The unit is equipped with modern machines and being run by educated, efficient and experienced technical personnels. Autogarment washing uses best recommended chemicals and other necessary materials in correct proportions in order to ensure desired quality of wash of garments. Strict Quality Control is in place to make sure that no sub-standard chemicals are used and expected look and handfeel have been achieved in the garments after wash.
Purpose of Fully Automatic Washing Machine
To determine the dimensional changed and outside of woven and knitted garmentss after home laundry. Principle of automatic washing machine is this test is intended to give an overall view of the durability and stability of garmentss during mc washsing and drying and is intended to replicate home laundry conditions and results as seen by the consumer. Each garments should be tested according to the order or selling region.
Apparatus
Automatic Front Load Washsing Mc; European style
Recommendation: Miele Washsing Mc or Wascator Models as specified in Test Method 4.02
Requirement: any other European Style Washsing Mc Models need to follow below specifications:
water ratio : load 5:1
5kg capacity
spin speed min. 1200 to max.1600 turns / minute
Domestic tumble dryer
5kg load
with a cool-down facility
Speed – 50(+/-5) rotations per minute
Automatic Top Load Washsing Mc, USA (Kenmore)
Kenmore/Whirlpool Washsing Mc – Dry load Capacity 8.2kg
All USA Top Load Washsing Mc Models have a liquor level of 48 litres
Detergent
Commercial / Household Washsing Detergent that is widely available in the order region or selling region
Recommendation: Tide, Persil or Ariel
N.B.: Powder Form only
Equipment
Ballast of bleached CO sheeting or single jersey 180g/m² ( size 1 x 1y hemmed pieces) or
Ballast of 100% Polyester Dummys -white (size each 14” X 14”) for dummy load to achieve the described mc load.
Hangers for Garmentss
DALO Marker and/or indelible ink marking pen for use with suitable rule, tape, marking template
Tape or rule calibrated in millimeters/inches
Balance capable of weighing 0 – 200g and accurate to 0.1g.
Balance capable of weighing up to 2.0kg accurate to 1.0g. – 5.0g.
Garments Preparation
Please N.B.: One garments from the same batch, size and colour must be retain as an original for comparison purposes.
Lay the garments flat, and without any tension on a table
Mark the measurement points in length and width direction according to the article description
Record the measurements between the benchmarks according to the article description before washsing.
Test Procedure by Automatic Washing Machine
Washs the garments in a European (Miele) Washsing Mc or Wascator being adjusted to an European washsing mc
If the specimen is being sold in the US region washs the specimen in a Top Load Kenmore washsing mc
Use the washsing temperature and cycle as specified in the care label of the garments.
N.B.: Garmentss of different colours/styles must not be washsed in the same washs load. It is preferable to washs only one garments at a time
For Washsing:
Using Front Load Mc
Add 50g of standard ECE detergent or washsing detergent for pre-washsing cycle and 50g for main -cycle. Add the garments and ballast. Remove the test washs load immediately after the final spin cycle and hang each garments on a hanger.
Using Top Load Mc
Add sufficient standard household detergent (e.g. Tide, Persil, Ariel) measuring 2 gram for every litre of water.
Example: for a washs with 48 litres of water add 96gm. detergent.
Add enough ballast to make a 2.0 kg ± .1kg load.
Please N.B.: Use only clean ballast that is free from Optical Brightening agents. Soiled or heavily stained ballast must not be used.
For Drying:
For Europe orders, allow the garments to dry on hangers in still air at room temperature.
For USA orders, tumble dry the garments according to the care label.
After drying the garmentss lay each of them without tension on a flat, horizontal table. Measure and record the distance between the benchmarks.
For tumble dried garmentss allow to cool back to room temperature before re measuring
Shrinkage Evaluation after 3 times washsing and 3 times (Line / Tumble) Drying:
Measurement before Washs – Measurement after Washsing
————————————————————- X 100 = shrinkage in %
Measurement before Washsing
less than 100% = shrinkage (N.B. this with ‘ – ‘ sign )
more than 100% = extension (N.B. this with ‘+’ sign )
Outside Assessment
Check the garments carefully after washsing / drying and N.B. the following:
shade changed in comparison to an original untested garments
cross staining
changed in surface characteristics eg: pilling (fuzziness), assess the outside of the garments as well as the inside
side seam twist
seam crinkling (pucker)
changed in outside and shade any of embroidery / print or motifs
changed in outside of labels
Test Reports ofFully Automatic Washing Machine
Using the autogarments Group standard reports format:
Reports the average changed in dimension of the length and width directions. Use a positive sign to indicate an increase in length and a negative sign to indicate a decrease in length. Quote the results to nearest 0.1%
Test Standard
Minimum Requirements
Line Dry
KNITS WOVEN RIB RIB
All Knit Fabric All Woven Fabric (Body Fabric) (Body Fabric)
Construction Construction Without Elastane Elastane
Fabric Properties
Content
Standard
(Length X Width)
Standard
(Length X Width)
Standard
(Length X Width)
Standard
(Length X Width)
100% Natural
Fibres
100% Natural
(± 5%) X (± 5%)
Maximum
(± 3%) X (± 3%)
Maximum
(+3/-5%)
X (+0/-5%)
Maximum
(+0/-5%)
X (+0/-5%)
Maximum
Blends:
(Chief Value
Natural)
> 50% Natural
(± 5%) X (± 5%)
Maximum
(± 3%) X (± 3%)
Maximum
(+0/-5%)
X (+0/-5%)
Maximum
(+0/-5%)
X (+0/-5%)
Maximum
100% Synthetic
100% Synthetic
(± 3%) X (± 3%)
Maximum
(± 2%) X (± 2%)
Maximum
(+0/-3%)
X(+0/-3%)
Maximum
(+0/-3%)
X (+0/-3%)
Maximum
Blends:
(Chief Value
Synthetic)
> 50% Synthetic
(± 3%) X (± 3%)
Maximum
(± 2%) X (± 2%)
Maximum
(+0/-3%)
X (+0/-3%)
Maximum
(+0/-3%)
X (+0/-3%)
Maximum
Ribs
Used as Trim
N/A
(+0/-8%) X (+0/ -8%)
Maximum
N/A
N/A
Test Standard
Minimum Requirements
Tumble Dry
KNIT WOVEN RIB RIB
All Knit Fabric All Woven Fabric (Body Fabric) (Body Fabric)
Construction Construction Without Elastane Elastane
Wascator washing machine is special type of Lab Washer-extractor. Standard wascator washing machine. Microprocessor controlled up to 999 wascator washing machine and drying programme can be designed as requirement, input through the keypad and stored in memory. The unit of wascator is programmed as standard with BS, ISO, and IWS test programme. Automatic Soap Dispenser, for multiple wascator washing machine cycles without intervention. Makeweights, stability templates and rules, reference detergents agents & conditioners also available, see following specifications.
Program List of Wascator Washing Machine
Level Check/Control
Temperature Check/Control
Start-up Program
BSEN ISO 26330/2A
BSEN ISO 26330/3A
BSEN ISO 26330/6A
BSEN ISO 26330/7A
BSEN ISO 26330/8A
BSEN ISO 26330/Handwash
11) EN ISO 6330/1A
EN ISO 6330/2A
EN ISO 6330/3A
EN ISO 6330/4A
EN ISO 6330/5A
EN ISO 6330/6A
EN ISO 6330/7A
EN ISO 6330/8A
EN ISO 6330/9A
21) 1984 ISO 6330/1A
1984 ISO 6330/2A
1984 ISO 6330/3A
1984 ISO 6330/4A
1984 ISO 6330/5A
1984 ISO 6330/6A
1984 ISO 6330/7A
1984 ISO 6330/8A
1984 ISO 6330/9A
1984 ISO 6330/Handwash
Program Details of Wascator Washing Machine
Program no. (04) BSEN ISO 26330/2A Total Program Time 68 min
Temperature: 600C
Mainwash 01 Fill Time 30 sec Temperature 200C(Normal)
Mainwash 01 Washing Time 30 sec Temperature 200C(Normal)
Mainwash 02 Fill C Temperature 400C
Mainwash 02 Heating Time 900 sec Temperature 400C
Mainwash 02 Washing Temperature 400C
Mainwash 03 Fill C Temperature 400C
Mainwash 03 Heating Time 900 sec Temperature 600C
Mainwash 03 Washing Temperature 600C
Drain 01 Time 60 sec Temperature Normal
Rinse 01 Fill C Temperature Normal
Time 180 sec
Rinse 01 Washing Temperature Normal
Drain 02 Time 60 sec Temperature Normal
Rinse 02 Fill C Temperature Normal
Time 180 sec
Rinse 02 Washing Temperature Normal
Drain 03 Time 60 sec Temperature Normal
Rinse 03 Fill C Temperature Normal
Time 120 sec
Rinse 03 Washing Temperature Normal
Drain 04 Time 60 sec Temperature Normal
Rinse 04 Fill C Temperature Normal
Time 120 sec
Rinse 04 Washing Temperature Normal
Dain 05 Time 60 sec Temperature Normal
Extraction 01 Low Speed Time 300 sec ———————–
Program no. (05) BSEN ISO 26330/3A Total Program Time 60 min
Temperature: 600C
Mainwash 01 Fill Time 30 sec Temperature 200C(Normal)
Mainwash 01 Washing Time 30 sec Temperature 200C(Normal)
Mainwash 02 Fill C Temperature 400C
Mainwash 02 Heating Time 900 sec Temperature 400C
Mainwash 02 Washing Temperature 400C
Mainwash 03 Fill C Temperature 600C
Mainwash 03 Heating Time 900 sec Temperature 600C
Mainwash 03 Washing Temperature 600C
Drain 01 Time 60 sec Temperature Normal
Rinse 01 Fill C Temperature Normal
Time 180 sec
Rinse 01 Washing Temperature Normal
Drain 02 Time 60 sec Temperature Normal
Rinse 02 Fill C Temperature Normal
Time 120 sec
Rinse 02 Washing Temperature Normal
Drain 03 Time 60 sec Temperature Normal
Rinse 03 Fill C Temperature Normal
Time 120 sec
Rinse 03 Washing Temperature Normal
Drain 04 Time 60 sec Temperature Normal
Extraction 01 Low Speed Time 120 sec ———————-
Program no. (06) BSEN ISO 26330/6A Total Program Time 40 min
Temperature: 400C
Mainwash 01 Fill Time 30 sec Temperature 200C(Normal)
Minwash 01 Washing Time 30 sec Temperature 200C(Normal)
Mainwash 02 Fill Time 30 sec Temperature 200C(Normal)
Manwash 02 Heating Time 30 sec Temperature 400C
Mainwash 02 Washing Time 30 sec Temperature 400C
Mainwash 03 Fill Temperature 400C
Time 900 sec
Mainwash 03 Washing Temperature 400C
Drain 01 Time 60 sec Temperature Normal
Rinse 01 Fill C Temperature Normal
Time 180 sec
Rinse 01 Washing Temperature Normal
Drain 02 Time 60 sec Temperature Normal
Rinse 02 Fill C Temperature Normal
Time 120 sec
Rinse 02 Washing Temperature Normal
Drain 03 Time 60 sec Temperature Normal
Rinse 03 Fill C Temperature Normal
Time 120 sec
Rinse 03 Washing Temperature Normal
Drain 04 Time 60 sec Temperature Normal
Extraction 01 Low Speed Time 120 sec ———————–
Program no. (07) BSEN ISO 26330/7A Total Program Time 35 min
Temperature: 400C
Mainwash 01 Fill Time 30 sec Temperature 200C(Normal)
Mainwash 01 Washing Time 30 sec Temperature 200C(Normal)
Mainwash 02 Fill C Time 30 sec Temperature 400C
Mainwash 02 Heating Time 30 sec Temperature 400C
Mainwash 02 Washing Time 30 sec Temperature 400C
Mainwash 03 Fill C Temperature 400C
Mainwash 03 Heating Time 180 sec Temperature 400C
Mainwash 03 Washing Temperature 400C
Drain 01 Time 60 sec Temperature Normal
Rinse 01 Fill C Temperature Normal
Time 180 sec
Rinse 01 Washing Temperature Normal
Drain 02 Time 60 sec Temperature Normal
Rinse 02 Fill C Temperature Normal
Time 180 sec
Rinse 02 Washing Temperature Normal
Drain 03 Time 60 sec Temperature Normal
Extrction 01 Low Speed Time 60 sec ———————–
Rinse 03 Fill C Temperature Normal
Time 120 sec
Rinse 03 Washing Temperature Normal
Drain 04 Time 60 sec Temperature Normal
Extraction 01 Low Speed Time 120 sec ———————–
Program no. (08) BSEN ISO 26330/8A Total Program Time 25 min
Temperature: 300C
Mainwash 01 Fill Time 30 sec Temperature 200C(Normal)
Mainwash 01 Washing Time 30 sec Temperature 200C(Normal)
Mainwash 02 Fill C Time 30 sec Temperature 300C
Mainwash 02 Washing Time 30 sec Temperature 300C
Mainwash 03 Fill C Temperature 300C
Time 180 sec
Mainwash 03 Washing Temperature 300C
Drain 01 Time 60 sec Temperature Normal
Rinse 01 Fill C Temperature Normal
Time 180 sec
Rinse 01 Washing Temperature Normal
Drain 02 Time 60 sec Temperature Normal
Rinse 02 Fill C Temperature Normal
Time 180 sec
Rinse 02 Washing Temperature Normal
Drain 03 Time 60 sec Temperature Normal
Rinse 03 Fill C Temperature Normal
Time 120 sec
Rinse 03 Washing Temperature Normal
Drain 04 Time 60 sec Temperature Normal
Extraction 01 Low Speed Time 120 sec ————–
Program no. (14) EN ISO 6330/4A Total Program Time 57 min
Temperature: 400C
Mainwash 01 Fill Time 30 sec Temperature 200C(Normal)
Mainwash 01 Washing Time 30 sec Temperature 200C(Normal)
Mainwash 02 Fill C Temperature 400C
Mainwash 02 Heating Time 900 sec Temperature 400C
Mainwash 02 Washing Temperature 400C
Mainwash 03 Fill C Temperature 400C
Mainwash 03 Heating Time 900 sec Temperature 400C
Mainwash 03 Washing Temperature 400C
Drain 01 Time 60 sec Temperature Normal
Rinse 01 Fill C Temperature Normal
Time 180 sec
Rinse 01 Washing Temperature Normal
Drain 02 Time 60 sec Temperature Normal
Rinse 02 Fill C Temperature Normal
Time 120 sec
Rinse 02 Washing Temperature Normal
Drain 03 Time 60 sec Temperature Normal
Rinse 03 Fill C Temperature Normal
Time 120 sec
Rinse 03 Washing Temperature Normal
Drain 04 Time 60 sec Temperature Normal
Extraction 01 Low Speed Time 120 sec wascator washing machine
Fusing t shirt heat press machine for garments is very much important to maintain the quality of the products. The press machine carries out fusing by holding the fabric & the fusible interlining between the conveyor belts while heating. To check the uniformity of the fusing area in the fusing area in the fusing machine the following method or procedure should be followed.
For Conveyor TypeHeat Press Machine
Three stripes of fabrics & fusible interlining should be taken; Length-42” (inch)—each pieces
The fabrics & interlining (taken before) should be fed into the fusing machine.
In t shirt heat press machine, machine bed should be divided into three zones ( like zone A,B&C) to identity the lack of uniformity in fusing bond.
After fusing three samples each of them to be tested for the fusing bond strength & fusing quality by pulling the interlining apart from the fabrics.
A visual inspection to be carried out in order to ascertain the sharing of the interlining glue with the corresponding fabrics stripes.
Conveyor Type Heat Press Machine
For Flat Bed Type Heat Press Machine
Three stripes of fabrics & interlining should be taken; Length-42” (inch)—each pieces
The fabrics & interlining (taken before) should be fed into the fusing machine.
In fusing machine, machine bed should be divided into three zones ( like zone A,B&C) to identity the lack of uniformity in fusing bond.
After fusing three samples each of them to be tested for the fusing bond strength & fusing quality by pulling the interlining apart from the fabrics.
A visual inspection to be carried out in order to ascertain the sharing of the interlining glue with the corresponding fabrics stripes.
To test fusing press machine light color solid T/C fabrics should be used.
This test should be done at least twice a month, & records should be kept in fusing check register. Test will be conducted between 1st to 3rd (First) & 15th to 18th (Second) day of each month.
Quality in-charge will be responsible to ensure the fusing uniformity of the fusing area to test the fusing machine.
Golden Rules to successful fusing
Check compatibility of fusing type with fabric end use.
Carry out tests as per attached test request form.
George approved certificate to confirm agreed standards for production use.
Fusing bed records.
Temperature checks.
Pressure check.
Time check.
Review peel strength
Wash and/or dry clean result of garment part being fused.
A sample of the fabric being fused should be maintained as a reference for the operative.
Heat Press Machine Maintenance
Keep a record of each press.
We have assembled this guide to make it easier for the factories to assure that the bond strength and the fuse line temperature are according to the requirement as stated in the
Vilene test report.
Once agreed compatibility for end use.
Heat Press Machine Maintenance
Daily Maintenance:
Clean the whole machine.
Check and clean the belt with a dried floor cloth when the operation is over.
Raise the scraper three or four times a day in order to clean.
Wipe off dusts using a dry floor mat, before inserting the material.
Check all the screw & nut & Bolt.
Monthly Maintenance:
Check the electrical wiring system.
Check the machine for visual damages
Tools
Spring loaded balance : A spring balance is a basic devise, which cannot be as precise as a computerised bond strength-measuring machine, however the results are close enough for comparison.
Temperature strips : Just proceed according to the instruction as follows
Method: Cut the interlining in a width of 7cm and a length of 17cm in machine direction (MD). Cut the fabric a little bit bigger to avoid contamination of the conveyor belt, also cut a small fabric piece as shown. Insert the little piece between the fabric and the interlining. Add also the temperature strip readingface to fabric. Put it through the fusing press according to the recommended conditions. After fusing cut alongside the temperature strip. Turnover the temperature strip and look for the black square of the highest reading, this is the fuse-line temperature. Here the fuse-line is 121ºC.
Fuse-line temperature reading 121ºC : The fuse-line temperature is the temperature achieved on the adhesive dots during the fusing process. Therefore the temperature strip is used between the fabric and the fusible interlining for correct measuring. It is recommended to always double check the fuse-line temperature prior to production start.
Personal Safety
Proper personal protective equipment i.e. gloves, visors, and aprons must be used.
This machine is used in high temperature, so pay attention to your hands and clothes not to be burned.
Always wait until the machine is fully stationary.
Do not push finger/ hand through the heated chamber.
Avoid wearing loose 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.
Do not operate the equipment in the presence of flammable gases or fumes.
Machine Safety
Switch off the machine.
After maintenance work always tighten released screw, nut-bolt connections.
Do not use compressed air on electric and electronic parts directly.
Confirm that the power plug is properly connected.
Pay sufficient attention not to make contact with the belt and the upper cover whose temperature rises high nor mount things on them.
Don’t put anything to the main unit of the press except the materials to be inserted.
SOP for Different Types of Garments Pressing
Pressing: It is the process of application of Heat or Steam or both on a finished garment to provide a desired appearance and stability to the garment making it appealing to the customers.
Importance of Pressing: Pressing is a very important parameter which affects the appearance of a garment. When any customer walks in a store to purchase a garment, he / she look for a visually appealing garment. Apart from this, pressing also provides dimensional stability to the garment.
When should be Pressing done: Pressing should be done just before Packing of the garment so that it is retained properly till the time it reaches the customer.
Different Types of Garment Pressing: Following are the different types of pressing methods done for garments:
Flat Iron
Steam Iron
Warm Iron
Inside Out Ironing
Ironing for Puckered Appearance
Ironing for Crushed Look
Tie and Dye appearance
Flat Iron: In Flat Ironing, the garment is pressed by the application of heat as well as steam. This results in formation of Crease Marks at the desired point of application. It is done usually for Formal Shirts and Trousers. The figure on the right refers to an example of Flat Ironing.
Flat Iron
Steam Iron: In this method, the garment is pressed only by the application of steam. It provides a Fresh Look to the garment highlighting overall garment. It is generally done for Denims, Skirts and Cargos where we do not want any shine marks. The figure on the right refers to an example of Steam Ironing.
Steam Iron
Warm Iron: In this method, the garment is pressed only by the application of heat. It provides a distinct appearance to the garment. It is done for formal non wash shirts and T-Shirts. The figure on the right refers to an example of Warm Ironing.
Warm Iron
Inside Out Ironing: In this method, the garment is pressed after inverting the garment. It is done to avoid any directional change in appearance. It is done for directional fabrics like Corduroy and Suede. The figure on the right refers to an example of Inside Out Ironing.
Inside Out Ironing
Ironing for Puckered Appearance: In this method, the garment is presses lightly. It provides puckered appearance to the garment. It is done for washed formal & casual shirts.
Ironing for Crushed Look: In this method, the garment is pressed roughly. It provides a natural crushed appearance to the garment. It is done for cargo pants and skirts .
Tie and Dye Appearance: Though Pressing plays an important role in appearance as well as dimensional stability of a garment, it is not necessary that all the garments need to be pressed before packing. Some garments are visually more appealing without any ironing. It is done for stylized skirts and wrinkle free trousers.
Job Summary of a Inspector for Fusing Press Machine
To make a clear understanding of all information regarding quality requirements of fused parts for every style and to collect all information of that style (e.g. Working Instruction, Sealing Sample, Swatch Card etc.) from Supervisor, QC.
To ensure that the fused parts in test run (control parameter of the fusing machine and quality of fused parts) is approved by the Unit-In-Charge, QC before the start of bulk production
To ensure that the control parameters of the fusing machine are tested properly during bulk production by maintenance personnel.
To inspect all fused parts of the garments (100%) according to inspection guideline and to keep records of all non-conformities.
To communicate with relevant workers and Supervisor (QC & Production) about the defect and to give a proper direction for minimizing the defect.
To send back all defect parts to the sewing section for replace cutting via cutting section and to re-inspect all the replaced parts of the garments.
To inspect the quality of interlining pasting in Make Section randomly and to ensure quality requirements.
To keep records of fusing test in fusing register and to ensure that the fused parts in test run are properly preserved.
To collect the information about the defects which are overlooked by them and identified in the Sewing and Finishing Section and take necessary corrective action.
To take care about the cleanliness and hygiene factors of the work place.
To maintain and practice COC (Code of Conduct) and ISO related activities regarding QC for the unit of t shirt heat press machine
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.
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
1st Quality Check (100% Checking)
Wet Processing
1st Wash (Minimum 100 Pcs lot or as advised by Washing Manager)
2nd 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, 1st 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, 2nd 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.
This auto glue machine which is widely used for the labeling of the round objects in such industries as fooding, medicine, daily chemical and so on. Auto Glue Machine work independently or by connecting to the production line. In addition auto glue machine is equipped with air-powered glue pump and label shortage warning device. To establish a standard preventive maintenance procedure of automatic glue labeling machine. To ensure safe and standard preventive maintenance procedure of Automatic glue labeling machine to meet the required smooth operation in cephalosporin production area.
Glue Machine Working Procedure
Inspection for voltage fluctuation
Proper earthing condition of machine
Inspection & retighten all electrical connection
Abnormal sound & any physical damage of turn table
Correct function of bottle placing & delivery to conveyor
Correct function of conveyor & hand wheel
Any physical damage of conveyor
Proper function for sucking label & helps transport of bottle
Any physical damage of draw off bar
Abnormal sound & proper function of gumming turret
Physical damage of rubber roller
Any physical damage of label grips & label box
Correct function of label grips & label box
Physical damage of rubber rollers & adjusting screw
Free movement of roller & correct function of screw
Correct function of safety switches
Correct function of proximity switches/sensors
Grease all seat bearings
Change the gear oil in gear box
Clean all moving parts and lubrication
After completion of maintenance record as per SOP EN/002
Maintenance Label Glue Machine
Item Description
Check points
Main power supply
01. Inspection for voltage fluctuation
02. Proper earthing condition of machine
Pneumatic connection
01. Inspection the supply pressure must be 4 kg/cm2
02. Check the any leakage of compressed air
Turn table
01. Abnormal sound & any physical damage of station
02. Correct function of bottle placing & delivery to conveyor
Conveyor & Hand wheel
01. Correct function of conveyor & hand wheel
02. Any physical damage of conveyor
Vacuum drum belt & vacuum drum
01. Proper function for sucking label & helps transport of bottle
02. Any physical damage of draw off bar
Gumming turret
01. Abnormal sound & proper function of turret
02. Physical damage of rubber roller
Label grips & label box
01. Any physical damage of label grips & label box
02. Correct function of label grips & label box
Rollers & adjustment screw
01. Physical damage of rollers & screw
02. Free movement of roller & correct function of screw
Safety switches
01. Correct function of safety switches
Proximity switches/Sensors
01. Correct function of proximity switches/sensors
