REPORT

By

IRFAN MEHDIINTERNSHIP

BASF PAKISTAN

INTRODUCTIONIn 1969 BASF Aktiengesellschaft, Germany in joint collaboration with Pakistani businessmen started the operation of BASF Pakistan (Private) Limited. The Company commenced production of textile and leather auxiliaries and pigment preparations in 1971. Later, it took to production of dispersions and gradually acquired a strong foothold in the country. In 1995 BASF AG further expanded its operations and formed BASF Chemicals & Polymers Pakistan (Private) Limited, a 100% owned company for indenting and merchandising of industrial chemicals.In April 2014, Mr.Faisal Akhtar is appointed Managing Director, BASF Pakistan (Private) Limited and member of Board of Directors, BASF Chemicals & Polymers Pakistan (Private) Limited. With Mr. Faisal vast experience in senior management positions as well as operational and functional area of activities, BASF’s policy to develop local talents put the company at an accelerated growth.

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Leadership, innovation, emphasis on human resources development and use of SAP system has made BASF Pakistan a truly progressive and closely integrated company. BASF Pakistan believes in practicing ethical values and standards in all of our transactions and takes pride in contributing towards the national economy. We exemplify the spirit of innovation and high quality products that benefit BASF customers worldwide.

PRODUCTSBASF’s core business in Pakistan includes local manufacturing and marketing of over 100 products. The product portfolio includes a wide range of Leather and Textile Pigments and Auxiliaries and General Purpose Polyester Resins. The company's strong presence in the Leather and Textile industries, backed by excellent technical support, is also playing an important role in promoting Pakistan's exports. The Production Plant situated at Landhi was ISO 9000 certified in 1998 and Environmental Management System 14001 certification in 2004. The state-of-the-art plant possesses a well-

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equipped quality control laboratory in conjunction with two application laboratories exclusively for Leather and Textile ensuring consistent quality and extending technical support to the customers. All these laboratories work in close association with the Sialkot application laboratory. In addition, the credit of introducing Unsaturated Polyester Resins in the domestic market goes to BASF Pakistan as well. BASF Pakistan takes pride in offering a diversified product portfolio, to its customers, comprising of:

LEATHER -

Bating Agents -

Wetting Agents -

Resin Tanning Agents

-

Fat Liquors -

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Dyes -

Binders -

Finishing Auxiliaries

TEXTILE -

Sizing Agents -

Pre Treatment Auxiliaries

-

Dyeing Auxiliaries -

Printing Auxiliaries -

Finishing Auxiliaries -

Pigments for Printing

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GENERAL PURPOSE POLYESTER RESIN

GENERAL PURPOSE POLYESTER RESIN

Pesticides, Intermediates & Fine Chemicals -

Textile/Leather Chemicals & Dyes Colorants -

Process Chemicals, Dispersions, Catalysts -

Phthalates, OXO Alcohols -

Solvents, Specialty Chemicals -

Polyethylene, Polystyrene, Styrene Copolymers, Expandable Polystyrene, PUR Raw Materials & Systems Nylon, PBT, POM

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Button Grade

Car Putty Gel coat

SUSTAINABILITY

Our goal is to make a positive contribution to a future worth living. For us, acting responsibly means improving safety, health and environmental protection and fostering awareness for these issues among our employees, customer and suppliers. In this way, we contribute to BASF’s sustainable success.

In Pakistan, not only uniform global safety procedures based on modern technology are adhered to, strict measures are also taken to safeguard the environment from the dangers of chemical waste and pollution. Investment in the Biological Wastewater Treatment Plant shows our commitment towards activities aiming at sustaining the quality of life and conservation of resources.

BASF can only be successful if we enjoy the trust and support of our neighbors. That is why we work at all our sites to be recognized as a reliable partner and an attractive employer that takes its social responsibility seriously. In this way, we add to each country’s competitiveness as well as our

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own. In Pakistan, BASF works hand-in-hand with government authorities on minimum wages of workers in the chemical industry as a member of the Minimum Wage Board of the Provincial Government. We also organize and participate in community projects in the area of education, environment and health protection as well as human rights projects to ensure sustainable growth and development in the country.

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INDEX

ENGINEERING DEPARTMENT

PumpTypes of pump1-Centrifugal pump2-diagharam pump

ValveTypes of valves1-Ball valve2-Butterfly valve3-Gate valve4-Globe valve5-Check valve6-Control valve

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Utility1-Boiler2-Chiller3-Air dryer4-compressor5-Generator

PSV and PMV

Engineering Store1-SAP2-Mechanical tools

Electrical Instruments

EHS DEPARTMENT

Waste water treatment process1-Primary treatment process2-secondary or biological treatment process

Safety precautions

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TEXTILE LABORATORY1-Manufacture of fabrics2-machines in textile laboratory2-Formadehyde test

QUALITY CONTROL AND QUALITY MANAGEMENT

PROUCTION DEPARTMENT

INDUSTRIAL RELATION

LOGISTICS DEPARTMENT

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ENGINEERING DEPARTMENTIntroduction:-

This department provides technical services to production department .It also perform various maintaince actoritsis on plant.

Naseer Vohra:-

Sir Naseer Vohra is the HOD (head of department) of engineering department. Brief about him is that he is the hierarchy of the department and various.

Mehmood:-

Sir Mehmood is the deputy manager of engineering department. He is the phenomenon of various utilities.

Danish Ali:-

Sir Danish is a senior instrument officer.

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Sir Zubair Hashmi:-

Sir Zubair is an electrical electronic engineer of the engineering department.

Sir Muneeb:-

Sir Muneeb is a mechanical engineer of the engineering department.

Sir M Faizan:-

Sir M Faizan is an AutoCAD officer of the engineering department.

Sir Kaashan:-

Sir Kaashan is the incharge of engineering store.

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Pump:-Definition:-

A mechanical device using suction or pressure to raise or move liquids, compress gases, or force air into inflatable objects such as tyres.

Pumps can be divided into two types

1-Centrifugal pump

2-Diagharam pump

1-Centrifugal pump:-

A pump that uses an impeller to move water or other fluids.

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Impeller:-

It is a rotating component of centrifugal pump, made up of iron steel or bronze. It is used as a rotor to increase or decrease the pressure or flow of fluids.

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Diaphragm pump:-

A diaphragm pump is a positive displacement pump that uses a combination of reciprocating action and either a flapper valve or a ball valve to transfer liquids. This pump is sometimes referred to as a

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membrane pump.

Valve

Definition:-

A device for controlling the passage of fluid through a pipe or duct, especially an automatic device allowing movement in one direction only.

Types of valve:-

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There are many types of valve. Some are

1-Ball valve

2-Butterfly valve

3-Gate valve

4-Globe valve

5-Check valve

6-Control valve

1-Ball valve:-

A one-way valve that is opened and closed by pressure on a ball which fits into a cup-shaped opening.

Working principle:-

A ball valve is has a spherical disc, which controls the flow of fluid through it.

The sphere has a hole or a port through the middle so that when the port is in line with ends, the fluid will flow and when the valve is closed

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the hole is perpendicular to the ends of the valve and flowing of fluid is blocked.

2-Butterfly valve:-

A valve consisting of a rotating circular plate or a pair of hinged semicircular plates, attached to a transverse spindle and mounted inside a pipe in order to regulate or prevent flow.

Working principle:-

The operation of butterfly valve is similar to ball valve which allows for quick shut off.

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They are mostly used because they are very cheap as compared to other types of valves and it is lighter in weight. Its disk is positioned in there center pipe. It is also called quarter turn valve because the disk is rotated in quarter turn.

3-Gate valve:-

A valve in a pipe or channel having a sliding plate that control the flow.

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4-Globe valve:-

A globe different from ball valve, is a type of valve used for regulating flow in a pipeline, consisting of a movable disk-type element and a stationary ring seat in a generally

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spherical body.

5-Check valve:-

A valve that closes to prevent backward flow of liquid. Or a valve that allows the fluid in only on direction.

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6-Control valve:-

Control are valve used to condition conditions such as flow, pressure, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "set point" to a "process variable" whose value is provided by sensors that monitor.

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UtilityDefinition:-

Utility are those devices that provide services to a processing process.

Example:-Chiller, boiler etc.

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Boiler:-

Definition:-

A boiler is a closed vessel in which water or fluid is heated and steam or vapors are generated.

Working principle of Boiler:-

The working principle of boiler is very simple and easy to understand.

The boiler is essentially a closed vessel inside which water is stored. Fuel (generally coal) is brunt in a furnace, through this the hot gases are produced i.e. fire. These hot gases come in contact with water vessel, where the heat of hot gases transfer to water vessel and steam is produced in the boiler. Then this stream is piped to plant where it needs.

Types of Boiler:-

There are many types of boiler utilized in different purposes like running a production unit, sterilization equipment, to warm up the surroundings etc.

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There are two types of boiler

1-Fire tube boiler

2-Water tube boiler

Fire tube boiler:-Definition:-

In this type of boiler hot gasses (fire) are passed through tubes which are surrounded by water.

Specification:-

Weight = 4 ton

Boiler Registration= S117

Serial no# 9422

Year of make= 1970

Operating pressure= 1.8psi

Steam pressure= 4kg/m2

Maximum capacity= 4 ton per hour

Minimum capacity= 0.5 ton per hour

Hydraulic pressure= 9.5 bar (285psi)

Working stream pressure= 10.78 bar (156.42psi)

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Water capacity= 10440 liters

Stream temperature= 180 degree centigrade

Hot water feed temperature= 105 degree centigrade

Maximum heat= 8400kcal/Nm3

Fuel consumption= 300Nm3/hour

Total evaporation= 88.18lbs.ph

No of tubes= 95

Size of boiler= 76.1 dia (3.2 thickness*length 46.10mm)

Size of boiler tube= 76.1 dia (3.2 thickness*length 4050mm)

Diagram:-

Components of Boiler:-

Gas line pipe:-

It is yellow colored pipe, used in boiler to supply the gas to the boiler.

Blower:-

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Mixture of (heat+oxygen+fuel) to produce the fire.

Regulator:-

It is used to control gas and oxygen.

Nonmetric air pressure well:-

It is attached to gas pipe (yellow colored to control the pressure of gas in the boiler.

Water gauge glass:-

It tell us the level of water in the vessel/shell.

Pressure gauge:-

It tell us the pressure of gas in the boiler.

Air system:-

1-Air filter 2-Air regulator 3-Air lubricant (oil present)

Pillet:-

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It contain selenite gas (yellow colored slim pipe). It is fired by ignition rod/sparking rod with the help of h.transormer coil.

Eye sensor:-

Its function is to open the main gas pipe.

Stream pressure:-

It is controlled by gauge.

Dumper:-

It is used to control the air that how much oxygen we have to given.

Dampers serve three basic functions:  modulating gas flow, diverting gas flow, and isolating equipment from gas flow.

Water Mobic system:-

It tell us the level of water in the boiler.

Feed water tank:-

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Boiler feed water is used to supply ("feed") a boiler to generate steam or hot water.

It contain hot water and have a temperature of 95 degree centigrade.

It supplies the water toward the boiler (fire tube) with the help of feed water pump.

It contain different chemicals.

It takes water from softener having nil hardness.

Safety valve.

A safety valve is a valve mechanism which automatically releases a substance from a boiler, pressure vessel, or other system, when the pressure or temperature exceeds preset limits.

It contains 2 safety valves at the upper portion of the boiler.

It is used in emergency to pass stream from the boiler.

Boiler blowdown Valve:-

Boiler blowdown is the removal of water from a boiler. Its purpose is

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to control boiler water parameters within prescribed limits to minimize scale, corrosion, carryover, and other specific problems. Blowdown is also used to remove suspended solids present in the system. These solids are caused by feed water contamination, by internal chemical treatment precipitates, or by exceeding the solubility limits of otherwise soluble salts.

Actually It drains the water of boiler, after checking the sample of water that whether it is useful or not. If it is useless then we drain it through blue don valve.

Exhaust chimney:-

It exhausts the waste gases from boiler.

Working principle of fire tube boiler:-

As it indicated from the name, it consists of numbers of tubes (95) through which hot gasses are passed. These hot gas tubes are immersed into water, in a closed vessel. Actually in fire tube boiler one closed vessel or shell contains water, through which hot tubes are passed. These hot tube contains fire. These fire tubes or hot gas tubes heated up the

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water and convert the water into steam and the steam remains in same vessel. As the water and steam both are in same vessel a fire tube boiler cannot produce steam at very high pressure.

Advantages of Fire Tube Boiler

1) It is quite compact in construction.

2) Fluctuation of steam demand can be met easily.

3) It is also quite cheap.

Disadvantages of Fire Tube Boiler

1) As the water required for operation of the boiler is quite large, it requires long time for rising steam at desired pressure.

2) As the water and steam are in same vessel the very high pressure of steam is not possible.

3) The steam received from fire tube boiler is not very dry.

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WATER TUBE BOILER

A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot gasses surround them.

Advantages of Water Tube Boiler

There are many advantages of water tube boiler due to which these types of boiler are essentially used in large thermal power plant.

1) Larger heating surface can be achieved by using more numbers of water tubes.

2) Due to convectional flow, movement of water is much faster than that of fire tube boiler, hence rate of heat transfer is high which results into higher efficiency.

Disadvantages of Water Tube Boiler

1) The main disadvantage of water tube boiler is that it is not compact in construction.

2) Its cost is not cheap.

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3) Size is a difficulty for transportation and construction.

Chilling process:-

Definition:-

Chiller is a device used to produce chiller water.

Basically it works on 2 cycles.

Specification:-

Make:-Hitachi water compressor.

Type:-water type chiller

Model:-RCUP150WXZ

Power supply:-380V, 3PH, 50Hz

Compressor motor:-380V, 3PH, 50Hz

Permissible operating voltage:-342-418V

Total input:-90.9kw

Running current:-156.9A

Refrigerant type:-R407C

Maximum working pressure high:-2.38MPa

Maximum working pressure low:-1.56MPa

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Production no:-47742828

Year of production:-2004

Starting current:-114A

Net weight:-2190kg

No of compressors:-3

1-Vapour compression cycle

2-Absorbtion cycle

1-Vapour compression cycle:-

Definition:-

Vapor compression refrigeration, in which the refrigerant undergoes phase changes, is one of the many refrigeration cycles and is the most widely used method for air-conditioning of buildings and automobiles.

COMPONENTS OF CYCLE:-

There are four components of vapor compression cycle.

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1-Compressor

2-Condensor

3-Expansion valve

4-Evaporator

1-Compressor:-

It is used to raise the pressure of low-pressure low temperature gas to high-pressure high temperature gas.

Specification:-

Model:-Hitachi screw compressor

Model:-4005SC

Motor:-30kw

Hydrostatic pressure test high:-4.5MPa

Pneumatic pressure test high:-3.0MPa

2-Condensor:-

It is a heat exchanger, it changes the state of high-pressure, high temperature gas to high-pressure, high temperature Liquid. This is achieved by passing ambient air (known as air-cooled) or water (known as water-cooled) over the condenser tubes.

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3-Expansion valve:-

The purpose of the device is to change the state of the refrigerant from high-pressure, high temperature liquid to low pressure low temperature saturated liquid.

4-Evaporator:-

It is also a heat exchanger. It is used to absorb the heat from room air or water, which in the case of a chiller is circulated around the evaporator coil. This will change the state of low-pressure, low temperature saturated liquid to low pressure, low/medium temperature gas.

Process:- In this process gas R-407C (a mixture of hydroflorocarbon) goes to compressor for compression, having the high temperature and pressure. Then this gas goes to condenser which have low temperature and pressure. As we know that condenser work as a heat exchanger. Condenser also have the water, which comes from cooling tower (cold water). Due to this heat exchanger the hot gas become cold. Then this gas passes through expansion valve. Basically the function of expansion valve is to decrease the

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pressure of gas, and this cold gas about converts is liquid form. Then this cold gas passes through the evaporator. As we know that evaporator is also a heat exchanger. Evaporator contain hot water, which came from plant. When the cold gas and hot water collide with each other then they exchange their temperature. The cold gas gives its coldness to hot water and the hot water give its hotness to gas, hence the water become cold and the gas become hot. Then this hot gas goes to compressor and this process repeats.

Cooling tower:- In all of the air conditioning systems we've described so far, air is used to dissipate heat from the compressor coils. In some large systems, a cooling tower is used instead. The tower creates a stream of cold water that runs through a heat exchanger, cooling the hot condenser coils. Cooling tower contain 2 fans.

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Air Dryer:-

A compressed air dryer is a device for removing water vapor (moisture) from compressed air. 

Specification:-

Make: Atlas Copco

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Compressor:-

Specification:-

ML-55 ML-75

Make: 1990 2010

Model: 55R-ML-55 M75

Capacity: 9.5m3/min 12.93m3/min

Generator:- Three generator are present in the plant.

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1-314KVA Capacity

2-511KVA Capacity

3-1000KVA Capacity

PSV and PMV:-PSV:-Pressure Measuring Valve.

PMV:-Pressure Measuring Valve.

Engineering store:-Introduction:- A place where merchandise is offered for sale.

Engineering store is one of the most important store. It contain all the inventories. This store is under control of sir Kaashan. He is a store in charge, He takes the responsibility of whole store, write everything in the MIV (material issuance voucher), when someone writes comes for any tool.

Inventory/Stroke:-

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All the material stored anywhere for usage in case of any fault criteria.

SAP:-

Sap stands for system application program.

SAP ERP is enterprise resource planning software developed by the German company SAP SE. SAP ERP incorporates the key business functions of an organization. The latest version (SAP ERP 6.0) was made available in 2006. The most recent Enhancement Package (EHP7) for SAP ERP 6.0 was released in 2013.

BASF is currently using eccc6 version of SAP. This version of SAP was implanted in 2012 by BASF in Pakistan. BASF in Pakistan is currently using following modules of sap.

Material management (MM Module) Production planning (PP Module) Plant maintaince (PM) QM module Material requisition planning (MRP) Sales and distribution (SD module) Finance and controlling (FICO) Human resource management (SAPHR) Transportation management (TM Module)

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Mechanical tools:-

1-Non written valve:-

It is the type of valve mostly used in pumps to stop the water.

2-Flange type Ball valve:-

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3-piston valve:-

A piston valve is a device used to control the motion of a fluid along a tube or pipe by means of the linear motion of a piston within a chamber or cylinder.

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4-Flanges:-

A flanges can also be a plate or ring to form a rim at the end of a pipe when fastened to the pipe.

A blind flange is a plate for covering or closing the end of a pipe. A flange joint is a connection of pipes, where the connecting pieces

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have flanges by which the parts are bolted together.

5-Globe y valve:-

Y-pattern globe valves offer lower and higher Cvs

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.

6-Y-Stainer:-

Strainers are placed in-line with process piping to remove large solid contaminants from the flow.  Strainers can be cleaned and reused. Strainers can be supplied as either an assembly or an element.  Strainer assemblies come equipped with a housing, cover or case, and a strainer element.

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7-Box Spanner:-

A steel hand tool with a handle carrying jaws or a hole of particular shape designed to grip a nut or bolt head. 

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8-Thermodynamic steam trap:- Thermodynamic steam traps have a unique operating principle which relies on the dynamics of water and flash steam. They are simple, robust and reliable and can operate up to very high temperatures and pressures.

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9-Drill bit:-

Drill bit are cutting tools used to create cylindrical holes, almost always of circular cross-section. Drill bits come in many sizes and have many uses. Bits are usually connected to a mechanism, often simply referred to as a drill, which rotates them and provides torque and axial force to create the hole.

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10-hacksaw blade:-

A saw consisting of a tough, fine-toothed blade stretched taut in a frame, used for cutting metal.

11-Embery paper:-

Emery paper is a type of sandpaper that can be used for sanding down

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hard and rough surfaces. It can also be used for resistant technology purposes to give a smooth, shiny finish to manufactured products and is often used in the finishing of high-end watch movements.

12-Reducer:-

A reducer is the component in a pipeline that reduces the pipe size from a larger to a smaller bore (inner diameter). The length of the reduction is usually equal to the average of the larger and smaller pipe diameter.

There are two main types of reducer:

Concentric

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Eccentric reducers.

13-Granding disk:-

A grinding wheel is an expendable wheel that is composed of an abrasive compound used for various grinding (abrasive cutting) and abrasive machining operations. They are used in grinding machines.

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Electrical Instruments:-

1-Level switch:- A float switch is a device used to detect the level of liquid within a tank. The switch may be used in a pump, an indicator, an alarm, or other devices.

2-Explosition proof switch:- Electrical apparatus (such as compressors, motors and switches) designed to contain explosions or flames produced within them (due to arcs, sparks, or flashes) without igniting the surrounding

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(external) flammable gases or vapors. This term may also include non-sparking tools.

Lock out switch:- Electrical lock out equipment is used for locking out switched off circuit breakers, preventing re-energizing, to control dissipation of residual energy, to ground electricity and also to effectively tagout equipment.

Electro-pneumatic Positioner:- Electromechanical positioners are conventional pneumatic positioners that have an additional integrated electro-pneumatic transducer. The transducer receives the DC analogue input signal from the control system and converts it to a proportional pneumatic signal which is then sent to the conventional positioner Almost every Fisher. Pneumatic positioner has the option of adding an integrated electro-pneumatic transducer.

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EHS DEPARTMENTIntroduction:-

Environmental, health and safety (EHS) departments, also called SHE or HSE departments, are entities commonly found within companies that consider environmental protection, occupational health and safety at work as important as providing quality products, and which therefore have managers and departments responsible for these issues. In BASF Sir Mehmood Hussain is the head of EHS department.

Waste water treatment processIntroduction:-

Waste water treatment process are designed to achieve improvement in the quality of waste water.

There are two methods for waste water treatment.

1-Primary treatment (mechanical) process:-

Definition:- Primary treatment process involves basic

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processes to remove solid waste and reduce its biochemical oxygen demand (BOD) by 20% to 30% and suspended solids by up to 60%.

Process:-

It is a mechanical process. In this process all types of waste water from different locations of factory came into the waste water tank. Then this water goes into the treatment vessel or tank. Each of tank contain 28 tons of waste water. This tank contain chemicals polymer and lime. Then we pick this solution in open air and check the PH. We will get the PH of solution 6. So for this we add alum in the solution to make it acidic PH is 7. We will check its PH. Finally the treated water came into the then the primary tank

Basically in this process we removes the solids and reduce the BOD.

Secondary/Biological treatment process:-

Definition:-

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Secondary treatment process uses biological processes to remove the dissolved organic matter missed in the primary treatment process.

Process:-

It is a biological process in this process the primary treated water (primary tank) with the help of pump then goes to the buffer tank where it is combined with the septic water after then it goes into aeration tank. There over air which is continuously provided with the help of blower to keep bacteria alive. From there, it goes into the pond tank and sludge is circulated between clarifier and aeriation tank, excess sludge goes into sludge beds. Water is used for gardening and floor washing purpose

Textile Laboratory ApplicationIntroduction:-

The Textile Chemicals business unit of BASF offers textile auxiliaries for weaving, pretreatment and dyeing, as well as comprehensive solutions for pigment printing,

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finishing and textile coatings. BASF products are manufactured and marketed worldwide.

Sir Atif Latif:-

Sir Atif Latif is the Lab incharge if the textile laboratory.

Sir Zohaib Jahangir:-

Sir Zohaib is the application chemist of the Textile Laboratory.

Sir Hassan:-

Sir Hassam is the application chemist of the textile Laboratory.

Manufacture of fabrics:-

Pretreatment: Natural fibers and synthetic fibers contain primary impurities that are contained naturally, and secondary impurities that are added during spinning, knitting and weaving processes. Textile pretreatment is the series of cleaning operations. All impurities which causes adverse effect during dyeing and printing is removed in pretreatment process.

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Pretreatment processes include desizing, scouring, and bleaching which make subsequent dyeing and softening processes easy. Uneven desizing, scouring, and bleaching in the pretreatment processes might cause drastic deterioration in the qualities of processsed products, such as uneven dyeing and decrease in fastness.

Objective of Pretreatment:

To convert fabric from hydrophobic to hydrophilic state.

To remove dust, dirt etc from the fabric. To achieve the degree of desire whiteness.

Steps in Pretreatment Process of Cotton and Natural Fibers:

Major steps involved in textile pretreatment are,

1-singeing

2-Desizing

3-Scouring

4-Mercerization

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5-Bleaching.

Textile Finishing:-

Textile Finishing is a process used in manufacturing of fiber, fabric, or clothing. In order to impart the required functional properties to the fiber or fabric, it is customary to subject the material to different type of physical and chemical treatments. For example wash and wear finish for a cotton fabric is necessary to make it crease free or wrinkle free. In a similar way, mercerizing, singeing, flame retardant, water repellent, water proof, antistatic finish, peach finish etc are some of the important finishes applied to textile fabric.

Water Proofing finishing of Textile:-

Water proofing:-

“Waterproofing is nothing but preventing the passage of both air and water through a fabric.” 

Purpose of Water Proofing: For certain uses

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such as Tarpaulin, Umbrella cloth, Rain coat fabrics etc., it is required to give this type of finish as these type of fabrics are generally used against the air and water in the normal life. So they should have some property to prevent both air and water passing through them. 

This finish makes the wearer feel uneasy and uncomfortable as the air circulation is not there.

Printing:-

Introduction:-

By the term textile printing we mean the localized application of dyes or pigment and chemical by any method, which can produce particular effect of color on the fabric according to the design. In this practical we print cotton fabric with cold brand reactive dyes in block and screen-printing methods in combination method. Block printing method is the oldest printing method. It is used mostly in sarees, handkerchiefs etc. in this printing method we use blocks of different designs. In screen printing a very little screen made by glass fibre is used. There are types of screen-printing, but we have done in our experiment was hand screen-printing.

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Style of printing:  Direct style. 

Method of printing:  Block and screen-printing method. 

Sample: 

One piece of square size bleached, scoured cotton fabric (small) and one piece of square size bleached, scoured cotton fabric (bigger) 

Recipe: 

Dyes = 4gm Urea = 10gm Thickener = 50gm Resist salt=1gm Soda ash=6gm Additional water = as required. 

Preparation of thickener: 

1) Starch and water are taken in bowl. 2) Heat is applied and solution is stirred continuously until a thick viscose solution is obtained. 

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3) By continuous stirring and boiling a specific viscosity is obtained. 4) The heat application is stopped otherwise viscosity falls down. So temperature is maintained strictly. 

Preparation of printing paste: 

1) At first we take required amount of dyestuffs in a bath. 2) Then little amount of water is added into the bath for mixing these dyes. And start stirring for mixing the three types of dye. 3) Then required amount of urea is added into the dye bath. 4) After then required amount of thickener is added 5) then continuous stirring is done for few minutes for mixing all the ingredients of print paste. 6) After mixing finally required amount of alkali is added to the dye bath and mix them with the help of stirring. 

Printing process: 

Block printing method: 

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1) The fabric which will be printed is placed on the printing table. 2) The printing paste is put on the tray box. 3) The block is selected and it is touched with print paste. 4) Then block is pressed upon the sample fabric. 5) After pressing the block on the sample fabric the block is put off from the fabric. 6) Finally we get the printed fabric of required dyes. 

Screen-printing method: 

1) The fabric is placed on the printing table of flat screen-printing machine. The table is made of soft by laying on it. 2) Then the screen is placed on the sample fabric. 3) The printing paste is taken on the screen perforation. 4) Thus we can find the printed fabric with a smooth wooden strike the paste is spread over the screen with slight pressure. 5) So that the dye particles can penetrate through the screen perforation. 6) Thus we get printed fabric. 

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After treatment:-

After getting printed fabric we put the fabric in the dryer for dry.

Machines in textile laboratory:-

1-Curring machine:

It is used for drying the fabric after fabric printing on fabric printing table. It contain the temperature of 150 to 170 degree centigrade.

2-Drying Machine:-

It is a machine used in textile laboratory, for drying the wet cotton. It contain 2 rollers. Pulleys, lever etc.

3-Stentor:-

A machine or apparatus for stretching or stentering fabrics. The purpose of the stenter machine is to bringing the length and width to pre determine dimensions and also

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for heat setting and it is used for applying finishing chemicals and also shade variation is adjusted. The main function of the stenter is to stretch the fabric widthwise and to recover the uniform width. The model present in textile laboratory is MS-001-TX.

Function of Stentor:-Heat setting is done by the stenter for fabric, synthetic and blended fabric.Width of the fabric is controlled by the stenter.Loop of the knit fabric is controlled.Moisture of the fabric is controlled by the stenter.Spirility controlled by the stenter.GSM of the fabric is controlled by Stenter.Fabric is dried by the stentering process.Shrinkage property of the fabric is controlled.Curing treatment for resin, water repellent fabric is done by the stenter.

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4-Screen Printing machine:-

A thin roller driven by a magnetic block rolling on the silk-screen, printing pressure is displayed digitally and adjustable. 

Application:-

Lab Magnetic Printer (Lab Printing Table)  

is magnetic printing machine with printing area, which is for technology experiment in various natural and synthetic fabric in lab.

5-Rota wash:-

Rota wash machines are capable of producing high quality wash, scrub and clean on all types of floor surfaces.

Washing machine:-

Specification:- ISO certified Model:- FOM71CLS High speed washing machine

Washing Machine:-

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Specification:- AATCC Standard

6-Crook meter:-

In order to determine the color fastness of dyed or printed textiles or leather, this test is used for the determination of color fastness against rubbing, either under dry or under wet conditions.

Specification:-

Model:-SDL Atlas

Features of Crock meter:-

To determine the Color Fastness of Textiles.The equipment consists of a counter.It is provided with a flat peg.It also consists of an operating handle.Tests the color fastness of the textile in a very accurate manner.

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It gives not only accurate but quick results also.

Working Principle of Crock meter:

1. The crock meter consists of a rigid flat metallic platform on which the test specimen can be held firmly and a abrading finger which rubs against it under a specified load. 

2. The platform is fixed over the base of the equipment and lies in a horizontal plane. 

3. The test specimen is held firmly over an abrasive paper which is pasted on the upper face of the platform, with the help of two pins holding it at both ends. 

4. The abrading finger has a flat circular rubbing face which is covered with 4 piece of white abradant fabric during the test. 

5. The abradant fabrics picks up color lost by the test specimen during rubbing. 

6. It is held over the finger with the help of a tapered ring.

7. Motion to the finger is given through a reciprocating arm with runs a two ball bearings to minimize friction and to apply a uniform load on the finger. 

8. The arm is moved by a manually operated crank and connecting line. The equipment is

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finished in dark metallic paint and bright chrome plating to give it a corrosion resistant finish.

OVEN:-

Oven is textile testing equipment used for heating and undertaking other oven dry tests in the laboratory for determining the effect of ageing on various physical properties of different materials.

Specification:-

Make:-SDL Atlas

Martindale pilling machine:-

The Martindale Abrasion and Pilling Tester is employed, throughout the world, for testing the abrasion resistance and pilling properties of textiles. You can choose from three differently sized models: Maxi- (9 stations), Midi- (5 stations) and Mini- (2 stations). Our Martindale exceeds the requirements of all known international standards and retailers' test methods.

Specification:-

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Model:-SDL Atlas

Serial no:-PT-001-TX

Formaldehyde test:- To check the formal aldehyde in the fabrics. Let we have 8 samples. We will take the distilled water of 100ml for each sample and 1 gram of sample of fabric of sample. Then cut these fabrics into small pieces after taking its weight. Put these small pieces of fabric in the 100ml of water in beaker. Then put these sample in the water bath at a temperature of 40 degree centigrade for one hour. Actually water bath contain the distilled water.

After one hour, take these samples outside from the water bath. The formaldehyde will come on the surface of these beakers. And leave these to cool. Then take 9 test tubes. One blank for zero reading. And take the 5ml of formaldehyde from each beaker of each sample and 5ml of Nash reagent in these 8 test tubes. And these 8 test tubes in the water bath for half hour at the temperature of 40 degree centigrade.

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After half hour, take these test tube outside from the water bath. And leave them to cool. After cooling these test tubes. We will check the wave length of these samples. Then take the average of these 8 samples.

Quality Control and Quality Management

Miss Iffat Zahra:-

Miss Iffat Zahra is the senior manager of QC.

Sir M Qasim:-

Sir Muhammad Qasim is the deputy manager of QC.

Sir Arif Qureshi:-

Sir Arif Qureshi is the shift chemist of QC.

Sir Waqas khan:-

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Sir Waqas is the shift chemist and ISO document controller of QC.

Sir Afzal:-

Sir Afzal is the shift chemist of QC.

QC:-

Introduction:- Quality control is a process that is used to ensure a certain level of quality in a product or service. It might include whatever actions a business deems necessary to provide for the control and verification of certain characteristics of a product or service. Most often, it involves thoroughly examining and testing the quality of products or the results of services. The basic goal of this process is to ensure that the products or services that are provided meet specific requirements and characteristics, such as being dependable, satisfactory, safe and fiscally sound.

Companies that engage in quality control typically have a team of workers who focus on testing a certain number of products or observing services being done. The products or services that are examined usually are chosen at random. The goal of the quality control team is to identify

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products or services that do not meet a company's specified standards of quality. If a problem is identified, the job of a quality control team or professional might involve stopping production or service until the problem has been corrected. Depending on the particular service or product as well as the type of problem identified, production or services might not cease entirely.

Steps:-

If the product is good after testing and inspecting, then we will give the company GRN (good receipt note), which means that their material is accepted.

If the material is accepted then we have 3 steps.

Step-1

Quality Insurance:-

In this step we will check the documentation of material.

COA: certificate of analysis. MSDS: Material Safety data sheet. TI: technical information. Ecological questions.

COA:-

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It stands for certificate of analysis. The function of this certificate is to check the detail of material which we buy from other company for usage.

MSDS:-

It stands or material safety data sheet. Its function is to provide safety of chemicals.

TI:-

It stands for technical information. Its function is to usage of product.

Step-2

In process testing:-

In this process, we take the sample of product from the reactors, and check their properties like PH. If it is not properly prepared then we will again inform to process the plant. And again check the properties of product again and again. Until the result comes.

Step-3

Finish good testing:-

In this step we will check the properties of final products.

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QM:-

Introduction:-

The function of QM is to maintain the documentation and quality as per defined standard.

Types of Management system:-

1-Quality management system (QMS)

Standard ISO 9001:2008 Quality of product.

2-Enviornmnet Management system (EMS)

Standard ISO 14001:2004 Safety of environment.

3-occupation Heath safety assessment series (OHSAS)

Standard ISO 18001:2007 Health and safety of workers who working

in the factory.

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EMS+OHSAS=IMF.

BASF have 2 certificates.

1-QMS:-Quality management system

2-IMS:-Integrated management system

Production DepartmentAdditive Area:-

In the plant, there are 5 additives means inputs or chemicals in liquor form which are being used in the plant for production. Now it depends upon us what we need to use. In the case of lack of additives in the tanks we fill these tank with the help of tankers. We make M.Amal by ourselves in the plant in case of lack of it. Each tank contain 25 tons.

The additives are: Ammonia (NH3) Caustic (NaOH) Diethyl Glycol (DEG) Formaldehyde M.Amal

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Tankform Area:-

Similarly like additives, there are three chemicals in liquor form in tankform area are used in the plant for production. These chemicals are filled by the same method through tankers in case of lack of chemical in the tank. These chemicals are:

Shellsol Styrene Butyl

Nitrogen tank:-

The plant contain the nitrogen tank in liquor form, with the tank an evaporator present which are heat exchanger and convert the nitrogen liquor into the gas form, which are used in the plant in case of need of nitrogen gas in the plant for production.

Reactor:-

An apparatus or structure in which fissile material can be made to undergo a

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controlled, self-sustaining nuclear reaction with the consequent release of energy.

The reactors in the plant are R-10,R-40,R-44,R-50,R-201,R-202,R-203,R-33A,R-34,R-25,R-13,R-14,R-23,R-24,R-35,R-36,R-37,R-39 .

Plant:

The plant is divided into 2 floors.

2nd floor:-Monomer vessel (R-13, R-33, R-35)

1st floor:-polymer vessel (R-14, R-24, R-36)

Ground floor:-Conditioning vessel (storage tanks 4, filtration area)

PLC:-

A programmable logic controller, PLC or programmable controller is a digital computer used for automation of typically industrial electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines.

In the BASF factory plant are controlled through PLC. All system is on auto and manual. Now it’s

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on operator of plant which are operating the whole system.

HMI:-

Human machine interface is the part of the machine that handles the human machine interaction. Membrane switches, rubber keypads and touchscreens are examples of that part of the Human Machine Interface which we can see and touch.

Industrial RelationsDefinition:-

The relations between management and workers in industry.

Sir Abbas:-

Sir Abbas is the tax officer in BASF.

FBR:-

FBR Stands for Federal Board of Revenue. Its function is;

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To identify the Withholding Agents;

To facilitate issuance of NTN (national tax number) to unregistered Withholding Agents in respective Regional Tax Office through Pakistan Revenue Automation Limited;

To assist FBR in developing an accounting policy for appropriation of the deduction to the Regional Tax Offices / Large Taxpayers Unit having jurisdiction over particular taxpayer(s);

To review and recommend suitable (automated) processes and filing structure of withholding statements that is compatible with income tax environment;

Collection of direct and indirect taxes.

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What is custom?

Custom is whatever things is being import (purchase) from foreign countries will have to go custom.

In 2011:-

Goods:-Federal government.

Services:-Provincial government

Every company has its own NTN number.

NTN:-National tax number.

FBR

Custom

Duties

Sales Tax

General Sales Tax @ 17%

Income Tax

WHTCorporate Tax

Federal Excise

One Time Levie

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SRTN:-It stands for sales tax registration number.

What is withholding?

A tax deducted at source, especially one levied by some countries on interest or dividends paid to a person resident outside that country.

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