The software requirements specification example of garments is listed here. It is a payroll system of a garments. E.g. For separated salary against separation ID. It should be count that way (present days with before holydays) pay basic salary & OT from basic salary = Total pay salary. Put summary for separate salary report, All Employee List (Id No., Proximate Card No., Name, Position, Salary, Unit/Department), Designation wise employee list, Department wise employee list, Fixed monthly salary report etc.
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Software Requirements Specification
Automatically pay E/L money after one year finished from joining date it is countable is this way: Total year 365 days – unauthorized days = Total working days / 18 days = Total E/L days pay money. Put summary for E/L report for Compliance Sheet
Pay slip (individual, section & selected wise)
Monthly Overtime Register Reports comes Total overtime (hour) & Total no. of overstayed days
Monthly Attendance Register Reports Comes Total Present days, Total Leave days & Total Absence days.
Daily OT count check Report, which parameter goes by date & out time.
Department wise OT Summary.
In Reports weekend day, leave day & Govt. holidays comes in separate such as if week end then W, Leave (LW, CL, SL, AL, ML) & if Govt. holiday then H)
Employee List Report through by parameter with From Department to Department & from Designation
To Designation
Employee Leave Information Reports
Leave Ledger
Maternity Leave Ledger
All kinds of Attendance Sheet Reports- Govt. holidays comes to H
Salary and Wages Reports
Summary of Salary & Wages Repots
Separate OT Payment Sheet Report
Salary & Wages Reports deduction comes to Absence Deduct & Stamp Deduct.
Manually OT & Attendance Deduct System.
When Employee Salary process then comes three kinds of reports:
Software Requirements Specification and Requirement
Fixed monthly salary report
Automatically pay E/L money after one year finished from joining date it is countable is this way: Total year 365 days – unauthorized days = Total working days / 18 days = Total E/L days pay money. Put summary for E/L report for Compliance Sheet
For separated salary against separation ID. It should be count that way (present days with before holydays) pay basic salary & OT from basic salary = Total pay salary. Put summary for separate salary report
Pay slip (individual, section & selected wise)
Monthly Overtime Register Reports comes Total overtime (hour) & Total no. of overstayed days
Monthly Attendance Register Reports Comes Total Present days, Total Leave days & Total Absence days.
Daily OT count check Report, which parameter goes by date & out time.
In Reports weekend day, leave day & Govt. holidays comes in separate
(Such as if week end then W, Leave (LW, CL, SL, AL, ML) & if Govt. holiday then H)
Employee List Report through by parameter with From Department to Department & from Designation
To Designation
Employee Leave Information Reports
All kinds of Attendance Sheet Reports- Govt. holidays comes to H
Separate OT Payment Sheet Report
Salary & Wages Reports deduction comes to Absence Deduct & Stamp Deduct.
Manually OT & Attendance Deduct System.
Salary Process all
Base Data Process all (In & Out
About Non Complains OT Deduct Process
Daily Reports
Present only
Late only
Absent only
Present/Absent/Late
Early Departure
Overtime
Daily Attendance Summary
Movement
Single Punch
Between Punch time (Time Card)
Monthly Reports
Maternity Leave Ledger
Monthly OT Register
Monthly Attendance Register
Overtime Report
Executive Attendance Summary
Worker Attendance Summary
Resign Attendance Summary
General Reports
Department wise Employee list
Section wise Employee list
Line wise Employee list
Male
Female
New Hire
Separation
Card Print
Yearly Reports
Leave Ledger
Leave Balance
Monthly Salary Reports
Pay Slip
Monthly Salary Summary
Monthly OT Sheet Summary
Regular / Running Salary Sheet
Left / Resign / Separate Salary Sheet
New / Join current month Salary Sheet
Software Requirements Specification other Reports
Designation List, Department Details, Yearly Holyday List, Department List, Salary Grade List, Leave Details, Employee Category List are special types of software requirements specification example for textile industry.
Sanforizing Machine is the last stage of woven fabric processing. This stage is called mechanical shrinkage. In this stage fabric shrinkage is controlled by means of mechanical application & using steam. The shrinking process takes place between the rubber belt and the heated shrinking cylinder. The pressure roll presses the rubber belt against the heated shrinking cylinder and the rubber belt is thereby stretched. Leaving this nip point, the pressure is relieved and the rubber belt contracts. The fabric between the rubber belt and the heated shrinking cylinder has to follow this contraction of the belt and thereby shrunk. Changing the rubber belt pressure changing result in the fabric shrinkage. The higher the pressure, the greater the shrinkage will be. In ATL Finishing there are two Sanforizing Machine. Machine details are given below
Specification of Monforts Sanforizing Machine
M/C Name: N
Origin: Germany
Pressure in Blanket = 2 – 3 bar
Speed for coarse fabric = 30 – 50 m/min
Speed for thin fabric = 60 – 70 m/min
Nominal width = 180 – 260 cm
Mechanical speed = 5 – 100 m/min
Sketch Diagram of Sanforizing Machine
Sketch Diagram of Sanforizing Machine
Flow diagram of Sanforizing Machine
Fabric inlet
↓
Guide roller
↓
Damping roller
↓
Water Spray
↓
Rubber belt
↓
Steam Cylinder
↓
Blanket steam drum
↓
Cooling cylinder
↓
Batcher
Operational Procedure of Sanforizing Machine
Fabric inlet of Sanforizing Machine: fabric passes over some free roller & guider then over the steam heated roller. In the steam heated roller the fabric is wetted a little bit.
Rubber belt shrinkage unit: The function of the machine is mainly controlled in this section. Here there is a rubber belt which is pressed by a steam heated stainless steel roller. This rubber belt is continuously cooled by passing water. When the fabric goes through the nip point of roller & blanket then the fabric goes to shrink. The amount of shrinkage depends on amount of pressure applied.
Drying cylinder: After shrinkage fabric goes through drying cylinder for drying.Here cylinder is heated by means of steam
Cooling cylinder: After drying the fabric is passed over cooling roller for lowering temperature.
Folder & batch winder: Finally the fabric pass over the folded roller to collect on fabric storage bench or it will roll on batcher. Then its go for final inspection.
Conclusion
In Auto different kinds of finishing m/c r available such as Stenter machine, Monforts Sanforizing machine, Emerizing m/c, Calendering m/c. By useing these m/cs here water proofing, flame proofing,rot proofing, attractiveness, service ability,fastness properties r increased..
Dr. William Jons, Textile Technologist, Osaka Textile Division, Germany
Peach finish machine is the process where the peach fabric becomes smoother. By this process especially for twill fabric the diagonal line become lowered with the application of microsand paper or carbon wire brushing. In Auto TL there is one peach finish machine. The machine description is given below.
Peach Finish Machine Specification
M/C Name: Lafer (SPA)
Drum speed: 90 m/min
No of r/r: 24 (Positive- 12, Negative- 12)
Speed: 20m/min (light peach)
Belt Pressure: 2.6 bar
Drum Pressure: 9 bar
Types of Peach Finish
There are 3 types of peach finish
Light
Medium
Heavy
Objective of Peach Finish
Wide range of brushing effects which can be replicated through time.
Completely defect-free fabric processing.
Flexible drawing-in in the various right-back side combinations.
Fabric inlet of Peach Finish Machine:Mercerized fabric is feed in the inlet section of the peach finish machine. Here the fabric is passed over some roller & guider to feed into the brushing zone.
Fabric inlet
Brushing unit of Peach Finish Machine: It contain 2 to 6 roller according to design. For microsand brushing each roller contains 24 rollers which move forward & backward with the same speed of containing roller. In carbon wire type machine all the roller contain carbon wire which performed brushing. The entire roller can control individually. Here belt pressure is 2.6 bar & drum pressure is 9 bar, which depend on quality of fabric.
Fabric outlet & batching: After that the fabric become smooth this is rolled on batcher for washing.
Control Panel of Peach Finish Machine: From control panel all types of instruction can be provide to the machinery. This machine has a full manual control panel. The operator controls every process by control switch.
Control Panel of Peach Finish Machine
Peach Fabric Lay in Section
Process Definition:The Process of receiving accurate amount of Gray Fabric from the Peach fabric Store & pilling them on a pallet to transfer to the next operation is called Lay-in.
Process Requirement: Equipment Used – Seizer , Key Accessories – Forklift, Wooden Plate, Measuring Tape, Sewing machine, Calculator etc are used for Lay-in. Material & Chemicals Used – Mask, Cap etc
Safety: Smoking is strictly prohibited in the factory premises.
According to the “Fabric layout Instruction” sheet producing personnel receives the specified quantity of fabric from the stores personnel.
Production personnel ensure that fabric is piled “Face to Face” on the process fabric lay-out Inspection sheet & then this pallet of fabric is transferred to the preparation department.
Product Quality Check:
Fabric Width
Fabric Construction
Sticker
Quantity
Fabric Face/Back
Sample Test: Fabric Width, EPI, PPI, shade Qty, construction, tensile strength, tear strength (weft), GSM, Face/Back, Wash Fastness, Lycra Properties etc Q.C. sample test are applicable for lay-in process.
Response to Equipment faults: If the lay-in is in face to back position, the lay-in person should take corrective actions.
M/C area cleaning: Must be mud, oil, grease free.
Forms & Documents Used:
Fabric lay out instruction sheet for Y/D.
Fabric lay out instruction sheet for Solid Dyed normal Order
Process Route card:
In route card every process has been men timed from peach fabric to finish inspection.
In route card two extra requirements are needed.
color: Red, lemon, orange, etc.
GLM: Gram per linear meter.
from peach fabric to finish inspection. In
Production Report
Peach Check report (Point Wise)
Sticker Khata
Document Flow: The Planning department fills the fabric lay-out instruction sheet (From No). the planning Department raises for both yarn & solid Dyed fabric & sends to the Lay-in. the issue quantity is mentioned only in case of solid dyed fabric. But in case of yarn dyed fabric, the lay-in personnel collects the fabric from the store according to the Weaving fault ( tangle warp, miss pick, stop mark, fungus spot, oil spot), selvedge condition, piece to piece width, construction & lot number as mentioned on the fabric lay-in instruction sheet & then starts the lay-in process.
Attachments: The following forms are used in the lay-in process
Peach quality control check: Here peach fabrics are checked by the operational techniques and activities that are used to fulfill requirements for quality.
The things which are checked here are given below:
tear and tensile
GLM × 100 (cm)
G.S.M (G.S.M= )
Width
Or, G.S.M =GLM/1.6
Shade per quantity
Listing check
Selvedge check
Weaving Check
Line mark
Lycra problem
Neps problem
PPI, EPI and width check.
Note : Finished EPI, PPI are less than the peach fabric.
Dr. William Jons, Textile Technologist, Osaka Textile Division, Germany
Best industrial washing machine is the most common operation during wet processing. A wet processed fabric goes several times in washing chamber. In woven fabric processing each machine having continuous washing ranges. But after few process no additional washing option for that an individual washing machine is required. After cold pad batch, peach finish fabric goes through an individual washing machine.
Chemical used by a best industrial washing machine
Water
Steam
Detergent
Compressed air
Best Industrial Washing Machine Specification
M/C Name: Ramisch Kleinewefers
M/C Speed: For dark shade = 25 – 30 m/min, For light shade = 40 – 60 m/min
Washing chamber = 6
All padder pressure = 2.5 bar
All compansator pressure = 3.5 bar
1st washing unit = 1 shower cylinder
2nd washing unit = 2 shower cylinder
Sketch Diagram of Washing Machine
Sketch Diagram
Flow diagram of Best Industrial Washing Machine
Fabric inlet
↓
J-Box
↓
Cold washing chamber – 1 (40) 400 L
↓
Washing chamber – 2 (90 / 100 ) 400 L
↓
Washing chamber – 3 (90 / 100 ) 400 L
↓
Washing chamber – 4 (90 / 100 ) 400 L
↓
Washing chamber – 5 (90 / 100 ) 400 L
↓
Cold washing chamber – 6 400
↓
Dryer
↓
J-Box
↓
Fabric outlet
Operational procedure of Best Industrial Washing Machine and Dryer
Fabric inlet of Best Industrial Washing Machine : Fabrics are directly feed into the inlet of washing machine. Where the fabric is passed over some free roller, guider & expander to ensure open width entry. Here there is a control panel to control fabric speed.
Fabric inlet
Washing chamber: Fabric passes through washing chamber where following works are performed:
Cold wash (1 & 6): In the first chamber & last chamber of washing cold wash is performed. Here temperature is around 30-40’c.Here padder pressure 2.5 bar.
Hot wash (2 – 5): After cold wash squeezing is occurred then the fabric is passed through the chamber for hot wash. Here temperature is around 90 – 100’C.In 2 / 3 chamber chemical or soaping is applied.
Here padder pressure 2.5 bar.
Recipe:
Soap :- 4 gm/lt
Acetic acid: As required to maintain ph.
M/C Speed: For dark shade = 25 – 30 m/min
For light shade = 40 – 60 m/min
Recipe for Reactive Dye: Fabric construction:- 108 X 52 / 45 X 34/2
Nova yellow CRG = 0.76 gm/l
Nova Red C- 2 BL= 0.72 gm/l
Nova Blue CR = 0.53 gm/l
Primasol-v = 10 gm/l
Primasol-NF = 2 gm/l
Urea = 50 gm/l
Soda ash = 10 gm/l
Fabric Speed – 5o m/min
Temperature – 120 -130°C
Recipe for Reactive Dye: Fabric construction:- 133 x 60 / 20X 16
After chemical padding by using above CPS chemical steaming and washing is done.
Dryer of Best Industrial Washing Machine: After washing & neutralizing for drying process 2 stage vertical cylinders dryer is used. It is heated by steam. Here the temperature is around 120 – 150’C.
Dryer
Cooling Roller of Best Industrial Washing Machine:Dried fabric is passed over two cooling roller. It is cooled by cold water passing through roller by contact of which fabric become cool.
Cooling Roller
Batching: Finally the fabric is rolled in batcher. Then it is transferred to finishing section for finish process.
Conclusion
By using industrial washing machine and dryer such as Pad-dry-cure m/c, Pad steam m/c, Cold pad batch dyeing machine, Jigger m/c, Washing m/c.The entire bulk of the material is changed physically or chemically and fabrics look mono uniform colored.
Dr. Joshep, DGM, Textile Division, Seotex Limited, USA
Pad Steam Dyeing Machine is used in textile industry. Thermosol run fabric must pass through pad steam for the development of color when CPS process is carried out. Here chemical padding is done through which color is fixed on the fabric. CPB run fabric does not require pad stem process. Here based on requirement additional dye can also be added.In ATL There are two thermosol machine (Monfort Montex, Thermex) in Dyeing floor. There also 1 CPB (Kuster) & 1 pad steam machine (Goller, Model- 1994) & 1 Zigger machine.For developing color it is the essential machine after thermosoling in CPS process. Generally the color which is applied on the fabric surface is fixed on this stage & provides required color. Here not only chemical padding is done but also application of color is also possible if required shade is not achieved.
Fabric inlet: From thermosol fabric is feed into the inlet of pad steam machine. Where the fabric is passed over some free roller, parpet roller & platter. Here there is a compensator to control fabric open width entry & controlling fabric speed.
Pad Steam Dyeing Machine – Chemical tank: Application of chemical is higher in pad steam machine. Based on the chemical setting shade is varied. Here for reactive process those chemical are used:
Chemical tank
A typical recipe for reactive dye:
Glubar salt – 250 gm/lt
Caustic – 5 gm/lt
iii. Soda ash – 20 gm/lt
A typical recipe of W/W dye:
Padder pressure = 3 bar
Speed = 3m/min
Steaming = 1.5 min
Nova yellow NC = 5.84 gm/l
Nova brown NC = 2.04 gm/l
Nova blue CD = 2.9 gm/l
R.salt = 3 gm/l
Glubar salt = 10 gm/l
Soda ash = 10 gm/l
Wetting agent = 2 gm/l
Chemical is mixed according to required based on pick up. Those are mixed on separate bath then feed. According to the command on control panel chemical comes to chemical tank for padding. If required color also can applied and can added to chemical tank for padding.
Pad Steam Dyeing Machine – Padding unit: Chemical comes from storage tank to maintain even range on padding tank. Here three bowl padding is occurred. Here padder pressure (2.6-2-2.6) bar is maintained.
Padding unit
Pad Steam Dyeing Machine – Steamer:In pad steam machine after chemical padding fabric goes through steamer for fixing. Its consists of two chamber. This chamber is steam heated & temperature is around 100- 105 ‘C. Here fabrics go over few rollers. The length of steamer is 90 meter & fabric is remain here for 1.5 min (approximate)
Steamer
Washing unit: After steaming dye is fixed in fabric. Now unfixed dyestuffs are removed by washing. Here both hot & cold wash is done on different chamber. In cold wash temperature is around 40’C & in cold wash temperature is around 90-100’C. There are 8 washing unit. Where 1& 8 is cold wash unit and 2-7 are hot wash unit.
Oxidation: In this stage, the leuco compound of vat dye is oxidized and converted to its original color & in soluble form. This oxidation is brought about by atmospheric oxygen. It is generally done in 2nd washing unit.
Pad Steam Dyeing Machine – Neutralizing unit: After washing neutralizing is done to control pH-7 of fabric. It is done by acetic acid. For reactive only one neutralizing chamber is used after washing. Here oxidation is not required.
Neutralizing unit
Pad Steam Dyeing Machine – Dryer:In Pad steam machine two stage vertical cylinder dryer is used for proper drying. Fabric passes over the surface of the cylinder and become dry. This dryer is steam heated. The temperature is around 120-140’C.
Dryer
Cooling roller: After drying in cylinder dryer fabric require cooling. So fabric is passed over the cooling roller. It is stainless steel roller through which cold water is passed.
Pad Steam Dyeing Machine – Fabric outlet: Finally fabric is passed over few rollers & rolled on batcher. If shade is ok then it becomes ready for finishing.
Fabric outlet
PDB process- Chemical and conditions
Chemical
Chemical composition
Dye (reactive dye)
As per requirement
Ant migrating agent
10 g/l
Urea
50 g/l for light shade, 100 g/l for dark shade
Soda ash
(10-15) g/l
Lyoprint RG
2 g/l (constant)
Wetting agent
(1-2) g/l (used when absorbency is poor)
Thermal condition used for PDB (Thermosol / Thermo fix): In reactive dyeing –
Dyeing temperature = (120/ 130) °C for 2 min.
Curing temperature = (150/160) °C for 1 min
Recipe for RC solution:
Caustic soda- 5 ml/ L
Hydro sulfite- 4 g/l
Water temperature- (60-70) °C
Chemical and condition for CPS process
Chemical
Composition
Dye
As per requirement
Anti migrating agent
10 g/l
Reduction inhibitor e.g. Lyoprint RG
3 g/l
Wetting agent
2 g/l
Chemical pad solution
Composition
Glubers salt
250 g/l
Caustic
5 g/l
Lyoprint
3 g/l
Pressure, speed, drying and curing parameter of PDD 1 and PDD 2
For heavy fabric drying temperature required for 2 min.These parameter are required only for cotton.
PDD 2
Process
Pressure(bar)
Speed(m/min)
Drying time
Curing time
Upto 5g/l
1.25
3
120(2MIN)
160(1min)
5-15 g/l
1
3
120(2min)
160(1min)
Upto 15 g/l
1
2.5
120(2min)
160(1min)
Process definition: A color development process (Lab dip) in which a sample of 100% cotton fabric is dyed using laboratory equipment to mach customer swatch with specification. There are three different laboratory processes that can be used for color development-
Pad dry bake (PDB): Mostly this process is used for color development.
Pad dry chemical pad steam process (CPS): For Royal Deep blue, Blake and Navy family this process is used.
Cold pad batch (CPB)
Process Requirement: Equipment Used – Mathis padder machine and Mathis drying & curing machine are used for continuous dyeing of 100% cotton and blended fabric.
Key accessories: Weighing machine, pipettes, iron
Safety: While using hazardous chemical the lab personal uses plastic eye gloves, hand gloves and apron.
Testing Required During Pad Steam Dyeing Machine Operation
Pick up testing,
Shade listing identification.
Pick up testing: Before going to Pad steam pick up of the fabric should be calculated & based on this result liquor is prepared.
Shade listing identification of pad steam dyeing machine: After each 1000 meter shade is tested in light box. Here listing problem is visualized & can be solved by increasing or decreasing pressure. Suppose in left color is lighter then lower the pressure.
