
3 alarms on different yarn fault and this is defined as cut alarm, quality alarm etc. It alarms on
following faults:
￭ Short thick place
￭ Long thick place
￭ Thin place
￭ Count deviation
￭ Foreign matters
￭ Polypropylene fibres
￭ Periodic faults
￭ Shade variation
￭ Continuous Shade variation
￭ Frequent neps
￭ Hairiness
4.9: Yarn Conditioning/Heat Setting:

Heat setting is a term used in the textile industry to describe a thermal process taking place mostly in
either a steam atmosphere or a dry heat environment. The effect of the process gives fibers, yarns
dimensional stability and, very often, other desirable attributes like higher volume, wrinkle resistance
or temperature resistance also used to improve attributes for subsequent processes. Yarns tend to have
increased torque just after spinning, cabling or twisting. Heat setting can influence or even eliminate
this tendency of undesirable torqueing.

Model 1000 KG LPG
Capacity 416 cones
Manufacturing SIEGER
company
Process parameters of Heat setting:

Product Temperature Time
Cotton, Cotton 60ºC 50 min

Melange

4.10: Packaging section:
Specification of Yarn Packaging Machine:
Model Zancancer
Country of origin Italy
Input Capacity 11 cones
Manufacturing Zancancer
company
Measurement of packing bag:

 Length of packing bag = 37 inch
 Height of Packing bag = 48 inch .
 Bag weight = 51.3kg
 A bag contains 24 cones
 Each cone contains 2.04 kg yarn
 Weight of paper cone (24 pcs) = 1.03 kg
Package label:
Package label contains following information:
 Yarn count
 Types of yarn
 Code no
 Lot no
 Factory name
 Date of making yarn
 Weight in kg

CHAPTER FIVE
Quality Control
5.1 Quality control system:

The quality control department is assigned to maintain consistently uniform quality of the material
in process and various stages of its manufacturing. Shohagpur Textile Mills Ltd. is more concern
about quality.
5.2: Plan of quality department:

 Raw cotton analysis.
 CV% & deviation control of gr/yd and count.
 Setting parameter control (B/R, Card setting, Roller gauge, Draft, TPI, Speed, Yarn clearer
etc.).
 Optimum quality (CV%, Thin, Thick, Neps, H%, Tenacity, Elongation, CSP).
 Wastage control (B/R to finishing).
 Machine fault find out by machine audit and rectification by responsible department (B/R to
Finishing).
 Operation control (m/c, floor cleaning, material handling, lot change, count change and
housekeeping etc.).
 Manpower training (market demand, operation, wastage/quality control, Work procedure,
housekeeping and safety).
 Yarn performance report (Observation market feedback report).
 Continual improvement by R&D.

5.3: List of testing equipment and their manufacturer and model no:
M/c name Manufacturer Model no No of

machine
Lea strength Tester MAG, INDIA YO261 1
Auto Wrap 10 MAG, INDIA YO121 1
USTER AFIS PRO-2 USA AFIS PRO-2 1
HVI MAG HVT Smile 100 1
USTER TESTER-6 Switzerland YGO41 1
5.4: Machine description:
a)Auto wrap 10:
Specification Details
Machine Name Wrap Reel
Model Auto Wrap 10
No. of M/C 03
Origin India
Fig: Wrap Reel
Function: An auto wrap reel is an automatic device for measuring yarn and making it into hanks of
a standard size. The reel is of a standard size and its revolutions are counted as the yarn is wrapped
around it. A set number of revolutions will be used so that the hank is of a standard size — a skein
or a lea. A skein of cotton would be 80 turns on a reel of 54 inches circumference, making 120
yards.

b) Lea strength tester:
Machine Name Lea Strength Tester

Model TYT-030
Brand TECHNO
Origin India
No of Machine 1
Fig: Lea Strength Tester
Function: A lea strength tester measures the strength of one lea yarn. One lea means 120 yards.
Strength is a measure of the steady force necessary to break a material and is measured in pound.
The m/c works in constant rate of extension.
c)USTER tester 6:
Fig: USTER Tester 6

Function: It is used to measure the unevenness of mass (Um %), co-efficient of variation of mass
(CV %), hairiness, imperfection index (IPI), thick- and thin places, neps etc. of yarns, rovings and
slivers. Principles of Uster evenness tester are capacitive principle and optical principle.
d) USTER AFIS PRO-2:
Fig: Uster AFIS Pro-2
This instrument is widely used instrument for neps measurement (Advanced Fibre Information
System) . This equipment has three modules.
 NC Module (Nep classification)
 L & M Module (Length and Maturity)
 Trash Module
Functions: To measure following fiber properties-
-Nep (Cnt/gm) L(n) (%CV)

SFC(n) (%<12.7) L(w) (mm)
Nep (μm) IFC (%)
UQL(w) (mm) Maturity ratio
SCN (Cnt/gm) L(w) (%CV)
L(n) (mm) SFC(w) (mm)
SCN (μm)

e) HVI:
Machine Name HVI
Model HVT Smile 1000
Brand USTER
Origin India
Function:
The USTER HVT Smile 100 measure the most important cotton fiber properties for cotton classing
purpose (and high throughput for spinning mills). These are length, uniformity, short fiber index,
micronaire, maturity index, strength, elongation, colour & Trash and moisture content.
Feature:
(High Volume Instrument) This equipment is used mainly for bale management. This equipment
contains three modules. They are:
 Micronaire (MIC)
 Length and strength
 Maturity

Different Test Specifications:

A. Micronaire: Different values of micronaire make difference in fiber grade as follows;
Micronaire values Fiber grade
Less than 3.0 Very fine
3.0 to 3.6 Fine
3.7 to 4.7 Medium
4.8 to 5.4 Coarse
5.5 to higher Very coarse
B. Maturity: The values of maturity index identify the level of maturity as follows;
Maturity Index Description
Below 0.75 Uncommon
0.75 to 0.85 Immature
0.86 to 0.95 Mature
Above 0.95 Very mature
C. Uniformity Index: The uniformity index expresses the ratio of the mean length to the
upper half mean length. It is an indication of the distribution of fiber length within the
fibro gram.
Uniformity Index Description
Below 77 Very low
77 to 80 Low
81 to 84 Medium
85 to 87 High
87 and higher Very high
D. Length: Fiber length in Inches and upper half mean length (UHML) in inches & millimeter
ratio are the main calculative result of length test as follows;
Fibre
length(Inches) UHM (inches) UHM (mm) Code (32nds)
<13/16 <0.79 <20.1
20.1-21.6
13/16 .80-0.85
7/8 0.90 – 0.92 22.9-23.4 29
15/16 0.93 – 0.95 23.6 – 24.1 30
31/32 0.96-0.98 24.4 – 24.9 31

1 0.99-1.01 25.1 – 25.8 32
1 1/32 1.02-1.04 25.9 – 26.4 33
1 1/16 1.05-1.07 26.7 – 27.2 34
1 3/32 1.08-1.10 27.3 – 27.9 35
1 1/8 1.11-1.13 28.2 – 28.7 36
1 5/32 1.14-1.17 29.0 – 29.7 37
1 3/16 1.18-1.20 30.0 – 30.5 38
1 7/32 1.21-1.23 30.7 – 31.2 39
1¼ 1.24-1.26 31.5 – 32.0 40
1 9/32 1.27-1.29 32.3 – 32.8 41
1 5/16 1.30- 1.32 33.0 – 33.5 42
1 11/32 1.33 -1.35 33.8 – 34.3 43
1 3/8 >1.36 >34.5 44
Wastage:
Section For 100% Cotton For PC or CVC

Blowroom Up to 4% (Dropping-2) 2.5%
Carding Up to 6% (Dropping-1) 3.5%

Breaker drawframe 0.5% 0.5%
Finisher drawframe 0.5% 0.5%
Simplex 1% 1%
Ring 2.5% 1.5%

Winding 0.35% 0.35%

CHAPTER SIX
Maintenance
6.1: Maintenance:
Maintenance is the combination of all technical and associated administrative actions intended to
retain an item in, or restore it to, a state in which it can perform its required function. Many
companies are seeking to gain competitive advantage with respect to cost, quality, and service and
on-time deliveries. The effect of maintenance on these variables has prompted increased attention
to the maintenance area as an integral part of productivity improvement. Maintenance is rapidly
evolving into a major contributor to the performance and profitability of manufacturing systems.
Objectives of maintenance:
 Minimizing the loss of productive time because of equipment failure.
 Minimizing the repair time and repair cost.
 Minimizing the loss due to production stoppages.
 Prolonging the life of capital assets by minimizing the rate of wear and tear.
 To keep all productive assets in good working conditions.
 To minimize accidents through regular inspection and repair of safety devices.
 To minimize the total maintenance cost which includes the cost of repair, cost of preventive
maintenance and inventory carrying costs, due to spare parts inventory.
 To improve the quality of products and to improve productivity.
6.2: Maintenance of machineries:
Electrical
Preventive Maintenance
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Break Down
Maintenance Mechanical
Maintenance

Break down maintenance:

Break down Maintenance is maintenance performed on equipment that has broken down. It is based
on a breakdown maintenance trigger.
Preventive maintenance:
Preventive maintenance is the care and servicing by personnel for the purpose of maintaining
equipment and facilities in satisfactory operating condition by providing for systematic inspection,
detection and correction of incipient failures either before they occur or before they develop into
major defects. This type includes maintenance of machine parts like gear changing.
6.3: Machineries used for maintenance:

The list of machineries used in Shohagpur Textile Mills Ltd. is given below-
 Grinding machine
Carding  Mounting machine
 Brush cleaning machine etc.
 Long cot grinding machine

Draw frame  Flyer washing machine
 Grinding machine etc.
 Cot grinding machine
Ring frame  Cot mounting machine
 Spindle oil change machine etc.
Fig: Grinding Fig: Grinding roller

6.4: Maintenance points:
S.N. Items need to be checked & serviced
1. Check and tightening all motor terminals.
2. Check and clean pressure sensor and tightening terminals
3. Check and clean the interfacing and data cables.
4. Check and tightening the proximity switch terminals.
5. Inspection, cleaning and tightening all the terminals in the panel.
6. Check and tightening limit switch, safety door guard and the emergency switch.
7. Functional test of the fibre, sliver, roving and yarn detector.
6.5: Machine maintenance schedule:
6.5.1: Maintenance for blow room:
Operations Frequency
Cleaning of dust and collected fly from the m/c Daily

Cleaning of motor air intake screens Daily
Cleaning of flat belts, v-belts and sprockets Every 7 days

Cleaning the brush roller Every 7 days
Checking the condition & tension of flat belt & chain drives. Every 7 days
Oil change in gear motors Every 30 days
Lubrication works of bearing of supporting shaft and tension Every 15 days

pulley.
Cleaning of fibre accumulating from the grid bars and the pins Every 7 days
of the beaters.
Cleaning of the intake grill of the fan cover of the driving motor. Every 15 days

6.5.2: Maintenance for carding:
General cleaning of machinery by the operator. Daily
Checking of stop motion switches Daily
Checking of belt tension and condition Daily
Ampere rating of motor Every 7 days
Checking of doffer to cylinder driving gears Every 30 days
Full setting/re-setting Every 30 days
Dismounting and cleaning of feed coupling plates and web units Every 30 days
Checking of auto leveler Every 30 days
Checking the condition of wire of cylinder, taker-in doffer and Every 30 days
flat combs Every 30 days
Checking the gauge of feed plate to feed roller Every 30 days
Checking the gauge of taker-in to cylinder Every 30 days
Checking the gauge cylinder to doffer Every 30 days
Under casings setting Every 30 days
Checking of trumpet, calendar roller & gears Every 30 days
Checking the bearings & motor shafts Every 30 days
Wire replacement of cylinder, doffer & f1ats. Every I5-18 months

6.5.3: Maintenance for Draw frame:
General cleaning of machine by operator Daily
Cleaning of top roller cots with suitable solvent Daily
Checking the drive/motion of clearer cloth, clearer pad,positive Daily

drive comb, can change drive
Checking the function of oil pump of outer side, gear end s ide, Daily
filling the oil in oil tank
Function of stop motion limit switches etc. Daily
Greasing the top bushes having bearings Every 7 days
Roller gauge checking/resetting Every 30 days
Pressure checking/resetting Every 30 days
Cleaning the bottom fluted roller with wire brushes Every 30 days
Cleaning and polishing of coiler and brush Every 30 days
Lubricating/greasing of the creel roller drivers Every 30 days
Tightening of the loose nuts, bolts, allan screws etc. Every 30 days
Checking the condition of trumpets, sliver guides, clearer tubes Every 30 days
yokes, air pipes grease nipples etc.
Checking of timing belt tension Every 30 days
Backlash checking of machine gears Every 30 days
Checking the eccentricity of top and bottom roller (if needed) Every 30 days
Oil change Every 60-90 days

6.5.4: Maintenance for simplex:
Check functioning of oil pump Daily
Topping of oil Every 15 days
Building motion setting Every 30 days
Top roller cot treatment/greasing Every 30 days
Roller gauge checking/resetting Every 30 days
Centering/alignment the sliver guide, collector and condenser in Every 30 days

relation to cot
Alignment of bottom apron tensioning pulley W.R.I. knurled Every 30 days

roller
Checking & tightening of loose nuts blots etc. Every 30 days
Pressure checking/resetting Every 30 days
Top roller cot grinding Every 30 days
Lubricating oil change Every 60-90 days
Replacement of top roller cots Every 60-90 days
Greasing the top roller arbour Every 360 days

6.5.5: Maintenance for ring frame:
Operation Frequency
Checking of oil pump Daily
Checking of push-button& motor amperes Every 7 Days
Refilling of oil Every 7 Days
Tension of V-belts and spindle tapes Every 7 Days
Checking of gears & gear meshing Every 20 days
Inverter checking A/C (input & output), D.C Every 20 days
Top roller cots treatment / greasing Every 36 days
Checking of spindle and lappet Every 36 days
Checking of ring rail parallelism Every 36 days
Checking of ring cup block gauge Every 36 days
Building motion setting Every 36 days
Roller gauge checking / resetting Every 36 days
Pressure checking / resting Every 36 days

Bottom roller turning (If required) Every 36 days
Checking of traverse motion, top & bottom rollers/top etc. Every 36 days
Greasing of all bearings, open gears etc. Every 36 days
Checking & tightening of loose nuts, bolts etc. Every 36 days
Top roller cots buffing / grinding Every 90 days

6.5.6: Maintenance for auto cone winding:
Operation Frequency
Checking and removal of blow cleaner waste Daily
General cleaning of blower motor, filter shaft, motor filter Daily

control box, clipper filters
Measuring head checking Every 7 Days
All micro switch checking Every 7 Days
Gauge checking/resetting Every 7 Days
Drum checking Every 30 Days
Checking of splicing unit Every 30 Days
Spray lubricant for cutters Every 30 Days
Checking of cone sensors Every 30 Days
Spray grease for drive gears/spindle oil for cam shafts Every 30 Days
Checking of drum bearing, splicing bearings, blower shaft Every 90 Days

bearings
Checking of drum brakes, shutter cutters, cassette type joint Every 180 Days
gears, reduction gears

CHAPTER SEVEN
Utility Services
In Shohagpur Textile Mills Ltd. the available utility services are:
Generator
A/C Plant
Electrical & Electronics
Compressor
7.1 Generator:
M/c Name Model Brand Country of Manufacturing Quantity

Name origin year
Generator VPH 7100 Waukesha USA 2000 2

GSID
Generator VHP 3604 Waukesha USA 2003 1
GSID
Generator 5904 GSID Waukesha USA 2005 1

LTD
Water pump KSB India 2003 4
(Generator cooling)

STML Power Generation Status at a glance:
Power Consumption
Mill-1 Mill-2 Mill-3 Mill-4 Security Colony Pump Cooling Lightening
Tower
256.90 1344.22 828.72 813.75 16 KW 70 KW 239.20 33.35 17.42 KW
KW KW KW KW KW KW
Generator + REB = 4831 KW
Power Status
Generator (850×2) + (800×2) 3300 KW
Total 3300 KW
Power Capacity
Generator (920×2) + (900×2) 3640 KW
REB 1191 KW
Total 4831 KW
a) Generator specification:
Type Gas generator
Total capacity 920 KW (each)
Frequency 50 HZ
Efficiency 70%

b) Electrical panel:
M/c Name Brand Country of Manufacturing Quantity
origin year
LT-Panel (4000AMPS) Siemens Germany 2007 3
PFI-Panel (500KVAR) Siemens Germany 2007 3

BDT (3200AMPS) Siemens Germany 2007 3
BDT (3200AMPS) Siemens Germany 2007 3
7.2: Cooling tower:
M/c Name Model Country of origin Manufacturing Quantity

year
Cooling tower Thailand 2012 7

350RT
Fig: Cooling Tower

7.3: AC plant:
M/c name Model Country of Manufacturing Quantity

origin Year
LUWA completer A/C plant DG 05 Switzerland 2010 3 (Unit-1)
LUWA completer A/C plant DG 05 Switzerland 2010 2 (Unit-3
A/C plant controls the relative humidity in different section during processing of yarn. The most
effective way to humidify a textile plant is to use a compressed air & water spray system. Air
humidity is measured as ‘Relative Humidity. It is defined as the amount of water in a sample of air
compared to the maximum amount of water the air can hold at the same specific temperature.
It’s expressed in a form of ―0 to 100.
Cold air can hold less moisture than warm air, therefore the humidity of air is relative to its
temperature. For example, a sample of air at 10ºc can hold less moisture than the same sample of
air at 20ºc. Even with the same amount of water present in both samples, the warmer sample has a
lower relative humidity as it can potentially hold more moisture than the cold air sample. The
properties like dimensions, weight, tensile strength, elastic recovery, electrical resistance, rigidity
etc. of all textile fibre whether natural or synthetic are influence by moisture regain.
Air conditioning is the process of treating air also as to control simultaneously its temperature,
humidity, cleanliness and distribution to meet the requirements of "conditioned space". An air
conditioning system may use heating, cooling, humidifying, de-humidifying and filtering units of
combination of these depending upon the outside weather.
The capacity of an air conditioning system is directly proportional to the heat load in the system.
The heat load consists of internal heat which is almost constant for textile mills and transmission
heat which varies from time to time and season.
The maximum heat load, which occurs during summer afternoons, determines the capacity of air
conditioning required for a department of the maximum heat load, roof heat load accounts 25% to

30%. Air conditioning plants are installed to maintain correct ambient condition for spinning process
to work smoothly. Norms of temperature and relative humidity for textile mills are established
through controlled experiments in laboratories and mills.
Relative humidity and temperature in different section:
Section RH Temp
Blow room - Simplex 48-58% 30ºC
Ring section 50-55% 35ºC
Finishing 60-66% 29ºC
7.5: Compressor:
Flow Chart of Compressor:
Motor
Suction Filter/ Air Filter
Compressor
Oil Separetor
Oil Filter
Condenser
Reserve Tank

M/c Name Model Country Manufacturing Quantity

of origin year
KAESER 2014 4 (Unit 01 & 03)
ELGI E-75 2010 3 (Unit 02)
KAESER Air dryer 2010 1 (Unit 01 & 02)

KAESER Air dryer 2010 1 (Unit 03 & 04)
Parameters of compressor:
Power consumption for a compressor 60 KW/Pcs
Voltage 41 V
Frequency 50 HZ
Capacity 13.6m/min
Normal pressure 5.5 bar
Pressure after compressed 8.6 bar
Fig: Compressor

CHAPTER EIGHT
Store & Inventory Control
8.1: Inventory control:

Store is the place where every type of raw materials, spares, finished goods are kept in proper
system. Inventory control means the accurate calculation of every type of raw materials, spares,
wastages and finished goods time to time. Inventory control is necessary-
 To know about the required amount of raw material,
 To be continued the production process,
 To find out the profit or loss of a company,
 Stock and stock value for consumption measuring etc.
8.2: Sections of store:
STML store consist of five sections:

a) Inventory System for spare parts:

In this mills required amount of spears of different machine are stored in mechanical store room.
All the spears are listed in a sheet which is controlled by mechanical and maintenance personal.
Spears are arranged in store room according their size, quantity and requirements.
b) Inventory system for finished goods:

STML supplies its finished yarn to different fabric manufacturing industry. So cone package yarns
are stored for short time in the finishing section. All the delivered yarns are noted on tally khata
according to lot no, count, quantity, buyer ‘s name and other technical parameter.
c)Inventory system for raw material:

 Raw materials partially received from production planning & directly from head office.
 Material receiving & inspection report (MRIR) is prepared. Received quantity is mentioned
and noted down.
 Submitted to Q.C. department. Some are OK & few rejected.
 Entry of data of goods.
 Goods are arranged according to OK or rejected group.
 As per requisition materials supplied & this record is noted down.
 All the raw cotton is stored in godown, near the blow room section.
d)Inventory system for general store:

In general store, there stored-
 Capital equipment’s.
 Accessories.
 Stationary.
 Maintenance parts etc.
All the particulars are labelled and the records of them are noted in record book.
e) Inventory system for waste cotton:

There is a waste cotton godown where hard waste and soft waste are stored. Dropping-1, dorpping-
2, flat strip, noils, bonda waste etc are sorted and stored as per as their usability.

8.3: Inventory procedure:

 Store requisition
 Store ledger account
 Daily inspection & package report
 Monthly stock & consumption report
 Monthly L/C wise delivery report
 Received delivery & balance stock

CHAPTER NINE
Marketing Activities & Cost Analysis
9.1: Consumers of product:

The regular consumers of STML product are like,
 Knit Concern.
 Kakado.
 J.S Design.
 Woolen & Wool.
 Keya Spinning mills.
 Metro.
 Aman Tex Spinning.
9.2: Exporting country:
Shohagpur Textile Mills Ltd. does not export yarn directly. They sell yarn to the various export
oriented factory. And after the factories make knitted garments & dyed fabric, then the final products
are exported.
9.3: Importing country:

Raw cotton is imported mainly from Uzbekistan, Tajikistan, Cameroon, South Africa, Australia
Zimbabwe, Tanzania, Azerbaijan, India, Benin, Uganda, Brazil, Zambia.
9.4: Local market:

STML produces not only export quality yarns but also supply yarns in local market.
9.5: Cost analysis:

The management of STML does not provide any information regarding these to the outsiders as per
their managerial policies.

9.6: Marketing strategy:

Marketing strategy is a very important factors to sale the products to the buyer. If the marketing
strategy is not so developed, it will be very hard to reach the goal. In Shohagpur Textile Mills Ltd.,
mainly senior marketing officers & higher officials deal with the buyer. There are some fixed buyers
of the industry. The buyers give their orders continuously all over the year. By both side
understanding the rate & the order quantity are fixed.
A well-defined marketing strategy has the following characteristics:
 Prompt service,
 Good commitment.
 Good quality,
 Low price or competitive price.

CHAPTER TEN
Administration, Account, HRD and First aid
10.1: Administration:
Administration department plays a vital role in manufacturing industry. It controls/maintains and

looks after all the task of all departments in industry. It communicates with different department in
regarding company’s target. It is said that, well administration is half success and well management
is the fame of company.
Administration is like a network which spread information, gather information, collect data, recruit
employee & worker, well distribution, try to improve the company’s environment, improve skill by
arranging training and soon. Objective and tasks are:
 To control/maintain and look after,
 To recruit the manpower,
 To improve environment of industry,
 To communicate with owner of the company, local, politician, legal adviser, if face any
unexpected problem,
 To ensure the security of properties and employees inside the factory,
 To arrange training for improving skill,
 To motivate employees and workers and aware about rules and regulations of industry.
10.2: Accounts:
All the financial activities are done by Accounts department. This department is responsible of any
transaction, pay wages, account receivable and payable, to inform to owner, make monthly sheet
and yearly sheet and so on.

10.3: Fire-fighting:
a) Equipment:
STML installed a modernized fire hydrant system covering the entire area of the factory. Fire
extinguishers of CO2 and ABC gas powder are available in every section of the factory. A fire can
rapidly spare in a spinning mill if it cannot be controlled. Cotton ignited very fast. The worker and
other related person are always ready for any kind of accident with their modern equipment.
b) Fire extinguisher:
There are 3 kinds of fire:
 A class – Solid fire (Cotton, fiber, bamboo, wood etc.)
 B class – Liquid fire (Diesel, petrol, octane etc.)
 C class – Gas fire
And there are five kinds of fire extinguisher:
 ABCE (It can be used in all kinds of fire)
 DCP (Dry chemical powder)
 CO2 (For electrical fire)
 Water type
 Foam type
Here, in STML, there are 200 fire extinguishers, 100 of these are dry powder, 20 of these are
water type, and 5 of these are foam type. There are 50fire house cabinets present in STML.
10.4: HRD department:

Human Resource Development department provides the facilities of employees and workers in
industry. This is also called facilitator department. Tasks of HRD are:
 Need to arrange training program for manpower development.
 To act as a bridge / catalyst / facilitator.
 To co-operate with other departments as per their requirements.

10.5: First aid:

First aid means primary treatment of any injury. It may be done by doctor, nurse, expert of medicine
and others. The main tasks of first aid team are:
 To provide necessary medicine
 To aware of workers about first aid
 To check up worker’s health
 To send injured to general hospital if needed
 To give proper treatment & medicine
 To call ambulance for serious injured

CHAPTER ELEVEN
Impact of the Internship
It gives me chance to learn new skills that add to my knowledge base while gaining
confidence in my abilities. Gain industry knowledge first hand from an organization and
professionals. Opportunity to practice communication and teamwork skills. Achieve a sense
of accomplishment by contributing to an organization.
Industrial attachment helps us to learn about the field from the inside and decide if this is the
right career field for us. It also helps us to work alongside in our chosen career area. Along
these, it helps us to observe the work place and see if it matches expectations.
Industrial attachment provides us evidence that I have initiative, are reliable, and have a sense
of responsibility. It helps me to achieve and make chance to apply some of the ideas learned
in school and provide a bridge between school and the professional world .

CHAPTER TWELVE
Conclusion
As an undergraduate of the National Institute of Textile Engineering & Research we would like to
say that this training program is an excellent opportunity for us to get to the ground level and
experience the things that we would have never gained through going straight into a job. We are
grateful to the Shohagpur Textile Mills Ltd. for giving us this wonderful opportunity. The main
objective of the industrial training is to provide an opportunity to under graduates to identify,
observe and practice how engineering is applicable in the real industry. It is not only to get
experience on technical practices but also to observe management practices and to interact with
fellow workers. It is easy to work with sophisticated machines, but not with people. The only chance
that an undergraduate has to have this experience is the industrial training period. I feel I got the
maximum out of that experience. Also we learnt the way of work in an organization, the importance
of being punctual, the importance of maximum commitment, and the importance of team spirit. The
training program having three destinations was a lot more useful than staying at one place
throughout the whole two months. In my opinion, I have gained lots of knowledge and experience
needed to be successful in a great engineering challenge, as in my opinion, Engineering is after all
a challenge and not a job.
Finally, we like to thank the directors and employees of STML for their support and encouragement
during our training period. By dint of that we have enriched our depth of knowledge on practical.
We believe STML will hold its name and fame in future too. We like to wish Shohagpur Textile
Mills Ltd. all success.
------The End------

Industrial Attachment of Shohagpur Textile Mills Ltd.

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Industrial Attachment of Shohagpur Textile Mills Ltd.

Uploaded by

Copyright:

Available Formats

INDUSTRIAL ATTACHMENT

National Institute of Textile Engineering & Research

NAME STUDENT ID SESSION

National Institute of Textile Engineering & Research (NITER) | 1

National Institute of Textile Engineering & Research (NITER) | 2

II. Executive Summary /Introduction

 To experience what it is like to work in a professional organization,

 2.5 weeks in Maintenance Department.

National Institute of Textile Engineering & Research (NITER) | 3

III. Table of Contents

Chapter 01: Description of Organization 08-10

Chapter 02: Man Power Management 11-16

Chapter 03: Material Management 17-18

Chapter 04: Machine Description & Production Planning Sequence &

Part 4.1: Process flow charts of ring spinning yarn production 19

National Institute of Textile Engineering & Research (NITER) | 4

National Institute of Textile Engineering & Research (NITER) | 5

Chapter 05: Quality Control 57-63

Chapter 06: Maintenance 64-71

Chapter 07: Utility Services 72-78

Chapter 08: Store & Inventory Control 79-81

National Institute of Textile Engineering & Research (NITER) | 6

Chapter 10: Administration, Account, HRD and First aid 84-86

Chapter 11: Impact of the Internship 87

Chapter 12: Conclusion 88

National Institute of Textile Engineering & Research (NITER) | 7

1.2: Purbani Group Subsidiaries:

 Karim Spinning Mills Ltd.

1.3: Information about Shohagpur Textile Mills Ltd.:

Name of the Factory Shohagpur Textile Mills Ltd.

Chairman Abdul Hai Sarker

Managing Director Shafiqul I. Sarker (Sohel)

Deputy General Manager Major Md. Mahbubur Rahman (Retd)

National Institute of Textile Engineering & Research (NITER) | 8

Head Office Sena Kalyan Bhaban (15th floor),

1.4: Overview on Shohagpur Textile Mills Ltd.:

Nature of the company Private Limited Company.

Number of spindles installed 44000

Product Mix Mélange Yarn, 100% Cotton Mélange, Neps,

Male Employee 650

Female Employee 750

Power Supply Gas generator

1.5: Different Departments of Shohagpur Textile Mills Ltd.:

National Institute of Textile Engineering & Research (NITER) | 9

National Institute of Textile Engineering & Research (NITER) | 10

Man power Management

National Institute of Textile Engineering & Research (NITER) | 11

2.2: STML Manpower setup:

Quality control department:

National Institute of Textile Engineering & Research (NITER) | 12

Production department (Unit- 1,2, 3):

National Institute of Textile Engineering & Research (NITER) | 13

Generator &Maintenance Designation Current manpower

Designation Current manpower

National Institute of Textile Engineering & Research (NITER) | 14

2.3: Job responsibilities of officers:

b) Assistant Quality manager, Quality Control Officer:

c) Senior production officer and Production officer:

National Institute of Textile Engineering & Research (NITER) | 15

National Institute of Textile Engineering & Research (NITER) | 16

3.1 Sources and different types of raw material: (Fibres)

3.2: Bale Information :

Binding material used for bales Steel wire

National Institute of Textile Engineering & Research (NITER) | 17