Commercial Gas Dryer Repair and Maintenance Procedure

Commercial Gas Dryer

To describe the preventive maintenance procedure Of commercial gas dryer which is applicable to all the Gas Dryer Machine. Clockwise and counterclockwise rotation of the internal tub of commercial gas dryer is computer controlled. This gas dryer is combined with a frequency inverter control and providing 7-step speed of internal tub to reduce tangle of dry clothes.

Personal Safety  :

• Proper personal protective equipment of commercial gas dryer i.e. gloves, visors, and aprons must be
• Two persons should always perform opening and closing of the hoods.
• Always wait until the machine is fully stationary and cooled down.
• Do not push finger/ hand through the rotating parts.
• For maintenance work in extreme height wear safety belts to avoid fall.
• Avoid wearing loose fitting wears.
• First aid equipment such as first aid kit, stretcher, and dressing material box must be stationed in the vicinity.
• Carefully observe announce location and operation of fire extinguishers.

Machine Safety:

• Switch off the commercial gas dryer.
• Do not turn main power on without correct power and grounding.
• Do not turn main power on without proper air pressure and conditioned air.
• Improper connections of gas burners can make an acute danger of explosion.

Daily Maintenance:

• Clean the whole commercial gas dryer machine.
• It is same like front loading washing machine
• Check the line drive for damage.
• Check all fans for contamination and damage.
• Check and clean the belt with a dried floor cloth.
• Check the air channels in the floor for damage.
• Check the exhaust installation for blockages and damage.
• Check the infrared radiators for breaks.
• Check the motor pulley guard.
• Check all the screw & nut & Bolt.

Weekly Maintenance:

• Check the electrical connections.
• Clean the air filters in the drier segments.
• Check explosion proof power box.
• Check and put oil if necessary all the joints.

Monthly Maintenance:

• Clean the air filter boxes of the heating segments.
• Check the line drive for damage.
• Check all fans for contamination and damage.
• Check the electrical connection of the driver for damage.
• Check the control cubicle for damage.
• Check the infrared radiators for breaks.

Standard Operating Procedures of Residue Chemical Control

Washing: It is the process of controlled Physical and Chemical treatment on the sewn Product to achieve a desired Shade/ Appearance and Hand feel of the product meeting customer expectations and Buyer’s requirement.

Importance of Washing: Washing is very important process as it affects the Appearance, Shade and Hand feel of the garment. The control has to be exact and precise to achieve desired results.

Washing Department: The following processes constitute the Washing department:

• Dry Processing
  • Whiskering
  • Hand Scraping
  • 1^st Quality Check (100% Checking)
• Wet Processing
  • 1^st Wash (Minimum 100 Pcs lot or as advised by Washing Manager)
    • Rinse – Enzyme – Rinse – Softener – Hydro – Drying – Heavy Cooling
  • 2^nd Quality Check (100% Checking for Shade and Dry Process)
  • Destruction (Grinding as per Style requirement)
  • PP Spray (Spray done to achieve desired shade as per style requirement)
  • Washing and Drying
  • Final Quality Check (100% Checking for Shade, Hand feel and Appearance)
• Resin Spray followed by 3D Crinkling (As per requirement of the Style)

SOP  for Washing gas dryer: First of all, Shade and Size wise input is taken from sewing section.

• Various lots are prepared based on shade and size and input is provided to the dry processing section as per requirement of the style.
• After dry processing, 1^st Quality Check (100%) has to be done.
• Quality Passed lots are sent for wet processing, where the garments are rinsed, treated with enzyme and softener followed by drying and heavy cooling
• Now, 2^nd Quality Check (100%) is carried out. If the lot fails, the garments are sent for rewash. The QC passed garments are sent for destruction, PP spray, washing and drying as per the style requirement.
• Final Quality check is conducted for checking shade, hand feel and appearance. If the lot fails, it is sent for rewash.
• Quality passed garments are sent for resin spray followed by 3D crinkling (as per requirement of the style).
• The garments are segregated size wise and dispatched to finishing section.

SOP  for Chemical Handling in Washing: The requisition written by the Washing Operator cross verified (signed) by washing manager has to be submitted to the Chemical Incharge.

• The requisition should have the following details: Style #; Lenny #; Color; Job Card #; Lot Size; M/C No. and Water Requirement.

• Lot wise recipe has to be prepared by the Washing Manager and copy has to be available with the following personnel:
  • Washing Manager, Chemical Incharge, Washing Operator
  • One copy has to be attached to the respective M/C register maintained by the Chemical operator.
• The Chemical Incharge has to do the entry in his register for the corresponding Washing Machine. He should issue the required chemicals in appropriate quantity to the operator exactly as per the recipe prepared by the Washing manager. The operator has to sign on the register after receiving the chemicals.
• Before putting the lot and chemicals in the machine for wash, the Chemical Incharge has to cross check the quantity of water in the M/C and has to sign on the respective operator’s Job Card. This is to ensure that the correct amount of water has been fed in the M/C.
• After the Job Card has been signed by the Chemical Incharge, the chemicals have to be put in M/C by the Chemical Incharge.
• The output has to be checked with the approved standard.
• If any deviation is observed from the approved lot, the garments are sent for rewash. The Rewashing recipe and lot size also has to be prepared by the washing manager in the same manner as for Fresh Lot. Also, the procedure of Chemical Handling has to be followed exactly in same sequence as for Fresh Lot.
• Once the pcs match the approved standard, the garments are sent for Final Quality Check. The passed pcs are segregated size wise and input is provided to finishing.

Check List for Chemical Handling: The Washing Q/C has to cross check the Job Cards of the washing operators and ensure that all the Job Cards have been signed by the Chemical Incharge. In case any deviation is observed, it has to be brought to the attention of the Washing Manager immediately.

• The washing Q/C has to check that the lot wise recipe is available in the register of Chemical Incharge and also available with the following personnel:
  • Washing Manager, Chemical Incharge and Washing Operator
• The Q/C has to check that the weighing M/C for issuing chemicals is calibrated or not. He also has to check for the next due date of calibration.
• The Washing Manager has to ensure that Lot Wise Rewashing recipe has also been prepared and the copy of same has been issued to the respective concerned personnel. The Chemical Incharge has to check the same before issuing any chemical against any requisition.
• The Washing Q/C has to check the register of the Chemical Incharge two times a day to ensure that all the records have been updated and no excess/ shortage chemical has been issued against any particular requisition.

Operating Procedure:

Carry out the following steps in sequence:

• Turn on the main switch position. After a self test, the temperature controllers will display the actual temperatures of the individual segments.
• Open the taps of the gas burners (at the gas input of the burners).
• Press the start button (1); the pilot lamp (6) will go out (after approx. 5 sec.). The pilot lamps(3) and (5) on the operator panel are lit
• Set the desired temperatures for each segment on the temperature controllers (13), (14), (depending on your             particular version): Observe the following procedure:
• Squared controller
• Press down the SET button. The current set value will be displayed on the controller.
• Press the Up or Down key (triangular symbols) while simultaneously holding down the SET key in order to set the desired temperature.
• The following factors help to reduce the warming-up time:
• low line speed
• exhaust air throttled
• infeed slot closed
• delivery slot opened
• use the push-buttons (7) or rotary switches (8); (9) (depending on your particular version) to turn on the heating segments. The pilot lamps (10), (11), (12)      (depending on your particular version) light when the heating segment is turned on. The heating segments of the commercial gas dryer (circulating air or infrared, depending on your particular version) can be connected separately in accordance with the particular technological requirements.
• Use the rotary switch (19) to turn on the cooling segment (if any). Turning on the cooling segment during the warming- up phase helps to reduce the warming-up time of the
• Continuous tunnel commercial gas dryer. The continuous tunnel commercial gas dryer is ready to operate once the warming-up time has elapsed, the temperature controllers have reached the set value and the technologically necessary settings have been made.
• The gas dryer should repair periodically

Engr. Kh. Mashiur Rahman, Garments Auto Machine Technologist, Web: www.autogarment.com, Email: sales@autogarment.com, Cell: +88 017 92 52 53 54