Carton strapping is permitted but use of staples is NOT permitted.
Cartons are not to exceed 15kg GW
All cartons should be 3 ply grade cardboard.
All cartons should have a cardboard insert on top of the contents to protect the goods when we open the carton
All cartons must be H sealed with Pelmark tape – see diagram
The following carton markings are required on all four sides and will be printed directly on to the cartons:
Supplier Name: Pelmark Direct
Item No: (Refer to matrix below for details)
Product Code: (Refer to matrix below for details)
PD Product Code: (Refer to matrix below for details)
TML PO Number: (Refer to matrix below for details)
KB PO Number: (Refer to matrix below for details)
PO Number: (Insert Pelmark PO number here)
Quantity:
Size: (Insert size for item in carton)
Colour: (Refer to matrix below for details)
NW:
GW:
Carton Dims:
SOP for Garments Carton Process
SOP for Garments Carton Process
A) AIM: To identify packaging and labeling standards for carton box marking and carton box content of products manufactured by Carton Machine
B) SCOPE: This procedure covers all products manufactured domestically and internationally for Tema Mağazacılık.
DEFINITIONS:
Polybag: A plastic bag used for packaging products individually.
Blister bag: A bag used for packaging together assorted products which are already packaged individually in polybags.
Solid colour-solid size: One size of each colour of a product.
Assortment: Size distribution of a product (E.g. S/1, M/2, L/2, XL/1).
Lot: A packaged assortment.
Solid colour-solid size Packaging: Packaging only solid colour-solid size products in one box. (E.g. 30 pieces in a box, Style: CITY, Colour: Navy, Size: S)
Single Lot Packaging: Packaging only one lot in one box.
Multiple Lot Packaging: Packaging two or more lots in one box.
Mixed Size Box: Packaging same-colour different-size products, which are not included to the order, in one box.
CARTON BOX CONTENT STANDARDS:
Products in one lot should be layered tidily on top of each other. Products should not be placed side-by-side in one lot.
A Lot Label should be attached to each lot package in a box. Please refer to Example-1 to see how the label is placed. The lot label should not be a thermal label.
Lot packages in a box should be firmly taped with a 4.5 cm-wide transparent tape. The lot label should not be on the same side as the tape. It should be attached on the opposite side.
All products in a box should have price hangtags. Price hangtag details should be visible; if there are any additional hangtags, they should be layered under price hangtags. Barcode IDs on price hangtags should definitely be visible.Product price hangtag, product inner barcode label, lot label and carton box marking barcode label should all have matching information.
The assortment distribution and the packaging should be made according to the assortment agreed for the order. Products which are not included in assortments should be boxed as solid colour-solid size.
Different sizes or styles, which do not match with the information on the lot label or box label, should NEVER be added to the package simply to complete missing sizes or colours.
Carton Separators should be put at bottom and top side of inner carton boxes, to avoid the possible damages to the garments when opening the boxes by knife, scissors etc.
Barcode coding system should be good. It is forbidden to use any other barcode coding system for labeling.
POLYBAG STANDARDS
The polybag quality should be 7-8 micron Polypropylene (PP).
The blister bag quality should be 9-10 micron Polyethylene (PE).
Polyethylene (PE) and Polypropylene (PP) based bags should not contain
The size of the polybag (product bag) should be selected correctly according to the product type.
The safety warning label given below should be attached to each product bag.Safety warning should be printed at backside of the polybag (which is the same side with sticker tape)
CARTON BOX MARKING STANDARDS
Carton boxes prepared for shipment should comply with the packaging standards given belowCarton Box Standards:
The size of the box should be selected correctly according to the type of the product. (Table.1) The same box size should be used for ALL orders of a particular style/option.
Please look the Table.2 for the products cannot be folded and placed in smaller size boxes (coats, jackets etc).
There should not be any empty space in the carton boxes after packing. The empty space in the carton causes possible damages, crushing and tearing of the boxes on the storage, and it harms the garments. There should be neither empty space in the carton boxes nor tumescent boxes (squeezed garments) while packing
Carton Box Short Side Label:
The external box label should not be a thermal label; the barcode scanner should be able to scan the label; it should not be erased, worn-out or multiplied with photocopy.
Carton Box Short Side Label should be attached on the middle of both short-side surfaces of the box.
The height of the carton box short side label should be 10cm, and its length should be 15cm.
Carton Box Short Side Labels of Solid colour-solid size and 2nd Quality products should be as shown in and they should all contain accurate information.
Since solid colour-solid size products are not assorted, they will not have “Assortment Total” and Lot quantity given in a circle on the top righthand side of the label.
Seperators should be used between different sizes when mixed-size products are boxed.
Carton box short side label given in should be used for mixed-size boxes.
There should be a “Mix Sizes” sign in a circle on the right bottom side of the label.
There is no barcode info on mixed-size box labels, as it is not defined.
Carton Box Long Side Label:
In addition to carton box short side label, a carton box long side label is used as well. The long side label includes the following information:
Name and address of our company
Special Code 1
Carton box gross and net weight
Carton box size measurements
Carton box number
Product – country of origin
These details should be present in the middle of both long side surfaces of boxes. The template for the carton box long side label can be printed in advance on the box. If printed boxes are not used, label information given in should be provided.
A printed box prepared for a particular style or colour should definitely not be used for another style or colour.
The size of the label (or the print) should be as follows: height 12 cm, width 20 cm.
Box Tape:
Boxes should be taped with suppliers’ colourful logo-printed special tapes. If supplier does not have a logo-printed tape, any tape with a logo or print (without any brand name) can be used.
The same type of tape should be used for the whole order. Tapes with different logos are not allowed for the same order shipment.
Boxes that are opened at the customs should be taped with the logo-printed tape of the related customs clearance company
Sticker:
Coloured stickers should be attached on boxes according to the product packaging type.
Depending on the packaging, the sticker should be as follow:
Solid colour-solid size : Blue
Single Lot Packaging : Yellow
Multiple Lot Packaging : Red
Mixed Size Box : Black
Carton Box Packaging for Air Shipments;
Boxes prepared for air shipment should be wrapped with naylon one-by-one and they should be strapped.
Carton Number:
Product Description
Item Number
PD Product Code
Product Code
TML PO Number
KB PO Number
Barcode
McLaren Team T-Shirt Baby – Small (1-2yrs)
TM2036
TM152009
157685
KBOW2
589/000117
5054130595627
McLaren Team T-Shirt Baby – Medium (2-3yrs)
TM2036
TM152009
157685
KBOW2
589/000117
5054130595634
McLaren Official Team Set Up T-Shirt – XSmall
TM2061
TM152020
157695
KBOW2
589/000118
5054130596174
McLaren Official Team Set Up T-Shirt – Small
TM2061
TM152020
157695
KBOW2
589/000118
5054130596150
McLaren Official Team Set Up T-Shirt – Medium
TM2061
TM152020
157695
KBOW2
589/000118
5054130596143
McLaren Official Team Set Up T-Shirt – Large
TM2061
TM152020
157695
KBOW2
589/000118
5054130596136
McLaren Official Team Set Up T-Shirt – XLarge
TM2061
TM152020
157695
KBOW2
589/000118
5054130596167
McLaren Official Team Set Up T-Shirt – XXLarge
TM2061
TM152020
157695
KBOW2
589/000118
5054130596181
McLaren Official Team Set Up T-Shirt – XXXLarge
TM2061
TM152020
157695
KBOW2
589/000118
5054130596198
McLaren Team Driver T-Shirt Male – XSmall
TM3050
TM152013
157698
KBOW2
589/000119
5054130596327
McLaren Team Driver T-Shirt Male – Small
TM3050
TM152013
157698
KBOW2
589/000119
5054130596303
McLaren Team Driver T-Shirt Male – Medium
TM3050
TM152013
157698
KBOW2
589/000119
5054130596297
McLaren Team Driver T-Shirt Male – Large
TM3050
TM152013
157698
KBOW2
589/000119
5054130596280
McLaren Team Driver T-Shirt Male – XLarge
TM3050
TM152013
157698
KBOW2
589/000119
5054130596310
McLaren Team Driver T-Shirt Male – XXLarge
TM3050
TM152013
157698
KBOW2
589/000119
5054130596334
McLaren Team Driver T-Shirt Male – XXXLarge
TM3050
TM152013
157698
KBOW2
589/000119
5054130596341
McLaren Team Driver T-Shirt Female – XSmall
TM3051
TM152014
157699
KBOW2
589/000119
5054130596396
McLaren Team Driver T-Shirt Female – Small
TM3051
TM152014
157699
KBOW2
589/000119
5054130596372
McLaren Team Driver T-Shirt Female – Medium
TM3051
TM152014
157699
KBOW2
589/000119
5054130596365
McLaren Team Driver T-Shirt Female – Large
TM3051
TM152014
157699
KBOW2
589/000119
5054130596358
McLaren Team Driver T-Shirt Female – XLarge
TM3051
TM152014
157699
KBOW2
589/000119
5054130596389
McLaren Team Driver T-Shirt Kids – Small
TM3052
TM152015
157700
KBOW2
589/000120
5054130596426
McLaren Team Driver T-Shirt Kids – Medium
TM3052
TM152015
157700
KBOW2
589/000120
5054130596419
McLaren Team Driver T-Shirt Kids – Large
TM3052
TM152015
157700
KBOW2
589/000120
5054130596402
McLaren Team Driver T-Shirt Kids – XLarge
TM3052
TM152015
157700
KBOW2
589/000120
5054130596433
McLaren Team Driver T-Shirt Kids – XXLarge
TM3052
TM152015
157700
KBOW2
589/000120
5054130596440
Written By - Robert Dkay, Manager, Golder Accessories Ltd. Narayangoang
It is a fine cleaning machine and it employs with cleaning roller which acts similar to carding roller. It opening, cleaning and removing micro dust and waste.
MACHINE SPECIFICATION:-
No. of machine = 5
Make = RIETER
Model = B 5/5
DRAW FRAME
Objective:-
There are mainly two objective of draw frame:
Drafting
Doubling
Doubling is done to reduce the unevenness that is weight per unit length. In the sliver generally 6-8 slivers are double in the draw frame drafting is done for parallelisation and to get the required hank of the sliver.
Here two draw frame line are used
Breaker draw frame
Finisher draw frame
Here six breaker draw frame, and six finisher draw frame are used. Draw frames used over here are made by RIETER of model SB51 and RSB951. These entire machine have 3/3 drafting arrangement. These models are equipped with an open loop auto levelling arrangement.
BASIC PRINCIPLE AND WORKING OF DRAW FRAME:-
During drafting tension on the fibre is given between the set of two or more roller. The major aim of drawing is to reduce the number of fibre in the sliver cross-section. To reduce the number of fibre in the sliver front roller is rotating at more rpm then back rollers. So there is Ferris ion on the sliver, no of fibre in the cross-section decrease and the fibre becomes more parallel. Most of the drawing machine consists of two zone drafting system. In which two drafting zones are there.
Back zone
Front zone
Drafting is given in both the zones.
The back draft varies between 1.3 and 1.7 depending upon the specification of the fibre. The function of the back zone or draft is essentially to prepare the material for the main drafting zone in the front.
DRAW FRAME
In Ring Spinning department there are total 8 Draw Frame.
4 – Breakers
4- Finisher
BREAKER DRAW FRAME:
Make – RIETER
Model -RSB-D15
Drafting – 3 over 4
Can diameter – 90 cm
Doubling – 6 sliver
Speed – 500-560 m/min
Production – 1300 to 1500 kg/hr.
FINISHERS DRAW FRAME:-
Make – RIETER
Model – RSB-D35
Drafting – 3 over 4
Can diameter – 30 cm
Doubling – 6 slivers
Speed – 500-560 m /min
Production – 1300 to 1500 kg/hr.
Written By – Jony Ahmed, Lab Technologist, Osaka Japan
Any fault found in the fabric is corrected over the beam and then handed over operators for normal running for all types of fabric the first of fabric is send to quality control department for subsequent parameter test upon getting to Quality Approval from QAD the operator start machine for bulk production.
Different type of grey fabric
Conclusion
In growing market for casual & leisure wear, Denim fabrics represent a very dominant market share. The annual global production of Denim fabric is estimate at about 3 billion square meters. The production growth rate is calculated at about 3%.
Up until now approximately 80% of the total production of Denims has been based on “classic fabrics” like blue/white, blue/blue, blue/black or black/black fabrics.
As in other branches of the textile industry, the production of Denim worldwide is following fashion trends.
There is currency a tremendous increase in market demand for lighter weight fabric, for fabrics with increased softness, fabric with a more elegant drape or fabrics with a “different touch”
To satisfy these trends, the demand for ring spun yarns has undergone enormous growth over the last few years.
In addition special yarns-such as slub yarns have been different developed to create fabrics which offer a different appearance & new aesthetics
A huge variety of garment wash processes have been developed, and garment dye have been introduced to produce colored Denims with special effects.
Besides the efforts already mentioned, fiber blends have become interesting for the manufacturer and consumers.
For example fiber blends specially blends of cotton and cellulose fibers chance to cross borders linked to the characteristics of different spinning systems.
Finally all these activities were targeted to create fabrics with unique characterizes or properties
Written By – Farid Ahmed, General Manager, Knit Dyeing Textile Ltd. Epz, Savar, Dhaka
The Finishing is the last stage of garment production where garment gets its final look. In this department each garment undergoes different finishing processes. It undergoes for quality checks which sets the garment free from defects. Buyer specifications and instructions are strictly maintained. Following are the different finishing processes-
Instrument Flow Chart
Trimming
Trimming is an important step in finishing, it involves cutting of unwanted threads and the cutting of extra loop lengths. Trimming of threads is done with the cutter, which is very user friendly. Tailor scissors are used for cutting extra loop length. Trimming process is carried out on wooden tables covered with the cloth of a color in contrast to the fabric color of the garment. By the end of the this section the garment is free from major irregularities like the protruding and left-over threads. In Auto Garments Ltd, the trimming section is at the end of the sewing line.
2. Quality Inspection
Trimmed garment pieces undergo quality inspection. Here, operator checks every garment piece and mark the defect on the garment with a sticker. This step is very important. Garments with stitching defects are sorted out and sent to ware house. Other small defects such as ripping of seam, small alterations etc. are marked for the alteration and after being referred to the quality control managers are sent back to their respective defect occurrence operation area.
As the trimming table, the quality checking is also done in the sewing line and marks the end of the processes of the sewing room.
The first 100 piece of a new style are checked by the quality assurance team and the work is carried on once they have an affirmation from the quality assurance department.
FINISHING DEPATMENT
The finishing department imparts the final touch to the garments and impart a soothing effect and improves the esthetics of the garment which loses it’s gloss because of so many operations especially in the cutting and the sewing dep. The finishing department works in the following sequence
01.Thread Sucking
The thread sucking is done to remove the threads, which stick on the garment after the thread trimming. The thread trimming results in the deposition of lose threads all over the garment, though it is taken care of at the thread trimming itself by beating the garment with the cello-tape mounted baton but to make the garment 100% stray thread free this process is n. The operator holds the garment and takes it in a suction chamber and due to heavy suction; the garment releases all the threads, which are on the surface. The garments are now bundled in a set of 10 pieces to provide a smooth flow over the floor.
2. Ironing
This is the most traditional form of providing creases and removing the unwanted ones from the garment. It becomes important when the garment needs to be packed because if the garment is ironed then it occupies less space and thus it becomes easy for the operator to pack the garment as well it makes the garment more presentable.
The garments are now ironed to give them a proper form and shaped. Wrinkles are formed on the garment because of many reasons, which mainly include the handling in the sewing room and the wrinkles present in the fabric itself and at the time of storing the fabric. The steam iron is used for cotton fabric but for the synthetic fabrics no steam is used. It is after this stage that the garments give a pleasant and a finished look and after this, the packaging processes start.
3. Buttoning and Neck Pressing
All the buttons of the shirt are closed. This step is immediately after the ironing and an operator stands on one side of the iron table for this purpose. In most of the cases, all the buttons are closed or in some cases there might be some other requirement of the buyer.
4. Inspecting
The buttoned garments are now inspected for the final look and it is checked if the piece is looking aesthetically all right or not. This inspection is 100% and all the pieces undergo this stage.
5.Collar Inserting/Button fly fittinAt this stage, the cardboard collar piece is inserted inside the collar to give it a rigid look and help it provide a better shelf look. The button fly is also inserted in the collar, to give a graceful look at the front end of the collar and also to keep the collar from falling after the packaging.
6. Folding
The garment is folded with the help of the buyer template based on the folding size required.
7. Poly-packing
In packing, the packaging material used is based on the request of the buyers, which in case of shirts is generally a simple poly bag. The carton plies are also mentioned by the buyer. Packing may require more than one step based on the buyer requirements of placing tags and labels. The tags are put with the help of tag-guns.
8. Assorting
The garments after being packed in the poly pack are sent for assortment and to be packed in the cartons. Each piece is picked, and put into the respective carton. This packing in the carton can be done in either of the 2 ways. Ratio packing – In this technique the garments are packed according to the ration of the sizes to be put in which is specified in the list given by the buyer. This is generally followed in the packing of shirts. Solid Packing – In this the garments are packed one shade and one size in one carton, this is easier and requires less time.
FINISHED GOODS STOCKING
After all these processes, the garment is ready to be dispatched, but this cannot be done before the dispatch date and the cartons have to be stocked somewhere. The finishing room on the 2nd floor itself has a lot of stocking space which is called the assortment area as the assortment is also done in this area only. The main finished goods stocking area is on the 1st floor above the central fabric store. From here, the goods are dispatched, once the merchandising departments orders to take the consignment for the port.
Metal detector:
Is there a metal detector on site: y/n
Where is it located:
What is the brand:
Date of last service:
What is the frequency of calibration:
Who is responsible:
Required supporting documents:
Photograph of metal detector in it’s permenant location
Scan of last calibration report
Copy of calibration policy / ways of working
Copy of current way of working to manage detected needles
Metal free zone
Is there is a metal free zone? Y / n
– if yes – please attach detail of how stock is managed through the mfz
– if no – please attach detail of how stock is managed following metal detection
Training:
Is there training in place in the production site for metal control policies? Y / n
– if yes – attach information relating to how this is managed
– if no – attach inforamtion as to how policies are communicated to staff
Other metal control policies;
Please attach any further information relating to other needle, metal, glass, plastic currently in place in the site
Stenter machine can be defined as a stente finishing process in which the open width form of the fabric is treated to set up the required width, weight, and fabric texture as per customer’s specification. These requirements from the customer are achieved by a single Stenter machine process (i.e. Chemical application, Overfeeding-Compaction, Drying- Curing and setting of Width and Yield).
Stenter Machine Process Requirements
Equipment used
Following equipment is used for Stenter Finishing process
Bruckner stenter machine
Key Accessories
Following equipment is used for Stenter Finishing process :
pH papers,
Buckets,
Sewing machine,
Measuring balance,
Measuring tape,
Scissors, and
Materials / Chemicals Used
The materials and chemicals used in the stenter machine process for TC fabric, 100% Cotton fabric, CVC fabric and for Water Repellent fabric are described below.
Types of Fabric
Materials/Chemicals Used
TC Fabric
Softener
Additive
Stiffener
Acetic acid to adjust the pH
100 % Cotton Fabric (soft)
Softener
Additive
Acetic acid to adjust the pH
100% Cotton Fabric (anti shrinking)
Softener
Additive
Resin
Catalyst
Wetting agent (when chemical absorbency is poor)
Acetic acid to adjust the pH
CVC Fabric (medium touch)
Softener
Additive
Stiffener
Acetic acid to adjust the pH
CVC Fabric (soft)
Softener
Additive
Acetic acid to adjust the pH
Water Repellent Fabric
Hydrophobic agent
Stiffening agent
Softener
Additive
Acetic acid to adjust the pH.
Safety
Following Do’s and Don’ts are to be followed during operation:
Do not wear loose dress that may entangle with the machine parts while running.
Always wear rubber shoes.
Never touch the uncurling roller while running the machine.
Be careful in manual pinning of fabric.
Do not insert hands between the rollers during running the machine.
Wear an eye goggle and hand gloves during preparation of chemical solution.
Do not touch the padder during operation.
Be careful about the selvage cutting blade.
Be familiar about volatile chemicals.
Be careful in handling the trolley of fabrics.
Be aware of the first aid treatment procedure.
Operation Procedure of Stente Machine
Operation Staff for stente machine
Operation stuffs of Finishing Process includes:
Manager
Textile Technologist / Production Executive
Production Co-ordinator
Operator
Assistant Operator for stente machine
Checklist Before Production
Operator must check the following items before finishing, re-finishing, heat setting and stretching process in Stenter machine process:
Machine parameters are set according to program.
Required manpower is available for feed side and delivery side.
Required chemicals are available.
Batch for Feed side is set.
Lead cloth is guided up through passage point to operator station.
Operation Procedure for 100% Cotton Fabric (Soft Finish)
Calculation of Solution Amount
Production officer or shift in-charge will provide the recipe with the process flow. The finishing procedure begins with the calculation of solution amount for a particular batch. The formula is as follows :
Solution Amount = Total Weight of Fabric ´ Pick-up Percentage (%) + Trough Content + 3% Wastage.
Suppose, we have 500 kgs of fabric, which are to be finished, and for that we need to prepare the solution.
(where 80% is the average pick up of knit fabric, and 50 litre is the trough content of machine trough).
Operation Procedure
Chemicals are measured using the electronic balance and taken in buckets separately. Chemicals are diluted with hot or normal water based on the references of the chemical literature provided by the chemical company.
Mixing tank is filled up with 50% of water to the required solution level and then chemicals are poured separately into the tank through a piece of filter cloth. Then water is added to get the target solution.
Chemicals are stirred for five to seven minutes by the electrical mixer impeller in the mixing tank and then send to the machine through. Then operator will run 1-meter fabric as a trial run to check the parameter(s), softness and hardness, shade match, etc. which is required by the customer. A small piece of fabric from that trial portion is given to the shift in-charge to check the parameter(s).
If the trial fabric matches with the customer-approved sample then production officer decides to go for the bulk production and operators starts the machine for production.
For the bulk production chemicals solution is prepared using the formula mentioned above and poured into the chemical trough.
The capacity of each tank is 400 litre.
Product Quality Check
Shade Check: During the processing of bulk production of any batch, operator checks the shade in the Stenter machine process. If any deviation is detected he informs the responsible shift officer who takes the necessary action to overcome the problem. If the officer fails to rectify the problem he informs the department head who finally gives the decision.
Fault Check in Stenter Machine Process: The operator checks for Knitting faults (i.e. double yarn, yarn contamination, fly yarn, etc.), Spinning faults (i.e. thick & thin yarn, barre mark, etc.) and other faults (i.e. dye resist mark, band line, chemicals spots, torn and hole, variation of shade, fabric structure, etc.) during the process.
In case minor faults occur within the half rolls of fabric (while running about 20-25 rolls of fabric) which is not resulted from previous process and also not recorded on the batch card the necessary action(s) to be taken is as follows :
Check the feed side to make sure that these faults didn’t occur from the previous process.
Stop the machine to identify whether these faults are occurring due to machine faults (i.e. from padder, chain bar, air duct, etc.) or the faults are due to the chemicals (check cleanliness, setting of machine parameter(s) and chemical composition).
If any spot on the fabric, which is not resulted from the previous process, is detected during processing, it indicates that the sequence of chemical pouring in the mixing tank is not correct which resulted in bad chemical reaction. If this happens, the process should be immediately stopped and responsible officer should be informed for investigation.
Width Check in Stenter Machine Process: Measure fabric width by using a measuring tape and compare it with the required width that is mentioned by production officer on the batch card or program.
Design, Fabric Bow and Slant Check in Stenter Machine Process: Check the design, bowing and slanting of fabric at the delivery side. Adjust the machine by straightening the courses line of the fabric for checking the bowing and slanting.
Pin Setting Check in Stenter Machine Process: Check at the delivery side whether the selvage of fabric is detached from pin and for minimum of 0.5″ each side pinning wastage is maintained, if any abnormality found, immediately inform the head operator.
Q.C. Sample Tests
1-meter sample is cut from each batch during processing and are sent to the Q.C. Department for lab testing. In Q.C laboratory, these samples are tested according to the quality requirement of the customer such as dimensional stability test, washing fastness, water fastness, light fastness, pilling test, crocking (dry & wet) etc.
After all necessary testing, the results are recorded on the Q.C. Sheet. Refer to Off Line QC Test Specification (Document No. 81-101) for details.
Applicable Forms & Documents
Forms & Documents Used
The necessary forms & documents for finishing process are listed below :
Process Batch Card
Daily Finishing Production Report
Machine Downtime Report
Recipe Sheet
Identification Sticker
Program Register of Stenter Machine
Production Register of Stenter Machine
Document Flow
The document flow of Finishing Process is as follows :
Operator fills out the Batch Card and the concerned officer put his signature on it upon verification. The Batch Card moves with the fabric for the next step of finishing process(e.g. Tubular Compactor, De-water, Drying or Slitting).
The Daily Finishing Production Report is prepared to show shift wise daily production of finishing section of BK. Production officer prepares it and sign on it. The department head, Finishing verifies the facts and figures and put his signature on it. Finishing department records this report for future reference.
Machine Downtime Report is maintained to keep record of any stoppage in production due to machine break down or any other reason. Operator fills this and the responsible officer sign on it upon verification
Recipe Sheet is used to give recipe for a particular machine in each shift. It is also termed as the Chemical Consumption Report. Responsible officer prepares it and the Department Head, Finishing verifies and signs on it.
Identification Sticker is attached with every fabric roll that includes the Order number, Customer, Batch/Roll number, Quality, Colour/Shade, usable width and composition. This helps the stores personnel to easily store and locate a particular roll of fabric at Finished Goods Stores.
Program Register of Stenter Machine is maintained against Recipe Sheet to keep track of the production progress of a particular batch.
Production Register of Stenter Machine process is used to keep records of date wise production details. Operator fills this out along with his remarks (if any) and this report is recorded for future reference.Attachments: Examples of all applicable forms and documents are attached. Know more it
Textile stenter machine parts are very important to complete the whole stente process. The steps process using stenter frame and relax dryer and compactor. The damp fabric runs through the relax dryer (no pins) at a fast speed because the fabric has only 30% water content. Fabric comes out dry at 68-70″. The Maintenance Department performs the preventive maintenance task as per the schedule. Refer to Maintenance Specification for details.
Stenter Frame
Stenter frame – 5 chamber (could be more or less but settings below would change) run at 230-260 degrees fahrenheit (normally running at 330-350 degrees f) 45-50 yards/min. The knit fabric is dyed in tubular form, then slit. The fabric goes into the stenter frame wet at 60-63″. The fabric is put on pins and needs to be stretched by 10-15 inches. This means that the wet fabric is put on the pins and then opened up by 10-15 inches into the stenter frame. If the fabric is not pulled open enough, it will not get the torque out of the fabric. Very important: fabric should exit stenter frame with 30% water – still damp
Run at 280-300 degree fahrenheit (normally running at 350 degrees f)
45-50 yards/min
**test**before the compactor, the fabric can be tested for torque and shrinkage to see if there are any problems. We test for torque by making 3 boxes across the fabric to see what the average is (see attached picture). This test is important. The torque at this point should be very low, under 3%. If it is not, the fabric wasn’t pulled open enough on entry to the shrink dryer or there is a knitting issue. **the length shrinkage should be 6-7% at this point. If length shrinkage is higher than this, the fabric wasn’t pulled open enough. If length shrinkage is greater than 6-7%, the compactor won’t be able to achieve the target shrinkage of 4×4% (5×5 is the specification). Very important: the fabric should be off-grain (not be strait) coming out of the stenter.
Compactor
The fabric then goes to the open width compactor. The fabric should be run natural through the compactor do not try to make the grain strait. The finished fabric should be off grain by about 8 inches out of the compator. The temperature on the compaction machine needs to be 104-115c (220-240 f) to create enough heat. Fabric is then rolled up.
Textile Stenter Machine Set-up
Machine set up for the Stenter machine is described below:
Machine Parameters
Set-up Value
Padder Pressure
2 to 8 bar (depends on the pick up requirement of the fabric.)
Temperature setting
(90-180)0C (according to the shade, quality and process of fabric.)
Blower fan setting
Low or high (according to the quality of fabric.)
Exhaust fan setting
Manual
Width of Textile Stenter Machine chain setting
110 cm up to 260 cm (according to the required width of fabric.)
Overfeed
0%-60% (as per the required weight of fabric.)
Burner gas pressure
30-50 m/bar
Machine speed
6 up to 60 m/m (according to the quality of the fabric.)
Light weight (100-140) gm/m2
20-30 m/m.
Medium weight (150-180) gm/m2
14-18 m/m.
Heavy weight (190-250) gm/m2
10-15 m/m.
Response to Equipment Faults
Following are the response to be taken in case of equipment fault during Stenter machine process:
Textile Stenter Machine Faults
Response
Pinning shoe problem
Mechanical Engineer should be called
Pinning brush problem
Mechanical Engineer should be called
Electrical sensor selvedge problem
Electrical Engineer should be called
Chain stops
Electrical Engineer should be called
J-box compensator problem
Electrical Engineer should be called
Chain width disturbance
Mechanical/Electrical Engineer should be called
Burner, blower, motor problem
Mechanical/Electrical Engineer should be called
Padder, plaiter problem
Mechanical/Electrical Engineer should be called
Machine /Area Cleaning
The daily and weekly cleaning works for Stenter Machine are described below :
Clean the padder & rollers after complete every batch (when the next shade is different from the previous shade)
Clean the sieves that can be reached from outside of the Textile Stenter Machine a minimum of once per shift.
Clean the entire screen filter in every shift.
Clean all the air ducts at least once a week.
Clean the chemical mixing tank once a week.
Clean all the buckets after every preparation of chemicals.
