ADT ADVANCE DYEING TECHNOLOGY A NEW GREEN DYEING TECHNOGY Implemented Wisteria Beraiter 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 OBJECTIVES

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 objects are simple to help dyeing industries for the followings:- 1.Enhance 1.Enhance earning more extra 15% to 30% with existing setup, 2.Increase 2.Increase productivity up to 30% more with existing setup, 3.Fresh 3.Fresh water usage only 50% than before implementing ADT, 4.Resulting 4.Resulting to reduce WTP/ETP cost 50%, so ETP plant size will smaller. 5.Improvement 5.Improvement of dyeing finishing quality like brightness, hand feeling & shrinkage etc. 6.Energy 6.Energy (Gas and Electricity)saving up to 35%, 7.Reducing 7.Reducing environmental impact 50% automatically. 8.Finally 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 1Water2560ltrConsidering 1:8 Liquor ratio 2Types of the Chemicals Brand nameDosingPrice/kgQtyValue 3Wetting AgentF.Zum1.00g/ltr425.00tk2.56kg tk 4Sequestering AgentSF g/ltr200.00tk2.56kg512.00tk 5Ant creasing AgentCM1.00g/ltr70.00tk2.56kg179.20tk 6Stabilizer AgentPH0.40g/ltr80.00tk1.02kg81.92tk 7Alkaline AgentCaustic2.00g/ltr78.00tk5.12kg399.36tk 8Bleaching AgentH2O2H2O2 3.50g/ltr29.00tk8.96kg259.84tk 19Per Oxide KillerPara0.40g/ltr120.00tk1.02kg122.88tk 10Neutralizing AgentA/Acid1.00g/ltr89.00tk2.56kg227.84tk 11Cationic SoftenerBD1.00g/ltr290.00tk2.56kg742.40tk 12Neutralizing AgentA/Acid1.00g/ltr89.00tk2.56kg227.84tk 13Soaping AgentRwy1.00g/ltr110.00tk2.56kg281.60tk tk Dyeing Bath 14Types of the Chemicals Brand nameDosingPrice/kgQtyValue 15Sequestering AgentSF400.50g/ltr200.00tk1.28kg256.00tk 16Leveling AgentDE1.00g/ltr130.00tk2.56kg332.80tk 17Ant creasing AgentCM0.50g/ltr70.00tk1.28kg89.60tk 18Migrating AgentSalt70.00g/ltr16.30tk kg tk 19Alkaline AgentSoda20.00g/ltr32.00tk51.20kg tk tk 20Total Costing for 320 Kg Fabric processing tk One company may follow their own recipe Then processing cost will vary accordingly.

Study-B: 420 KG Fabric Processing cost without ADT Pre & After Treament 1Water3360ltrConsidering 1:8 Liquor ratio 2 Types of the Chemicals Brand nameDosingPrice/kgQtyValue 3Wetting AgentF.Zum1.00g/ltr425.00tk3.36kg tk 4Sequestering AgentSF g/ltr200.00tk3.36kg672.00tk 5Ant creasing AgentCM1.00g/ltr70.00tk3.36kg235.20tk 6Stabilizer AgentPH0.40g/ltr80.00tk1.34kg107.52tk 7Alkaline AgentCaustic2.00g/ltr78.00tk6.72kg524.16tk 8Bleaching AgentH2O2H2O2 3.50g/ltr29.00tk11.76kg341.04tk 9Per Oxide KillerPara0.40g/ltr120.00tk1.34kg161.28tk 10Neutralizing AgentA/Acid1.00g/ltr89.00tk3.36kg299.04tk 11Cationic SoftenerBD1.00g/ltr290.00tk3.36kg974.40tk 12Neutralizing AgentA/Acid1.00g/ltr89.00tk3.36kg299.04tk 13Soaping AgentRwy1.00g/ltr110.00tk3.36kg369.60tk tk Dyeing Bath 14 Types of the Chemicals Brand nameDosingPrice/kgQtyValue 15Sequestering AgentSF400.50g/ltr200.00tk1.68kg336.00tk 16Leveling AgentDE1.00g/ltr130.00tk3.36kg436.80tk 17Ant creasing AgentCM0.50g/ltr70.00tk1.68kg117.60tk 18Migrating AgentSalt70.00g/ltr16.30tk235.20kg tk 19Alkaline AgentSoda20.00g/ltr32.00tk67.20kg tk tk 20Total Costing tk Without ADT in 400KG Machine 420KG fabric processing is not possible

Study-C: 420 KG Fabric Processing cost in 400KG Machine with ADT Pre & After Treament 1Water1680ltrConsidering 1:4 Liquor ratio 2 Types of the Chemicals Brand nameDosingPrice/kgQtyValue 3Wetting AgentF.Zum1.00g/ltr425.00tk1.68kg714.00tk 4Sequestering AgentSF g/ltr200.00tk1.68kg336.00tk 5Ant creasing AgentCM1.00g/ltr70.00tk1.68kg117.60tk 6Stabilizer AgentPH0.40g/ltr80.00tk0.67kg53.76tk 7Alkaline AgentCaustic2.00g/ltr78.00tk3.36kg262.08tk 8Bleaching AgentH2O2H2O2 3.50g/ltr29.00tk5.88kg170.52tk 9Per Oxide KillerPara0.40g/ltr120.00tk0.67kg80.64tk 10Neutralizing AgentA/Acid1.00g/ltr89.00tk1.68kg149.52tk 11Cationic SoftenerBD1.00g/ltr290.00tk1.68kg487.20tk 12Neutralizing AgentA/Acid1.00g/ltr89.00tk1.68kg149.52tk 13Soaping AgentRwy1.00g/ltr110.00tk1.68kg184.80tk tk Dyeing BathWater=2100ltr1:5 Liquor ratio 14 Types of the Chemicals Brand nameDosingPrice/kgQtyValue 15Sequestering AgentSF400.50g/ltr200.00tk1.05kg210.00tk 16Leveling AgentDE1.00g/ltr130.00tk2.10kg273.00tk 17Ant creasing AgentCM0.50g/ltr70.00tk1.05kg73.50tk 18Migrating AgentSalt70.00g/ltr16.30tk147.00kg tk 19Alkaline AgentSoda20.00g/ltr32.00tk42.00kg tk tk 20Total Costing tk

EXTRA MARGIN DUE TO ADT This is totally extra for 400Kg machine 420Kg fabric processing This is totally extra for 400Kg machine 420Kg fabric processing TK Extra Earning: Tk( ) = TK Extra Earning: Tk( ) = TK If total machine capacity is 10 Tons Than Total Extra Margin per Month = Tk ( /400)X10,000 x 25 = Tk 30,93,300/00 Than Total Extra Margin per Month = Tk ( /400)X10,000 x 25 = Tk 30,93,300/00

REFERANCE RECIPE ADT is a Mechatronics 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 ADT is a Mechatronics 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%Electricity saving 35% Gas Saving 35%Gas Saving 35% Fresh water, WTP cost and ETP cost saving 50%Fresh water, WTP cost and ETP cost saving 50% Better hand feelings, better brightness and homogeneity of dyeing.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 minimum ii.Average Color: 5 Batch minimum iii.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: