The print head of the stalwart machine consists of up to four print rollers, which run in troughs containing a thin print paste with the caret pile to be printed being pressed against the upper surface of the print roller from behind. The print rollers are arranged at 45 to the vertical one above the other. Maximum running speed is about 6m/min.The individual print rollers consist of steel centered wooden bowl on the surface of which is mounted the design. The design is cut from thick rubber covered with a nylon or polyester pile. Read about Rotary-Screen Printing Machine
Limitation of the Stalwart machine:
As the narrowest rubber strip that can be mounted on the roller about 4 mm wide. The machine has however proved ideal for the production of the so called shadow-printed effects on the long pile carpets, which have remained in fashion for many years.
Material:
Mainly it is used yarn wool (raw material). Most of the yarn
used in ring yarn, acrylic yarn, synthetic yarn etc. These yarns are collected
from Narayangong. The yarns are buying by a lot system and this lot gets
different types and color of yarn.
To produce carpet use the frame of wood, bamboo and iron rod
etc.And also use different instrument like kamana, golla, panga (reed) etc.
They are also used some specialized yarn shanel yarn, smaglin yarn etc.
Wool Washed and Drying:
Wool is one kind of natural fiber. So, different types of
impurities involved in wool yarn. If we remove impurities the final product
will fine. So we have to washed and dry the wool.
Objective of Wool Washed and Drying:
To remove the impurities from yarn.
To remove oil y properties of yarn.
To increase soft handling properties.
To suitable for the next process carding.
Procedure:
It also done by manually. In Egypt, Malaysia, also
Bangladesh carpet manufactured by manually:
First have to mix the detergent into water at a bath.
Then drops the yarn into bath.
Stirling the yarn in to water by any stitch.
Then dry the yarn by sunlight.
Carding:
This is the process of spinning where it is functions are to
separated align and delivery the fiber in a sliver form and remove impurities.
Objective of Carding:
Opening to individual fibers.
Elimination of impurities and dust.
Elimination of impurities Short fiber.
Fiber blending.
Fiber orientation
Spinning:
The process by which convert of fiber to yarn.
Objective of Spinning of carpet:
By spinning 3,4,5,6,7,8,9 ply yarn can be produced.
Cost analysis of Carpet:
We don’t know about foreign carpet
yarn cost due to barrier of project. But we know imported carpet cost from new
markets shop. In Bangladesh there have some carpet manufacturer. We visited
Millat camp, Society handicrafts. We collected some yarn cost from them. Some
cost analysis is given below,
Yarn
Cost per kg
TC
320tk
Jute
150tk
Wool
500tk
Acrylic
370tk
Smarkling
450tk
Cost difference in Local Carpet and Imported Carpet:
Carpet
Types
Local
Carpet/sqft
Foreign
Carpet/sqft
Twist Carpet
120tk
90tk
Balika Carpet
110tk
70tk
Tapestry Carpet
130tk
100tk
Maya Design
85tk
70tk
Mozaik Design
95tk
70tk
Diamond Design
90tk
65tk
Leaf Design
110tk
90tk
Difference between properties of Foreign and Local Carpet:
Foreign Country: Belgium, Dubai, China, Malaysia, Turkey, India, Pakistan, Egypt are
the main source of Carpet in all over the world.
On the basis of countries the different type’s carpet name
are given below,
1. Egyptian carpet
2. Pakistani Carpet
3. Malaysian Carpet
4. Turkish carpet
5. Persian Carpet.
6. English Carpet
7. French Carpet
8. Chinese Carpet.
Source of yarn in Carpet raw materials in Bangladesh:
►Mirpur (From Zhut business man)
►Narayangonj
►Chak bazar, Dhaka.
►Gulistan, Dhaka.
Export and Packaging:
Object:
►To package the product.
►To dispatch to Buyer
3.4.3Pretreatment of carpet:
In front of the printing machine there are the conventional
carpet take up rolls, a space for butt sewing a j-box or compensation roller
storage unit followed by a back better and a lint extraction system.
It is not usual to give wet pretreatments to the carpet
before printing because the materials that may still be on the fiber such as
spin finishes do not in general interfere with the absorption of the print
paste or the fixation of the dyes. An exception arises with some carpet
qualities improve if they are pre washed a about 60 C BEFORE PRINTING.
This rewashing produces a bulking effect on the fiber which
can not be achieved by steaming alone although pre steaming is sometime use in
place of hot water treatment.
In some cases superior penetration is obtained on pre wetted
carpet one example is the printing of longer pile carpet. After wet
pretreatment the carpet is passed over powerful extraction slots to reduce the
residual moisture the between 50 and 80 pick up, depending on carpet quality.
Carpets may also be pre added with a ground shade for certain resists,
displacement and discharge process
3.4.4After Treatment:
No dyes can be completely fixed on carpet fibers so that
residual dye as well as the chemicals and thickening agents must be removed by
cold water alone is used in contrast to textile printing practice. Only in the
case of polyester and acrylic carpets are heated wash tanks considered. Two or
three bath preferably with countercurrent water flow is used. A typical carpet
printing range requires a wash water flow of 20-40×103 1h. To accelerate the
interchange between the liquor on the carpet and the wash water various
agitator systems have been used in addition each exit path form the liquor
should have a spray pipe and mangle squeeze or better an extraction slot. A
particularly good effect can be achieve using perforated drum wash units in
which the liquor actually passes through both the pile and the backing of the
carpet
Where heavy very shades are being produced cross staining of washed off on to pale or whit ground shades may occur. This can be avoided by passing the carpet through a mildly alkaline bath as it leaves the steamer. This also improves the wet fastness of the print as the alkali aids the removal of unfixed dye.
Carpet Manufacturing Process
Wool Sorting
Wool Wash and Drying
Carding
Spinning
Natural Dyes
Pot Dyeing
Designing and Graphing
Dyes Yarn Shorting
Hand Knotting
Washing
Wash Rug Drying
Shearing and Trimming
Final Touch and Finishing
Packing and Export
Description of Carpet Manufacturing Process Flow Chart (Hand made basis):
Wool Shorting:
Wool yarn is mainly used in carpet manufacturing. In carpet
manufacturing process yarns have to sort we know there are different grades of
yarn min together. They have different shade variation, staple length
variation, etc. For this reason we have to sort first those yarn.
Objective of Wool Sorting:
Differentiate same grade yarn.
To combined the same length yarn.
To eliminate the faults of carpet.
To helpful for next carpet manufacturing process.
Procedure:
It is a manual process .It is mainly done by hand.
From wool lot, we have to diffeintiate different kinds of
yarn according to their length color or shade and difference grade.
Then it wills suitable next process.
Carpet design in Bangladesh:
In “Society Handicrafts” different kinds of design can be
done. They can do any kind of design. Aarrong gave them swatch or design and
finally they sketch in graph paper and also make a sample of carpet. Then they
a take an approval from Aarrong and go for bulk production.
The owner of Society Handicrafts first designed a design.
Then supervisor draw design in all looms.
In Society Handicrafts design name are given below,
Design for Twist and Balika Carpet,
1. Maya design
2. Mosaic design
3. Zamdani Design
4. Zebra Design
5. Blue stripe
6. Blue shade diamond
7. Brown shape weaves design
8. Multi color design
9. Maxican Design
10. Toner step
11. Brown Step
13. Plastic design
14. Ardeko Design
15. Leaf design
Design for Tapestry Carpet:
1. Human being design
2. Boat design
3. Foreign boat design
4. Flower design
5. Elephant design
6. Peacock design
7. Kingfisher design etc
Any kinds of design can be making in Society Handicrafts.
The first establishment was originally started in Paris in
the famous “Saint Germain des Prés” area under the name of Jules
Flouron, a relative of Georges Cholleton senior who managed it after his return
from World war I, from 1919 to his death in 1956, it was then operated by his
son Pierre Cholleton (a former officer from the French free forces during World
war II and during war in French Indochina) till 1978 year of his desperation.
Over the 20th century Cholleton became one of the main
French company specialized into outside blinds, awnings and canvas as one the
very first globally specialized into blackout as flame retardant fabrics for
hotels and hospitalities curtaining.
Already in the 60’s and the 70’s Cholleton’s blackout fabrics
were specified all over Europe, including the ex SSRU, in Africa or Middle East
as for prestigious hotel contracts in the Far East.
Over a hundred years, the Cholleton Company became also one
the very first globally specialized into blackout as flame retardant fabrics
for hotels and hospitalities curtaining. It was already involved at that time
into major hotel projects all over the world, such as Hotel Cosmos Moscow in
Soviet Union, Hyatt hotel in Bangkok, Orchard Hotel in Singapore, first
Meridien Hotels in Saudi Arabia as former UTH hotels (which was the roots of
Air France Hotels group) all over Africa, Middle East and Far East as Ivory
Intercontinental hotel in Abidjan – Ivory Coast or several Hilton and Sheraton
hotels in France and abroad.
Tissues and Stores Cholleton (Cholleton Blinds and Fabrics)
was also the supplier of prestigious customers such as the French National
Assembly (French National Parliament) ,the Palace of The Elysée (Housing and
offices from the President of the French Republic), the RITZ and BRISTOL hotels
in Paris, or the NEGRESCO in Nice as numerous four and five stars hotels in
France and all over Europe.
From 1978 to 1982 the group went thought a major
reorganization following the desperation of Pierre Colleton and his son Georges
P. Colleton was the one who decided from 1982, after having met the just-new
owner at that time of Trafford carpets UK the re-orientation into the contract
carpet world and more specifically into ax Minster contract carpets for hotels
and hospitalities.
Axminster contract carpets custom made for a casino.
Today’s Agence Cholleton is still a wool carpet specialist
and the sole agent and exclusive distributor for some of the best European
residential and contract carpets manufacturers for France, several European
countries and of course the entire Middle East and North Africa, but we have
also now implemented over the last few years our own residential and contract
carpets collection worldwide distributed.
The factory has a Group Insurance policy for the workers
No Child Labour
The factory do not employ child labor
The factory maintains age & fitness documents for all employees
The age & fitness documents certified by a registered doctor
Is the factory employed child labor in the past 12 months?
Rights of the workers
Is there a written employment contract signed between the workers and the factory?
Is the workers given a copy of the contract?
Is the workers provided with a photo ID card at company cost?
No Bonded Labour / Forced Labour
Are workers employed voluntarily?
Is the probationary period reasonable?
Can workers refuse to work overtime without penalty or any consequences?
Are workers forced to work overtime against their will?
Are incentives related to attendance or efficiency forfeited if a worker does not work overtime?
No Discrimination
Is there equal pay for equal work regardless of gender?
Are female workers asked about their pregnancy status during recruitment or interview?
Are the maternity leaves adequate and paid for the eligible workers?
The Right of Freedom of Association and Collective Bargaining
Is there any workers organization in the factory?
Is workers can free to join any workers organization?
Is there a proper grievance procedure in place?
Anti-Harassment & Abuse
Is factory has anti-harrasment and abuse policy?
Is factory has grievance committee and fuctional?
Is factory has the system to communicate this with the workers?
Is any management system to communicate any anti-harrasment and abuse issues by the workers?
Does the factory arrange anti-harrasment training for new and existing workers?
Customs Compliance
Is factory has customs compliance policy?
Is factory aware about customs compliance?
Security Compliance
Is factory has security compliance policy?
Is factory aware of security compliance policy?
Is factory provide regular training on security compliance?
Is factory maintain proper loading & unloading system?
Is factory maintain vehicle check system?
Is factory has the system to maintain visitor access control system?
Is the factory maintain others security system like patrolling, perimeter checking, key control, enclosed check etc.
Is factory has environment management policy & procedures?
Is factory has functional ETP?
Is factory regularly testing the waste water with all applicable parameter?
Is factory has the chemical management policy?
Is factory maintain proper chemical management system?
Is factory provides regular training on chemical management system?
Ethical Business Behaviour
Is factory has ethical business behavior management policy & procedures?
Is factory has the system for protection of any corruption and bribery?
Is factory has the system to give grievance, complain and suggestion if detected any corruption and bribery?
Is factory has the proper communication/reporting system for corruption and bribery issue?
Is factory maintaining it regularly?
Is factory has the system to take disciplinary measures if identified any corruption and bribery?
Is factory provide training Ethical Business Behaviour?
Conclusion
Laboratory Steamer and Steam Generator is very important for factories. Is factory regularly giving awareness on Ethical Business Behaviour? Read about Generator Protection and Metering System
Yarn Package Dyeing Machine Minimum 3 Kg yarn capacity 4emperature up to 140 °C High Temperature/High Pressure Package Dyeing Machine 17, Suitable for 1 – 6 packages Additions tank High Temperature drain Touch-screen PC Controller linked to PLC. Batch Storage of all inputs/outputs. Read about Deep Dyeing
Knit Yarn Dyeing price
Sl.No
Type of Yarn Colour
Unit Price/Kg
Remarks
01.
White
Shade
$ 1.00
02.
Light
Shade
$ 1.50
03.
Medium
Shade
$ 1.80
04.
Deep/
Dark Shade
$ 2.50
05.
Special
Shade
$ 2.60
Dyeing Machine : Cheese Korea
Capacity:
Machine No-1= 1,000 kg=1 set
Machine No-2= 500 kg=1 set
Machine No-3= 400 kg=2 set
Machine No-4= 300 kg=2 set
Machine No-5= 100 kg=2 set
Machine No-6= 50 kg=1 set
Machine No-7= 40 kg=1 set
Machine No-8= 20 kg=1 set
Machine No-9= 15 kg=1 set
Machine No-10= 10 kg=1 set
Machine No-11= 05 kg=1 set
Machine No-12= 03 kg=1 set
Total dyeing machine capacity : 5,000 kg per day
Soft winding machine capacity : 6,000 kg per day
Hydro instructor machine capacity : 6,000 kg per day
Dryer machine capacity : 6,000 kg per day
Hard winding machine capacity : 8,000 kg per day
N.B. This Price Will Be Negotiable In Volume Of Order’s, Season & Situation. Offer Could Be Changed Without Prior Information According To Market Situation.
Compliance Check list for textile factory
Special Protection for Young Workers – N/A
Is the factory has young labor management policy?
The factory maintains age & fitness documents for all employees?
The age & fitness documents certified by a registered doctor?
Is the factory employed child labor in the past 12 months?
Is factory maintaining all facilities for young workers as per law?
Is factory maintain working hours for young workers as per law?
Is factory provide training on young labour
Is factory regularly giving awareness on young labour
No Precarious Employment
Is factory has policy & procedures on recruitment and hiring?
Is factory system to protect precarious employment?
In case of employed any precarious labour, do the factory has the system to remediate it?
Is factory provide training on precarious labour?
Is factory regularly giving awareness on precarious labour?
Conclusion
Yarn Package Dyeing Machine is used in textile industry. Is the factory has the proper monitoring system to protect precarious labour?
Single-end Sizing Machine4arn materials: Cotton, Polyester Cotton, Kevlar, Carbon, Glass, Jute or similar
mg materials: PVA, Starch, Wax etc.
ier of packages to be sized at a time: 1 or more Speed: 190 m / min or higher Sizing temperature range: 90-100 °C Length measuring sensor
Electrical-heating in sizing tank
Hot air drying
Yarn break sensor
Power back up for emergency shut down in safe mode Real time data acquisition / analysis system (fixed) All parts / accessories required to make machine operational on site List of similar installed machines in universities/industry in Pakistan and worldwide with their contact information.
List of trained engineers available for after sale service/maintenance keel Capacity for Sizing: 12-16 beams or Spindles
Drying System: Electrical or Steam heated with speed and temperature controlled
Size Cooker: Detachable and temperature Controlled Spare parts: 01 set
Definition and Causes: In medium to heavy weight woven fabrics, which are dyed in Jigger machines or in a continuous dyeing range, this is a very common and reoccurring problem.
Generally, the main causes are
Incomplete de-sizing of the fabric (removal of yarn’s starch),
The uneven distribution of dyes during the dyeing process.
This is due to the fluctuation and variation of the pressure in the winding and unwinding rollers.
In knit and some light weight woven fabrics which are dyed in Jet dyeing systems, this problem can rarely be seen.
This, however, occurs more in the finishing process and will be discussed in the finishing section.
Preventive Suggestions:Regular maintenance and upkeep of the dye machines will
contribute towards reducing this problem. Preparation of the greige goods prior
to the dyeing is also very important.
Corrective Measures:In most cases, stripping and removing the base color and
re-dyeing will correct the problem.
In severe cases, over-dyeing to a darker shade or black may be the only solution.
Irregular Sizing (Slashing)-
Definition and Causes: During the slashing process, in order to increase the tensile strength of the yarns and prevent breakage, starch based chemicals are applied. In some cases uneven application of the starch causes uneven surfaces in the yarn which can cause breakage and holes.
Preventive Suggestions:Correct and precise slashing is of utmost importance.
Corrective Measures:For this problem no corrective measures are available.
Yarn Breakage-
Definition and Causes: Due to the elastic nature of the Elastane-based stretch yarns, controlling the in-feed tensions of these yarns, fed individually or in plated form, is a critical part of the knitting process.
Slight increase in the applied tension will result in
breakage of the yarn particularly in finer counts (20, 30, and 40 Denier
counts).
Preventive Suggestions: Constant measurements of the tension must take place. For most structures, the tension should not exceed 4 grams.
Corrective Measures: For this problem no corrective measures are available.
Oil Stains-
Definition and Causes:
The distinctive oil stains which appear on the surface of the greige goods are normally a result of knitting machine’s needle lubrication system.
During the knitting loop formation, due to machine’s speed of revolution and the frictional forces between the yarns and the needles, a certain degree of heat is generated.
In order to prevent the elevation of this temperature, at certain pre-determined intervals the lubrication system is made to function and sprays of oil mists are applied to the needles and the cam areas.
During this process and in a lot of cases the greige goods get contaminated.
Normally, however, if the oil that is used is of the water-soluble and natural based type it can easily be removed by a simple scouring process.
In some cases, as a cost saving measure, some knitters use non-emulsified type of oil which is rather difficult to remove. These types of oil stains will appear as lighter shade spots after dyeing.
Another type of oil stains are the ones from the silicone based lubricants that are normally applied to the Spandex yarns.
In some cases, during the knitting process, and due to the generated heat some residue of this lubricant remains on the fabric. This type of oil stain is also very difficult to remove.
Preventive Suggestions:
The use of water-soluble knitting oil is strongly recommended.
Also, to the extent possible, Spandex yarns with non-silicone lubricant must be used.
Corrective Measures:
In most cases an “oil-scavenger “type of industrial detergent will be able to remove the stains.
In more severe cases a strong solution of an alkaline based chemical such as Sodium Hydroxide or Soda ash may be required.
When dealing with Spandex related stains care must be taken to ensure that the stretch and the recovery of the yarn is not adversely affected.
These are common problems with basic synthetic knit
structures such as Single jersey and Interlock, particularly when textured
filament yarns of higher filament contents are used (96 and above).The causes are basically the slippage of the fibers and the
ease with which the knitting loops can slide over each other.In most cases, these runs are directional which means that
the start of the knitting roll exhibit more runs than the end of the roll.
Preventive Suggestions:
In order to reduce and control these runs and stabilize and reinforce the Wales, at the start of the knitting, for approximately 30 knitted courses, cotton yarns are knitted in to the greige goods. This is also repeated at the end of the roll. This will ensure that no runs occur during the dyeing process thus reducing the fabric damage.
Corrective Measures
During the finishing process, in order to reduce the fiber slippage, the dyed fabric needs to be treated with an anti-slippage chemical through padding. This chemical is usually a solution of Colidal Silicate. Basically this chemical increases the fiber’s coefficient of friction and creates a non-slippage condition.
The application of this treatment might, however, affect the
softness of the fabric and must be used in small quantities.
