Paramount textile ltd

Southeast University Industrial Attachment
1
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
Paramount Textile Ltd
Southeast University
1
INDUSTRIAL TRAINING
1
INDUSTRIAL TRAINING

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Department of textile engineering
Industrial Attachment
Supervising teacher
Prof. Syed Fakhrul Hassan Murad
Chairman
Department of textile engineering
Banani, Dhaka.
Submitted By:
Name Id. No. Contact Remarks
Anup Kumar Biswas 2009000400120 01923862487
anup_seu@yahoo.com
MohimenurRhaman 2009000400032 01673909394
sumon032@gmail.com
M. SadayatHossain 2009000400036 01675652545
sadayathossain@gmail.com

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Abstract
The aim of industrial practice is to make us familiar with any kind of industry, the whole
process going on the industry, its environment and also with the management system of the
industry. As a student Textile engineering department, the target of any student should be to
know the production process and the management system. It is because of the fact that to run
any industry not only production department is obvious but also the capability of managing
the whole system is an obvious matter. It is also a responsibility of an engineer is to develop
the ongoing process into a better system to cope with the present competition. Thus a
diversified challenge emerges in front of the manufacturer and other organizations. With a
view to overcome this consequence a new generation of engineering graduates with leadership
skills and management capabilities altogether are in demand.
We the students of Textile Engineering Department were sent to different industries and
assigned to different tasks. We were assigned to Paramount Textile Ltd. (Paramount group
Ltd.). This report is a presentation of our experience in the garments and also a details
presentation of our works in that industry.
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Abstract
3
Abstract

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Acknowledgement
All praises to Almighty Allah alone, the Most merciful and the most compassionate and His
Holy prophet “ Muhammad “ (Peace be Upon Him) the most perfect and exalted one among
and of ever born on the surface of earth, who is forever touch of guidance and knowledge for
the humanity.
The work presented in this manuscript was accomplished under the guidance generous
assistance, constructive criticism and enlightened supervision of Lecturer Md. Mahamudul
Islam. His efforts towards the inculcation of spirit of constant work and the maintenance of
professional integrity besides other invaluable words of advice will always serve as beacon of
light throughout the course. We take this humblest opportunity to our deepest sense of
gratitude and thankfulness to him.
This internship report is not the result of individual effort. It is a result of wonderful team-
work.
We are really thankful on HoripodoDev who is the General Manager of Admin & HR, of
Paramount Textile Ltd. who gave us the approval for making of that regard. We are also really
thankful on Mohammad ShahdathHossen who is the Deputy General Manager (Weaving) of
Paramount Textile Ltd. who helped us for getting information about our internship.
We are thankful to all those who supported us and provide us great help for completion of this
task. We have tried our level best to prepare this event with high level of accuracy but no one
claim to perfect other than Almighty Allah.
Executive summary

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This report is the result of two months internship. During the internship it was required to
study the organization, department of the organization and critically relate the theoretical
aspects of the Textile to the practical situation.
Paramount Textile Ltd. operates throughout the world with over 2287employees as part of
PARAMOUNT team. Paramount collection has a wide selection of quality 100% cotton,
CVC, Cotton-polyester, competent professional staff, a team of talented merchandisers,
excellent supplies & support services, and state-of-the-art technology is the driving force
behind Paramount’s phenomenal growth in the past years. Paramount has expanded its
operations to include the Internet, and has taken advantage of the variety of international trade
facilitated by the Web. Now Paramountuses state-of-the-art client/server technology for its
market information processes to coordinate its network of global buyers and agents around the
world. Environmental Organizational and the individual challenges which are to face by the
department of “Paramount Textile Ltd.”. The motive of joining the Paramount is to have an
exposure of textile sector and potential to avail a sound and promising career. There are
noformal union in Paramount Group.
Methodology of internship

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Every research program should follow some basic form of procedures. However mainly this
report is written on the basis of experience gathered during the period of Internship. We
carefully observed the various activities of different department, especially fabric section of
Paramount Textile Ltd. A qualitative research is used to conduct this study.
In order to make the report more meaningful and presentable two sources of data and
information have been used widely. Both primary and secondary data have been used to
prepare the report
Content

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Topics Page no.
Introduction 9
Objectives of Internship 10
PARAMOUNT TEXTILE LIMITED AT A
GLANCE
11-12
PARAMOUNT TEXTILE LIMITED AT A
GLANCE
13
Head office (marketing)
CAD/Swatch
Fisibilitycheck
Preparation of dispo
Store
Soft winding
Yarn dyeing
Hard winding

8
Warping
Sizing
Draw-in
Weaving
Gray inspection
Singing
Washing
Stantaring
Sanforing
Quality assrunce
Conclusion
Reference

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Initial Conversation
Industrial attachment is the first step to professional life of student, especially of technical
Side. It’s an indispensable part of study a practically running processing technology of an
industrial unit for a student .In our university , processing machines are not in continuous
running condition, so it would only provide demonstration of mechanical features &
processing technology of the material in accomplishment of the theory there of but not of the
situational variables to achieve practical knowledge. So two months industrial attachment
program in a dyeing mill was arranged for us.
Textile education can’t be completed without industrial training. Because this industrial
attachment program minimizes the gap between theoretical and practical knowledge and make
me accustomed to industrial environment. I got an opportunity to complete two month long
industrial training in PARAMOUNT TEXTILE Ltd, which is a 100% export, oriented
Weaving Industry. It has well planned & equipped fabric and Yarn dyeing-finishing units in
addition to facilitate weaving & woven fabric manufacturing.
The rationale behind the existing structure and future expansion of PARAMOUNT
TEXTILE Ltd is to capture value-added at each stage of the textile manufacturing process.
Despite Bangladesh’s lack of indigenous cotton production capacity. PARAMOUNT
TEXTILE Ltd has leveragedBangladesh’s labor cost advantage and export competitiveness
to the Maximum.

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Objectives of Internship
Objective:
The objective of the report is to learn about the overall activities of different departments in
Paramount Textile Ltd. A primary textile industry Academic knowledge is not perfect without
practical knowledge.
Specific Objectives:
This intern paper has been prepared for fulfilling the following specific objectives:
 To enlarge the dimension of knowledge regarding fabric manufacturing as well as
others.
 To define and evaluate the performance of fabric manufacturing Department as well as
others.
 To observe the effectiveness of fabric manufacturing as well as others.
 To get the additional knowledge in different sections of the organization.
 To interchange opinions of the officials regarding their organization.
 To know the economic condition of Bangladesh through Paramount Textile Ltd. of
Bangladesh.
 To identify the difference between theory (what we have learned from the text) and
practice (what is really happened).
 To compare the improvement of the present condition of the Paramount Textile Ltd.
with the previous years.
 To mention the problems that the Paramount Textile Ltd. face in the process of
production and delivery of garments & give some suggestions.
 To identify the strengths, weaknesses, opportunities and threats of the Paramount
Textile Ltd.

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PARAMOUNT TEXTILE LIMITED AT A GLANCE
Name of the factory PARAMOUNT TEXTILE LTD.
Chair person Md. ShakhawatHossain
Head Office Chaklader House (Level-5&6),
House # 22,
Road #113/A,
Gulshan-2,Dhaka-1212,
Banladesh
Factory Village: GilarChala,
P.O: 1 No C&B Bazar,
Thana: Sreepur,
Dist: Gazipur,
Bangladesh.
Phone No. (+8802) +8809890618,9890467 (H) 880-6825
52555(F)
E-mail ptexltd@gmail.com
Website www.paramountgroupbd.com
Bank 1. National Credit and Commerce Bank Limited.
Dilkusha Branch, Hossain Chamber,
43 Dilkusha C/A, Dhaka-1000.
2. ShahjalalIslami Bank Limited.
Gulshan Branch, Dhaka.

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Space 24 Bigas
Manpower 2287
Fabrics quantity 50,000 m /day
Dying capacity 60 ton / Day.
Fabrics
a. In Tappet loom.
i. Plain.
ii. Twill.
iii. Sateen.
iv. Some combination weaves
which are possible in tappet.
v. Oxford. (Warp rib and weft
rib).
vi. Queen’s Oxford.
vii. Matt.
viii. Double cloth
b. In Dobby loom:
i. Various types of weave.
ii. Diamond.
iii. Diaper.
iv. Herring bone.
v. Honey comb.
vi. The designs which are possible

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in 16 healed frames.
Main Customers H&M, C&A, TEMA, NEXT, NORWEST, STUDIO TE,
OLYMP, DAVID, CHERRY, MONDIAL, LEVIS,
MAYARA, MARKS & SPENCER , CYAN FASHION, VF-
ASIA, S-OLIVER
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ASIA, S-OLIVER
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ASIA, S-OLIVER

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HISTORY OF PARAMOUNT TEXTILE LIMITED
Paramount Textile limited was incorporated under the companies Act (Act-8) of 1994 inJune
12, 2006 and went into commercial production in November 2008.
One of the leading manufacturers of fabric in Bangladesh. Having started the journey in 2006.
We commenced commercial production in 2008.Paramount textile produces high quality yarn
dyed woven fabric for fashion brands and retailers across the world. PARAMOUNT
TEXTILE is anOeko-Tex certified (Class#1) 100% export oriented woven fabric manufacturer
equipped with state of the art machineries sourced from LeadingEuropean and Asian
manufacturers, producing 15 million yards of fabric annually. The Factory is located in
Sreepur, Gazipur an hour drive from the Dhaka International Airport, Sprawled across 35 acre
of factory premise and 2287 numbers of skilled worker and employees. Paramount Textile
today is a name to be reckoned with both nationally and globally.
 Factory area : Approx. 180acres. (Including ETP)
 Type of the factory : Horizontally integrated
 No. of employees : Approx. 2287.
 Project cost : Approx. 350 Core taka
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14

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Organogram of PARAMOUNT TEXTILE Ltd,

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Management system
 Intercom telephone
 Fax
 E-mail
 Written letters
 Oral
Product name:
Woven yarn dyed, solid dyed, 100% Cotton & TC
Product Mix :
A. Gray fabric:
1. Solid dyed
2. Yarn dyed.
i. Stripe.
ii. Check.
B. Design.
1. In Tappet loom.
i. Plain.
ii. Twill.
iii. Sateen.
iv. Some combinations weave which are possible in tappet.
v. Oxford. (Warp rib and weft rib).
vi. Queen’s Oxford.
vii. Matt.

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2. In Dobby loom:
i. Various types of weave.
ii. Diamond.
iii. Diaper.
iv. Herring bone.
v. Honey comb.
vi. The design which are possible in 16 heald frames.
Annual production capacity: 18millions per year.
Different Departments
A. Administration.
B. Human Resource and Development Dept.
C. Weaving Preparatory
D. Weaving.
E. R & D(Research & Development)
F. Woven finishing.
G. Yarn dyeing Dept.
H. Store.
I. Planning Dept.
J. Utility Dept.
K. Procurement & Purchasing

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L. Marketing
M. QA Dept.
N. Inspection Dept.
O. Mechanical Dept.
P. Electrical Dept.
Job description
AS A SENIOR PRODUCTION OFFICER:
In a weaving factory a senior production officer plays a great role in production and man
power management who are production related. Here we enlist the duties of senior production
officer:
1) Follow up weaving production,
2) Regular observation of weaving floor,
3) Prepare weaving order status regularly,
4) Maintain the quality of the product,
5) To help the senior prod. Officer & co-operate with others for fulfilling the required
destination,
6) Utilization of manpower.

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PRODUCTION OFFICER:
Production officer is the right hand of senior production officer and he is directly related with
production manpower and informs senior production officer time to time. Here are his listed
duties:-
1) Follow up overall weaving production,
2) Decide every m/c utilization during production,
3) Recruit new labor,
4) To inform the authority on the overall weaving prod. and make it financial
profitable,
5) Regular m/c maintenance,
6) Maintain sub-contract orders,
7) Help weaving manager& also guide the junior officers of the section, etc.
8) Daily production calculation.
9) Daily production report submitted to higher authority.
10) Sub ordinate worker facility.
11) Fabric fault analysis.
12) Maintain environment of the weaving floor.

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Shift Change Schedule
There are three shifts per day in P.T.L. So each shift contain eight hour.
Shift Duration
A 06.00 AM – 02.00 PM
B 02.00 PM – 10.00 PM
C 10.00 PM – 06.00 AM
General shift 09.00 AM – 06.00 PM
General shift, which is applicable for some officers.
Man power in different section
1. Weaving
a) Stuff & Officer-65
b) Worker-772
2. Dye House
a) ) Stuff & Officer -35
b) Worker -124
3. Yarn Dyeing
a) Stuff & Officer -78
b) Worker -589
4. Administration

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5. Compliance
6. Utility
a) Stuff & Officer -16
b) Worker-48
7. Security-86
Total Manpower of the factory -2287
Some Buyer of Paramount Textile
 H&M
 C&A
 TEMA
 NEXT
 NORWEST
 STUDIO TEX
 OLYMP
 DAVID
 CHERRY
 MONDIAL
 LEVIS
 MAYARAL
 MARKS & SPENCER
 CYAN FASHION
 VF-ASIA
 S-OLIVER

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 PVH
 DAVID HAWERD
 MARUBENI
 VERTEX
Input & Output Sequence of the factory
Yarn
↓
Store
↓
Soft Winding
↓
Yarn Dyeing
↓
Hard Winding
↓
Warping
↓
Sizing
↓
Drawing & Denting
↓
Weaving
↓
Finishing
↓
Inspection
↓
Delivery

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Raw Materials
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Raw Materials
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Raw Materials

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Some of the manufacturing companies from where Paramount procures there yarn are
1. Zaber Spinning Mill (Bangladesh)
2. GTM (India)
3. Nahar spinning mill (India)
4. Vardaman(India)
5. Jiangsu (China)
6. Winsome
7. Gulshan spinning mill (Bangladesh)
Some common type of yarns are tabulated below with local price
Count Type
10/1 Autocone
16/1 Autocone
16/1 Comb
20/1 Autocone
20/1 Comb
20/1 Card

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20/1 Open end
30/1 Comb
40/1 Comb,Compact,Organic,BCI
50/1 Comb
60/1 Comb
40/2 Comb
80/2 Comb
100/2 Comb
24/1 Slub
30/1 Slub
16/1 Card
45 TC,PC,CVC
32/2
20/2

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Winding
Section
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Winding
Section
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Winding
Section

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Winding Section
In fabric manufacturing (weaving) process this is the first stage where rewinding of supplied
yarn is done on to a desired package suitable for use in the next process.
Types of Winding:
1. Soft Winding.
2. Hard winding
Soft Winding Section
Soft Winding: where the grey yarn is wound on to a special dye spring or plastic bobbin and
the package (spool) is made softer and bulkier to make it suitable for dye penetration in the
(package) dyeing machine.
Dye Spring Plastic bobbin
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Winding Section
Types of Winding:
1. Soft Winding.
2. Hard winding
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Winding Section
Types of Winding:
1. Soft Winding.
2. Hard winding

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Flow Chart of winding
DISPO
↓
Store Requisition
↓
Receive the yarn
↓
Setting & Running
↓
Winding
↓
Checking (dia)
↓
Stop winding
↓
Quality assurance
↓
Root card making Delivery for dyeing
There are used two types of winding M/C
M/c Name CORAL TEXTILE
Manufacturer Shanghai Coral Textile machinery Co. Ltd
MFD 2008
R.P.M. of Motor 750
No. of Head 54
No. of Drum /head Grooved drum
Traversing system Individual

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Stop motion Automatic
No. of m/c 01
Production per m/c 10,858 km /day [Assuming 80% efficiency]
Manufacturer Taizhrljingwi Textile, China
MFD Oct’2008
R.P.M. of Motor 750
No. of Head 54
No. of m/c 15
Production per m/c 1,62,876 km /day[Assuming 80%
efficiency]
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No. of m/c 01
MFD Oct’2008
R.P.M. of Motor 750
No. of Head 54
No. of m/c 15
efficiency]
29
No. of m/c 01
MFD Oct’2008
R.P.M. of Motor 750
No. of Head 54
No. of m/c 15
efficiency]

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Package density Calculation
We know package density ρ =mass (m)/volume (v) gm/cc
Volume= π (R2
-r 2
) h
R= outer radius of package
R= inner radius of package
h= height of package
Now we consider a sample of 40/1 cotton yarn whose
R=4.138
r= 1.59
h=15.24
Mass m=1000gm
So package density ρ=1000/π (4.1382
-1.592
)15.24 gm/cc
=1.433 gm/cc
Production calculation
We know production= speed (m/min) ×60×24 ×1.09/(840×40×2.2045)
Kg/day/head
When speed is 800m/min at 80% efficiency
Production=800×60×24×1.09/ (840×40×2.2045)kg/day/head
=10.5976kg/day/head
Total production=10.5976×54×12kg/day
=6867.2448kg/day

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Dyeing
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Dyeing
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Dyeing

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Dyeing
OBJECT:
To dye grey yarn for producingthe check and stripe fabric.
Flowchart of dyeing
Demineralization
↓
Bleaching
↓
Hot wash
↓
Dye run
↓
Neutralization
↓
Finishing
↓
Hydro extracting
↓
Drying

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Dyeing Curve
400
c
Dyeing recipe:
Process Recipes
Demineralization Ladiquest 0.5g/l
Acetic acid 0.1g/l
70°-15min
Chemicals
Dosing
Dyes
Dosing
Salt
Dosing
Dosing
Soda ash
Progressive
70%
Shade
check
550
c
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Dyeing Curve
400
c
Dyeing recipe:
Process Recipes
Acetic acid 0.1g/l
70°-15min
Chemicals
Dosing
Dyes
Dosing
Salt
Dosing
Dosing
Soda ash
Progressive
70%
Shade
check
550
c
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Dyeing Curve
400
c
Dyeing recipe:
Process Recipes
Acetic acid 0.1g/l
70°-15min
Chemicals
Dosing
Dyes
Dosing
Salt
Dosing
Dosing
Soda ash
Progressive
70%
Shade
check
550
c

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In dyeing section three types of dyeing M/c are used. Those are_
Yarn Dyeing (Fong’s)
Model ALLWIN-85
Serial No 36028258
MFD(Manufacturing Date) 2011
Country of Origin China
Temperature 140C
Safety valve test 520 MPa
Design Pressure 520 MPa
Function Dyeing
Manufacturing Company Fong’s national engineering Co.
Yarn Dyeing (Go Front)
Model GRO-08
Serial No 112
MFD(Manufacturing Date) July’2011
Country of Origin Chang Cheng
Temperature 160C
Design Pressure 520 MPa
Bleaching Caustic 1g/l
Per- oxide 4g/l
115°-20min
Dyeing Ladiquest 0.80g/l
Salt 40g/l
Suffix Yellow SPD 4%
Suffix Red SPD 0.2325%
Suffix Navy Blue 0.5663%
Soda ash 10g/l
Washing off Ladiphore RSK 0.4g/l
Finishing Permafix RDX 0.7%
Acetic acid 0.2g/l

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Function Dyeing
Manufacturing Company Go Front Holding Ltd.
Yarn Dyeing (Scdo Mat)
Model 1800
Serial No Y-802-4
MFD(Manufacturing Date) Aug’08
Temperature 140C
DESIGN Pressure 520 MPa
Function Dyeing
Manufacturing Company Xinlong Electricity Co. Ltd
Dryer M/c specification:
Dryer M/C 02
Model SP-02170
Serial No 90815
MFD(Manufacturing Date) Sep’2009
Speed 17
Function Dry the Yarn
Manufacturing Company STALAM Dyeing & Printing Co Ltd.
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Function Dyeing
Model 1800
Serial No Y-802-4
Temperature 140C
Function Dyeing
Dryer M/C 02
Model SP-02170
Serial No 90815
Speed 17
35
Function Dyeing
Model 1800
Serial No Y-802-4
Temperature 140C
Function Dyeing
Dryer M/C 02
Model SP-02170
Serial No 90815
Speed 17

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Observing Hydro Extracting Cycle & production calculation
Hydro extracting cycle is with time required
Lowering (30sec)
↓
Circulation (12 sec)
↓
Operation (5min, 40sec)
↓
Lifting (21sec)
Hydro M/C 03
Model RZT 60
Serial No 217
Power Supply 16 KW,50 HZ+2%,32 A
Net Wt. 2500 Kg
Max Rotation (Drum) 1530
Function Dehydration
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Lowering (30sec)
↓
↓
↓
Lifting (21sec)
Hydro M/C 03
Model RZT 60
Serial No 217
Net Wt. 2500 Kg
36
Lowering (30sec)
↓
↓
↓
Lifting (21sec)
Hydro M/C 03
Model RZT 60
Serial No 217
Net Wt. 2500 Kg

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Water removing Efficiency:
Weight of cone after dyeing: 2.38kg
Weight of cone after drying: 1.11kg
Water removing Efficiency= (2.38-1.11)/2.38%
= 53.36%
Production calculation of RF Dryer
Length of RF Dryer=13m
At 28rpm it takes 21 min 9 sec to pass this length
Along this length it can accommodate 416 package 416kgs
So at 21 min9sec or 1269sec it can dry 416kgs
So in 1hr or 3600sec it can dry=416×3600/1269 kg/hr
=1180.14 kg/hr
So Production per day=1180.14×24kg
=22658.688 kg
=22.66 tons

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Hard Winding
38
Hard Winding
38
Hard Winding

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Hard Winding
Where the grey yarn dyeing machine is converted from spool to paper cone, to make the yarn
easily be fed to the sectional warping machine.
Flow Chart of hard winding
Root card
↓
Checking
↓
Receiving
↓
Prepare batch card
↓
Start Hard Winding
↓
Measuring weight
Finding out package density
We know package density ρ =mass (m)/volume(v) gm. /cc
Volume= π( R2
-r2
)h
R= outer dia. of package
r = inner dia. of package
h= height of package
Now we consider a sample of 40/1 cotton yarn whose
R=3.99cm
r= 1.60cm

40
h=15.24cm
Mass m=1000gm
So package density ρ=1000/π (3.992
-1.602
)15.24 gm. /cc
=1.563 gm. /cc
Production calculation
We know production= speed (m/min) ×60×24 ×1.09/(840×40×2.2045)
Kg/day/head
When speed is 800m/min at80% efficiency
Production=800×60×24×1.09/(840×40×2.2045)kg/day/head
=10.5976kg/day/head
Total production=10.5976×54×12kg/day
=6862.32kg/day
Faults in winding section
Faults Causes
1. Excessive Hard package Excess tension
2. Excessive Loose package Less tension
3. Ring Faulty drum
4. Stitching Vibration of Package
5. Ribbon Ribbon breaker problem.
6. Bulging Improper alignment of Package
7. Entanglement Jerking package
8. Bunch Improper store and handling
9. Cut cone Package drop
10. Reverse winding Low pressure

41
Types of Maintenance:
1. Schedule maintenance.
2. Break down maintenance.
Spare item types:
1. Readymade / purchase
2. Fabrication tool in work shop / other side
3. Import item
Quality Control in winding Section:
The following quality is maintained in preparatory stage.
Shade matching:
The dyed yarn compared with lab drip sample or swatch card.
Level Checking:
During package dyeing dyes chemical enter in to package by pressure. So there is a possibility
to differ level in inner and outer side. It is checked and allow up to (5 -6) %.
Fastness:
Water and color fastness is checked.
Strength:
CSP, tenacity, CV% of tenacity, elongation are tested.
Package hardness:
Soft wound package is checked by hand if it is hard improper dyeing will occur, the hard
wound package also checked if it is less hard or too hard it will create problem in subsequent
process.

42
Material Handling Equipment for Winding Section:
1. Creel.
2. Trolley.
1. Creel: 2. Trolley

43
Warping
43
Warping
43
Warping

44
Warping
In general terms, Warping is transpiring many yarns from a creel of single ends packages
forming a parallel sheet of yarn wound onto a beam a section a beam. Today’s warping m/c
can process many kinds of materials including course and fine filament & staple yarns, mono
filament, texture yarn & smooth yarns, silks & other synthetics yarn. Usually a static
eliminator device isrecommended for yarns that can generate static electricity.
The warp beam that is installed on a weaving m/c is called a weaver’s beam. A weaver’s beam
can contain several thousand ends & different reasons it is rarely produce in on operation.
Warping is aimed at preparing the weaver’s beam to be set up on the weaving m/c. Warping
carries out following operation:
 Creation, out of a limited number of warp threads (Creel load), of a warp composed of
any number of threads with desire length;
 Arrangement of above-mentioned threads according to the desire sequence;
 Manufacturing of a warp beam with said characteristics;
 If the creel capacity is equal or higher number of warp threads, the warping would
simply entail the direct winding on the warp beam of the threads coming from the
creel. Generally, this condition does not take place & even with creels of high capacity
the number of creel position never corresponds to the number of threads, which is
always by far higher than the number of bobbins, which is creel can contain.
 This problem has been solved by dividing the warping operation into two phases:
o 1st
phase: Unwinding the threads from the bobbins & their winding on
intermediate carriers, till attainment of the required total number of warp
threads;
o 2nd
phase: Simultaneous rewinding of all these threads & subsequent winding
on weaver’s beam; the contemporaneity of these two operations is prerequisite
to produce a beam where all the treads show same tension & the length.

45
Types of warping:
Warping
Sectional (Conical drum or dresser) Direct (Preparatory beam)
Flow Chart of warping:
Cree ling
Knotting (Optional)
Drawing
Denting
Reed
Measurement Roller
Evener roller
Drum
Beaming

46
Layout plan of preparatory section

47
Operation Procedure Direct Warping:
1. As per production program given by assistant manager, preparation through the yarn
warp record register, the supervising officer collects griege yarn from store as per
required count, lot number and quantity.
2. The machine operates and helpers open / break the yarn cartoon and place the cones in
the creel head as per program and draw the head end of the cone through pretension
rods, feeler guides, yarn guides and then through expanded comb of beaming unit.
3. The basic creel data setting and machine data setting are done according to the
requirement as per m/c manufacturer operating instruction.
4. An empty beam is set in between driving clutch and engaged by means of electric
switch.
5. All the ends from the creel is wrapped around the beam manually one round.
6. The press roller is moved towards the beam by means of electric switch.
7. The m/c is then run slowly and checked for yarn alignment with beam flange on both
sides. To ensure alignment the expanded comb may be moved either to the right or left
as required by switch.
8. Thus the m/c is ready and the operational switch is to be turned on.
9. As the present length is achieved the m/c will stop automatically. The beam is doffed
by switch and another beam is mounted.
10. In this way a set of beams are made to feed the subsequent sizing process.

48
The m/c feature of sectional warping:
There are four sectional & one direct warping m/c using in PARAMOUNT Textile. Between
the machines two are UK IL & another two are Rabatex.
Warping M/C (UK IL) 02
Model UI-501 SI
Serial No 5-359
Country of Origin Korean
Creel Capacity 720
M/C Motor RPM 400-500
Function Sectional warping
Manufacturing Company UK IL m/c Co. Ltd
Warping M/C (Rabatex) 02
Model VM 108
Serial No 46/6
MFD(Manufacturing Date) Feb’10
Country of Origin India
Creel Capacity 800
Function Sectional Warping
Manufacturing Company Rabatex Industries Co. Ltd
Warping M/C (TSUDAKOMA) 01
Model TWS-E
Serial No 999
MFD(Manufacturing Date) Apr’08
Country of Origin Japan
Creel Capacity 644
Function Direct Warping
Manufacturing Company Tsudakoma Corporation
.

49
Causes of yarn breakage in warping:
1. Weak yarn.
2. Sloughing off.
3. Over lapping.
4. Knots/ bad splice.
5. Slubs.
6. Loose yarn.
7. Pig tail.
8. Cut yarn.
9. Bad tip cone.
10. Short cone.
Observing the end breakage
Serial no Position of breakage Time consumed
1 Between reed& drum 12sec
2 Near package 1min 4sec
3 Far package 1min 44sec
4 Between reed& drum 13sec
5 Missing end on Drum 2min 21sec
6 Between reed& drum 25 sec
7 Breakage from pkg 1min 33 sec
8 Missing end on Drum 2 min 33 sec
9 Missing end on Drum 2min 25 sec
10 Missing end on Drum 2 min

50
Monitor Display Sectional warping:
Drum Diameter: 3.35
Tension Device: Electromagnetic type (Auto controller)
If Stripe is, big shape or size then not necessary to cross lease, shape is small then used to
cross lease.
Reed Movement:
Sectional warping motor type:
 3 phase induction motor
 Rotation by Encoder
 RPM : 350-400 (Drum)
 AMB : 40C
 Rating : Count Wise
 Serve Factor : 100%
Patrol wash is used to cleaning the guide bar.
Jog –To maintain the yarn tension for loose yarn after creel.
TPM 500 Section 15
Speed 350 Width 70”
P-Roll 1.5 Total ends 5100
Count 20 Revolution 37.9
Type Cotton S-Width 118.63
Density 28.68 Feed 1.4276

51
Sizing
51
Sizing
51
Sizing

52
Sizing
Although thequality and the characteristics of the warp yarns coming out of the winding and
warping processes are quite good, they are still not good enough for the weaving process for
most of the yarns. The weaving process requires the warp yarn to be strong, smooth and
elastic or extensible to a certain degree. To achieve these properties of the warp yarns, a
protective coating of a polymeric film-forming agent(size) is applied to the warp yarns prior to
weaving; this process is called sizing or slashing. Sizing is not a value added process inwoven
fabric manufacturing. This is because, after the fabric is woven, the size materials will be
removed from the fabric during the finishing operation, which is called desiring.
Purposes of sizing
 To increase the strength of the yarn.
 To reduce the yarn hairiness that would cause problems in weaving process.
 To increase the abrasion resistance of the yarns against other yarns and various
weaving machine elements.
 To reduce fluff and fly during the waving process for the high speed weaving
machine.
 To increase the weave ability of the warp yarn, this is the main goal of sizing.
52
Sizing
Purposes of sizing
machine.
52
Sizing
Purposes of sizing
machine.

53
Sizing quality:
Flowchart of sizing
Flange Beam
Beam Stand
Feeding
Guide roller
Immersion Roller
Squeezing Roller
Paddler Roller
SIZING
SIZING RECIPE
SIZING PICK-UP
OPERATOR
HANDLING
SIZING MACHINE DESIGN
ADJUSTMENT
YARN
MATERIAL
TYPE QUALITY

54
Saw Box
Cavity box
Dryer
Water tank
Cooking tank
Reservoir tank
Mahalu
Lease Rod
Reed
Dropper
Pressure Roller
Guide Roller
Sized Yarn
Sizing agent
 True starch
 Modified starch
 Carboxyl methylcellulose (CMC)
 Polyvinyl alcohol (PVA)
 Polyacrelate

55
 Polytex-460
 Polytex BI
 Wax
In PARAMOUNT textile, Polytex-460 &Polytex-BI are used as the sizing comical. Polytex-
460 &polytex BI is the combination of all others sizing agent except Wax.
Sizing Calculation:
Total required chemical = (total length* total ends*30%)/(1.6933*count*1000)+200L
Sizing M/C: There are two types of sizing M/C
Sizing M/C (TSUDAKOMA) 01
Model HS-40
Serial No 254
Beam Capacity 16
M/C Motor RPM 80 m/min (Max)
Function Sizing
Manufacturing Company ITOCHU Textile M/C Ltd.
Sizing M/C (Jupiter) 01
Model MP0000.2195
Serial No 03
Beam Capacity 1
Function Sizing
Manufacturing Company Jupiter Industries
55
 Polytex-460
 Polytex BI
 Wax
Sizing Calculation:
Model HS-40
Serial No 254
Beam Capacity 16
Function Sizing
Model MP0000.2195
Serial No 03
Beam Capacity 1
Function Sizing
55
 Polytex-460
 Polytex BI
 Wax
Sizing Calculation:
Model HS-40
Serial No 254
Beam Capacity 16
Function Sizing
Model MP0000.2195
Serial No 03
Beam Capacity 1
Function Sizing

56
Units of the m/c:
1. Back Beam unit
2. Sizing Unit
3. Drying Unit
4.Leasing Unit
5.Beaming or Take up unit
Controlling Points:
1.Speed of the Yarn Passing
2.Drying Unit-Cylinder temperature must not exceed 150˚C to maintain R.H. less than 6%
which is a requisite for cotton yarn.
3. Squeezing Pressure: A typical roller pressure for wide variety of cotton yarn is given below.
First Squeeze: 0.12MPa
Secondsqueeze:0.2MPa
Immersion roller:0.1MPa
4.Separation Unit: Distances between the lease rods are to be carefully set up for solid dyed &
yarn dyed fabrics
5. Headstock: All the settings are done from here.
Size Box:
There are two size boxes and one hot wash box
Main parts of size box are
301= TENSION DETECTION ROLL
302= IMMERSION ROLL
303= FIRST SIZING ROLL
304= FIRST SQUEEZE ROLL
306= SECOND SIZING ROLL
56
Units of the m/c:
1. Back Beam unit
2. Sizing Unit
3. Drying Unit
4.Leasing Unit
Controlling Points:
yarn dyed fabrics
Size Box:
302= IMMERSION ROLL
56
Units of the m/c:
1. Back Beam unit
2. Sizing Unit
3. Drying Unit
4.Leasing Unit
Controlling Points:
yarn dyed fabrics
Size Box:
302= IMMERSION ROLL

57
308= SIZE BOX
307= SECOND SQUEEZE ROLL
310= LEVEL ADJUSTER
311= STEAM PIPE
312= COVER
Some typical size recipes used in PARAMOUNT given below with their function-
Construction: 30x30/120x70
Total ends: 6876
Recipes:
Recipes: Yarn count 30/1
Total ends:6876
Yarn count 30/1
Total ends:6876
Water 600 Lt 600 Lt
Sure Bond 60 kg 60 kg
CMC 20 kg 18kg
Size CA 15 kg 18 kg
Wax 2 kg 3 kg
Polytex. 460 20 kg 20 kg
Function:
1. Sure Bond: It work’s as adhesive to increase solidity percentage in the size recipes.
2. Starch: It also works as adhesive. As its price is of low it is mainly used to reduce the
size cost when yarn count is coarser
3. CMC: It is a synthetic adhesive used mainly to help in penetrating other chemicals
into yarn.
4. PVC:This adhesive is only used on finer count yarn.
5. Size CA:Its mainfunction is to bind protruding fibers with yarn.
6. Wax: It acts as a lubricating agent.

58
Costing of Size Ingredients
Ingredients Cost taka/kg
Sure bond 43-53
Starch 29
CMC 139
PVA 267
Size CA 70
Wax 255
Measuring of size take up% of a particular sample
Yarn count 40/1
Total ends 7420.
Recipes:
Water: 600 Lt
Sure bond: 60kg
Starch: 20kg
CMC: 20kg
Size CA: 15kg
Wax: 2kg
Wt. of 1m of total yarn before sizing = 0.12kg
Wt. of 1m of total yarn before sizing=0.1340kg
So, Size take up %=(0.134-0.12)/0.12%
=11.67%

59
Drawing, Denting
59
Drawing, Denting
59
Drawing, Denting

60
Drawing, Denting Section
Process definition:
After a sized beam or weaver’s beam is made, it is time to mount this beam over the loom.
There are two methods used to prepare this beam for mounting on a loom.
1. Warp tying or knotting (Quick style) change process.
2. Reaching – in /Drawing – in and beam gaiting.
Warp tying:
This method is limited to use where and exactly same article or quality of fabric is to be made
that is already running in the loom. The following points are considered-
1. The total number of warp ends should be the same as that of running.
2. The count of yarn and weave design should be same.
Before tying a new beam with an older one, the new beam is to undergo a process called
leasing, whereby the adjacent yarns are kept separated by placing a yarn in between them.
This is very essential in case of tying a yarn dyed beam; otherwise the warp pattern scheme
will be disturbed and lost.For monocular beam (solid dyed beam), tying is performed without
leasing.
Drawing – in:
The method of mounting weaver’s beam on to the loom, which is adopted for the same style
of working of adjacent warp yarns or yarn interlacement, compared to that of running in
looms.In this method warp yarns are separated individually as per count or color pattern from
the adjacent yarn and hooked to the access of drawer’s hook called reaching – in.
The yarn as it comes to “reach” or drawer’s hook is then drawn through dropper (or drop wire)
and then passed through the split of the reed dent called denting.

61
Operation procedure:
Warp tying:
1. According to that plan, knotting – in – charge & Drawing – in – charge jointly arrange
leasing of beams, the respective beams being identified from the sizing data sticker.
2. As leasing is completed the beam is transported to a specific loom and mounted on
loom beam bracket. The tying frame is set on proper position.
3. The ends of old beam and the ends of the new beam are accurately brushed and
gripped by the frame sothat older and newer ends make and upper & lower set of yarn
placed in proper tension.
4. The warp tying head is mounted over the tying frame. In case of STAUBLI machine,
number of knots per repeat of color pattern is entered in to machine.
5. Then the machine is started. After the programmed number of knots per color is
reached, knotting will stop. Operator will check the correctness of the knot and start
again by switch.
6. Thus knotting will be completed up to the end of set, tying up per set of older yarn
with lower set of new warp.
7. As knotting is completed, the knotting operator make a quality card mentioning
customer name, work number, beam number beam length, knotting operator’s name
and date and time of knotting.

62
8. The sizing date sticker is set over the quality (of doffing) card and the card is set over
the loom.
9. The knotting operator also makes a work record in his register book.
10. As knotting is completed, tying head and frame are removed, the old piece odd knotted
yarn is pulled through the machine, i.e. through heald wire and reeds and thus new
warp set is allowed to pass and made ready to run.
Drawing – in and reaching – in
1. The customers fabric swatch is sent to the weaving section, generally after warping is
done, either by enclosed to the order sheet to form or separately. Assistant manager
(weaving) then analyzes the swatch for reproduction. In this stage the determines –
a. The design of sample i.e. whether dobby or tappet or combination of two.
b. The drawing – in, denting and lifting or tappet/ cam setting plan.
c. The required number of healed frame and reed count, draw width etc.
2. Then whenever the sized beam is ready, the worked out drawing – in plan, reed count
etc. against an order number is given to the drawing – in – charge for production.
Drawing – in – charge for production. Drawing – in – charge makes a work program
considering the following:
a. The availability of the run out loom for beam.
b. The availability or required number of reed count.
3. Drawing – in – charge and senior drawer find out the desired sized beam number from
the sizing production record, check against the specific work order number and from
transport these to the drawing – in – section by trolley and start working there.
4. According to the work order number each design/ drawing – in plan is recorded in the
register book, the produced sample being attached thereafter.

63
5. After drawing – in/ denting is completed each beam is set with a quality/ doffing card,
the sizing data sticker is being attached on the card.
6. During deciding the loom number the drawing – in – charge takes into consideration
designing scope and color insertion scope of the respective loom.
7. Finally beam gaiters carry this beam along with dropper, healds and reed with trolley
onto the specified loom and mount.
8. They will pull the new yarn from the beam and set in the loom with dropper, healds
and reed properly positioned and tie the new yarn with the old piece of cloth wrapped
around the surface roller with a number of small knots.
Knotting M/c:
Knotting (STAUBLI) 02
Model TPM-201-PC
Serial No GI 514344
Country of Origin Switzerland
Volt. 48 V
Amp. 2.5 A
Function Knotting
Manufacturing Company TOPMATIC M/C Co Ltd.
Equipment used in Drawing denting and pinning Section:
Denting plate (Patti):

64
Drawing Hook:
Drop Wire:
64
Drawing Hook:
Drop Wire:
64
Drawing Hook:
Drop Wire:

65
R&D
65
R&D
65
R&D

66
R&D
Design Cell is one of the most important departments of PARAMOUNT TEXTILE
LTD.(weaving). When an order comes to the marketing or merchandizing officer he/she send
the fabric to the design cell that is it possible or not possible in PARAMOUNT. They send a
Article request paper. Design cell analyze the fabric design and test the feasibility of
production and create an Article code and send this article code the marketing or
merchandizing officer and input data to the Data tax which is a software used in
PARAMOUNT for all types of information by networking.
PARAMOUNT’s Design department is equipped with hand loom and sophisticated software
“TEX-DESK DOBBY” From India & KOPPERMANN from GERMANY.
After getting Article code planning discuss with marketing officer about costing. Then
marketing officer send mail or discuss directly to the buyer about pricing of the product.
If buyer agree with the price then marketing officer send mail to the central planning section
with Article code.
Planning take a print of dispo paper for the article code from the system data tex. After
printing dispo paper they send it to the design cell to check or verify. Design cell check and
give drawing and denting plan and send it to the planning section again.
Planning then send it to the various section where these information required and at a time
requisition all necessary raw materials or other materials.
Flowchart of R&D:
Head office (marketing)
CAD /Swatch
Feasibility Check
Create Dispo number
Create CAD (Koppermann&Textronic)
Color Analysis
Dispo Dispatching
Yarn Dyeing Lab/Lab Dip
Planning
CCI Warping

67
CCI Sizing
CCI Loom
Sample sends in Marketing Dept.
Buyer Approval
Bulk Order
Feasibility check
Possible Ends per inch by using Available Reed in Inventory in PARAMOUNT by denting 2,
3 and 4 in a dent for yarn dyed fabric.
Hand Loom Section:
In PARAMOUNT Textile Ltd there is a hand loom section. There are several hand loom
section with combined section, such as treadle, treadle pad dobby, treadle and jacquard. There
is also hank winding frame, sample high speed warping machine, sectional warping machine
also.
When PARAMOUNT gets a new order without any swatch, then a cad is prepared and sends
it to the Hand loom section. There a small size of sample is prepared. If the sample is prepared
successfully according to specification, then the planning department took necessary step for
bulk production.
After getting Article code planning discuss with marketing officer about costing. Then
marketing officer send mail or discuss directly to the buyer about pricing of the product.If
buyer agree with the price then marketing officer send mail to the central planning section
with Article code.Planning take a print of dispo paper for the article code from the system data
tex. After printing dispo paper they send it to the design cell to check or verify. Design cell
check and give drawing and denting plan and send it to the planning section again.Planning
then send it to the various section where these information required and at a time requisition
all necessary raw materials or other materials.
WhenOrder comes to the Marketing Section, then they contact with the Product development
(in case of new product) or Design cell (in case of available product) that, is it possible or not

68
possible in PARAMOUNT. They Send an Article Request paper. After reaching the Article
Request paper Design cell produce Article Code and send mail to the planning and marketing
section.
Dispo paper contains following types of information:
1. Fabric Specification.
2. Yarn composition
3. Finished type.
4. Finished fabric’s EPI x PPI
5. Finished fabric’s width.
6. Required length.
7. Reed count.
8. Grey EPI and PPI.
9. Grey width.
10. Reed width.
11. Reed EPI
12. Required greige length.
13. Required warp length.
14. Ground Ends.
15. Selvedge Ends.
16. Cover Factor.
17. Numerical Plan (Warp & Weft)
18. Drawing & Denting Plan.

69
P.O No:
2012/902 Line No :
01
Count ( Warp x Weft) 40X40
Customer: C & A Yarn Composition (Warp x
Weft)
100 % Cotton
Finished
Fabric
Details
Dispo No:
F205896
Ref :
Swatch
Ends × Pick (Finished) 84×80
Fabric Type Check Finish fabric width (inch) 57/58”
Design Plain Required finished length
(meter)
6913
Finish Regular
Soft
Delivery Date (Finish) 10/12/2012
Grey
fabric
Details
Dispo No:
W205896
Request
No:
P25695
Ends × Pick (Grey) 78×80
Buyer Ref DH#
16634B
Grey Width (inch) 62.11
Color Navy/Mint
check
Require Grey(meter) 7514.13
Reed No 74.25/2 Required loom
Production(meter)
7667.48
Reed Width
(inch)
65.45 Required warp length
(meter)
8519.42
Delivery Date 08/12/2012 Ground inch 4860
R & D Selvedge inch

70
Comments
Color break
down
Color Breakdown:
Count Shade Color Code Quantity ( kg) Length (Mtr) Cones
Warp
40/1 Cream BE11760 308.72 77447.30 270
40/1 Navy NV45321 308.72 77447.30 270
Warp Total 617.44 Section : 9
Weft
40/1 Cream BE11760 308.52
40/1 Navy NV45321 308.52
Weft Total 617.04
Dyed Yarn Details
Dispo No: Y205896 Delivery Date: 18/11/2012
SL no Count Shade ALD No Grey yarn
(Kg)
Dyed yarn
(Kg)
Yarn Type
1 40/1 Cream BE11760 633.07 617.24 Combed
2 40/1 Navy NV45321 633.07 617.24 Combed
Total 1266.13 1234.48

71
Dispo paper goes to the following sections
1. Design cell.
2. Store.
3. Winding.
4. Yarn dyeing.
5. Warping.
6. Sizing.
7. Drawing and denting.
8. Loom.
9. Finishing

72
WEAVING
72
WEAVING
72
WEAVING

73
WEAVING SECTION
Process definition:
The act of inter lacing Warp yarn(of a beam) with the inserted weft yarn in a definite order to
form a fabric suitable for use as a dress material, domestic or industrial purpose is called
weaving. The machine used for this purpose is called loom.
Process equipment:
Air jet loom
Loom shed – 1:
Total no of loom - 178
Loom shed – 2:
Total no of loom - 40

74
Lay out plan of weaving
Shed 1:
Shed 2:
74
Shed 1:
Shed 2:
74
Shed 1:
Shed 2:

75
EQUIPMENTS OF LOOM SECTION
The machine used for the purpose of weaving can be categorized as follows:
Brand name of the
Loom
Shedding Device Weft Insertion RPM No. of Looms
Picanolomniplus 800 Tappet 06 600-700 10
Picanolomniplus Tappet
Dobby
04 450-550 52
Toyota JAT 710 Cam 06 700-950 15
Toyota JAT 710 Dobby 06 600-700 01
Toyota JA 600/610 Tappet
Dobby
2+4+6 525-650 34
Tsudakoma ZAX
9100
Cam 06 750-850 12
Tsudakoma ZAX Dobby Tappet 04 500-650 13
Tsudakoma ZAX
205,205i
Cam 02,06 450-600 81
Total 218

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SPECIFICATIONS OF AIR JET LOOM:
GENERAL SPECIFICATION
Motor R.P.M : 1410
M/C speed : 625 PPM
Motor pulley dia. : 100mm
M/C pulley dia. : 225mm
Reed : Profiled reed
Shedding : Cam, Electric Dobby
Take up motion : Electronic
Let off motion : Electronic
Warp stop : Electrical
Weft stop : Electronic
HEALD SHAFT SPECIFICATION
Brand Name : New light
Manufacturer : Nankai industrial Co. Ltd.
Origin : Japan
PHOTO ELECTRIC SENSOR
Model : CY-21P-SK
Manufacturer : Sunx Ltd.
Origin : Taiwan
LENO BOBBIN WINDER
Brand Name : Precision spooler
Model : PS
Manufacturer : Sankin engineering Co. Ltd.

77
Origin : Japan
SIGNAL LAMP
Manufacturer : Hayashi feeler Co. Ltd.
Origin : Japan
CABLE
Manufacturer : Mitsubishi Cable Industries Ltd.
Origin : Japan
REED SPECIFICATION
Brand Name : (i) RTOS (ii) Setiakiji reed
Origin : Japan
Type : Profile reed
Reed Count : 129, 121, 116, 106, 99, 92, 88/2,
74/4, 72/4 etc.
Reed Width 172.50cm
WARP BEEM CARRIER
Brand Name : TODO
Model : S-1500
Maker : Marubeni Corp
Origin : Japan
OVER ALL CLEANER
Brand Name : LUWA
Type : Suction
LOOM MOTOR SPECIFICATION (3 Phase Inductor Motor)
R.P.M : 1410
Maker : Meidensha Corp
H.P : 3KW

78
SIGNAL LAMP:
COLOR INDICATION
Red : Warp breakage
Green : Weft breakage
White : Loom stop
Yellow : Selvedge leno bobbin breakage
LENO SETTING:
Right side : 10°
Left side : 280°
How to release or wind a weft:
This screen always appears when the machine Stops.Each drum number is displayed.
Releasing a weft:
Release Single, Turn switch. This switch releases a single turn of wefton the drum.
78
SIGNAL LAMP:
COLOR INDICATION
Red : Warp breakage
White : Loom stop
LENO SETTING:
Right side : 10°
Left side : 280°
Releasing a weft:
78
SIGNAL LAMP:
COLOR INDICATION
Red : Warp breakage
White : Loom stop
LENO SETTING:
Right side : 10°
Left side : 280°
Releasing a weft:

79
Release Turns
Release Turns switch. This switch releases turns of weft on thedrum.
Forward inching switch:
This switch should be pressed with INTER-LOCK switch a held down.Holding down
FORWARD inching switch runs the machine in the forward direction at allow speed;
releasing it stops the machineoperation.
Air jet weaving machines run at a speed several times higher than in the conventional ones.
Therefore, adjusting them requires instruments suitable for measurement of fast revolution
motions, such as pressure gauges, stroboscopes, tension meters, and others as listed below.
79
Release Turns
79
Release Turns

80
Production Procedure
Operation stuff:
Assistant Manager – section in charge
Production officer – shift in charge
Loom Technicians – shift wise running loom checking/ tuning/ setting & gauging
Senior loom operator – as a line jobber, for production & Q.C.
Loom Operator
Helpers & movers – for supplying yarn and yarn cartoons
Casual worker – For keeping the machine & section clean
Different parts of Air Jet loom:
1. EDP (Electronic Drum prewinder).
2. Tappet(Cam).
3. Lever and Puller.
4. Reed.
5. Dobby.
6. Easing roller.
7. Back rest.
8. Take up roller.
9. Cloth roller.
10. Weft Feeler.
11. Dummy selvedge stop.
12. Weft cutter.
13. Drop wire and bar.
14. Leno selvedge attachment.
15. Main nozzle.
16. Sub nozzle.

81
17. Tample.
18. Dummy selvedge system.
19. Monitor and Mother board
20. Pressure control Switch.
21. Grease tank.
Adjustment of setting:
Cutter to reed distance: 1mm
Temple to reed: 3mm
EDP pins to bend: 0.5mm.
Sub nozzle to sub nozzle: 88mm.
Two pick gear: 0.23m
Shed Size
→Plain:
Shed angle: 30°
Shed depth: 3 – 3.5cm
→Plain + Shateen:
Shed angle: 20°
Shed depth: 2.5cm
→Twill:
Shed angle: 25°
Shed depth: 3.5cm

82
FABRIC INSPECTION
PROCESS DEFINATION:
Fabric inspection is the process of identifying weaving faults in the fabric just after the grey
fabric production in the loom.
Equipment:
1. Inspection table
2. Fabric inspection machine(Nazer, L 90p, Pakistan)
Key Accessories:
Nipper, Pointer, Cutter, Comb etc.
Machine set-up
M/C Set Value & Parameter
Check
: M/C Set Value & Functionality
Check
1. Guide roller speed : 40 meter/min
2. Light : Artificial day light
3.Length measuring meter : Attached with the fabric & the m/c
4. Automatic cutter(knife) : Functionality check
5. Slippage measuring roller : Functionality observe
6. Batcher : Check batcher setting with motor
Operation Procedure:
The steps involved in the Inspection Process are as follows:
1. Inspector connects the batcher with motor and feeds the fabric by the guide roller. The
fabric goes through a special table where there are arrangements for special lighting to
detect faults in the fabric visually.

83
2. Fabric is inspected as per inspection procedure of 4-point system. After the inspection,
the fabric is rolled or folded without any crease and is packed by polythene paper. The
inspector puts the Identification Sticker on the fabric roll with details of the fabric (i.e.
order no, customer, batch no, shade, roll no, usable width composition etc.).
Type of fabric : Maximum Roll size
(meter)
1. Poplin : 250
2. Yarn dyed : 250
3. T.C Fabric : 300
4. Twill : 150
3. The good as well as reject quantities are entered in the MASH module of Datatex
system with respective quality codes and then they are transferred to the finished goods
stores.

84
FINISHING
84
FINISHING
84
FINISHING

85
Finishing Section
Finishing Machineries
1. Singeing De-sizing 1 set
2. Washing machine 1 set
3. Stenter 1 set
4. Peach Finishing 1 set
5. Sanforizing 1 set
Singeing – Desizing
Singeing is a process by which projecting or floating fibers stand out on the surface of the
fabric are burned off. Singeing is done to remove hairy fibers projecting from surface of cloth
and given a smoothen face. It is also done to increase luster in the finished fabric and to
prepare the fabric for next process.
De-sizing is the first wet processing textile finishing technology employed to remove the
sizing material from the fabric. It depends on the solubility of the film forming polymer, on
the effects of numerous subsequent wet processing steps, on the interactions with added
chemicals. It is done to remove starch from the fabric and to increase absorbency of the fabric.
85
Finishing Section
3. Stenter 1 set
85
Finishing Section
3. Stenter 1 set

86
Scouring and Bleaching
Scouring is the process by which all natural and adventitious impurities such as well as oil,
wax, fat etc. are removed to produced hydrophilic and clean textile material. It is vital process
of wet processing. It is done to make the fabric highly hydrophilic and to remove impurities
such as oils, waxes, gum, husks as completely as possible.
Bleaching of textile material is chemical or commercial process which can be defined as
destruction of natural coloring matters to impart a pure permanent and basic white effects
suitable for the production of white finishes, level dyeing and desired printed shade with the
minimum or on tendering or without diminishing the tensile strength. It is done to ensure a
pure and permanent basic white color fabric and to destruction of natural coloring matters
from the fabric.
Scouring & Bleaching M/C 01
Model LMHO-022
Serial No 200R
M/C Temp. (60-90)C
Function Scouring & Bleaching
Manufacturing Company Jiangsu Redflag Printing & Dyeing Co Ltd.
86
from the fabric.
Model LMHO-022
Serial No 200R
M/C Temp. (60-90)C
86
from the fabric.
Model LMHO-022
Serial No 200R
M/C Temp. (60-90)C

87
Stentatering
Stentering is done to soften and to control width of the fabric. It is done to give the required
finish to the fabric.
Stentering (VIROCK) M/C 01
Model LV K4000-200×8
Serial No 0807
MFD(Manufacturing Date) 28th
Aug’2008
Power Supply 30V ,<16A
M/C rpm 60m/min
Function Soft & Width Controlling
Manufacturing Company WUXI Dakal Dyeing & Printing M/C Ltd.
Some finishes:
1. Soft/regular finish
2. ETI (Easy to Iron)/wrinkle free finish/resin finish
3. Easy care
4. Paper touch finish
5. Peach finish
87
Stentatering
Serial No 0807
Aug’2008
M/C rpm 60m/min
Some finishes:
3. Easy care
5. Peach finish
87
Stentatering
Serial No 0807
Aug’2008
M/C rpm 60m/min
Some finishes:
3. Easy care
5. Peach finish

88
Typical recipe:
Soft finish:
Tubingal 11/2: 8 gm/L
Jinssofter AS852: 20 gm/L
Terasil NNO: 10 gm/L
Acetic acid: 0.5 gm/L
Resin finish:
Fixapreat eco: 50 gm/L
CondensolFm: 10 gm/L (Catalyst)
Siligenpcp: 20 gm/L (Softening agent)
Aniston EPD: 20 gm/L (Softening agent)
Jinsofter AS822: 20 gm/L (Softening agent)
Karoline jet B: 1gm/L (Wetting agent)
88
Typical recipe:
Soft finish:
Resin finish:
88
Typical recipe:
Soft finish:
Resin finish:

89
4. Peach finish:
Peach finishing is done to give soft, hairy and smooth surface effect to the fabric. For this
emery rollers used.
Peach Finish M/C (Xetma) 01
Model DE-08280-Aue
Serial No 160-008/NW 2200
Country of Origin Germany
Compressed Air 6 bar
Power Supply B/PE/NAC-4000/+10%,50 Hz,200 A
Function Finishing
Manufacturing Company XetmaVollenweider GmbH Co Ltd.
Sanforizing
Sanforizing is mainly done to control shrinkage of the fabric. It is also done to give a better
softening effect and controlling width of the fabric.
Step wise process:
Spraying Unit Steam Roller Rubber Belt Cylinder Steam Roller
Blanket Cylinder (Ironing for permanent shrinkage control)
Sunforising M/C 01
Model LMH-442-200
Serial No 804
Steam 2.5 Kgf/cm2
Pressure 2.8KN
Function Calendaring

90
Finishing
To ensure safe and consumer friendly fabric PARAMOUNT has its own high- tech
laboratoryand computer data processing system. The laboratory is fully equipped with modern
testing equipments enabling them to check the fabrics in all the stages of required testing
criteria and performances. Testingequipments are sourced from renowned companies, such as-
JAMES H HEAL-UK
SDL ATLAS-UK
DATA COLOR SpectroPhotometer-USA

91
QA
91
QA
91
QA

92
Four Point Inspection System:
Generally any piece of fabric with less than 40 points fault per 100 square yard is allowed to
pass however for a roll; the average value should not exceed 28 points per 100 square yards.
More than 40 points fault per 100 square yards is recorded as reject. Normally fabric faults are
recorded using the 4-point system given below:
4-Point Grading System
Fault length Points to be assigned
(0 to 7.5) cm or less than 3” 1 points
(7.5 to 15) cm or (3” to 6”) 2 points
(15 to 22.5) cm or (6” to 9”) 3 points
More than 22.5 cm or 9” 4 points
Assessing Fabric Fault
Faults name Definition Faults area Points
Double pick In full width an extra pick 0 to 9 inch
over
4
Miss pick Missing of one or more picks 0 to 9 inch
over
4
Reverse pick After arriving reverse back and causes
double pick
0 to 3 inch
over
1
Broken or half pick Pick less than full length 0 to 9 inch
over
4
Crack More than three pick missing 0 to 9 inch
over
4
Snarling Bunch of weft yarn woven in one place 1 inch 2

93
Pressure loose Loop formed in the fabric Between 1
yards
4
Let-off mark Weft way mark for irregular pick dense 0 to 9 inch
over
4
Wrong pattern Design broken on warp way 0 to 9 inch
over
Starting mark Weft way mark while starting the loom Full width 4
Reed mark Reed having more gap than the normal
way.So warp way line visible
Reject
Temple mark Along the temple one or more pin mark
visible
Reject
Count mixing Mixing of various count Reject
Slubs Bunch fibers in yarn 0 to 1 inch 1
Double yarn One extra warp yarn woven along with
regular warp
Reject
Loose warp One or more warp yarn having more looser
than another warp
Mandible Reject
Tight warp One or more warp yarn having more tighter
than another warp
Mandible Reject
Stitch/warp float One or more warp yarn not properly
interlaced with weft for some distance
0 to 3 inch
over
1
Oil spot Oil drop in the fabric
Zala Bunch of warp yarn breakage 0 to 9 inch
over
4
Bad selvedge Narrow or higher width of selvedge Informed
weaving

94
Quality Assurance Dept
Finished Fabric Test Report Date:
Order No. : Test Std. : P.T .L
Customer : Construction :
Shade : Fiber Comp. : 100% Cotton
Recipe No. : Finish Type :
Test Parameters Test Method Requirement Results Remark
Threads Per Inch Ends
Picks
Yarn Count ISO 7211-5 Warp
Weft
FabricWidth(Inch) Overall
Useable
Fabric Weight (gm/m
2
) EN ISO 12127 Max deviation 5%
Dimensional Stability
To Washing
EN ISO
6330/4A:2000
Shirt/Dress Crepes. Voiles
Warp +/-3.0% Max. 5%
Weft +/-3.0% Max. 5%
Tensile Strength ISO 13934-2:1999 Warp 140 N 100 N
Weft 140 N 100 N
Tear Strength ISO 13937-1:2000 Warp 7 N 6 N
Weft 7N 6 N
Seam Slippage ISO 13936-1:2004
(6 mm)
Warp 80 N 60 N
Weft 80 N 60 N
Abrasion Resistance
(Martindale)
EN ISO 12947-2:1998 Lt. Shade Dk. Shade
4c @ 10’000revs 3c @ 10000 revs
Pilling Resistance ISO 12945-2:2000 ¾ @ 2’000 Revs.
Color Fastness To
Crocking
ISO 105 x 10 Lt. Shade Dk. Shade
Dry- 4s 3s
Wet- 3/4s 2s
Color Fastness To Wash ISO 105 C06, 60℃ Change- 4c Change- 3/4
Staining- 3/4 Staining- 2/3
Color Fastness To Water ISO 105 E01 Change- 4c Change- 3/4
Staining- 3/4s Staining- 2/3
Color Fastness To
Perspiration
ISO 105 E04 (Acid) Change- 4c Change- 3/4
ISO 105 E04 (Alkali) Change- 4c Change- 3/4
Color Fastness To Light ISO 105 B02 Change- 5c, White & Pastels- 4c
………………….. ……………………….
Tasted by Approved by

95
PHYSICAL TESTS
Test Name Equipments Manufacturer
Thread per inch Thread counter James. H. Heal &
Company, Halifax,
England
Gram per square meter G.S.M tester James. H. Heal &
Company, Halifax,
England
Width test Measuring tape N/A
Tensile strength Elmendorf tearing tester
1653
James. H. Heal &
Company, Halifax,
England
Seam slippage Alphatens James. H. Heal &
Company, Halifax,
England
Abrasion resistance Nu-Martindale
Abrasion & Pilling tester
James. H. Heal &
Company, Halifax,
England
Pilling resistance ICI pilling box James. H. Heal &
Company, Halifax,

96
England
Thermal stability Roaches Roaches engineering
limited
Crease resistance Shirley crease
recovery tester
James. H. Heal &
Company, Halifax,
England
CHEMICAL TEST
Wash Fastness Gyro wash James. H. Heal &
Company, Halifax,
England
Water Fastness Perspirometer&
Carbolite
James. H. Heal &
Company, Halifax,
England
Sweat Fastness Perspirometer&
Carbolite
James. H. Heal &
Company, Halifax,
England
Light Fastness Light fastness
Tester(Mercury vapor lamp)
James. H. Heal &
Company, Halifax,
England
Crocking Fastness Crocometer James. H. Heal &

97
Company, Halifax,
England
Washing stability Wascator James. H. Heal &
Company, Halifax,
England
ANALYSIS
Fiber analysis Electronic microscope James swift U.K.
Fabric analysis Balance, Thread counter N/A
Design analysis N/A N/A

98
Utility
98
Utility
98
Utility

99
It is one of the important sectors of a textile factory.
Generator, Air compressor, Boiler, Chiller, Water
treatment plant (WTP), Effluent treatment plant (ETP),
Humidification plant, Dryer
99
99

100
ETP
The effluent generated from different sections of a textile mill must be treated before they are
discharged to environment. Various chemicals & physical means are introduced for this
purpose. The effluent treatment plant in PARAMOUNT TEXTILE LTD. is biochemical
combination process developed by India.
Objects:
This process is provided for treating the effluents of dyeing, finishing, weaving & thus allow
discharging it s per norms given by World Bank dept of environment of Bangladesh. This
process comprises of collecting, pumping, clarification, Characteristics of raw effluents:
Volume : 140 cubic meter / day
Peak flow : 148 cub met / hr
pH : 7.6-7.8
BOD : 250-800 PPM
COD : 500 PPM
TDS : 2000 PPM
TSS : 200 PPM
D.O :0.50- 0.60 PPM
Color : Reddish- Black

101
Requirement of discharge effluent as per World Bank:
pH : 7- 7.5
BOD : < 50
COD : < 198
TSS : < 100
TDS : 602
DO : 5-5.5
Color : No.
Chemicals used & their colors:
Chemicals used Appearance
Ferrous sulphate Granular solid, greenish color
Lime White granular solid
Poly acrylate White granular solid
Sulphuric acid Clear liquid

102
Product Quality Check:
Following chemical tests are carried out to check the quality:
- BOD
- COD
- Total suspended solids
- Total dissolved solids
- Color
- pH
Flow Chart of Effluent Treatment:
Raw effluent
↓
Equalization
↓
Collection Sump
↓
Pump station
↓
Clarifier
↓
Aeration tank
↓
Setting tank
↓
Clear water, pH check
↓
Drain

103
Sludge Separation:
Sludge of DAF
↓
Sludge thickening plant
↓
Sludge drying be

104
Typical Output of the Plant:
This information we collect from the regular ETP operation chart
Raw effluent treated 15000 LPH
Raw effluent color Reddish Black
Raw effluent pH 7.8
Raw effluent TDS 1998
Raw effluent TSS 200
Raw effluent DO 0.52
Raw effluent BOD 250
Raw effluent COD 500
Treated effluent color Nil
Treated Effluent Temp 380
C
Treated Effluent PH
7.2
Treated Effluent TDS 600
Treated Effluent TSS 100
Treated Effluent DO 5
Treated Effluent BOD 45
Treated Effluent COD 198

105
WTP
WTP means water treatment plant. In normal water there are including many type of organic
compound such as Mg, Ca, Zn, K, Fe etc. To remove this compound WTP are used in textile
industries. Otherwise after dyeing some mark are found in woven fabric. Another many
problems are found in a fabric such as shade matching problem, dyes problem. To minimize
this type of problems WTP are used. So it is very useful for textile industries. In paramount
textile there are 2 water treatment plants.
Objective
 To make suitable water for Dyeing, Sizing, Finishing etc.
 To minimize various type of marks.
Effect
 Various type of mark in fabric, dyeing problem etc.
Working process of WTP
There are 3 tanks in WTP, which are:
1. Multi Grad Filter
2. Braine Solution Tank
3. Softener Tank (Resin are include in Softener tank)
Flow diagram of WTP:
Ground water
Pump
Multi grad filter
Braine solution
Softener
Yarn dyeing section Sizing Finis

106

107
Aeration
In between the aeration tank, the Fe is removed mainly. Basically Fe is not removed in general
way. So it is very match tough to remove. By oxidation Fe is remove easily.
Multi Grad Filter
It is a7 layers tank where the bacteria remove. These 7 layers are made by sand which work as
filter.
Softener Tank
In softener tank, Mg, Ca, Zn, K is removed. Actually all these metal parts are formed in “ion”
and reacts with resign and water made metal free.
Brine solution
When capacity of ionization power of resign is discriminately low then brine solution is
helped to recover the power.
Capacity
Three plants are working here.
A. 150 m3/hr
B. 100 m3/hr
C. 60 m3/hr
Different M/c which are used in Utility section:
Diesel Engine 01
Model GSW 275
Serial No 0237044/006
MFD(Manufacturing Date) Jan’08
Country of Origin UK
WDG 311
Frame Core UCD 274K
RPM 500
Power 50 Hz, 400 V
Function Power Generate
Manufacturing Company PRAMAC Co. Ltd
Chiller 01
Model YSX 437 (3)-174
Serial No 011
MFD(Manufacturing Date) Nov’11
Chilled water Temp 7C

108
Chilled water Flux 273 M3
/Hr
Cooling water Inlet 32C
Cooling water Flux 425 M3
/Hr
Fuel Gas Inlet Temp 195C
Fuel Gas Flux 16729 Kg/Hr
Steam Pressure 8 MPa
Steam Consumption 1860 Kg/Hr
Power Supply 3 , 400V,50 Hz
Electric Power 72 KW
Working Wt. 24.1 Ton
Ex Work No SXHL 1331
Function To Cool the water
Company Name Jiangsu Shungliang Air Conditioning
Equipment Co. Ltd
Pump 15
Model Y 160 ML 2
Serial No 080429079
MFD(Manufacturing Date)
Cos  0.88
Power 15 Hp
RPM 2930
Power Supply 50 Hz, 380 V, 21.8 A
Function Water Supply
Manufacturing Company
Generator 05
Model JGS 320 GSNL
Serial No 5849181
Country of Origin Austria
Rated Power 1415 KW
Rated Voltage 400/231 V
Current 2042 A
Mass 15500 Kg
Max Temp 30 C
Function Current Generate
Manufacturing Company GE Jenbacher GmbH & Co. Ltd
Boiler (Danlim Royal) 02
Model ZL-Z
Serial No 014A
MFD(Manufacturing Date) Jun’08
Country of Origin Korea
Actual Evaporation 8000 Kg/Hr

109
Design Pressure 1 Mpa
Heat Efficiency 90 %
Fuel Consumption 42 Nm3
/Hr
Heating Surface 97 M2
Capacity 100 M3
/Min
Power 15 KW
Normal Size 40 A
Manufacturing Company DanelimRoyel Boiler Co. Ltd
Boiler (Weihupt) 01
Model G 70/2-A
Serial No 0085Q 0723
Country of Origin Germany
Gas Type Natural (N)
Rating (Min 800-Max 8500) KW
Supply Pressure (Min 15-Max 500) mbar
Electric Rating 2389 KW
Power 400 V, 1-50 Hz, 10 A
Manufacturing Company Max WeishauptGmpHCo.Ltd
Air Compressor 06
Model ZT 250 VSD
Serial No APF 154024
Country of Origin Belgium
Working Pressure 8.6 Bar
Input Power 240 KW
Rotational Shaft speed 2370 r/min
Manufacturing Company Atlas Copco Air Power Co. Ltd
Air Dryer 06
Model FD 1250 A FS
Serial No 8573-1
Country of Origin Belgium
Working Air 13 Bar
Weight 860 Kg,
Power Supply 400 V, 50 Hz, 8.3 KW
Ambient Max 45C
Manufacturing Company Atlas Copco Air Power Co. Ltd
Cooling Tower 08
Model ZONZLG 760

110
Serial No 200-0-11-920
MFD(Manufacturing Date) Nov’08
Power 11 KW
RPM 180
Model Of Blower Fan JTLZ 58
Output Temp 32C
Input Temp 38C
Water Pressure 44 KPa
Frame Wt 3820 Kg
Manufacturing Company SHUANGLIANG FRP COOLING
MACHINARY CO.

111
Maintenance
111
Maintenance
111
Maintenance

112
Maintenance
Maintenance is one of the main concerning points for any production oriented organization.
PARAMOUNT having its own maintenance department is a strong section. It has a skilled
group of maintenance manpower.
Manpower:
Section Name of No of Description
Man
Required
Coverage for off
day, Total
Machine/Job Machine per Shift
leave &
absenteeism
In charge 0 0 1
Asst Engineer 0 0 1
Maintenance Mechanical 218 Forman 0 0 1
loom Senior Fitter 2 2 8
Fitter 2 2 8
Asst Fitter 2 3 9
Helper 3 3+General shift6 18
Total=46
In a weaving factory, Maintenance is done mainly on Sizing machine and on looms.

113
Maintenance of sizing machine
Periodical Inspection
Daily Inspection
Remove any lint on the suction filter for the cooling fan for the driving motors in each section.
Check any trouble and the following points:
→Abnormal noise,
→surface condition, vibration, rotation irregularity of each roll;
→Tension in each section;
→Steam, air size and oil leakage;
→Steam pressure:
a. Main supply pressure
b. Supply pressure to the drying cylinder
c. Supply pressure to the sizing section.
→Air pressure:
a. Main supply pressure,
b. Pressure during power failure-at the beam stand and the middle section,
c. pressure due to the cut mark device-standard 0.3MPa.
→Steam drain exhaust;
→Squeeze roll pressuring condition;
→Exhausting drain in the air filter equipment.

114
Weekly inspection
→Exhaust drain from the air compressor and the pressure reducing valve with the filter;
→Remove lint from the static electricity eliminator.
1. Roll chain tension
Adjust tension with tension wheel. If the chain has slack replace it.Some check points are-
a. Sizing section: Sizing roll driving
b.Drying Section: Pre-cylinder drying and main cylinder drying.
c.Take-up section:Warp beam and doffing driving,Taking-up roll driving.
2. V-Belt Tension
Slide the motor base and the V-belt tension. Checkingpoint’s are-
a.Size circulation pump
b.Winding motor
Every three month inspection
1. Steam strainer cleaning:
Clean the strainer two or three days after starting operation for the first time. Clean it every
three months after that.
2. Take up box frame and hydraulic unit:
Check the oil amount in the take up box frame and hydraulic unit. Supply if it is necessary.If
oil is dirty replaces it.
3. Pressuredrop after passing the air filter in the pneumatic piping
When the pressure difference between the primary and secondary side reaches 0.1MParepace
the element.

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