WHITE
133 X 72
45 X45
With cotton handfeel
POP TC CS
1688
1
2
2
2
1
32773
05/12/05
Vessel Departure
BY SEA
TO RECEIVE FOR APPROVAL :
– Fabric labdips
– Production fabric 10 cm x 10 cm
– Care label
– Button
– 1 counter sample to submit before 15 TH
OCTOBER 05
Waiting for your confirmation and your proforma invoice. Best regards, Alexandra for Delphine CHANDESRIS.
AFTER TREATMENT (WASHED PRODUCT)/WRINKLE FREE
Examine the garment and place a check mark under YES, NO or
N/A-
Check if hand feel is correct to approved washed standard
with regards to surface appearance, softness etc.
Check for color and cast of garment against approved
standard to ensure that they are very close or within the approved shade band
between light and dark.
In the case of indigo denims or piece dyed fabric or over
dyed garments, arrange a few garments flat on table over lapping each other
and place the shade bands (dark and light) on either side of the garments to
verify correctness of shade. Repeat this check for every half dozen garments
from the sample lot.
In the case of heavier washed product, check for appearance
such as abrasion and any destruction to see if they are up to original
approved standard.
For garments with wrinkle free treatment, check for seam
smoothness against approved standard and/or AATCC standard replicas for seam
smoothness Test Method 88B.
Also for wrinkle free garments check for fabric smoothness
against approved standard and/or AATCC standard for fabric appearance test
method 124.
If there is crease on leg panels for wrinkle free
programs, check for sharpness of crease (also known as retention of creases)
against approved standard and/or AATCC standard replicas for retention of
creases Test Method 88C.
Energy Saving System – We are using enzymatic pre-treatment partially; let say 10% of total production. It is suitable for Dark & medium to Dark shade combined bio-scouring & bio-polishing. We provide CRM Contact Management System and CRM Integration Free
Low temperature Wash off: We are doing low temperature wash off at 60˚ instead of 95˚. We are saving substantial thermal Energy Saving System, water & time every day.
High Fixation dye stuff: We use high fixation dye stuff like Avitera (Huntsman), RGB
series of Dystar & SS series of Suncolour.
It requires less water than traditional dye stuff.
It requires less amount of dye stuff.
As a result there is less pressure on energy consumption & ETP.
Over all good quality is maintained.
On line Quality Control:
We do on line quality control to ensure 100% quality dyeing.
Our experienced operators are well trained to do so.
93% RFT:
Here we use some transparent sheet in the roof of dyeing floor. Daylight entered into the this transparent area thus no need to light on the energy saving lamp during day time.
Saving Energy by using high efficiency m/c:
We are using modern dyeing machinery, finishing machinery; where most of the driving motors are servo motor, hence consuming less energy thus reducing carbon emission.
Using Energy Saving System lamp:
We are replacing the conventional tube light by energy savings lamp.
When we used normal lamp we need 26 KW/hr, but after using energy saving lamp we need
16 KW/hr.
Saving energy by using condensed steam:In dyeing m/c a lot of condensed steam is produced. We recycle the condensed steam and make it boiler feed water.I can expain it shortly—At present we use 80 degre celcius hot water in boiler as feed water. Before that we used normal water (30 degre celcius) as boiler feed water. We have two boiler. One is 7700 kg and another is 5000 kg capacity.
For 7700 kg boiler,
Now, To produce 128 kg steam/min we need 4.5 m3 gas, but before it was 9.4 m3 gas
For 5000 kg boiler,
Now, To produce 83 kg steam/min we need 2.4 m3 gas , but before it was 5.2 m3 gasSo it’s a big saving of natural gas in every minute.
Saving energy by using heat recovery system:
We have Sclavos dyeing machines which contain Heat Recovery system named POZZI; By using this type of m/c we can save water and energy.
Saving energy by using bio-scouring method:
We partly use enzymatic product which replace conventional harsh chemicals ( NaOH) in fabric pretreatment and reduce the processing temperature and water usage.
Saving energy by using low temperature wash off agent:
We are using third generation wash off ( Dekol RSA)( manufacturer: BASF) which reduce the processing temperature( 95 degree Celsius to 80 degree Celsius), thus reducing carbon emission.
Saving water and Energy Saving System by optimizing process parameter
We are still maintaining 93% RFT with our existing traditional machineries.
Where as 85% is the world bench mark for such machineries.
Process optimization:
We have experts in dyeing process who are working in this trade for 15-20 years with outstanding performance.
Our engineering team still does process re-engineering to optimize process as well as production.
They examine closely & try to optimize process by omitting any unnecessary process steps.
Conclusion
We optimize process parameter by trial and error method,
on line process parameter control, thus achieving RFT( Right First Time) 94% in
dyeing of fabric; hence optimize natural resources usage. We have implemented
above steps to be a part of worlds latest slogan greener or cleaner production.
Thus we can be more cost effective, more viable in respect of environmental
aspect and we can make our earth suitable for living ours—ours next
generation.
Shell Tube and Copper Heat Exchanger unit: should be made of metal (Stainless Steel) having no. of 1 Shell pass and no. of 2 Tube passes preferably having following specifications and dimensions: Thickness= 4mm, L= 20inch, SS pipe, D= 4inch, 1 SS tubes, L= 20inch, D,=9mm, Do= 12mm, 10-18 Baffles with 25% cut, 3 SS Flanges D= 6inch, Thick= 12mm, 4 SS nut & bolts, 16 Socket SS welded, D= 3/4inch, 4 all welded argon. Temperature indicators: Thermocouple K-Type with individual no. of 04 display units. Electric panel. We provide CRM Contact Management System and CRM Integration Free sss
Training
Point for Heat Setting
Roll to roll sewing before heat setting must be straight.
Stenter should be nonstop during heat setting.
Burner net should be cleaned in every batch
Check pin clip before heat setting, if required perform maintenance.
Check burner before heat setting .
Check padder pressure is correct according to specification.
Check set width according to specification.
Check exhauster according to specification.
Check temperature according to specification.
TESTING PROTOCAL FOR HEAT SEAL1
Heat seal manufactures should advise heat seal machine variables for each individual product they supply, including temperature, pressure and dwell time.
A specification sheet by style should be available during
the heat seal process showing above requirements.
First production of each color should be tested 25
launderings for adhesion.
Each individual heat seal machine should tested twice a day for adhesion with 3 launderings. Copper Heat Exchanger
Cooling Tower -Packing column: for the flow of hot water from top to bottom. The column should be made of acrylic preferably having following dimensions: L=28 inch, W= 6.5 inch, D=6.5 inch with packing of plastic plates, Thickness of acrylic column=5-6 mm sheet, Thickness of flange sheet=10-12 mm.
Water Cooling Tower Specification
Air blower: Power= 1.0 hp, Flow rate = 120 Liter/sec.
Electrical heater: P1 = 0.5 KW, P2=1.0 KW.
Rotameter(acrylic/glass): Flow=0-5.0 liter/min.
Rotameter: for the measurement of air flow
Pump: Flow = 3-5 lit/min, (01 No.)
Temperature indicators: Thermocouple K- I ype with indivicual no. of 06 display units
Manometer (Inclined tube): To find out the pressure drop across the column.
Plate and Frame Heat Exchanger -Sieve plate column: should be made of metal (Stainless Steel) preferably having following dimensions: Column height= 1000mm, Column dia.= 50mm, No. of sieve plates= 6 (150 mm apart from each other). Holes area= 60 % of column area= 1178 mm2, sieve plate hole dia.= 3mm, Pitch= 6mm (equilateral triangle pitch), Weir height= 15 mm, Weir length= 35 mm, down-comer width= 10mm, distance between bottom of down-comer and top of below plate= 10mm, Plate thickness= 3mm, Holes distance from column wall= 10 mm
Plate and Frame Heat Exchanger Specification
Still storage capacity: 12-15 Liters.
Electric heater (immersed): 1.0 KW with temperature controller (PID controller), Range= 5¬100°C, Accuracy= ±0.5°C, (01 No.)
Plate type Heat Exchanger unit: should be made of metal (Stainless Steel) having no. of 7-10 plates, L= 14inch, W= 5 inch. (01 No.)
Rotameter (acrylic/glass): for both hot and cold fluid/water. (02 No.)
Temperature indicators: Thermocouple K-Type with individual no. of 04 display units for both hot and cold fluid/water (04 No.) as under:
TI=Temperature of inlet cold water, T2=Temperature of outlet cold water, T3 =Temperature of inlet hot water/steam, T4=Temperature of outlet hot water/steam
Electric panel: L= 2ft, H= 10inch, 8= lft (The panel should contain 04 temp. indicator lights, Pump and eaters ON/OFF buttons etc.)
Hot water tank: L= 2ft, W= lft, H= lft. (01 No.)
Electrical heater: Power= 2.0 KW. (01 No.)
Temperature indicators: Thermocouples K-Type with individual no. of 02 display units for both top plate and Still (02 No.)
Top product tank: Capacity = 1-2 Liters
Horizontal condenser: = 150mm x 200mm (Shell & Tube type)
Conclusion
Plate and Frame Heat Exchanger -Material of construction of all parts which are in contact with vapors & liquid should be of stainless steel. All equipments should be mounted on square steel pipe frame mounted on wheels. All the external parts should be sprayed/painted either black or grey.
