It is a packaging machine of garments accesories company. To establish a standard preventive maintenance procedure of Automatic blister packaging machine. To ensure safe and standard preventive maintenance procedure of Automatic blister packaging machine to meet the required smooth operation in solid & liquid production area. Responsibility by Engineering Personnel
Blister Packaging Machine Maintenance Procedure
Inspection for voltage fluctuation in blister packaging machine
Proper earthing condition of machine
Inspection the supply air pressure must be 5-6 bar.
Check the any leakage of compressed air
Check the proper circulation of chilled water
Check the any leakage of circulating water.
Abnormal sound in running time of forming station
Any physical damage of forming station
Abnormal sound in running time of sealing station
Knurling condition of Upper sealing plate
Any physical damage of sealing station
Free movement of draw off bar of blister packaging machine
Any physical damage of draw off bar
Abnormal sound in running of punching station
Sharpness of punching blade
Any physical damage of belt
Abnormal sound when running the belt
Check the abnormal sound of gear box
Oil leakage of gear box
Check all bearings if any damage change it.
Check all cams for proper fixing with main driving shaft and any physical damage
Check the tension of all springs
Correct function of safety switches
Correct function of proximity switches/sensors
Correct indication of pressure gauge
External cleaning of pressure gauge
Gears, Cams, Lubricating nipple (By grease)
Over all surfaces in the panel board and all circuit breaker, Magnetic conductor,
Pneumatic component and outer surface electric motor.
Replace chilled water
Replace gear oil
After completion of maintenance record as per SOP EN/002
Reference Document for blister packaging machine
Supplier Instruction Manual
Maintenance Chart.
Blister Packaging Machine Checklist
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 5-6 bar.
02. Check the any leakage of compressed air
Chilled water connection
01. Check the proper circulation of chilled water
02. Check the any leakage of circulating water.
Forming station
01. Abnormal sound in running time
02. Any physical damage of station
Sealing & perforation station
01. Abnormal sound in running time
02. Knurling condition of sealing upper plate
03. Any physical damage of station
Draw of station
01. Free movement of draw off bar
02. Any physical damage of draw off bar
Punching station
01. Abnormal sound in running of station
02. Sharpness of punching blade for blister packaging machine
Outlet belt
01. Any physical damage of belt
02. Abnormal sound when running the belt
Gear box
01. Abnormal sound
02. Oil leakage
Others
01. Check all bearings if any damage change it.
02. Check all cams for proper fixing with main driving shaft and any physical damage
03. Check the tension of all springs
Safety switches
01. Correct function of safety switches
Proximity switches/Sensors
01. Correct function of proximity switches/sensors
Pressure gauge
01. Correct indication
02. External cleaning
Lubrication
01. Gears, Cams, Lubricating nipple (By grease)
Cleaning
01. Over all surfaces in the panel board and all circuit breaker, Magnetic conductor, Pneumatic component and outer surface electric motor.
Replacement
01. Chilled water of blister packaging machine
02. Gear oil for blister packaging machine
Engr. Nitish Chandra, Blister Packaging Machine Co. Ltd, India
The purpose of this automatic spray painting machine procedure is to ensure that spray and painted is carried out in a safe and efficient manner. Painting operations can give rise to a range of health and safety problems. Problems of acute and chronic health effects can be cause by the over exposure to hazardous substances used in painting operations. Therefore safety is particularly important where risk to the health of personnel is prevalent. The risks to health of employees in any painting process are covered by the provisions of the control of Substance Hazardous to Health Regulations.
Scope of Automatic Spray Painting Machine
This procedure is applicable to all situations where automatic spray painting machine and painting will be done on the jobsite.
To prevent the hazards affecting personnel, it is essential for all personnel to be aware of and understand the nature of the hazards, and how to protect themselves against these hazards.
Responsibility
Project Manager :The project manager is responsible for ensuring that the requirements of this procedure are adhered strictly to during execution of the project.
Section Manger : The section manager is responsible for supporting its application and ensuring that all entities at the site actively participate.
Manager: The manager is responsible for monitoring and ensuring that the automatic spray painting machine & painting work are conduction in safe manner.
Supervisor : The supervisor will check which all workers are performing the automatic spray painting machine and painting work in safe manner, and if there are offenders, correct and advise to offenders.
Instruction of Spray Painting Machine
General: automatic spray painting machine and painting operations shall be conducted in accordance with internationally recognized standards.
Spray and painting shall only be performed by competent and trained employees.
Spray and painting shall only be performed in areas designated for the purpose. Where it is required that spray and painting be done on site contract must take adequate precautions to protect other employees and equipment in the area.
Areas in which spray and painting is to be carried out shall clearly identified and a sign erected stating “Spray and Painting Area – Authorized Persons Only”. Minimum signs should be written in English and the local language.
Adequate protective equipment is to be provided for use by persons involved in automatic spray painting machine and painting. Protective equipment shall include an approved cartridge respirator designed to protect against organic vapors and protective clothing.
All Hot Work shall be prohibited in the vicinity of paint stores and work areas.
Suitable barrier creams shall also be provided for the protection of exposed parts of the skin.
When spraying two-part epoxy or polyurethane paint or when painting is to be conducted within a confined space where paint fumes might become concentrated, an air supplied respirator is to be used.
Suitable hand cleaning compounds are to be made available to spray painters for removing paint from hands and exposed skin. Thinners or harsh solvent – based materials are not to be used for cleaning skin.
All necessary precautions are to be taken to unsure over-spray and fumes do pollute public places and living quarters.
No smoking, naked lights or other forms of lights or other forms of ignition are permitted in areas where automatic spray painting machine and painting is being performed. Only approved electrical equipment is to be used in the vicinity of spray and painting.
Unwanted flammable materials including paint thinners, rags and cotton waste impregnated with flammable spirits or paint, are to be kept in metal drums with close fitting lids and disposed of in a safe manner away from spray and painting areas.
Flammable materials are to be stored well clear of spray and painting areas.
All waste paint, solvent, contaminated rags or other similar material must be disposed of following approved disposal methods.
Stand by fire fighting equipment shall be provided in all areas where printing machine activities will be conducted including painting materials storage area. Type ABC Dray chemical powder Fire Extinguishers shall be located in areas where it is easily accessible at visible. Proper marking shall be posted near the location of Fire Extinguisher.
Since automatic spray painting machine produced a lot of fumes which are flammable and hazardous to health when working in covered area, sufficient exhaust ventilation shall be provided to keep the concentration of solvent vapors below ten (10) percent of the lower explosive limit. Frequent tests shall be made by a competent person to ascertain the concentration.
When personnel are not involved directly in, but are required to be in proximity to, the painting process and may be exposed to hazardous levels of fumes or vapors, they shall be supplied with adequate respiratory protective devices.
Foodstuffs shall not be brought into or consumed on premises where paint is stored handled or used.
All painting application equipment to be used shall be properly maintained and tested prior to use, and where necessary the equipment shall be correctly certified. Electrical equipment shall be examined only by the authorized person electrical.
Where appropriate local ventilation equipment will be installed to reduce levels of solvent vapor, paint or dusts so as to remove the problems of health hazards and explosions. Particular attention being paid when working in confined or enclosed spaces as specified in the Permit to Work system.
The person supervising the painting works must ensure that all necessary safe working conditions have been addressed. That tool box talk are carried out, as required, and that all employees are aware of possible hazards as well as fully trained in the use of the required PPE.
Some paints exert harmful effects, the main routes into the body being inhalation, skin absorption and ingestion. The person supervising the painting works must ensure that all necessary safe working conditions have been addressed. That tool box talk are carried out, as required, and that all employees are aware of possible hazards as well as fully trained in the use of the required PPE.
For more details for disposal of waste, refer to the concerned “Waste Management Plan Procedure”.
Personal Protective Equipments :
Persons performing spray and painting work shall wear :
Air supplied respirator’s helmet.
Coverall with hoods.
Safety boots.
Full body harness.
Lather aprons.
Hearing protection
Hoods and aprons must be certified according to a recognized international standard and marked accordingly.
Respirator’s helmet shall be provided with air at a rate of not less that 0.17 cubic meter per minute that has passed through.
An efficient filter to remove dust, oil, gas and other potentially harmful contaminates.
An efficient conditioner which will deliver air at a temperature not higher that ambient temperature.
An efficient condensate trap with drain cock to remove any condensed liquid.
An efficient pressure reducing or limiting device.
The helmet shall be fitted with wide-angle transparent visors.Permit to work
A permit to work is requirement for all automatic spray painting machine and painting work at site.
It is the motto of chemical purchase Policy of Auto Textiles/ Washing Ltd. to procure dyes & chemicals in environmentally & eceonomically sustainable way. All possible impacts should be assessed before confirming any dyes/chemical procurement. Environmental health & safety of direct user group should be the first priority of this policy. The dyes & chemical management team must always look for newer innovations in chemical application through continuous Alternative Chemical Assessment. For the complete implementation of this policy, Auto Textiles Washing Ltd. will follow the norms of Bangladesh Environmental Conservation Rules (ECR’97). It will also comply the REACH & EPA standards as well as various buyers’ code of conduct like H&M, TESCO, and JULES etc. Implementing the policy, Auto Textiles Washing Ltd. will try to do its level best to procure safer dyes/chemicals which will ensure doing business in environmentally sustainable manner.
Chemical Purchase Procedure:
Chemical Purchase Initiation & Requisition:
After checking the present inventory & assessing the need of chemical/dyes, the concerned person/department will place requisition to Chemical Purchase system for desired chemical/dyes item. Actually this person/department primarily takes step to initiate the procurement procedure. This should be one of the prime concerns of Director Procurement & Sr. Manager (Production) to check the issues for keeping the inventory up to date & well functional. In some cases, Store Department can communicate with Director Procurement & Sr. Manager (Production) and asks for placing requisition. Before purchase chemical we need to flow safe chemical handling procedure and policy.
Chemical Procurement Criteria:
There must be a Chemical Procurement Body which will consider certain issues for procuring any dyes/chemical such as:
Recognized Suppliers: All the dyes/ chemicals should be procured from recognized world class manufacturers/suppliers. There should not be any compromise regarding the quality of dyes/chemicals if they are collected/procured from local suppliers.
Chemical Entity: The chemical must be recognized/legal entity i.e. the chemical/dyes item must not contain any substances which is banned by government & ECHA. The dyes/chemical industrial chemical suppliers must be able to provide all supporting documents such as Technical Data Sheet (TDS), Material Safety Data Sheet (MSDS), dyes/chemical label & others if applicable.
Impact Assessment: The possible impacts on direct user group & environment have to be assessed through back ground investigation & search in MSDS. Director Procurement or someone on behalf of him will try to figure out the possible impacts of target items of dyes/chemicals. Environmental responsible person can help in this issue as well.
Environmental Concern: Environmental well-being should always be the first priority during dyes/chemical selection & chemical purchase. Dyes/chemical with less environmental impacts should be prioritized.
Alternative Chemical Assessment: The Chemical procurement concerns must always look for newer innovations in chemical application so that the best available technologies can be adopted. After brining all the above mentioned issues into account, dyes/chemicals procurement/purchase should be approved.
Dyes/Chemical Supplier Selection:
Dyes/chemical can be procured from international suppliers as well as local supplier abiding national rules & regulations. Best available suppliers such as Dystar, Huntsman & CHT should be selected for quality dyes/chemicals.
How to Open Cash L/C
Dated : 31/01/2016.
To
The Manager,
Auto Bank Ltd.
Motijheel Branch,
Dhaka.
Sub: Request for opening cash L/C at 10% margin and balance taking facilities of LTR in favour of M/S MATEX INTERNATIONAL LTD. FOR USD: $ 36,285.00
Dear Sir,
We would like to inform you that we need to import chemical for fabric dyeing and to maintain the good quality of fabric against which we require to open L/C as a urgent basis. We also like to mention that the supplier is chasing for L/C to ship the goods as our urgent need. We also affirm that payment will be made from LTR facilities and Loan will be adjusted our related export proceeds or available FC-Held or FDCAD account no. 104576745439981 L/C opening charges are on our respective non chequing CD account of our company.
As such, we request you to kindly accord us permission to open L/C for USD $ 89,285.00
The relevant copy of proforma invoice and other documents are attached herewith for your kind information and necessary action.
Thanking you in anticipation.
Yours faithfully,
GM,
Abc Textile Ltd.
LAB Test of Sample dyes/chemicals:
Known dyes/chemicals from renowned industrial chemical suppliers are directly procured from supplier/manufacturers. On the other contrary, sample of new dyes/chemical must pass the in-house LAB test for new product development or to be nominated for final purchase. If the sample dyes/chemical cannot pass the LAB test equipment, it should be omitted from supplier/manufacturer list. The following in-house LAB test criteria is carried out before final selection:
Good color fastness to: – Washing – Water – Light – Perspiration – Rubbing or crocking
Reproducibility in Dyeing: – Shade – Levelness – Least Metamerism
Sensitivities in Finishing: – Shade change during drying – Thermo Migration – Application of chemicals
In-house Laboratory will forward the test result to Director Procurement & Sr. Manager (Production). If the items pass the LAB test, they are selected for next procurement procedure. Nonconforming dyes/chemicals items should be omitted & chemical procurement concerns like Director Procurement & Sr. Manager (Production) will be looking forward for newer/better items.
Purchase Approval & Merchandising:
Collection of PI (Proforma Invoice): After considering the necessity & possible impacts of the dyes/chemicals, factory in charge & Sr. Manager (Production) will collect PIs from relevant suppliers & forward them to factory Managing Director (MD) for approval.
Approval for Purchase: If the Managing Director (MD) finds them worth buying, he will approve & forward the PIs to Commercial Department to proceed on.
Opening L/C: After receiving the approval for final chemical purchase, concerned Commercial Department will open L/C in favor of respective supplier.
Receiving Merchandise: In due time, concerned Store Department will receive the expected merchandises as per terms & conditioned mentioned in the L/C.
Local Purchase: In case of local purchase, after receiving the final approval from Managing Director (MD), the concerned Store Department will directly negotiate with local industrial chemical suppliers for merchandising.
Return of nonconformity items:
The dyes/chemicals which show nonconformities or cannot meet standard must be returned to concerned supplier as per terms & conditions. There should be clear negotiations about empty container management. It has to be ensured whether the industrial chemical suppliers take back the empty dyes/chemical containers or not.
Overall Communication & Implementation:
In case of dyes/ chemical purchase, technical expert like the factory in charge/ Director Procurement & Sr. Manager (Production) will responsible for overall communication (internal & external) & implementation. They will directly negotiate with dyes/chemical supplier/manufacturer & can decide the best option for the industry. In this regard, they can take steps to change/modify any formal procedure. If they face any drawbacks, they can call for meetings & council among themselves to break down the difficulties and take necessary correctional actions to step forward.
Restricted substances list is very important factors for apparel industries. Environmental responsibility is a fundamental part of our approach to corporate Social Responsibility. We recognise that buyer business has many environmental and social impacts. Some of these are associated with the activities of the suppliers. Buyer want to promote more sustainable practices within buyer own operations and here possible influence you as Supplier to improve the environmental standards in the Supply Chain. It is mandatory that effluent is controlled to Local and National in-country regulations at all sites involved in the manufacture of fabric & garments for buyer including sub-contracted units, for example Laundry Facilities. Any textile and washing factory should have chemical purchase policy to minimize the risk
Storage and handling of dyes and chemicals must be made the subject of high standards of industrial hygiene and safe working practices, the objective being to prevent or to reduce to an absolute minimum, the exposure to the workforce and the associated health risks. Exposure can occur through Skin Absorption, Contact with the Eyes, Ingestion or Inhalation.
Working procedures should be established to avoid exposure by all these routes. As far as possible, this should be achieved by engineering means such as containment and/or effective ventilation, including the use of dust free or liquid products. Protective clothing & headgear, where applicable, should always be worn i.e. gloves, goggles or face masks. No smoking, drinking or eating is allowed in areas where chemicals are handled. There is a number of restricted substances that buyrs does not allow or only allow a restricted substances list to be present in any of their products, be it in the fabric, trims, accessories, packaging, garment processing etc. For a list of these restricted substances on fabrics please see the buyer Fabric Assurance Manual. For restricted substances list on accessories, trims, interlining, packaging and in garment processing please see below:
1. Formaldehyde
Formaldehyde is a volatile organic compound that can be found in dyeing and printing for fixation (e.g. easy care finish), preservation of dyes and prints, tanned leather, interlinings, bonded fabrics and for anti-shrinking treatments. In larger quantities, it can cause allergy, skin and respiratory tract irritations and is a suspected carcinogen. It can be present in 2 forms: free on the surface (to determine the level of Formaldehyde present in the fabric or garment to give an indication on the risk of handling the product), or released in a vapour form (to determine the level of Formaldehyde given off by the fabric into the atmosphere to give an indication as to the risk of respiratory problems). Any items for buyer should not exceed the following levels:
Free formaldehyde – 30ppm
Released formaldehyde – 75ppm
Alternatives: Use pure finishes where possible. In the case of applications such as flock or appliqué then formaldehyde containing agents should be avoided. Where this is not possible the above standards must apply to be included as part of (and not separate from) the whole sample test result (i.e. base material plus application together must not exceed above values
2. Nickel
All components used for buyer must be nickel free: Nickel is an allergenic, can cause contact dermatitis and suspected to be carcinogenic. It is a silver white metal that is added to or plated on other metals to improve the hardness of alloys and corrosion resistance properties, particularly associated with a bright metal finish. These are often present in accessories for garments, such as zips, buttons and rivets as well as earrings, bracelets, zippers, watches, studs, rivets, belt buckles etc
3. Phthalates
All products supplied to or for buyer orders must be phthalate free. Phthalates are plasticisers that are used to soften PVC, which can be used in computers, paints, printing inks, adhesives, in plastisol prints, cosmetics, footwear, stationary, clothing, accessories, toys and many packaging operations. Phthalates can migrate into the body, if they come into contact with saliva/sweat and are suspected to be an endocrine disruptor and carcinogens and are known to disturb the endocrine system
4. Cadmium
All products supplied to or for buyer orders must be cadmium free. Cadmium is commonly used in the industry as pigment, dye, paint stabiliser and plating for functional and decorative purposes. Therefore it may be found in a variety of products including packaging, plastics, paint, plastisol printed areas, PVC, PU, coated or laminated fabrics, toys, batteries, furniture, apparel and clothing accessories, such as buttons, zips etc.
5. Chlorinated Organic Dye Carriers
These can affect the nervous system and might have an irritating effect on skin and mucous membranes and are therefore prohibited in buyer products. Dye carriers can be based on trichloro benzene, biphenyl phenol, orthophenyl phenol & halogenated aromatic hydrocarbons. Used as carriers in the dyeing process of polyester or wool/polyester fibres. They can dye at boil to cut costs.
Alternatives: High temperature dyeing of polyester by aqueous or continuous dyeing techniques only should be used. Use only permitted dyestuffs. Substitute chlorinated carriers with toxicologically acceptable carriers such as Carboxylic Acid Esters.
6. Organo Tin Compounds
Organo Tin Compounds must not be present in any Buyer products. Tributyl Tin (TBT) Triphenyl Tin (TPT) is used for anti-microbial finishing and in some printing inks. For textile product it is used for preventing the bacterial degradation of sweat and unpleasant odours in socks, shoes and sport clothing. It is a catalyst and stabiliser for PVC and PU, used in coated or laminated fabrics e.g. imitation leather, bags, shoes.
High concentrations of these compounds are repro-toxic. They are persistent organic pollutants (POP), causing immense damage to water supplies and aquatic species and absorbed through the skin may affect the nervous system. Dibutyltin (DBT) is another Organotin with various applications, such as intermediate for stabilisers of PVC, a catalyst for electrodeposition paints, a catalyst for various types of polyurethanes and as a catalyst for esterification.
7. PCBs & Polychlorinated Terphenyls (PCTs)
PCBs and PCTs must not be present in any Buyer products. Chlorinated organic carriers such as PCB and PCT are mainly used as pesticides but also as softeners, carriers and flame retardants. They are large, stable molecules that can easily accumulate in organisms and environment. They can affect liver, hormone, immune and nervous system.
Alternatives: Modern processing techniques do not require use of PCBs.
8. Chlorinated Phenols – PCP
Chlorinated Phenols are chemical compounds that include PCP and TeCP. Orthochlorophenol, Pentachlorophenol (PCP), Penatachlorophenol & TeCP should be avoided in the production, storage or transportation of any product. It is used as an antifungal agent in leather/textiles e.g. heavy duty cotton and can also be used as preservative in sizing agents/adhesives and printing pastes. They are bio-accumulative, if persistent in the environment they can be harmful to human health and toxic to the aquatic environment and can cause allergy and be cancer inducing. Like most chlorinated compounds they degrade to dioxins on combustion. Dioxins are one of the most toxic non degradable restricted substances list around.
Buyer requests that their concentration in any product should be nil.
Anything treated with PCP must be disposed of by methods other than burning.
Alternatives:Seek supplier advice. Use should not be required if long term storage is not
needed
9. Prohibited Colourants
Azo Dye ‘Blue Colourant’ The azo dye ‘blue colourant’ known by the trade name ‘used for colouring textiles and leather must not be used in any products for buyer. It has got a high aquatic toxicity and reaches the environment via waste water from the dyeing processes.
Azo Dyes: Azo Dyes are a group of synthetic dyestuffs based on nitrogen. They are suitable for all natural and synthetic textile fibres used in textiles (dyed, printed and white) and leather products including clothing, bedding, towels, leather gloves, toys, yarns and fabrics intended for final use by the consumer. They get into the product through the colouration process, especially printing or dyeing. Azo Dyes can break down and produce aromatic amines that have been found to be carcinogenic and allergic and pose a risk to workers and consumers
Carcinogenic Disperse Dyes: These are commonly used to dye polyester, acetate and nylon, also used to colour plastic jewellery and PVC/PES film and found in printing. They can cause cancer and allergies.
Allergenic Disperse Dyes: These are commonly used to dye polyester, acetate and nylon and can cause dermatitis. The following dyestuffs have been implicated in cases of contact dermatitis. Suppliers must be able to certify the absence of restricted substances list of dyestuff. Again adequate alternatives exist without restricting the colour palette.
Alternatives: There is no reason to restrict colour palettes as adequate alternatives of both the Disperse Dyes & other colorants exist. Use only permitted dyestuffs
10. Chromium (VI)
Chromium VI (hexavalent chromium) or its derivatives must not be present in any buyerproducts, as Chromium (VI) and compounds are classified as carcinogenic and can cause allergic reactions, are bio accumulative, highly toxic as well as being environmentally persistent. It is found in dyes, pigments, dye additives, pre/after treatments in dyeing processes particularly associated with the leather industry.
Alternatives: Avoid 2 bath chrome tanning as it uses Chrome VI directly. Carefully control 1 bath tanning to avoid the conversion from Chrome III to Chrome VI. Avoid strong alkaline conditions (e.g. treatment with Ammonia before tanning and strong alkaline glues). Careful selection of neutralizing agents (replace with reducing agents) and fat liquoring agents
11. Alkylphenols (APs) and Alkylphenol Ethoxylates (APEOs)
Alkylphenol Ethoxylates are a class of chemical which are used as non-ionic surfactants with an emulsifying and dispersing action. They are considered to be harmful and toxic to the environment and are possible endocrine disrupters. The most common usage is in detergent products, scouring agents and emulsifying agents in printing. The second most common use is in textile processing (in particular with fibres such as linen and silk, whose naturally occurring gums and resins make them difficult to wet out) where it is used in various textiles auxiliaries including wetting agents and in the manufacture of water based pigment pastes to improve pigment dispersion.
At the processing stage , approximately 50% of APEO are used as emulsifiers for emulsion polymers based on styrol butadiene, Styrol acrylate, Pure acrylate or PVC systems. The range of products where APEO’s can be found includes plastic coating, paper coating, textile coating, dispersion paints and varnishes, sealants and similar products. The use of APs and APEOs specifically containing Octyl Phenols (OP), Nonylphenols and Nonylphenol ethoxylates is prohibited in all areas of buyer production. Nonylphenol Ethoxylate (NPEO), Octylphenol and their Ethoxylates (Alkyl Ethoxylates)
Alternatives: Alcohol ethoxylates are an acceptable alternative.
12. Fluorocarbons – PFOS, halides, amides and other derivatives
The use of fluorocarbons containing Perfluoro Octanoic Acid (PFOA) and Perfluoro Octanyl Sulphonates (PFOS) are prohibited in buyer products, as these are persistent in the environment, possibly carcinogenic, bio-accumulative and harmful to mammals. PFOS are found in coatings for fabrics to provide water or soiling repellency.
Alternatives: Chemical suppliers are now able to offer adequate alternatives.
13. Flame Retardants
Flame retardants such as tris-(2,3,-dibromopropyl)-phosphate, polybromobiphenyles; Polybrominatedbiphenols (PBB), Ttris-(aziridinyl)-phosphineoxide, Pentabromodiphenylether (PentaBDE) and Octabromodiphenylether (OctaBDE) are not allowed buyer products.
Flame retardants used in the manufacture of various items to inhibit or prevent combustion and to reduce the flammability of a product, are chemicals causing allergic reactions. They are carcinogenic, mutagenic, persistent organic pollutants, repro-toxic and toxic. They are restricted substances list under the Dangerous Substances and Preparations (Safety) Regulations 1980. Flame retardants may be found in the finishing or manufacturing process of apparel, homewares, furniture, toys and electronic products.
14. Alkanes – Short Chain Chlorinated Paraffin’s (SCCP’s)
Short chain chlorinated paraffins are toxic to the environment and are prohibited for the use in buyer products. They are often used as softeners on flame retardant treated fabrics. Also used as degreasers and softeners for leather.
15. Biocides & Biocide Finishes
Biocides are harmful to health and the environment and are prohibited to be used in buyer products. Biocides are often used to impart properties such as “antimicrobial” or “anti-odour” in textile products. Biocide finishes include Anti-allergy/bacterial/fungal/microbial finishes. As these can contain harmful chemicals, biocide finishes are not allowed to be used on any buyer product.
Alternatives: Seek advice from chemical supplier.
16. Triclosan
This is an active ingredient in antimicrobial finishes and is an environmental hazard. buyer will therefore not allow any Triclosan to be used on it’s products.
17. Yellowing
There has been a considerable increase in the use of phenol and aromatic amine antioxidants and stabilisers. These compounds are now widely found in products such as packaging, lubricants and foams. The most commonly used is BHT (butylated hydroxyl tolulene). In urban areas and areas of high traffic density, atmospheric pollution from oxides of nitrogen and anti-oxidants is known by various names: yellowing, warehouse yellowing or elusive yellowing. Practical steps for prevention:
Don’t allow diesel-powered fork-lifts in the production or warehouse areas
Exclude exhaust fumes from garment storage areas
Avoid direct gas or oil heating systems
Specify BHT-free polythene for packaging
Specify BHT-free lubricants during manufacture
Finish fabric on the acid side of neutral (pH 5.5-6.5), to avoid skin irritation and burns.
18. Soluble/Extractable Heavy Metals
Heavy elements such as:
Antimony (Sb)
Arsenic (As)
Barium (Ba)
Cadmium (Cd)
Chromium (Cr)
Cobalt (Co)
Lead (Pb)
Mercury (Hg)
Selenium (Se)
Tin (Sn)
refer to any metallic chemical element that has a relatively high density and is toxic or poisonous at low concentrations. All heavy elements have a very negative effect on human health and are found in the pre-processing or in some dyestuffs and chemicals, including printing inks and print pastes, accessories for textiles and clothing (such as buttons, zips, clasps), paints, trims, plastics and metal components.
Alternatives: The use of fabrics, prints & finishes and accessories containing these metal elements must be avoided.
Found as solvents in dyeing and printing, also finishing agents, flame retardants and plasticizers, solvents for fats and oils used as stain removers and scouring assistants. These restricted substances exist as liquid or gas and can affect the nervous system, with irritating effects on skin and mucous membranes. The above are restricted substances list in several EU countries and are banned to be used for any products supplied to buyer
20. Persistent organic pollutants (POPs)
Persistent organic pollutants (such as polychlorinated naphthalenes (PCNs) and short chain chlorinated paraffins (SCCPs) are organic compounds that are resistant to environmental degradation
21. Solvent based pigment printing systems & Ozone depleting solvents
The use of solvent based pigment binder systems is prohibited and aqueous based binder systems must be used instead. Solvents are principally used as cleaning agents but are also found in other products such as adhesives and dye carriers. All processes where solvents are used must comply with the following criteria:
Authentic date & safety sheets must be available to all operatives. Due regard must be paid to the health and safety of the operative when operating with solvents with adequate ventilation, sufficient personal protective equipment and proper records kept of operative exposures.
The solvent must be recoverable.
In the case of adhesives an aqueous based alternative should be used where possible.
Spot stain removal should be done where possible using aqueous based agent.
Solvent operations should be minimised with no residual solvent left on the final product. Extreme caution should be exercised when handling solvents with proper risk assessment as to their usage undertaken. In any event the use of ozone depleting solvents as defined in the Montreal protocol is prohibited.
Alternatives: Aqueous based binder systems & aqueous cleaning systems to be used.
22. Mothproofing Agents
The use of mothproofing agents in the production of clothing is prohibited.
Alternatives: There is no alternative to moth proofing agents. Use of agents giving similar properties is not necessary in a properly controlled production environment.
23. Organochloride Pesticides
Pesticides are used as a defence against insects etc during the cultivation of natural fibres such as cotton, they may also be used to protect other products such as leather or feathers. Pesticides may harm the environment through soil, air or water pollution. Some chlorinated pesticides may convert to dioxins which are extremely toxic.
Alternative: Checks to be made with supplier as regulations are regularly changing.
24. Fungicides
Fungicides may be applied or inserted in products for protection against mould whilst in transit.
Fungicides containing Dimethyl fumarate can cause allergenic reactions when in contact with the skin.
25. Latex
As natural rubber can cause allergic reactions in some people it is not allowed to be used in any of buyer products.
26. Mercury (Hg)
Mercury is used in certain caustic soda processes in fabric/garment manufacture. It has detrimental effects on the central nervous system and is an anticipated carcinogen.
Mercury containing products are prohibited and all caustic soda treatments must be mercury free.
Alternatives: Use of non Mercury containing products required.
27. PVC (Polyvinyl Chloride)
PVC can be used in many areas such as coatings, accessories and zips. As PVC is closely related to phthalates (for softening) and organotins (as stabiliser) the use of PVC is prohibited.
Alternatives: Non polyvinylchloride, Polyurethane or Acrylic containing products are readily available.
28. Chlorine Bleaches
The use of chlorine-containing bleaches should be avoided wherever possible or practicable. In the bleaching and processing of fabric and garments, where there is a choice, peroxide based bleaching systems are preferred.
29. Potassium Permanganate
This is a purple chemical that is used as a bleaching agent and can be toxic, skin & respiratory irritant, as well as a hazard to the environment
30. Residual PH
Textile processing can use extremes of alkalinity and acidity. All finished products must fall within an acceptable limit to avoid any skin irritation.
Upper Limit – pH 7.5
Lower Limit – pH 4.5
The preparation, dyeing and finishing of Textiles can involve the use of chemicals that have high levels of acid and alkali. The final washing process is usually where the pH is monitored and corrected.
31. Dyestuff suppliers
It is strongly recommended that dyestuffs are only supplied by members of ETAD (Ecological & Toxicological Association of Dyes & Organic Pigment Manufacturers).
Please visit the ETAD website at to find the latest information on an ETAD members list.
32. Uzbekistan Cotton
The use of organised and forced child labour is completely unacceptable and leads us to conclude that whilst these practices persist in Uzbekistan cannot support the use of cotton from Uzbekistan in our clothing.We will require you, wherever possible, to identify the source of raw cotton used in buyer Clothing and document this. For all purposes, including all Wal-Mart supplier agreements, this requirement concerning the origin of the cotton is a product specification of all purchase orders for Wal-Mart merchandise containing cotton. Additional information on the issues surrounding Uzbekistan cotton can be found on the following website(s):
33. Dimethyl Fumarate (DMF)
This is found as a fungicide on leather and textiles, paper, wood and anti-humidity bags. As it can cause severe skin irritation plus other health hazards, Dimethyl Fumarate is prohibited in any products/items supplied to buyer
34. Polycyclic Aromatic Hydrocarbons (PAHs)
We need to maintain safe chemical handling procedure and policy. PAHs are considered to cause several health problems due to their carcinogenic and genotoxic properties. PAHs are formed during the incomplete combustion of organic materials such as wood, oil and animal fats. Rubber and plastics are at most risk of containing PAHs. The restricted substances list are defined above clearly.
There are different types of digital textile printing machine and garment printing machine is manufactured by the companies. Example of some machines are – Block Printing Machine, Roller Printing Machine, Screen Printing Machine, Flat-Screen Printing Machine, Rotary Printing Machine, Transfer Printing Machine, Stencil Printing Machine, Digital Printing Machine, Batik Printing Machine etc.
Marking is done on printing machine bed for correct and accurate placement. Cut parts are placed on the m/c bed and screen is placed on top of cut parts.Prepared emulsion in form of paste is poured over the screen and is squeezed with help of roller or squeegee. Emulsion passes through screen and is fixed on the cut parts thus printing is done on cut parts.
Hand Curing : After printing when cut parts are removed from machine Manual hand curing is done with the help of a dryer. This is done to dry the print so that it does not spread out.
Machine Curing: Temperature and run time of curing machine is adjusted according to nature of fabric Then cut parts are placed on the conveyer belt of curing machine and is passed through thus the print is completely dried up and printing is over.
Pilot Run and Bulk Production: After Order confirmation Bulk Production starts on planned date. Work stations are defined samples and mock-ups are kept for reference. Hourly Targets are given by IE dept at the time of Bulk Production. Same printing recipe is used which was developed at sampling stage.
The first 50 pcs are the pilot run samples which after sewing are sent for washing and after wash garments are reviewed. If after wash print quality is not ok then modification is done in recipe and recipe is finalized accordingly and we proceed with bulk production.
Quality Assurance: Approved Mock-ups are visually displayed in printing dept for reference. Marking is done on digital textile printing machine for correct print placement.Operators are being trained by supervisors and technicians. Operators have also been trained for self checking the pcs to ensure 100% quality. Recipe is written into local language Bangla which is best understood by the Supervisors and Operators.
Supplies Responsibilities:
Color: If colors are chosen from suppliers color palate, no lab dips are required. If colors are chosen from pantone, scotdic or another source, lab dips are submitted to customer following color approval procedure.
Testing: The Supplier must test blanks of all styles and all colors, following customer performance testing requirements. Note: If the same color/same style was used in a previous season , the supplier must have the color/ same style was used in a previous season, the supplier must have the style/ color retested. An exception would be an ongoing, uninterrupted program. In case, only new colors must be submitted for approval. Testing of all blanks is required on a yearly basis, following standard testing procedure.Bulk fabric should be sewn into approved style in supplier sample room and submitted for testing, prior to shipping to sewing factory.Submit to intertek testing under protocol 12- Garment testing, following the minimum sample requirements for the garment testing and additional color testing.
QA Audits : Perform the CWIQ evaluation on all colors. Conduct a Final cutting QC on all styles/shipments. This is including the measurement portion of the audit, following supplier spec sheet.
Vendor responsibilities : Conduct pre-production meeting to review the approved sample requirements, screen placement and any other customer requirement. Confirm all the colors match approved bilk sample garment, following customers colour approval procedure. Confirm main label and care label are correct as ordered.
During production : In-line inspection of all the operations being performed. Opportunity to identify any machinery, operator, construction, workmanship or measurement issues and immediately correct. PTL sample is pulled and sent to Technical designer.
CWIQ Evaluation: Perform CWIQ evaluation on all colors and all screen prints. This should be completed during 1st print run per color.
Final Random Inspection: Conduct final random inspection(FRI), including both measurement and workmanship audit. The measurement portion of the audit is required, due to heat being applied during the printing process. Supplier spec should be followed for this audit.Sampling plan to be used for both the workmanship and measurement audit is based upon single sampling/S-4/Reduced, per color and for all purchase orders, regardless of size. 13 piece sample size, reject at 4.
Customer responsibilities: Customer will verify all the styles have a passed intertek test report by season , noting the exception indicated above.Customer may select styles/purchase orders to be inspected our 3rd party. Factory inspection procedure.
Advantages of Block TextilePrinting Machine Works
Simple method of printing
No expensive equipment required
No limitation in repeat of size of style
Prints produced have great decorative value and stamp of craftsmanship
Disadvantages of Block TextilePrinting Machine Works
Involves much manual work
Method is slow and therefore low output
Good skilled labors needed for multi color design
Fine and delicate designs hard to produce
Advantages of Roller Printing Machine Works
Large quantities of fabric at the rate of 914-3658m per hour can be printed.
Faulty joints or joint marks are absent.
Fine sharp outlines and good prints can be obtained which is difficult to get in block printing.
Disadvantages of Roller Printing Machine Works
Not economical for short run of fabrics.
Difficult to produce blotch designs.
Repeat of design limited to the size of the rollers.
Setup cost of roller printing m/c is high
Advantages of Stencil Printing Machine Works
Simple and cost effective.
Stencils can be made rapidly and can be used for small orders.