ADT ADVANCE DYEING TECHNOLOGY A NEW GREEN DYEING TECHNOGY Implemented Wisteria Beraiter Chala, Nutun...
-
Upload
imogen-roberts -
Category
Documents
-
view
218 -
download
4
Transcript of ADT ADVANCE DYEING TECHNOLOGY A NEW GREEN DYEING TECHNOGY Implemented Wisteria Beraiter Chala, Nutun...
ADTADVANCE DYEING TECHNOLOGYA NEW GREEN DYEING TECHNOGY
Implemented
WisteriaBeraiter Chala, Nutun Bazar, Sreepur, Gazipur
Most of the knit dyeing industries in Bangladesh or outside the country are doing dyeing process based on 1:8 or 1:7 liquor ratio. Modern machines are doing with 1:6 or 1:5 also.
Particularly for last several years new industries are not coming due to gas and electricity connection problem.
In last 15 years land, energy, manpower, machine, dyes, chemical etc. cost percentage increased. Opposite side dyeing charge per kg not increased significantly. At present situation one factory can earn after ex-factory cost hardly 10% to 15%, not more than that.
Many factories are suffering for insufficiency of gas and electricity problem, even few factories has the machines they are not getting gas or electricity connection. In the mean time they are counting the cost of capital for the investment.
If any factory able to earn more 15% to 30% without investing extra for the machine or dyes-chemical or space, than their income volume will reach on which state that we can understand easily.
ADT objects are simple to help dyeing industries for the followings:-
1. Enhance earning more extra 15% to 30% with existing setup,
2. Increase productivity up to 30% more with existing setup,
3. Fresh water usage only 50% than before implementing ADT,
4. Resulting to reduce WTP/ETP cost 50%, so ETP plant size will smaller.
5. Improvement of dyeing finishing quality like brightness, hand feeling & shrinkage etc.
6. Energy (Gas and Electricity)saving up to 35%,
7. Reducing environmental impact 50% automatically.
8. Finally to run the factory which has the gas and electricity problem by alternate solution.
Considering above eight points seek dyeing industry become benefitted.
ADT IMPLEMENTATION TECHNICAL CONSIDERATION
When ADT implementation will start the for the existing system, than there will be:-
• No Fabric damage,• No Dyes Chemical loss,• No Machine problem,• No Shade, • No Tangle,• No Batch problem.
FINANCIAL ANALYSIS FOR ADT
Machine Capacity is 400Kg and Fabric is 160GSM
Fabric loading will be 320 KG based on 80% considering loading capacity.
In 400KG machine 420KG fabric loading means: more 31.25% extra loading. (420/320X100=31.25%).
Which is not possible without ADT
Study-A: 320 KG Fabric Processing cost in 400KG Machine without ADT
Pre & After Treament
1 Water 2560 ltr Considering 1:8 Liquor ratio
2 Types of the ChemicalsBrand name Dosing Price/kg Qty Value
3 Wetting Agent F.Zum 1.00 g/ltr 425.00 tk 2.56 kg 1088.00 tk
4 Sequestering Agent SF 40 1.00 g/ltr 200.00 tk 2.56 kg 512.00 tk
5 Ant creasing Agent CM 1.00 g/ltr 70.00 tk 2.56 kg 179.20 tk
6 Stabilizer Agent PH 0.40 g/ltr 80.00 tk 1.02 kg 81.92 tk
7 Alkaline Agent Caustic 2.00 g/ltr 78.00 tk 5.12 kg 399.36 tk
8 Bleaching Agent H2O2 3.50 g/ltr 29.00 tk 8.96 kg 259.84 tk
19 Per Oxide Killer Para 0.40 g/ltr 120.00 tk 1.02 kg 122.88 tk
10 Neutralizing Agent A/Acid 1.00 g/ltr 89.00 tk 2.56 kg 227.84 tk
11 Cationic Softener BD 1.00 g/ltr 290.00 tk 2.56 kg 742.40 tk
12 Neutralizing Agent A/Acid 1.00 g/ltr 89.00 tk 2.56 kg 227.84 tk
13 Soaping Agent Rwy 1.00 g/ltr 110.00 tk 2.56 kg 281.60 tk
3613.44 tk
Dyeing Bath
14 Types of the ChemicalsBrand name Dosing Price/kg Qty Value
15 Sequestering Agent SF40 0.50 g/ltr 200.00 tk 1.28 kg 256.00 tk
16 Leveling Agent DE 1.00 g/ltr 130.00 tk 2.56 kg 332.80 tk
17 Ant creasing Agent CM 0.50 g/ltr 70.00 tk 1.28 kg 89.60 tk
18 Migrating Agent Salt 70.00 g/ltr 16.30 tk 179.20 kg 2920.96 tk
19 Alkaline Agent Soda 20.00 g/ltr 32.00 tk 51.20 kg 1638.40 tk
5237.76 tk
20 Total Costing for 320 Kg Fabric processing 8851.20 tk
One company may follow their own recipeThen processing cost will vary accordingly.
Study-B: 420 KG Fabric Processing cost without ADT
Pre & After Treament
1 Water 3360 ltr Considering 1:8 Liquor ratio
2Types of the Chemicals
Brand name Dosing Price/kg Qty Value
3 Wetting Agent F.Zum 1.00 g/ltr 425.00 tk 3.36 kg 1428.00 tk
4 Sequestering Agent SF 40 1.00 g/ltr 200.00 tk 3.36 kg 672.00 tk
5 Ant creasing Agent CM 1.00 g/ltr 70.00 tk 3.36 kg 235.20 tk
6 Stabilizer Agent PH 0.40 g/ltr 80.00 tk 1.34 kg 107.52 tk
7 Alkaline Agent Caustic 2.00 g/ltr 78.00 tk 6.72 kg 524.16 tk
8 Bleaching Agent H2O2 3.50 g/ltr 29.00 tk 11.76 kg 341.04 tk
9 Per Oxide Killer Para 0.40 g/ltr 120.00 tk 1.34 kg 161.28 tk
10 Neutralizing Agent A/Acid 1.00 g/ltr 89.00 tk 3.36 kg 299.04 tk
11 Cationic Softener BD 1.00 g/ltr 290.00 tk 3.36 kg 974.40 tk
12 Neutralizing Agent A/Acid 1.00 g/ltr 89.00 tk 3.36 kg 299.04 tk
13 Soaping Agent Rwy 1.00 g/ltr 110.00 tk 3.36 kg 369.60 tk
4742.64 tk
Dyeing Bath
14Types of the Chemicals
Brand name Dosing Price/kg Qty Value
15 Sequestering Agent SF40 0.50 g/ltr 200.00 tk 1.68 kg 336.00 tk
16 Leveling Agent DE 1.00 g/ltr 130.00 tk 3.36 kg 436.80 tk
17 Ant creasing Agent CM 0.50 g/ltr 70.00 tk 1.68 kg 117.60 tk
18 Migrating Agent Salt 70.00 g/ltr 16.30 tk 235.20 kg 3833.76 tk
19 Alkaline Agent Soda 20.00 g/ltr 32.00 tk 67.20 kg 2150.40 tk
6874.56 tk
20 Total Costing 11617.20 tkWit
ho
ut
AD
T i
n 4
00
KG
Ma
ch
ine
42
0K
G f
ab
ric
pro
ce
ss
ing
is
no
t p
os
sib
le
Study-C: 420 KG Fabric Processing cost in 400KG Machine with ADT
Pre & After Treament
1 Water 1680 ltr Considering 1:4 Liquor ratio
2Types of the Chemicals
Brand name Dosing Price/kg Qty Value
3 Wetting Agent F.Zum 1.00 g/ltr 425.00 tk 1.68 kg 714.00 tk
4 Sequestering Agent SF 40 1.00 g/ltr 200.00 tk 1.68 kg 336.00 tk
5 Ant creasing Agent CM 1.00 g/ltr 70.00 tk 1.68 kg 117.60 tk
6 Stabilizer Agent PH 0.40 g/ltr 80.00 tk 0.67 kg 53.76 tk
7 Alkaline Agent Caustic 2.00 g/ltr 78.00 tk 3.36 kg 262.08 tk
8 Bleaching Agent H2O2 3.50 g/ltr 29.00 tk 5.88 kg 170.52 tk
9 Per Oxide Killer Para 0.40 g/ltr 120.00 tk 0.67 kg 80.64 tk
10 Neutralizing Agent A/Acid 1.00 g/ltr 89.00 tk 1.68 kg 149.52 tk
11 Cationic Softener BD 1.00 g/ltr 290.00 tk 1.68 kg 487.20 tk
12 Neutralizing Agent A/Acid 1.00 g/ltr 89.00 tk 1.68 kg 149.52 tk
13 Soaping Agent Rwy 1.00 g/ltr 110.00 tk 1.68 kg 184.80 tk
2371.32 tk
Dyeing Bath Water= 2100 ltr 1:5 Liquor ratio
14Types of the Chemicals
Brand name Dosing Price/kg Qty Value
15 Sequestering Agent SF40 0.50 g/ltr 200.00 tk 1.05 kg 210.00 tk
16 Leveling Agent DE 1.00 g/ltr 130.00 tk 2.10 kg 273.00 tk
17 Ant creasing Agent CM 0.50 g/ltr 70.00 tk 1.05 kg 73.50 tk
18 Migrating Agent Salt 70.00 g/ltr 16.30 tk 147.00 kg 2396.10 tk
19 Alkaline Agent Soda 20.00 g/ltr 32.00 tk 42.00 kg 1344.00 tk
4296.60 tk
20 Total Costing 6667.92 tk
EXTRA MARGIN DUE TO ADT
This is totally extra for 400Kg machine 420Kg fabric processing
Extra Earning: Tk(11617.20- 6667.92) = TK4949.28
If total machine capacity is 10 Tons
Than Total Extra Margin per Month = Tk (4949.28/400)X10,000 x 25 = Tk 30,93,300/00
REFERANCE RECIPE
ADT is a Mechatron
ics process setup which
works for cost
saving, based on amount of
Dyes Chemical used, not on market
price of Dyes
Chemical. So, it is
Universal
•Electricity saving 35%
•Gas Saving 35%
•Fresh water, WTP cost and ETP cost saving 50%
•Better hand feelings, better brightness and homogeneity of dyeing.
Moreover the above financial benefit, the following benefits are there after implementing ADT.
Industry with old machines easily can fit in the market competition without buying new machines.
Purchasing cost of new machine with new technology is huge.
With old machines dyeing also possible with 1:3 liquor ratio with ADT.New Machines are designed for 1:4 ratio but production possible with1:3 ratio
WE CAN PROVIDE BEST ADVISE if the following information are available to us
1. Total production Capacity: ?2. Capacity of each Machine : ?
i. Machine Maker Name / Brand: ?ii. Year of Commissioning :?
3. Last 7 days Production report details : ? 4. Gas and Electricity Bills for last 3 months separately ?5. Recipe: ?
i. White: 5 Batch minimumii. Average Color: 5 Batch minimumiii. Black: 5 Batch minimum
6. Other Factory overhead details: ?7. Our physical inspection of the factory and meeting with the
management.
Moreover pollution can be reduced by making effluent half.
It is the best contribution for green Earth
THANK YOU
YOU ARE VALEABLE TO US
We will take care about your Productivity and Extra income
Engr. Shahid: [email protected]