Deep dyeing machine Deep dyeing is the process by which the is dyed partially. In this process dyeing is completed by sinking the garments in the dye bath. This gives the garments a unique look. Influencing Factors for Dyeing During dyeing with reactive dyes, following important factors are to be considered
The pH of the bath Pretreatment Process
The temperature of bath
The concentration of the electrolyte
The time of dyeing
The liquor ratio
Process Requirements Equipment used Special type of machine is used for deep dyeing program. It consist hanger where the garment are hanged. Key Accessories Key accessories used in dyeing with reactive dyes are : • Mixing tank • Machine Tank • pH meter • Hanger Pretreatment Process • Eye protecting glass • Hand gloves • Hand lifter for carrying the batch, and • Gum boot. Materials / Chemicals used Following materials/chemicals are used in the dyeing with reactive dyes process: • Water • Steam • Compressed Air • Wetting agent • Sequestering agent • Acid • Anti-creasing agent • Glauber salt, • Soda ash, etc.
Safety: In order to ensure floor and personnel safety floor personnel are instructed to follow the safety guidelines given below: • Smoking is strictly prohibited in the factory premises. • Put on the safety masks while mixing or transferring alkali and acid. • Be cautious while handling caustic soda and use hand gloves, eye protecting glass for safety. • During production, after reaching at the optimum temperature (above 800C), operator must use hand gloves, eye-protecting glass etc. while performing such task for safety.
4 Operation Procedure
4.1 Operation Staff
Operation stuffs for Dyeing process include:
Factory Manager
Assistant Manager
Sr. Production Officer
Production Officer
Supervisor
Operator
Helper
4.2 Checklist before Operation
Following are the items to be checked before production:
a) Checking the programme in Beacon Controller
b) Machine set-up
c) Garment weight
d) Garment quality
e) Dyes availability
f) Chemical availability
g) Power availability
h) Steam availability
i) Water availability
j) Compressed air
k) Manpower availability
l) Garment stitch is done properly
4.3 Operation Procedure
The sequence for deep dyeing process with Starfix dyes is as follows:
Hot wash the garments
Hang the garments in the hanger
Take water bath in deep dye machine at required level
Add dyes solution in the water bath
Add G.salt and soda ash
Mix them well
Hang the garments in the machine in the machine hanger
Now gradually sink the garments by manual operated up down switch
The lower portion of the garments will be deeper then the upper portion
Check the shade with approved shade
Rinse and Drain
Unload
4.4 Machine /Area Cleaning
The daily cleaning for machines are described below:
a) Clean chemical chambers by water flow.
b) Clean the floor by water flow.
c) Machine Oiling by oil or greases done by the Mechanical Maintenance Department.
5 Applicable Forms & Documents
5.1 Forms & Documents Used
Following forms and reports are used for dyeing process:
Process Batch Card
Process Recipe Card
Production Report Format
Document Flow
Document flow for the pre-treatment process can be enumerated as below:
Dyeing Department receives the Process Batch Card attached to it from the Batch Preparation Section.
Based on the shade and other specification plans for the machines are prepared.
Print-out of the recipe is taken from the computer. The Recipe Card is used as an internal document to keep record of dyeing for a particular batch.
Availability of chemicals and dyestuff is checked and program is put in the Bacon Controller.
The recipe shit Card is used to keep track of the dyeing procedure continuity. Production Officer fills out different areas of the form. This is an internal document of the dyeing department.
The Operator fills out the Production Report and it is sent to the Planning department. This report contains information like the Quantity produced, Machine wise production, Amount of re-process, Machine utility percentage (%) and shift wise production.
Upon completion of dyeing for a particular batch, if the dyeing is ‘OK’, then this garment is sent to the Finishing Department along with batch card.
Sachet Pack Machine – We would like to inform you that today we dismantled the wooden box of your supplied Sachet Pack machine at our factory. We found the following parts are in damage condition..
EC35 Auto Speed Electronic Controller. BHAVMARK system. Part No.EC-109962
It is the duty of management to make available the
appropriate tools, to ensure that operatives are properly instructed in how to
use them and to provide competent supervision to ensure that work is correctly
and safely performed.
Quality:
Buying cheap tools is a false economy. They don’t last
and they can become dangerous, effort must be made to ensure tools are of good
quality.
Handles:
Handles are necessary for ease of manipulation and for
protection of the hands. Depending on the tool in uses they should be of good
quality plastic or well- seasoned ash or hickory of smooth finish and firmly
fixed. They should be regularly checked for splits or cracks and wedged where
necessary to keep them tight.
Cleanliness:
Grease, moisture and dirt should be regularly cleaned
off. Any movable and adjustable parts should be lightly oiled to protect
against corrosion and to prevent wear and misalignment. Tools made of cast
steel or iron is less liable to crack in cold weather if kept clean and dry.
Cutting Edge:
Cutting edges should be kept sharp to permit accurate
working and to avoid the hazards arising from unnecessary pressure. Sharpening
is a relatively skilled job-good carborundum or oil store should be used. Saws
are usually sharpened using a machine grinder or hand file. Where abrasive
wheels are employed only a little of the edge should be ground at a time and
the toll rest kept close to the wheel. The tool itself should be held lightly
to prevent overheating and cooled with water to retain the hardness of the
metal.
Inspection:
All hand tools shall be inspected periodically as per
the existing client and company regulations and color coded.
Summery
Sachet Pack Machine -The Auto Speed Electronic Controller body is partially damaged and some connector pins are broken. The 3PIN & 4PIN jacks are also broken which are not usable. So we could not run the machine to see the machine status. Therefore you are requested to send the above
A cheese of grey-state cotton yarn is immersed in a solution containing a de-aerating agent and the volume of air expelled is measured at given intervals of time.
weigh empty spindle, note weight
mount spindle on package support and fix on winding device
wind 15 g yarn onto spindle (ca. 45 s winding time)
attach 5 g “loading weight” to one end of the metal tube
Preparation of test liquor
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make up 5% stock solution / emulsion
make up 200 ml test liquor with a concentration of 2 g/l and 4 g/l
product to be tested
temperature 25°C
Testing routine
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pour 200 ml test liquor into 250-ml measuring cylinder
have stopwatch ready
drop package (cheese) into measuring cylinder
When the package is totally immersed in the liquor,
start the stopwatch
note the volume on the 250-ml measuring cylinder every 10 seconds
i.e. difference between liquor level
and 250-ml graduation.
Maximum testing time 2 min.
Assessment
1 ml volume difference = 3%
de-aeration *
Calculation example:
measured volume difference x
3%
—————————————————– = %
de-aeration
1 ml
Plot a graph of the volumes noted at 10-second intervals.
Note
Attaching a 5 g “loading weight” to the tube ensures that the package
(cheese) becomes totally immersed in the liquor immediately.
“Instantaneous air displacement” is hence invariably achieved, and
this is particularly important with products which have poor wetting and
de-aerating properties.
Product: In the aspect of 5 ps of Marketing quality the products are of good quality. In the core category the shirts and trousers represent world class quality standards. The brand name is excellent, packaging is well designed, styles of the products are of western mark, fabric quality is also up to the standard, the other features like collar lining, stitches per inches, sleeve cuts, bottom button holes, trademark pockets, seams, plackets and interlining are of international benchmark.
Price: 5 ps of Marketing -Due to the high import tax barriers the prices of the products have become almost three times than the purchase cost. This has taken our products to a price range which stands as the most critical obstacle in gaining customer acceptability. As the same brands are widely available in the local retail stores at a much lower price the brand could not achieve the market acceptance it had anticipated for.
Place: In the aspect of location selection we have failed to identify the best locations for our business. Low foot falls accompanied by lack of cooperation form the market premises owners have made some of our out lets simply obsolete.
Promotion: The irregular promotional programs were not well designed and monitored. So there have been serious non-continuous errors in launching and supporting phases of the previous promotional campaigns. The basic objectivity of offering two separate out let identities like Planet Fashion and Peter England were crucial mistakes by the management. So none of them could gain strong foot hold among the target segments.
People: Lack of coordination, proper product oriented training, absence of any sort of target oriented environment, incentive based salary structure has turned AUTO ’s current business into a chronic case of “Planning Failure”. As a result of that, over the years , corruption, financial mis -apportionments, breaking up of the chain of commands, and lower employee morale has turned the HR system into a negative bottleneck.
Financial department’s negligence: In every company the responsibilities of carrying out regular inventory for products in the show rooms lies with the finance and accounts department. Failure to conduct a regular product inventory both software wise and physical inventory have resulted in the creation of opportunities for sales assistants to become involved in mis-chiefs.
Learn from our mistakes
In the pursue of 5 ps of Marketing the PE manufacturing options we don’t want to repeat those mistakes. Proper product strategies supported by the right pricing policies should be well offered to the customers in the right locations. If we can attain these all with a coordinated and well planned promotional strategy then we do believe that PE is going to be the strongest retail ware brand for men in Bangladesh with an excellent market share.
Assumptions 5 ps of Marketing
After the first year sell will increase 25%
After the second year sell will increase 25%
At the first year advertising & promotional cost will be
30% of the revenue
At the second year advertising & promotional cost will
be 15% of the revenue
At the third year advertising & promotional cost will be
12% of the revenue
An international brand like Peter England (PE) will gain 28% market on the first year. Proper product strategies supported by the right pricing policies should be well offered to the customers in the right locations. If we can attain these all with a coordinated and well planned promotional strategy then we do believe that PE is going to be the strongest retail ware brand for men in Bangladesh with an excellent 5 ps of Marketing share.
