Internship Report at Texeurope (BD) Ltd. by Azad

Industrial attachment report on Texeurop (BD) LTD

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CONTENTS

Chapter No. Topics Page No.

Chapter-I Project Description 01-08

Chapter-II Man power Management 09-13

Chapter-III Machine Description 14-47

Chapter-IV Raw Materials 48-54

Chapter-V

Production Planning Sequences

& Operations

55-66

Chapter-VI Quality Assurance System 67-81

Chapter-VII Maintenance 82-94

Chapter-VIII Utility services 95-102

Chapter-IX

Store & Inventory Control

103-106

Chapter-X Cost analysis 107-110

Chapter-XI Marketing activities 111-114

Chapter-XII Conclusion 115-117


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CHAPTER-I


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Texeurop (BD) LTD. an 100% export oriented composite knit textile unit

Established with the commitment to care the Global needs for knit and casual clothing. The project

has employed the State-of-Art technology in its very pieces of investments. Aiming at the context of

the changing Global demand pattern, international environment on trade specially the withdrawal of

quota system and GSP and the availability of craftsmanship in the country, the project encompassed

the knitting, dyeing and processing of fabrics and ready-made Garments production to be available

from one stop service.

The project is a new one established in 2004 if compared the with other well established textile

factory, but the manpower engaged in the projects to carry out the day to day business are all highly

skilled, purely professional, vastly experienced. The unique combination of organized Managerial

and Technical term in one hand and latest, advanced and balanced technology on the other hand

made the project one of the top to be referred in this field in the country. The best use of continuous

development of Human Resources by providing them International Standard Environment and equal

opportunity is the keys for achieving comprehensive competence in all the level Organizational

Hierarchy.

Texeurop (BD) LTD. has been established with the objective and vision to cater the needs of 21st

century of world wide knit apparels markets from one stop service being committed to One-time

Delivery, Quality Assurance, Price Affordability and Social Accountability.

The project is located in Vogra, Joydebpur under the district of Gazipur, about 37 km distance from

the International Airport Dhaka, Bangladesh. A well developed Road Communication is there to

reach the factory from the Airport as well as from the Dhaka City. The head office of the project is

Located in the heart of Dhaka City in Tejgoan Industrial Area.

TEXEUROP (BD) LTD. AT GLANCE Name of the project: TEXEUROP (BD) LTD.

Type: Composite knit fabrics & garments (with dyeing & finishing) mill.

(100% export oriented industry).

Status: Private Ltd. company

Year of establishment: 2004.

Location:


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Location Of Texeurop (BD) Ltd

Address:

Factory & Corporate Office:

Vogra, Joydebpur

Gazipur, Bangladesh.

Tel: +880-2-9261986, 9261988,9261993,9262163-4,9262701-2, Fax: +880-2-9261582 Website:www.texeuropbangladesh.com E-mail: [email protected]

Sponsors: Texeurop (BD) Ltd is a joint venture company in which there are four partners.

* Chairman : Mr Eric sauvage

* Managing director : Md Abdul majid khan

* Director : Md Ibrahim khalil

* Director : Md Mhafuzul haque

*A major portion of project cost is financed by Dutch –Bangla Bank ltd.


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PRODUCT MIX:

a) Knitted grey fabrics : Plain single jersey, Heavy Jersey, Polo Pique, Lacoste, Rib

&Interlock double jersey , Drop needle, 2/3 Thread fleece(Brushed/ Un-brushed), Collar &

cuff etc.

-100%Cotton

-100%Polyester

-Grey mélange (15% viscose + 85% cotton,

30% viscose + 70% cotton

10% viscose + 90% cotton 1% viscose + 99% cotton) -Cheap value of cotton -Polyester-Cotton blends.

b) Knit Garments: T-shirt, Polo shirt, Sweat shirt, Golf shirt, Cardigan, Jogging suit,

Short/Trouser, Legging, Fashion dress & Children wears etc.

PRODUCTION CAPACITY:

Knitting Section: 3-4 tons/day ..

Dyeing Section: 25 tons/day

Garments Section: 20,000 pcs/day.

Final products name: T-Shirts, Polo Shirts, Ladies Wear, Sports Wear, Tank Tops, Kids Wear, Jog suits,

Reversible garments.

Project cost: TK. 67 corers (approx.)

History of the project development:

Texeurop (BD) Ltd. has been established with the objective and vision to satisfy the needs

of 21st century of world wide knit apparels markets from one stop service being committed

to One-time Delivery, Quality Assurance, Price Affordability and Social Accountability.

Basically Pantex garments factory was the mother textile at Narayangonj of Texeurop

(BD) Ltd. from which the factory was expanded with collaboration of European partner.


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The project is located in vogra joydevpur under the district of Gazipur, about 25 km distance

from the International Airport Dhaka, Bangladesh. A well developed Road Communication

is there to reach the factory from the Airport as well as from the Dhaka City

Different departments:

a) KNITTING SECTION:

Knitting

Inspection

b) DYEING SECTION:

Batch section

Dye house

Dyeing lab.

Quality control

Finishing

c) GARMENTS SECTION:

Merchandising

Sample

d) MAINTENANCE SECTION:

Electrical

Mechanical

e) STORE SECTION

Supporting Departments:

a) Personnel administration

b) HRD

c) Marketing

d) Procurement

e) Finance and accounting

f) Security department


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Major Customer/Buyer:

a) JC Penny

b) Walmart

c) H & M

d) Teba group

e) Vertbaudet

g) Pierre Cardin

h) Obaibi

i) LPP

j) S.Oliver

k) Okaidi

l) Gerry Weaber

m) Street one


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Physical Infrastructure:

The mill is built in such a way that there is possibility for further expansion

of the mill. The structure such as mill, office buildings, record rooms,

guardrooms & dining room etc. are made of solid hard concrete & brick mtls. .

The whole area is surrounded by safety brick wall .The main set up for m/c’s

are built of corrugated iron & iron sheet, transparent hard plastics with enough

ventilation & scope for passing light & air.

Total area of the industry : 12500 sq Meter

Factory land area : 10000 sq. Meter

Building : 8 Storied.

Floor space (Knitting) :5000 SFT

Floor space (Dyeing &Finishing) : 20,000 SFT

REMARKS:

Texeurop (BD) Ltd. Is a Modern textile industry. Every facility of a modern

textile mill exists in this factory. It has a no. of renowned buyers especially at

Europe. So Texeurop (BD) Ltd. is getting popular throughout the Textile

sectors and its buyers. This Factory has a good communication system from the

capital city Dhaka.


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Chapter-II


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Organ gram of Manpower:

Chairman

Managing director

Director (admin) Director (production)

Administration:

(Administration)

Manager Manager Manager

(CRD) (Account) (Store)

Account Officer Store keeper

Asst. Accountant Asst. Store keeper

Helper

H R officer Compliance Officer IT executive

Director

(Administration)


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Production:

Director (Production)

AGM Manager Manager Manager Manager

(Garments) (Dyeing) (Knitting) Maintenance) (Merchandising)

Cutting/ Asst. Manager Asst. Manager Asst. Manager Sr. Merchand-

Sewing ising

P.O. Knitting master Main. Officer Jr.Merchand.

Supervisor Supervisor Supervisor Supervisor Supervisor

Operator Operator Operator Operator Operator

Helper Helper Helper Helper Helper

Management System:

Intercom telephone

Fax

Written letters &

Oral


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SHIFT CHANGE: There are three shifts in this factory and each shift is of eight hours. Shift is

changed after a week on Saturday.

Shift Change/ for worker of Security:

A Shift – 07:00 – 15:00

B Shift – 15:00 – 23:00

C Shift – 23:00 – 07:00

General shift :

10:00 – 19:00

Office Time

10:00 – 19:00

RESPONSIBILITIES OF PRODUCTION OFFICER:

From getting an order of upper level all responsibilities are on the production

officers. They work with a troop of operators, helpers, fitters etc. to finish the production in

due time. In the meantime production officers bear all hazards, problems. They have to

explain to the manager for any type of production hamper. So, all production activities and

its success depend on the production officers.

Job Allignment of P.O & S.P.O:

Job title: Production officer & Senior Production officer

Report to: Production Manager

Purpose:

To control shift according to the plan made by the production manager

Territory: Dyeing section (major)

Batching and Finishing section (minor)

Nature and Scope:

Role within the organization:

Responsible for own shift production with good quality and minimum time.

Environment:

Production officer has to work under huge stress. He has to work in acute heat

under physical and mental pressure. Also he has to work in acute heat all the year round.


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Job Description of Production Officer:

Report To: Sr. production officer

Job Summary: To plan, execute & follows up the production activities & control

the quality production with related activities.

Duties & Responsibilities:

Overall supervision of dyeing, finishing production.

Batch preparation & PH check.

Dyes & chemical requisition issue & check.

Write fabrics loading & loading time from m/c.

Program making, sample checking, color management.

Control the supervisors, operator, asst. operator & helpers of dyeing m/c.

And also any other work as & when required by the management.

Job Description of Sr. Production Officer:

Report To: P.M (production)

Job Summary:

To plan, execute & follows up the production activities & control the quality production

with related activities.

Duties & Responsibilities:

Overall supervision of dyeing, finishing production.

Checks the different log books of different areas & report to management.

Checks the sensitive parameters of different machine for smooth dyeing.

Checks out the plan to control the best output from supervisor & workers.

To trained up & motive the subordinates how to improve the quality production.

Maintenance of machine & equipment. Any other works & when required by the

management.

Control the supervisors, operator, asst. operator & helpers of dyeing m/c.

REMARKS:

Production runs with the help of mechanical fitters. For any kind of mechanical

fault of any machine they fix and work under technical in-charge. Production officers’ takes

account of daily production by running after the two supervisors and workers so on.


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Chapter-III


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Introduction: Texeurop (BD) LTD. is an integrated computerized company. It has total 20 dyeing

machines among of them 10 machines are known as sample dyeing machine on the basis of

their production capacity. The machines are controlled by high skilled operators. On the

other hand Knitting section contains 18 machines, among of them 13 are circular knitting

machine and another 5 are flat bed machines.

Knitting Section Process requirements: In Texeurop (BD) Ltd. three types of machines are used for producing and

inspecting knitted fabrics.

These are:-

1) Circular knitting machine (Single& Double Jersey Machine).

2) Flat knitting Machine (Cuff & Collar).

3) Fabric inspection machine

And the whole knitting section is devided in four sections,

1. Circular knitting section

2. Flat knitting section

3. Fabric inspection section

4. Store section

Total no of machine at a glance:

1.Circular Knitting Section:

This section contains 13 circular knitting machines. Circular knitting machines are

of different types, made by different manufacturer and also have different specifications. In

this section body fabric for knitted garments is produced. The different specifications of

different machines are given one after another

M/c type Total no of machine Ground total

Single jersey 05

18 Rib 04

Fleece 04

Flat bed 05


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Specification of circular knitting machine:

M/c no Brand of

machine

Origin

of

machine

M/c type Dia(inch) Gauge No of

needle

No of

feeder

01 JIUNN

LONG

Taiwan Rib 36 18 2040*2 72

02 JIUNN

LONG

Taiwan Rib 34 18 1920*2 68

03 JIUNN

LONG

Taiwan Rib 34 18 1920*2 68

04 JIUNN

LONG

Taiwan Rib 32 18 1800*2 62

05 JIUNN

LONG

Taiwan Single

jersey

23 24 1740 69

06 JIUNN

LONG

Taiwan Single

jersey

24 24 1812 72

07 JIUNN

LONG

Taiwan Single

jersey

25 24 1872 75

08 JIUNN

LONG

Taiwan Single

jersey

28 24 2112 84

09 JIUNN

LONG

Taiwan Single

jersey

30 24 2256 90

10 GOANG

LIH

Taiwan Fleece 36 20 2256 102

11 GOANG

LIH


12 GOANG

LIH


13 GOANG

LIH


2. Flat Knitting Section:

Generally collar, cuff of knitted garments is produced in this section. In this section

there are 5 flat knitting machines, all of them are same type and also have same

specification. The specification of all machines is given below.


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Specification of flat knitting machine:

Serial no M/c brand Country of

origin

Maximum

width

M/c type M/c

gauge

No of

feeder

01 JIUNN LONG TAIWAN 152 V-Bed 14 8





3. Cloth Inspection Section:

In cloth inspection section one machines is available. Specification of this

machines is given below.

Type

Cloth Inspection Machine

Manufacturer name Uzu fabric Inspection

Country Thailand

Model No. UZ 900.31

List of Machines

Department Machine type No. of machine

Grey Fabric Store & inspection Fabric inspection m/c 1

Batching Turning m/c 02

Overlock m/c 03

Dyeing floor

Winch dyeing m/c

(Environmental ) 16

Winch dyeing m/c (High

Pressure) 4

Dark Room

Light Box 03

LaB Dip Machine 03

Electric Pipet 02

Electric Balance 02


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Lab

Spectrophotometer(Data Color) 01

Computer 01

Printer 01

Philips Hot Iron 01

Washing Machine 01

Tumble Dryer 03

GSM Cutter 03

Crock meter(wet & dry Rub) 01

pH Meter 01

Dryer 01

Washing Section

Washing Machine 07

HydroExtractor 01

Tumble Dryer 03

Finishing Section

Hydroextractor 01

Sqeezer 01

Slitting & Dewatering m/c 02

Dryer(tube) 01

Tube Compactor 01

Open Compactor 02

Stenter 01

Stenter(Mahlo) 01

Caleder 01

Brushing m/c 01

Suiding Machine 01


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DYEING SECTION:

Specification of Different Machines:

Dyeing Machine Fongs-01, 02, 03, 04:

Type Small production Dyeing Machine

Name Jet Dyeing Machine

Manufacturer name FONG’S

Country HONGKONG

Temp. Range 00-1400C

Used Utilities Water, Steam, Electricity, Compressed Air

No. of Nozzle 1, 1, 1, 1

Production Capacity 10 Kg, 60 Kg, 120 Kg, 280 Kg

Winch speed 250-300 m/min

Dyeing Machine Fongs-05

Name Dyeing Machine

Type Jet Dyeing Machine


Country HONGKONG

Model No. ECO-38-1T



No. of Motor 7

No. of Nozzle 1

Production Capacity 150 Kg


Name Dyeing Machine



Country HONGKONG

Model No. HSJ-2T



No. of Motor 7

No. of Nozzle 1



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Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-6T



No. of Motor 8

No. of Nozzle 6



Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-8T



No. of Motor 8

No. of Nozzle 8

Production Capacity 2000 K


Name Dyeing Machine

Type HT/HP Dyeing Machine


Country HONGKONG

Model No. HSJ-4T



No. of Motor 13

No. of Nozzle 4



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Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-6T



No. of Motor 8

No. of Nozzle 6



Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-2T

Year of manufacturing 2003



No. of Motor 8

No. of Nozzle 2



Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-4T




No. of Motor 8

No. of Nozzle 4



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Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-4T




No. of Motor 8

No. of Nozzle 4


Sample Dyeing Machine Fongs-14

Name Dyeing Machine



Country HONGKONG

Model No. ECO-38-3T



No. of Motor 8

No. of Nozzle 4


Dyeing Machine-15

Name Dyeing Machine

Type HT/HP Dyeing Machine


Country HONGKONG

Model No. GN-6-2T



No. of Motor 13

No. of Nozzle 4



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Dyeing Machine Fongs-16, 17, 18, 19, 20 :

Type Sample Dyeing Machine

Name Jet Dyeing Machine


Country HONGKONG



No. of Nozzle 1, 1, 1, 1, 1

Production Capacity 30 Kg, 30 Kg, 10 Kg, 10 Kg, 10 Kg

Different Finishing Machinery

01.Hydroextractor m/c:

Model: Local.

rpm: 700-746(max).

extraction% : 60%(apprx.)

Use: Loose structure fabric like rib, interlock etc.

Fig-1 : Hydroextractor m/c

02.Slitting m/c:

Function:

To cut the tubular fabric for opening.

To check the fabric fault.

Rubber pressure roller removes a slight amount of water.

Softener can be at the tank.

Utility Used: Air, Water, Electricity.

Main points:

o Speed : 100 m/min.


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o For single jersey fabric line speed is maintained as 5 m/min.

o For other fabric line speed is maintained as 1 m/min.

o Production capacity: 7 tons/day

Fig-2: Slitting m/c

03.Open squeezer:

Main parts:

Squeeze roller(dewatering)

Over feeding roller(to delivers as per feed)

Folding device(to delivers the fabric in folded form)

Softener tray.(to impart soft finish)

Utilities used: Electricity.

Compressed air.

Padder pressure: 4.5-5 bar.

04.Squeezer:

Main parts : Revolving platform.

J-box squeezer.

Detwisting unit.

Stretching unit(for adjusting dia)

1st tank to remove dust, hairy fiber etc.

Over feed system.

2nd tank to apply different chemical finishes like flame retardant, softener, fixer.

Speed: 80 m/min(max)

Pressure of 1st padder : 3

Pressure of 2nd padder : 4-5

Water extraction%: 36-40%


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Fig-3:Squeezer

05.Dryer m/c:

Function: To dry the fabric properly.

To dry the fabric without tension.

To gain the finished GSM.

Specially used for lycra, piping, twill tape, Rib collar.

Main parts:

1.Heat chamber.(3)

2.Burner.(3)

3.Blower.(6)

4.Exhaust fan.

5.Synthetic blanket.

6.Folding device.

Utility used:

Steam

Electricity.

Steam pressure: 5.5 Kg/sq.cm(78 psi) at 155C.

Speed: 45 m/min(max)

Blower Speed: 230 rpm(max)

Fig-4:Dryer m/c


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Setting according to fabric construction:

Fabric type Speed

(m/min) Temperature(C)

Overfeed

speed(%)

Single jersey 14-16 140 20

Interlock 10 140 25-30

Rib 12-13(220 gsm),

9-10(250 gsm)

140

150

15-20

14-16

T/C,P/C,Viscose 20-23 130 20-25

Lacoste 30 140 20-25

Collar 12 160 20-25

Lycra fabric 17 130 15-20

O6.Tube Compactor :

Functions: To minimize the shrinkage.

Overfeed given to achieve the finished gsm.

Hairy Fibers can be removed to improve the handle.

Spirality & Boeing can be minimized. Features:

Maximum line speed :100 m/min.

Maximum dia. :62".

G.S.M : Maximum 20% increase after compacting.

Shrinkage : ±5%(max)

M/c temperature :95.

Production capacity :7 tons per day.

Utility used: :

Gas.

Electricity.

Steam.

Sensor position: On the stretcher.

After compacting unit.

On the conveyor.


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Fig-5:Tube Compactor

07.Stenter m/c (4 chamber):

For Lycra fabric Heat setting is available only.

Width is set in such a way so that it gives the required GSM & shrinkage.

Suitable for open compactor.

Course and wales become align and even distribution by Mahlo in the feed

side i.e to minimize Bais & Boeing problem.

For Rib Fabric blower speed is less due to its loose structure.

8 burner, 4 chamber, 8 blower.

In case of heavy fabric temp 210C and for light fabric it is 180-190C . Maximum width is not used because pin penetration is difficult and chains are

locked.

Over feed speed is maintained as per delivery speed so that it can give the

desired quality.

Temperature control depends on shade condition.

In every chamber fabric width should be same.

Glue is used along the selvedge to prevent curling.

Two set of padders with tank are used to apply chemical finishes &

squeezing.

Padder pressure must be controlled carefully.

Controlling points:

Fabric speed.

Fabric width.

Temperature.

Over feeding speed. Utility used:

o Gas.

o Electricity.

o Steam.


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Settings: Fabric type Over feeding

(%) Temperature (C) Speed

(m/min)

Blower

Speed Single jersey 65% 140-150 20-30 60

Rib 50% 170-190 20-30 35-45

Interlock 55% 160-170 20-30 40-45

Lacoste 50% 145-150 20-30 45-55

T.C 60% 190 20-30 40-50

P.K. 50% 140-150 20-30 50

**For heat-setting overfeed % is kept 20%.

**For heat-setting temp. is kept 180-185ċ.

**Overfeed%: Fabric tension Shrinkage GSM .

Fig-6: Stenter m/c (4 chamber):

08. Open compactor :

Functions: To impart dimensional stability.

To provide better cohesion.

To obtain required width and G.S.M.

Main parts: o Heated cylinder(steam)

o Steaming device.

o Blanket.

o Teflon roller.

o Sensor.

o Overfeed %: upto 50%.

o Steam pressure: 5-6 bar.

Machine Specification:

Brand name: Ferraro

Type/model no: COMPTEX-RE 2800.

Company: Italy

No of motor: 08

Over feed = 35%


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Machine speed =80 m/min

Speed range: 30-40m/min

Termperature range: 100-1500C

Maximum width 86

Minimum width 36

Applied for: Open fabric

Left over feed: -20%+20%

Right over feed: -20%+60%

High production: -20%+60%

Front over feeding cylinder: -20%+60%

Production Capacity :24 tons/d

Special finishing machine

Sueding

A sueder is sometimes referred to a s a sander since the machine consists of one or more

rolls covered with sand paper as the abrasive. Fabrics traveling over these rolls develop a

very low pile and the material's surface can be made to feel like suede leather. The hand will

depend on the fiber composition, the filament count in the yarn and the intensity with which

the fabric is worked.

Filament fabrics can be made to feel like a spun fabric and all fabrics will have a softer hand.

It also known as pitch finish or carbon finish.

Tasks:

To develop soft feeling at the face side.

To increase the aesthetic properties on the garments

To provide warm feeling to the garments.

Sueding M/C :

M/C quantity : 01

Brand :Unitech- Santalucia

Model: 10 GS X 1952

Origin-Italy

Voltage - 400 V

Normal Current - 96 amp.

No of Pile :03

No of Counter-Pile :03

Setting Point :

Taker -in- Tension (14 K/g)

Drum Tension (47 K/g)


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Fabric Return Tension (15 K/g)

Plaiter Tension (14 K/g)

R.p.m of drum (22) Production capacity:15 tons/day

Fig-7:Sueding M/C :

Raising m/c:

Raising is a permanent mechanical finishing process of lifting a layer of fibers from the body

of the fabric which stand out from the surface. Raising is most commonly done for Fleece

fabric.

Tasks:

o To provide warm and smooth feeling.

o To satisfy the buyer needs like heavy, medium & light brushing.

o To produce a heavier surface made of fibers.

Machine specification:

Brand name: I KVANG M/C Works Ltd.

Type/model no: RG2-200

Country: Taiwan

No of motor: 04

No of pile roller: 35

Speed of main drum: 50 rpm

Manpower Required: Worker: 05

Production Capacity: 2 tones/day

Actual production: 1.5 tones/day

Utility: Electricity, Compressed air


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Fig-8:Raising m/c

REMARKS:

Texeurop (BD) Ltd. has different type of dyeing machines for small to large scale

production. As the quality of the machineries of dyeing, finishing & testing section are good,

so the quality level of the product is also good. The machines are controlled by skilled and

experienced operators. The machines are erected at the dyeing floor at two rows at a well

planned manner that facilitates loading and unloading of the fabric on the machines.


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Garments section: Here the machines are categorized by the concerned section.these are section of the

TEXEUROP BD Ltd garments section.

Sample section

Cutting section

Sewing section

Finishing section

Sample Section

Cad room : Cad room has the following machine-

Dizit board-copy the handmarking pattern

Fig- 9 :digitizing board

Printer-1.consumption(mini rint

2.plotter(big print)


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Fig-10:Plotter machine

Pattern cutter machine :

Brand: Winda

Fig-11: Pattern cutter machine

Software:

1.madarite software(for design+parts+grading)


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2.diamino software(for marker making)

SL

NO

MACHINE TYPE NO OF

MACHINE

DESCRIPTION

O1 PAIN MACHINE(LOCK STITCH) 57 1 NEEDLE

02 OVERLOCK MACHINE 27 4 THREAD(2 NEEDLE,2

LOOPER)

03 FLAT LOCK MACHINE 22 3,4,5 THREAD

04 BUTTON HOLE MACHINE 1 1 NEEDLE

05 BUTTON ATTACHING MACHINE 1 1 NEEDLE

06 BARTACT MACHINE 1 1 NEEDLE

07 SNAP MACHINE 1

08 PREQUITTING MACHINE 2 2/4 NEEDLE

09 RIB CUTTING MACHINE 1

10 FEED OF THE ARM 1

11 KANSAI SPECIAL(CHAIN STITCH) 2 SPECIAL

12 KANSAI SPECIAL(BACK TAP) 1 SPECIAL

13 KANSAI SPECIAL(SMOKE

MACHINE)

7 SPECIAL

=124

Cutting section In cutting section following machines are use-

1. Cutting m/c

Completely manual: Hand operated scissor.

Manually operated powered knife:

i. Straight knife

ii. Band knife

Computerized cutting machine:

i. Vector fashion mx-latest

ii. Vector fashion 7000

2. Spreading machine

i. Brio 1000(no of machine 4)

ii. Konsan (no of machine 1)

Equipments in cutting section

Cutting table

Perforated paper

Marker

Auto sticking m/c

Gsm tester

a) Gsm cutter


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b) Electric balance

Machine secificaion: Vector pilot mix

No of machine -1

Origin : France

Section: 3 (spreading-cutting-unloading)

Table size: width=86’’ length=1152

Marker size: width=72 length=144

Fabric width= marker width+(1-2)’’

Latest machine

Working procedure:

Section: 3(spreading cutting unloading)

Software set up in computer monitor

Area set up

Cutting

Knife specification:

Tools to be used : 2.4 * 8.5 blade(thickness* width)

Speed: 30 m/min

Acceleration : 3 m/s2

Vibration: 5000-5500 turns/min

Machine requirements:

m/c power supply-electric voltage-440v

knife pneumatic supply -6 bar

vector fashion 7000 No of machine-1

origin:france

section:3(spreading-cutting-unloading)

table size:width=82’’ length=1140

marker size:width=70’’ length=128

fabric width=marker width+(1-2)”

conventional than Vector pilot mix m/c

straight knife: No of machine-2

Company:BLUISTER

Knife length:8’’ & 10’’

Knife width: 2cm

Knife thickness: 0.1cm

Cutting height: 4 (standard)

In this m/c, m/c is movable but fabric is fixed

Suitable for cutting large garments parts


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Fig-12 : straight knife

Band knife : No of machine-2

Model: max-700A

Voltage:220V

Knife length: endless

Knife width: 0.5cm

Knife thickness: .02cm

G.W: 295 kg

N.W: 230 kg

Origin: China

In this m/c, m/c is movable but fabric is fixed

Suitable for cutting small garment parts,round shape etc.

No of motor: 2

1 for perforated bed for easy cutting

Another for m/c running


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Fig-13 : Band knife

Sewing section

List of machinaries

SL SWEING MACHINE QUANTITY BRAND 1 1-NEEDLE LOCKSTITCH 551 JUKI,BROTHER,SUNSTAR,PUFF 2 1-NEEDLE CHAIN STITCH 25 JOJE,FEIYUE 3 VERTICAL TRIMMER 50 JUKI,SUNSTAR 4 2-NEEDLE LOCKSTITCH 22 SUNSTAR 5 2-NEEDLE CHAIN STITCH 50 KANSAI, JOJE,FEIYUE 6 MULTI NEEDLE CHAIN STITCH 46 KANSAI 7 4-THREAD OVERLOCK (WITH

ELECTRICAL CHAIN CUTTER) 451 JUKI,PEGASUS,KANSAI

8 2-NEEDLE PIPING (BACKTAPE) 25 PEGASUS,KANSAI 9 2/3-NEEDLE COVERING STITCH

(FLATLOCK)

461 JUKI,PEGASUS,KANSAI

10 ZIG-ZAG MACHINE 10 JUKI,SUNSTAR 11 BARTACK MACHINE 110 JUKI,BROTHER,SUNSTAR 12 BUTTON HOLE MACHINE 63 JUKI,BROTHER 13 BUTTON SWING MACHINE 65 JUKI,BROTHER 14 SMOCKING MACHINE(12 & 33

NEEDLE)

15 KANSAI

15 PICO TING MACHINE 11 KANSAI 16 RIB CUTTING MACHINE 31 IDEA,IU-922 17 BLIND STITCH(OVERLOCK) 58 PEGUSUS 18 SNAP BUTTON 33 NYTO,UZU,MAX 19 FUSING MACHINE 15 HASHIMA Grand Total=2948


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CHAIN STITCH MACHINE:

Description:

The machine comes with a thread spreading mechanism and an adjustable needle guard to prevent stitch skipping. The thread clamp mechanism, tension release mechanism and needle thread draw-out mechanism enable the machine to leave thread of a uniform length after thread trimming, and prevent slip-off of the needle thread. All of these mechanisms contribute to upgraded sewing.

Fig-14 : Chain stitch Machine

Model Name MH481

Maximum sewing speed 5500st/min

Stitch length 1-4mm

Pressure foot By knee 4mm

Needle TV×7


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LOCK STITCH MACHINE:

Description:

The thread take-up mechanism ,feedmechanism,thread paths and hook have been further improved to enhanced responsiveness to material changes & ensure stitch quality

Fig-15 : Lock stitch Machine

Model name DDL-8300N

Max. sewing speed 5500sti/min

Max. stitch length 5mm

Needle DB×1

BUTTON HOLLING MACHINE:

The LBH-1790A Series follows the world's highest sewing speed and dry-head mechanism of its predecessor model. In addition, this machine comes with the latest model operation panel which is installed with a USB port. Furthermore, all drive mechanisms have been digitalized to manage each sewing pattern individually.

Model name LBH-1790A

Max. sewing speed 3,600sti/min

Number of stitches 54～345 (by gear-change method)

Buttonhole length 6.4～38.1mm

Needle DP×5 #11J, 134 Nm75


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Fig-16:Button Holling Machine

BUTTON SEWING MACHINE

LK-1903B Series

The machine achieves sewing speed of 2,700sti/min. The machine's starting, stopping, thread-trimming and automatic presser lifting speeds have been increased to significantly shorten total cycle time.

Fig-17: Button sewing Machine


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FEED-OF-THE-ARM MACHINE

Description:

The thread guide located between the needle bar thread take-up and the intermediate tension release lever, the timing to tense the needle thread can be decreased. As a result, the machine is capable of beautiful stitches with a soft appearance even when heavy-weight material issued.

Fig-18:Feed Of The Arm Machine

Model name LK-1903B


Number of stitches 8, 16, and 32 stitches

Feed length (crosswise feed) 2.5～6.5mm

Stitching shape

Applicable button Shank button, Wrapped-around button, Snap,Label, Metal button, Stay button

Button size φ10～28mm

Needle TQ×1 (#16) #14～20


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BARTACKING MACHINE: LK-1850 series The machine is provided with a material-drawing mechanism which draws the right and left parallel portions of an eyelet buttonhole near to one another. The machine performs bartacking with the right and left parallel portions of the eyelet buttonhole drawn near to one another after the buttonhole is clamped under the work clamp foot, thereby finishing highly durable and well-tensed eyelet buttonholes

Fig-19:Bartaking Machine

Model name LK-1850


Lift of the work clamp Max. 17mm

Needle DP×5

Model name MS-1190


Needle gauge 3.2mm (1/8")～6.4mm (1/4")

Stitch length 1.2～3.2mm

Needle TV×64-NY (#12)


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OVERLOCK MACHINE:

MO-6700 series Since the machine comes with a needle-thread take-up mechanism as well as a looper thread take-up mechanism, to offer upgraded responsiveness from light- to heavy-weight materials with a lower applied tension.

Fig-20:Overlock Machine

Model Name

MO-6700

Types 3, 4 & 5 threads

Stitch Per Minute (SPM)

6500-8500

Stitch Class

500

Group

Chain stitch

Seam class

Super imposed

TPI

15-16 (3 thread), 17-18 (4 thread) 21-22 (5 thread)

Needle no

1 needle, 2 loopers (3 Thread); 2 needles, 2 loopers (4 Thread) 2 needles, 3 loopers (5 Thread)


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KANSAI MACHINE (FLATLOCK):

Fig-21:Kansai Machine(Flatlock)

Place of Origin Japan

Brand Name KANSAI

Model Number DFB1404PSF

Type Industrial Sewing Machine

Stitch Formation Chain Stitch

Mechanical Configuration Flat-Bed

Max. Sewing Speed 4500spm

Max. Sewing Thickness 8mm

Stitch Length 3/16-3/4-3/16

Kansai Japan


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FLAT LOCK MACHINE:

Fig-22: Flat lock Machine

Brand Name

Pegasus W600 Yamata

Stitch formation

Chain Stitch

ELECTRIC SNAP FIXING MACHINE:

Suitable for punch snap on garment

Easy to change mould Main shaft lubricated

Operated by motor

Moving pulley enclosed with bearing


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46 P a g e

Fig-23: Electric snap fixing Machine

Needle group & size :

MACHINE NAME TYPE OF NEEDLE NEEDLE SIZE

PLAIN M/C DB#1 9,10,11,12,13,14 OVER LOCK M/C DC#1/27 7,8,9,10,11

DOUBLE NEDLE M/C DP#5 9,10,11,12,13,14 FLAT LOCK DP#128 9,10,11,12,13,14

BUTTON HOLE DP#5 9,10,11,12,13,14 BUTTON ATTACHING

(AUTO) DP#17 10,11,12,13,14

BARTACK DP#5 10,11,12,13,14 SMOKING DV#57 10,11,12,13,14

BACK TAPE MACHINE UY#128 10,11,12,13,14 PICOTING MACHINE UO#163 10,11,12,13,14

CHAIN STITCH DY#128 10,11,12,13,14 EMBROIDERY DB#1 9,10,11

Uses of Machines: Plain m/c: All types of Woven fabric stitching. Over lock m/c: All types of sewing of light and heavy fabric garments for edge neating and side

joining. Double needle m/c: All types of sewing of heavy and light weight fabric garments. Flat lock m/c: All types of sewing of heavy and light fabric garments specially for hemming and

decorative purpose. Button hole m/c: All types of sewing of heavy and light fabric garments for button holing. Button attaching m/c: All types of sewing of heavy and light fabric garments for button attaching. Bartack m/c: All types of sewing of heavy and light fabric garments.Specially in the seam joining

area,belt loop trouser.


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47 P a g e

Chain stitch: All types of sewing of heavy and light fabric garments. Blind stitch m/c: All types of sewing of light and heavy fabric garments hemming.

Machine brand:

MACHINE BRAND COUNTRY

SUNSTAR KOREA KANSAI SPECIAL JAPAN

JUKI JAPAN PEGASUS JAPAN BROTHER JAPAN

PUFF JAPAN

Finishing Section:

In finishing section following machines are use-

Sl no Finishing machine Quantity Brand 01 STEAM IRON 158 VEIT,SLIVER STAR,NISHO

02 VACCUM TABLE 148 VEIT,SLIVER STAR,NISHO

03 METAL DETECTOR 3 CINTEX

04 NEEDLE DETECTOR 12 CINTEX,HASHIMA

05 HAND METAL DETECTOR 5 KM,HASHIMA

06 STRAPPING MACHINE 2 TOYO

07 SPOT REMOVING

MACHINE

12 UZU

08 TAG ATTACHER MACHINE 6 ARTEKA

TOTAL 346

Remarks: Texeurop is a well planned factory.Everything which is necessary is available here is a well furnished

factory.


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Chapter – IV


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49 P a g e

Raw Material for Knitting Section:

As we know the raw materials for knitting is the yarn. Different types of yarn of wide range of count

are used for this purpose. In yarn store section we had the chance to know about different yarns of

different count used in Texeurop (BD) Ltd. knitting. We also have known different yarn

manufacturer/suppliers name for this knitting section i.e. sources of yarn. . There are different types

of yarns are used as raw materials in this factory. These are –

1.Cotton Yarn

Combed.

Carded.

2. Polyester yarn:

Normal.

Micro.

3. CVC.

4. Grey mélange.

5. Other mélange.

6. Spandex (Lycra).

7. Different types of colored yarns for Auto-striper.

PRICE OF RAW MATERIALS:

Price of yarn varies mill to mill and as different count. Here, we collect a price sheet of overall price

for all the spinning mills of home and abroad of different count from merchandizing section:

PRICE AND SOURCE OF RAW MATERIALS:

Yarn Types. Yarn

Count

Source of Yarn Price of

Yarn

100% Cotton, Combed. 40/s Shinha Tex $ 3.55/kg

100% Cotton, Carded. 40/s Rahmat Tex $ 2.90/kg

100%Cotton, Combed. 34/s Akij Tex $ 3.08/kg

100%Cotton, Carded. 34/s Shamim Tex $ 2.70/kg

100% Cotton, Carded. 32/s Shamim Tex $ 2.56/kg

100% Cotton, Carded. 30/s Akij Tex $ 2.55/kg


100%Cotton, Combed 30/s Keya Tex $ 3.00/kg


100% Cotton, Carded. 26/s Keya Tex $ 2.45/kg

100% Cotton, Carded. 24/s Akij Tex $ 2.45/kg


100%Cotton, Combed 20/s Keya Tex $ 2.90/kg

Grey mélange(85% Cotton

+15% viscose)

34/s Shamim Tex $ 3.05/kg

Grey mélange (”) 26/s Shamim Tex $ 2.85/kg

Spandex ( Lycra) 20/d Korea,Chine&Taiwan $ 08-18/kg


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50 P a g e

Other source of raw materials is as follows-

Jamuna Spg. Mill Ltd,

Paradise Spg. Mill Ltd

Utha Spg. Mill Ltd

Amber Spg. Mill Ltd

J.K Spg. Mill Ltd

Cotton concern Spg. Mill Ltd

Square Spg. Mill Ltd

Talha Spg. Mill Ltd

Viyellatex LTD.

Annual Requirement of Yarn:

This factory required 1200 to 1300 tons yarn per year.

Raw Material for Dyeing

Texeurop (BD) Ltd. is a knit composite textile industry. In this industry the raw materials

used for production of colored or white finished fabrics which are ready for the preparation

of garments are:

1. Grey fabrics

2. Dyes

3. Chemicals.

Grey Fabric:

According to Fibers:

100 % Cotton fabric

CVC fabric

PC fabric

Lycra twill fabric

Grey mélange. According to Fabric Structure:

o Single jersey

o Single jersey with lycra

o Polo pique

o Single & double lacoste

o Fleece

o Interlock & its derivatives

o Interlock with lycra

o Rib & its derivatives (1Χ1 Rib, 2Χ2 Rib)

o Rib with lycra

o Different types of collar & cuff

o Piping, Twill tape & other decorative accessories.


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51 P a g e

Grey Fabric Source:

Dyeing department of Texeurop (BD) Ltd. receive grey fabric from knitting department of

this company. According to buyer order, store officer receive the grey fabric and he

maintains the delivery of finished fabric.

Annual Requirements of Grey Fabric: Determination of annual requirements is very

tough. It mainly depends on the buyer order and subcontract order. When the buyer order is

large then the consumption is high and vice-versa.The annual requirements of grey fabric

depend on the buyer order and the requirements of dyes and chemicals depend on the colour

depth.

Dyes: Following are the dyes that are used for the coloration of the Scoured & Bleached

Fabric. The Dyes are listed below:

SL

No Trade Name Source Origin Dyestuff

Type

Price Tk/Kg

1 Reactobond Blue RR Meghmani Dyes And Intermediates

Ltd.

India Reactive 718.87

2 Reactobond Red RR Meghmani Dyes And Intermediates

Ltd


3 Reactobond Yellow RR Meghmani Dyes And Intermediates

Ltd


4 Remazol Blue RR Dystar Singapore Reactive 829 5 Remazol Red RR Dystar Singapore Reactive 738.45 6 Remazol Yellow RR Dystar Singapore Reactive 1090 7 Imcozine Blue E-NR Impocolor Germany Reactive 2101 8 Imcozine Red E-3BF Impocolor Germany Reactive 800 9 Imcozine Yellow E-3R Impocolor Germany Reactive 822 10 Indofix/Reactive N Blue

ME-GL

Perfect Dye-Chem India Reactive 364

11 Indofix/Reactive Yellow

ME4GL

Perfect Dye-Chem India Reactive 485.85

12 Reactive Orange ME-

2RL


13 Reactive Black HFGR Perfect Dye-Chem India Reactive 412 14 Reactive Red ME4BL Perfect Dye-Chem India Reactive 315.45 15 Reactive G.Yellow

MERL


16 Reactive Black B Perfect Dye-Chem India Reactive 550 17 Parfix Black WNN Perfect Dye-Chem India Reactive 350.35 18 Drimarine Yellow CL2R Clariant Switzerland Reactive 2500 19 Drimarine Red CL5B Clariant Switzerland Reactive 750 20 Drimarine Yellow CL2R Clariant Switzerland Reactive 750 21 Drimarine Yellow HFR Clariant Switzerland Reactive 2400 22 Drimarine Navy CLB Clariant Switzerland Reactive 1200 23 Drimarine Blue Turquis

CLB

Clariant Switzerland Reactive 450


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52 P a g e

24 Reactive Turo. Blue

H2GP

KIRI TEX India Reactive 560

25 Solazol Blue RSPL Solar Fine Chemical CO. Ltd. Taiwan Reactive 390 26 Syno White 4BK Orient Chem Taiwan Brightener 300.03 27 Reactobond Orange 3R Meghmani Dyes And Intermediates

Ltd.

India Discharge 488.82

28 Solazol Navy WB Solar Fine Chemical CO. Ltd. Taiwan Discharge 450 29 Remazol Dark Blue SLT Dystar Gemany Reactive 560 30 Reactobond Red 3GX Meghmani Dyes And Intermediates

Ltd

India Reactive 1250

31 Reactobond Red BB Meghmani Dyes And Intermediates

Ltd

India Discharge 1218

32 Reactobond Navy DB Meghmani Dyes And Intermediates

Ltd

India Discharge 560

33 Reactobond Black DX Meghmani Dyes And Intermediates

Ltd

India Discharge 470

34 Reactobond Yellow

RGB

Meghmani Dyes And Intermediates

Ltd

India Discharge 600

35 Reactobond Blue H2R Meghmani Dyes And Intermediates

Ltd


36 Reactobond N. Blue

GG

Meghmani Dyes And Intermediates

Ltd

India Discharge 650

37 Reactobond Blue BB Meghmani Dyes And Intermediates

Ltd


38 Levafix Blue CA Dystar Germany Reactive 1841

39 Levafix Fast Red CA Dystar Germany Reactive 2071

40 Levafix Amber CA Dystar Germany Reactive 1305

41 Levafix Rubine CA Dystar Germany Reactive 2019

42 Novacron Brill Red Fn-

3GL

Huntsman Switzerland Reactive 2400

43 Novacron Blue-FNR Huntsman Switzerland Reactive 2500

44 Novacron Red FNR-01 Huntsman Switzerland Reactive 1290

45 Novacron Yellow FN-

2R

Huntsman Switzerland Reactive 1540

46 Disperse Red CBNSF Meghmani Dyes And Intermediates

Ltd

India Disperse 2600

47 Disperse Black EXNSF Meghmani Dyes And Intermediates

Ltd

India Disperse 374.13

48 Disperse Blue SGL Meghmani Dyes And Intermediates

Ltd

India Disperse 648.41

49 Disperse Orange RSF Meghmani Dyes And Intermediates

Ltd

India Disperse 400

50 Disperse Yellow F-5GL Meghmani Dyes And Intermediates

Ltd

India Disperse 550

51 Dispertex Black RK7 Meghmani Dyes And Intermediates

Ltd

India Disperse 170

52 Dispertex Blue MN 12 Meghmani Dyes And Intermediates

Ltd

India Disperse 460

53 Dispertex Marine RS Meghmani Dyes And Intermediates

Ltd

India Disperse 530

54 Dispertex Red FRC 46 Meghmani Dyes And Intermediates India Disperse 490


.

53 P a g e

Ltd 55 Dispertex Carmin Ln Meghmani Dyes And Intermediates

Ltd

India Disperse 510

56 Dispertex Orange FR Meghmani Dyes And Intermediates

Ltd

India Disperse 475

57 Dispertex Yellow GR Meghmani Dyes And Intermediates

Ltd

India Disperse 510

Chemicals & Auxiliaries:

SL

No Trade Name Source Origin Type Price

Tk/Kg

1 Imerol PCLF Clariant Switzerland Wetting Agent 177.49

2 Sirrix 2UD LIQ Clariant Switzerland Sequestering

Agent

120

3 Kappasoft SM Kappa Chem Germany Softening

Agent

253.71

4 Kappasoft BD Kappa Chem Germany Softening

Agent

250

5 Kappaquest FE Kappa Chem Germany Multifunctional 134.28

6 Prozyme Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Enzyme

7 Prostab S2 05 Omar Endustrail Kimyasallar

San Ve Dis TIC L

Turkey Stabilizer 99.24

8 Ionactive PP 105 Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Levelling

Agent

116.30

9 Cleanol RB 104 Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Washing Agent 98.29

10 Fixoline FZ-106 Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Fixing Agent 189.09

11 Provent POL 103 Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Anti-Creasing

Agent

98.98

12 Geistab RS Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Stabilizer 97

13 Geisoftcan Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Anti-Creasing

Agent

97

14 Geiclean WA Omar Endustrail Kimyasallar San

Ve Dis TIC L

Turkey Washing Off

Agent

97

15 Geisoft WCS Omar Endustrail Kimyasallar San Turkey Whitener 250


.

54 P a g e

Ve Dis TIC L

16 Syno White 2BX Orient Chem Taiwan

17 Syno White BYB Orient Chem Taiwan

18 Sapamine CWS Huntsman Switzerland Softening

Agent

277.50

19 Hydrogen

peroxide50%

H P Chemicals Bangladesh Bleaching

Agent

20 Hydrose BASF Germany Reducing

Agent

167.14

21 Acetic Acid Jubilent India Acid 102.20

22 Soda Ash Orient Link (Hong Kong)

Limited

China Alkali 19.47

23 Caustic Soda Opsonin Bangladesh Alkali 55

24 Glaubar Salt Orient Link (Hong Kong)

Limited

China Electrolyte 11.67

25 Jinfix SR Orient chem Taiwan Fixing agent 325.40

26 Antimussol HTS Oasis India Anti-foaming

agent

275

27 GSS Kappa Chem Germany Exhausting

Agent

1390

28 Green Acid Huntsman Switzerland Acid 90

29 Common Salt Opsonin Bangladesh Electrolyte 9.73

30 Invatex PC Huntsman Switzerland Peroxide Killer 139

Annual Requirements of Dyes :

The annual requirement of Dyestuffs, Chemicals & Auxiliaries was not determined as necessity of

these are assessed by volume of production. Annual requirement of dyes & chemical depend on the

order of production. But for various reasons such as improper weighting, carelessness of operators,

hydrolysis of dyes, uneven process control, wrong recipe formulation, incorrect batching, improper

storage facilities& for different unwanted expenditure , extra dye consumption increased dye &

chemical requirement.

Remarks:

Texeurop (BD) Ltd. Fabrics Ltd is very careful & conscious about its raw materials. The raw

materials are always collected from those suppliers who supply the dyes & chemicals of

higher quality. The best Quality Raw Materials are selected to ensure and satisfy the Buyers

requirements.


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CHAPTER –V


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Sequence of operation : Lab dip approved

▼ Grey fabric inspection

▼ Batching

▼ Scouring & Bleaching

▼ Enzyming ( If required Or buyer requirements )

▼ Dyeing

▼ Bath Drain

▼ Cold Wash

▼ Neutral With Acetic Acid

▼ Soaping

▼ Fixing (If required )

▼ Softening

Production Parameters :

Process Temp(▫C) pH Time min M : L ratio

Scouring -Bleaching 98 11.5-12 60' 1:8

Enzyme Wash 55 4.5-5 60' 1:8

Enzyme Deactivation 70 10'

Reactive Dyeing (Light Shade) 60 10.2-10.8 60' 1:6

Reactive Dyeing(Dark Shade) 60 10.9-12 60' 1:6

White Shade 98 10.5-11.5 20' 1:6

Turquish color dyeing 80-90 10.9-12 90' 1:6

Polyester dyeing 130 4-4.5 45' 1:6

Softening Water 40 4-5 45 1:6

Grey Fabric Inspection : In grey fabric inspection the available faults are

Hole/Loop

Needle breaking

Neps, Thin & Thick places

Needle mark


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57 P a g e

Sinker Mark

Yarn problem

Bar/Stripe

Wheel mark

Oil mark

Foreign Fiber

Hair

Lycra drop

Contamination

Batching :

Batching preparation is the process where inspected grey fabrics are divided into different

batches with reasonable quantity according to machine capacity, nozzle number in order to

make them suitable for the further operation In batching. It must be carefully observed that

each Nozzle of a machine contains equal length of fabric.After batching some fabrics are

tuned to backside to minimise the risk of faulty dyeing.

Following are the fabrics those are tuned back by turnig machine:

Single Jersey

Lacoste (Single & Double jersey)

Fleece(if asked)

Sequence of Batching :

Grey fabric divided into batches

▼

Batches divided nozzle wise according to lengh & Dia

Instrument used :

Turning m/c

Plaiting m/c

Weighting m/c

Back sewing m/c

Overlock m/c Information checked :

Order No

Color

Yarn Count

Yarn lot

Yarn brand

Knitting factory

Machine No

Roll No

Pre-treatment:

For scouring & bleaching at first the fabric is loaded on to the

bath .

Required amount of water is taken to the bath .

Wetting Agent & Anti creasing Agent is added.

Scouring Agents (Caustic/Soda) & Stabilizer are added by the

aid of dosing when the emperature reaches at 50° C.


.

58 P a g e

H202 is added by the aid of dosing system for 5' .

Temperature is raised to 98° C & the process is carried for 6O'

The liquor are drained at 80° C.

After that chemical wash & enzyme wash are done.

Curves for Pre-treatment:

Scouring & Bleaching:

Chemical Wash:

Room Temperature

60▫C × 5'

98▫C × 60'

2▫C /min

80▫C

H2O2

1 2 3 4 5 6 7

Anticreasing

Wetting Agent

sequestering Agent

Antifoam

stabilizer

Soda

Caustic

Cold Wash Cold Wash

5' 5'

Room Temperature

60▫C × 5'

80▫C × 15'

1 2

1) Oxalic Acid

2) Peroxide Killer

Cold

Wash

5' 5'

Cold

Wash


.

59 P a g e

Enzyme Wash:

Dyeing Light /Medium Shade:

Dyeing Bath Preparation :

Auxiliaries are added at 50° C.

Salt added by dosing system ( time : 10-20') .

pH maintained at 6.5-7.

Color dosing at 6O° C for 20'.

Exhaustion & Fixation :

After 30' soda ash added by dosing for 30-35' .

pH checked & maintained at 10.5

Dye bath is kept at 60° C for 40-60'.

After every 10' the sample is checked fixation occurs during this time.

Rinse for 10' & the bath is drained.

Neutralization :

The material should be neutralized to remove alkaline condition at room temperature by acid

wash for 15 min & rinsing will be carried on for 10 min.

Soaping :

o Then soaping agent is added & temperture raised to 90°-100°C for 10 min.

o The bath is cooled 7 rinsed for 10 min.

o Dye bath temperature then cooled to 60° C.

Cold Wash Cold Wash

5' 5'

PH= 4.5-5

55▫C × 60'

70▫C × 10'

1 2

1) Acetic Acid

2) Bio-Polish


.

60 P a g e

Softening:

Softener is applied to soften the fabric as well as it improves the hand feel. The material is

treated at 60°C for 20 mins. Then rinsing again & material unload.

Procedure of Dark shade :

At first the bath is set at 50° C & take the right volume of water in the dye bath.

▼

Required amount of wetting agent is added.

▼

Caustic soda is added & second heat command 60°C & stabilizer is added also.

▼

H202 is dosed & 10' runs.

▼

Temperture raised to 100° C & run the material for 30'

▼

Cooling the bath at 75°C & bath is drained .

At 90° C the material is run for 15 mins

▼

Cooling the bath to 75°C to darin

▼

Add Acetic Acid to neutralize the whole bath of fabric & run time is 20'

▼

Rinse the fabric for 5' & bath is drained .

▼

New water from reserver is taken & pH should be 4.5-5 .

▼

Enzyme is injected to the bath . Run time is 60' at 55°C

▼

Temp. raised to 70° C & run time 10' & then drain

▼

Again new water is taken & dosing of glaubar salt for 20' & pH should be check

(pH =7)

▼

Color dosing for 30' at 50°C

▼

Soda is added by dosing for 40'at 50°C

▼

Then raise the temp. & run the fabric for 35-60'.At this time after every 10' the sample is

checked.

▼

Rinse the material for 10' & bath is drained.

▼

http://temp.is/


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61 P a g e

At room temp. acid treatment is done for 20'& rinse the material for 5'

▼

Soaping is done at 90°C for 10 min & bath is drained.

▼

Fixing agent is added at 50° C & run time is 20' & bath is drained

▼

Softening is done at 60° C for 20'& balli is drained.

▼

Finally the fabric is unloaded.

White Shade:

At first Scouring bleaching chemicals are added to the bath & they are treated at 98°C for 60'

▼

Temperature is lowered at 80°C & OBA is added.Run time is 10'.

▼

Temperature is raised to 98° C & Run time is 20'.

▼

Then enzyme treatment is applied & then softening occurs

Dyeing Curve:

Normal Hot:

60▫C × 10' Acetic acid

20'

Cold Wash Cold Wash

5' 5'

Cold Wash

5'

Room temperature

60▫C × 60'

1 2 3 4

1) Auxilaries

2) Salt

3) Color dosing(20-30')

4)Soda dosing(30-40')


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62 P a g e

Chemical Hot:

Fixing & Softening (if dark shade):

Softening:

Stripping Recipe:

-First of all these two chemicals are taken & treated with fabric in cold temperature for 30

min.

Soda ash =0.5 g/L

Bleaching powder =0.5 g/L

Then Direct drain is done.

-After that some other chemicals named below are treated at 98°C for 45 min.

Anticreasing Agent =0.3 g/L

40▫C × 20′

Softener & Acetic

acid

Acid

50▫C × 20′

Fixing agent Softner

20′

60▫C

90▫C

80▫C

80▫C

Soaping chemical


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63 P a g e

Levelling Agent =0.3 g/L

Wetting Agent =0.3 g/L

Caustic soda =1-2 g/L

-After that 3-5 g/L Reducing Agent is taken and treated at 80°C for 10'.

Then Direct Drain is done.

-After that half or full scouring takes place

-Lastly fabric is treated by acetic acid.

Stripping for white :

-First of all these two chemicals are taken & treated with fabric in cold temperature for 30

min.

Soda ash =0.5 g/L

Bleaching powder =0.5 g/L

Then Direct drain is done.

-After that these two chemicals are taken & treated with fabric at 98°C for 60 min.

Hydrose =1-2 g/L

Caustic Soda =1-2 g/L

-Lastly fabric is treated by acetic acid.

Machine Wash:

Add hydrose (6 g/L) & caustic Soda (6 g/L)

▼

Run 20' at 110° C

▼

Run 10' at 95° C

▼

Run 10' at 80° C

▼

Run 10' at 60° C

▼

Run 10' at 40° C

▼

Drain

FINISHING

Textile finishing, in a restricted sense, is the term used for a series of processes to which all

bleached, dyed, printed & certain grey fabrics are subjected before they are put to market.

OBJECTIVE OF FINISHING:

Improving the appearance,luster, whiteness etc.

Improving the feel, which depends on the handle of the material & its softness,

suppleness, fullness etc.


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64 P a g e

Wearing qualities, non- soiling, anticrease, antishrink comfort etc .

Special properties required for particular uses -water -proofing flame proofing etc .

Covering of the faults in the original cloth .

Increasing the weight of the cloth .

FINISHING EFFECTS:

Easy care .

Crease recovery.

Dimensional stability

Good abrasion resistance

Improved tear strength

Good sew ability

Soft or stiff handle

Shine or luster

SEQUENCE OF OPERATION:

For Open fabric:

Slitting

▼

Stenter( Softener used )

▼

Compactor

For tubular fabric:

Padder (Softener used)

▼

Drying

▼

Compactor

FINAL INSPECTION REPORT:

For final inspection , Inspection table & Inspection m/c is used .

The 4-point system is given below-

Size of Defect Penalty point

Less than 3 inches 1

3-6 inches 2

More than 6- 9 inch 3

More than 9 inch 4

Size of holes & opennings-

1 inch or less 2

More than 1 inch 4

Some general rules of the inspection are-


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65 P a g e

Not 1 metre of cloth is penalized more than 4 points.

Cloth is inspected on face side only unless specified.

If the total defect parts per 100 yards of fabric are 40 or more the fabric will be

rejected.But it may be changed according to buyer’s requerments.

Ratio Between Salt & Soda according to shade % :

For all colors Shade % Salt/Soda

<.09 10/2

.10 - .20 15/3

.20 - .40 20/4

.40 - .80 25/5

.80-1.20 30/6

1.20-1.60 40/10

1.60 – 2.50 50/12

2.05 – 3.50 60/15

3.50 – 4.50 70/17

4.50 – 5.50 78/18

5.50 and above 80/20

For Drimarine Colors

Shade % Salt/Soda

<.05 10/2

<.05 -.10 15/3

.10 - .30 20/4

.40 - .60 25/5

.60 – 1.0 30/6

1.0 – 1.50 40/10

Color Mixing Temperature for most commnly Used Dyestuffs :

These dyes are solubilised at 60-70C

Reactive Orange ME-2RL

Reactive Black HFGR

Reactive Red ME4BL

Reactive G.Yellow MERL

Reactive Black B

Reactive Black GR

Reactive Black WNN

Reactive Navy Blue ME2GL

All Turquise color are solubilised at 80C Temperature


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REMARKS:

Texeurop (BD) LTD. strictly follow up the production parameters like Temp, M:L ratio,

pH check etc.Textile Engineers of this factory are highly skilled and they have vast

experience. They are capable to prducce any shade demanded by buyres.But it requires more

times for the production of comlicated shade(eg Turquise color dyeing).The production

officer & Sr. production Officer try their best to reduce the production time.


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Chapter-VI


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Introduction : The Quality assurance Department is assigned to maintain consistently uniform quality of

the material in process and various stages of its manufacturing. Texeurop(BD)Ltd. is more

about concern about quality. In this factory quality assurance is more preferred than quality

control, but both are in advancement.

After collecting fabric rolls from different m/cs, they are needed to be inspected or assured

required quality by the quality inspectors as if there were no big production hampered and no

complain from the buyers. Here are the details about it.

Objects of Quality Control:

1. Research.

2. Selection of raw materials.

3. Process control.

4. Process development.

5. Product testing.

6. Specification test

Scope for quality control, quality assurance and testing:

1. Testing lab

2. Machine auditing system

3. A good training system

4. Excellent analytical back up

5. Technical expertise

Quality Control Flow Chart:

Yarn receiving

Sample Knitting

Batching


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Dyeing (Check shade & Faults of dyeing)

Dewatering & Untwisting

Drying (Check diameter, Pretreatment, Shrinkage Spirality and GSM)

Compacting

Final inspection

If sample OK go for bulk production

Quality Control in Grey Fabric Inspection:

Some Points Are Needed To Maintain For High Quality Fabric:

a) Brought good quality yarn.

b) Machines are oiled and greased accordingly.

c) G.S.M, Stitch length, Tensions are controlled accurately.

d) Machines are cleaned every shift and servicing is done after a month.

e) Grey Fabrics are checked by 4 point grading system.

List of Equipments:

In this factory there is a list of equipments to assure quality:-

1) Inspection m/c # 1

2) Scissors

3) Electronic balance

4) GSM cutter

5) Indication sticker

6) Measuring tape

Quality Assurance Procedure:

1) Body & Rib Inspection:

All rolls are kept in front of the inspection m/c time to time and are inspected over

the inspection m/c visually in a pre-set speed against light. For any major or minor

faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle

line, slubs etc are recorded in inspection report to classify the fabric based on the four

point system.


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2) Collar & Cuff Inspection:

Collar& cuff are inspected visually under the light box, any major or minor faulty

collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round

problem etc properly counted and recorded.

Quality Standard:

Texeurop(BD)Ltd. maintains the ISO: 9002 standard in case of quality. They also

posses SGS & Oeko tex certificate Therefore, the four point system is followed to inspect

the body & rib fabric. The defects found and points given against are recorded in the

inspection sheet. Following table shows the four point grading system followed by

inspection at Texeurop(BD)Ltd.

The following fofmula is used for determining points/100 sq yds in a roll of a fabric:-

Points/100 sq yds = (0.08*Roll points*A.GSM) / Roll wt in Kg

Four point grading system

Size of defects Penalty

3 inches or less 1 point

Over 3 inch but not over 6 inch 2 point

Over 6 inch but not over 9 inch 3 point

Over 9 inch 4 point

Hole <1 inch 2 points

Hole >1 inch 4 points


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Grading calculation based on Points:

Following table shows common body and rib faults and response by inspection section at

Texeurop(BD)Ltd.:-

Following table shows common collar and cuff fault and response taken by inspection

section at Texeurop(BD)Ltd.:-

Points grade

Up to 10 points A

10-20 B

20-30 C

30- 40 D

Above 40 Reject

Rejection criteria for body & ribs

No. Faults Response

1. Needle mark Major needle line is rejected

2. Stripe Major needle line is rejected

3. Barre mark Rejected

4. Contamination & fly Approved for color but for white shed 1

point is assigned

5. Slubs 1 point

6. Thick thin place Reject

7. Pin holes 1 point

8. Wrong design Reject

9. Mixed yarn Discuss with manager

10. Sinker mark Major sinker mark is rejected.

11. Missing yarn Use 4 point

12. Holes Do

13. Oil line/stain Do

14. Chemical Do

15 Dirt stain Do

16. Crease line Do

17. Uneven tension Discuss with manager


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72 P a g e

Rejection criteria for collar & cuff

No. Faults Response

1. Wrong ply Reject

2. Hole Reject

3. Needle line Reject

4. Slubs Reject

5. Wrong design Reject

6 Fly & contamination Acceptable for color but not for white

7. First round problem Reject

8. Uneven tension Discuss with manager

9. Missing yarn Reject

10. Crease line Reject

11. Rust line Reject

12. Oil stripe Reject

13. Thick-thin Reject

14. Wrong tube Reject

Quality Control in Dyeing And Finishing:

The Texeurop(BD)Ltd assures the quality of the products of dyeing section in the following

three steps:

1. In laboratory

2. In Dyeing section &

3. In Finishing Section

Procedures are described below:

In laboratory:

Swatch card from buyer according to their requirement

Recipe prediction for sample dyeing

Sample dyeing until matching with swatch card

Fastness & other tests of the fabric or yarn are done here.

In dyeing section:

According to the buyer’s sample, sample dyeing is done in sample dyeing machine

in dyeing shed & again matched with the approved sample.

If result is OK, then bulk production.


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73 P a g e

During dyeing, samples are taken until accurate shade matching. The interval may

be 30-40 minutes.

After dyeing sample is collected after softening matching is done.

Last of all, sample is collected after fixation & matched.

Then allowed the fabrics to be finished.

In finishing section:

By using a series of finishing machines correct width, softness & appearance are

maintained according to requirements.

Then sampling is done for several times to test GSM, Shrinkage & fastness

properties.

Finally fabric is inspected & prepared for delivery.

Quality Standard:

Texeurop(BD)Ltd follows the quality standard: ISO-9002:2000, It also posses SGS

and oeko Tex certificate. So it maintains SGS and Oeko Tex requirements.

List of Equipments: -

In the Quality Assurance Department the followings equipments are used -

KERN Electronic Balance

Iron

Ahiba Nuance Lab. Dip Dyeing Machine

Digital Pipette

Creda Dryer

Rota Wash

Crock Meter

Incubator

Spectro Photometer with software (Data Color)

PH meter

GSM cutter

Tests There are two types of tests are done in Quality Assurance Department. They are –


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74 P a g e

1. Physical Tests

2. Chemical Tests

Physical Tests:

GSM test

Shrinkage test

Spirality test

Abrasion resistance

Lycra% determination

Crease resistance

Chemical Tests:

Fastness to washing.

Fastness to light

Fastness to actual laundering

Fastness to water

Fastness to Perspiration

Fabric Inspection:

The inspection of fabric is a procedure by which the defects of fabric are identified

and fabric is classified according to degree or intensity of defects. The fabric inspection is

done for both grey and finished fabric.

Grey Fabric Inspection:

Grey fabric inspection is performed according to 4-point system.

Finished Fabric Inspection:

4 point numbering system is followed for finished fabric inspection. Defects found in

the final inspection:

1. Uneven shade

2. Oil spot

3. Neps

4. Crease mark

5. Machine Stoppage mark

6. Listing

7. Line mark

8. Pick missing

9. Double yarn


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75 P a g e

10. Dead cotton

11. Bowing

12. Fly yarn contamination

Inspection checking points:

1.Enzyme quality.

2.Handfeel on fabric surface

3. uneven on fabric surface

4.Running shade on fold to fold.

5.Color spot on fabric surface

6. Softener spot on fabric surface

7.Oil spot on fabric surface.

8.Bowing line

9.Bias on Grid line

10.Line mark on fabric surface

11.Dia variation in one roll fabric surface

12.GSM of fabric against required GSM

13.Needle mark or slit mark

14.Pin mark on febric surface

15.Sinker mark

16.Crease mark

17.Dia mark

18.Neps,contamination,thick&thin place.

19.Patta problem

20.Stripe bowing

21.,Fabric elasticity

22.Fabric strength

23.Brush quality

24.Suided/piece finish quality

25.Color fastness to wash and water

26.Rubbing fastness to dry and wet

27.Shrinkage and Spirality.

Procedure of the Different Tests:

Different types of fastness tests of the dyed fabric are done in quality control

department of the Texeurop(BD)Ltd. Different types of method (Standard or buyer’s

recommended) are followed for different types of tests. The process of the different tests of

fabrics & lab. dip dyeing is described in the following section:


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COLOR FASTNESS TEST PROCEDURE

Color Fastness:

The “color fastness” of a colored textile is defined as its resistance to these changes

when subjected to particulates of conditions. It follows that color fastness must be specified

in terms of these changes and expressed in terms of the magnitude.

1. Color Fastness to Wash Test

Required materials:

1. Sample size 10 4cm

2. Multifiber at 10 4 cm

3. ECE detergent (WOB) – 4g/L

4. Sodium Perborate (Na2BO3.H2O2.3H2O2-1g/L) - 1g/L

5. Distilled water

6. Normal cold water

7. Steel balls

Required instrument:

1. Rota Wash

2. Scissor

3. Stitch machine

Procedure :

1. Cut sample & multifibre at 100 40 mm and then stitch.

2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the

sample.

3. The sample is kept in 600C for 30 minutes in Rota Wash Machine

4. Rinse the sample twice with cold water.

5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not

be more than 150°C.

Report:

Dry the specimen and the change of shade & degree of staining is measured by Grey

Scale & Staining Scale.

2. Color Fastness to Perspiration Test

Test specimen:

Sample fabric – 10 cm 4 cm


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Multifibre fabric – 10 cm 4 cm

Same fabric – 10 cm 4 cm

Cut the multifibre into two piece

Sandwich the test specimen between two pieces of fabric

Testing Solution:

1. Alkaline Solution:

Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 0.5 g/L

NaCl – 5.00 g/L

Disodium hydrogen orthophosphate (Na2HPO4.2H2O) – 2.5 g/L

PH – 8 (Adjust by 0.1 N NaOH)

2. Acidic Solution:

Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 0.5 g/L

NaCl – 5.00 g/L

Sodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.2 g/L

PH – 5.5 (Adjust by 0.1 N NaOH)

Method:

- The composite specimen is put in a biquor (2 specimen of a sample).

- Solution (Alkaline & Acidic) is taken in the two biquor. Here, M: L is taken 1:50.

- The specimen is put for 30 minutes at room temperature.

- Then the liquor is poured off without removing the sample.so that sampke

remains wetted.

- Then Specimen placed between two glass plates.

- Then specimen & glass plate is placed into the incubator at (372) 0C for 4 hours.

- The specimen is dried (Temp 600C)

Report:

- Change of shade & degree of staining is measured by the Grey Scale & Staining

Scale.

3. Color Fastness to Water Test

a)Cold water

Test specimen:




Sandwich the test specimen between two pieces of multi fiber


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78 P a g e

Testing Solution:

Water is taken as required

Method:

- The composite specimen is put in a biquor (2 specimen of a sample).

- Water is taken in the biquor as required.

- The specimen is put for 30 minutes at room temperature.

- Excess water is poured off and the specimen is placed between two glass plates.

- Then composite specimen & glass plate is placed into the incubator at (372) 0C

for 4 hours.

- The specimen is dried (Temp 600C)

Report:


Scale.

b) Hot water:

Test specimen:




Sandwich the test specimen between two pieces of multifibre

Testing Solution:

Distilled water of slightly acidic is taken as required

Method:

-At first the composite specimen is wrappedround a glass rod of 5 to 8 mm dia and

tied loosely with a thread.

- Then placed into a liquor .

- Distilled water (slightly acidic of pH-6, can be maintained by acetic acid) is taken

in the biquor with M:L is 1:30.

- The specimen is put for 30 minutes (702) 0C .

- Then taken out ,unwrapped

- The specimen is then dried at Temp 600C.

Report:


Scale.

5. Color the Fastness to Rubbing (Dry & Wet) Test

Sample:


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79 P a g e

- Dyed fabric – 15 cm 5 cm

- White Test Cloth - 5 cm 5 cm

Procedure:

- White test cloth is put on to the grating and stag by steel wire.

- The sample is run twenty times manually for ten seconds. and the rubbing

fastness of the sample cloth and degree of staining is accessed.

- For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked

and squeeze. The wet rubbing cloth is placed on to the grating and stag with

stainless steel wire and run ten times manually then assess the staining on to the

rubbing cloth and the rubbing fastness of the sample cloth is accessed.

Report:

- Change of shade of the sample is measured with grey scale and degree of staining

of the white test cloth is measured by Staining Scale.

There are also some tests are done in the lab. And the process is described below-

A. Measuring the Dimensional Stability (Shrinkage & Spirality):

Sample:

Two piece of 50 cm 50 cm fabric is taken for test.

Procedure:

a. At first the sample to be tested should be put in table for 4 hrs for conditioning

before starting test.

b. Then a rectangular bed is made and then 50 cm * 50 cm line is taken in both

side(length & width)

c. Put sample in washing machine and run according to buyer’s choice.

d. Then drying is done by tumble dryer

SHRINKAGE TEST CALCULATION:

Before wash – After wash

Shrinkage % = X 100

Before wash

Spirality test calculation:

S = (S1+S2) / 2

Spirality = (S/ L)*100.

Suppose,

S1 = The right side distance of the specimen from the stitch line after

wash.

S2 = The left side distance of the specimen from the stitch line after

wash.

L = Length before wash


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80 P a g e

B. Strength test for Soda Ash:

Reagent:

1. HCl 0.1N solution

2. Phenophthalein indicator(0.1%) in Ethanol

3. Methyl orange indicator(0.1%) in Ethanol.

Procedure:

1. Take 5 gm soda ash and dried it for 1 hr at 105 C in a glass beaker/.

2. Take 0.2 gm soda ash (from dried 5 gm) and mix it with 50 ml distilled water.

3. Add 2 drops Phenophthalein indicator and titrate by 0.1 N HCl to the

disappearance of red. Take the 1st reading.

4. Add 2 drops methyl oeange indicator and titrate by 0.1 N HCl. End point of

methyl orange indicator. Take the 2nd reading.

Result:

(2nd reading – 1st reading)* 0.1*0.084*100

Sample weight

Standard result: 80-100.

C. pH of a Dyed Fabric Test :

Test specimen:

2 gm of dyed fabric is taken.

The fabric is cut into pieces of (0.5 cm 0.5 cm)

Procedure:

1. The sample is taken into conical flax.

2. 100 ml distilled water (slightly warm) is taken into the conical flax.

3. The conical flax is put on the Magnetic Stirrer for 30 minutes.

Report:

The PH of the conical flax is measured by Digital PH meter.


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Response of Q.C Officer:

Response to Q.C Faults:-

Faults Response

Yarn fault Inform yarn supplier

Knit fault Inform knitting department

Dyeing fault Inform dyeing manager

Response to Machine Fault:-

Faults Response

Any electrical fault Inform electrical maintenance

Any mechanical fault Inform mechanical maintenance

Remarks:

The Texeurop(BD)Ltd always aware about the quality of the product. The quality of

the product is always approved by the buyer. They follow the quality standard: ISO -

9002:2000, SGS & Oeko tex requirements. The Texeurop(BD)Ltd is well equipped for

checking the quality of the product. They sent the quality report to the buyer time to

time/batch to batch.


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CHAPTER-VII


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Maintenance is considered as important as other engineering functions. It makes responsible

for provision of a condition of machines, buildings and services that will permit

uninterrupted implementation of plans requiring their use.

Objectives Of Maintenance:

To keep the factory-plants, equipments, machine tools etc. in an optimum working

conditions.

To ensure specified accuracy to products and time schedule of delivery to customers.

To keep the down time of machines to the minimum thus to have control over the

production program.

To keep the production cycle with in the stipulated range.

To modify the machine tools to meet the augmented need for production.

To improve productivity of existing machine tools and to avoid sinking of additional

capital.

To reduce the maintenance costs as for as possible thereby leading to a reduction in

factory overheads.

To prolong the useful life of the factory, plant and machinery, while retaining their

acceptable level of accuracy of performance thus avoiding or prosponding incurring

of heavy capital expenditure involved in their replacement.

Maintenance Of Machinery:

Maintenance

Preventive

maintenance

Break down

maintenance

Mechanical maintenance

Electrical

maintenance

Mechanical maintenance Electrical

maintenance


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Preventive maintenance:

Preventive maintenance is a predetermined routine actively to ensure on time

inspection/checking of facilities to uncover conditions that may lead to production break

downs or harmful dcscription.

Break down maintenance:

In this case repairs are made after the equipment is out of order & it can not perform its

normal functions.

Routine maintenance:

Maintenance of different machines are prepared by expert engineer of maintenance

department. Normally in case of dyeing machine Maintenance after 30 days complete

checking of different important parts are done.

Economic Consideration Of Maintenance

It is very profitable activity & ensures maximum productivity at minimum costing.

It improves product quality.

It ensures less time to produce a specific product.

It improves machine accuracy.

It maintains a long life of the machine.

No chance of back order.

Maintenance Flow Chart:

Head of Maintenance

Technician

Assistant


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Manpower Set-Up For Maintenance

A Shift 6 AM - 2 PM

B Shift 2 PM - 10 PM

General Shift 9AM - 6 PM

Functions Of Maintenance Personnel:

Inspection or Check-Ups:

° External inspections: Watching and detecting defects form abnormal sound,

vibration, heat, smoke etc when machine is in operation.

° Internal inspections: Inspection of parts such as gears, bushes, bearings,

tolerances in the parts etc. when machine is under pre-planned shutdowns.

° Inspections of important machines: Machines, which can disrupt whole of

the production, are delicate and require much time for the repair. Attentions

are given for inspection of these machines and schedule for inspection,

cleaning lubrication are done rigidly.

° Inspections of ordinary machines: Frequency of inspection of ordinary

machines is kept as low as they do not affect the production.

Lubrication: Mechanical components like gears, bearings, bushes and other friction

surfaces etc. give good performance for long periods when they are systematically

lubricated. Systematic lubrication means the application of right type of lubricants at

the right time, at right place and in right quantity. For lubrication, a lubrication

schedule should be prepared and that should be followed strictly. Here lubrication is

done whenever is needed.

Planning and scheduling: Every preventive maintenance work should be pre-

planned in detail on the basis of the analysis done on the past records. A scheduled

programme thus prepared should be followed strictly. Thus programme should be in

detail specifying the point-requiring daily, weekly, monthly, half yearly or yearly

attention.


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Records and analysis: Good record keeping is essential for good maintenance, as

it helps in for casting maintenance. For this purpose following records are generally

maintained:

° Operation manual

° Maintenance and instruction manual

° History Cards and History Registers

° Spares Procurement Registers

° Spare Procurement Register

° Inspection Register

° Log books

° Defect Register etc.

Training of Maintenance personnel: For the success of maintenance a sound

training is essential for the maintenance personnel. Hence the technicians and

supervisors are trained to carry out maintenance, inspection and repaired in a

systematic way.

Storage of Spare Parts: Sometimes machine remains idle for want of spare parts

for considerable time and thus it affects considerable loss of production. Hence it is

essential to keep the spare parts so as to avoid loss of production.

Maintenance Tools/Equipments & Their Functions:

Maintenance tools/equipments Functions

1. Adjustable wrench Used for setting nut & bolts

2. Pipe Spanner For pipe fitting

3.Spanner Fixed Spanner for nut & bolts fitting

4.Socket spanner Handle system for nut & bolt fitting

5. hammer To apply load where required

6. Screw driver To release any screw

7. Punch Used to fit any worn out shaft

8. Lock opener To open the clip of bearing

9. Hack saw To cut any metallic thing

10. Outside calipers To measure outside dia

11. Inside calipers To measure inside dia

12. Slide calipers To measure very small dia

13. Vernier scale To measure very small dia

14. Chain ton To lift heavy load


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15. Welding machine To join metallic parts

16. Grinding machine To make the smooth fabrics

17. Tester To test electric circuit

18. Pliers To grip anything & cut anything

19. Avometer/Voltmeter To measure voltage

20. Steel tape To measure length, width & height

21. Chisel To cut any metal

22. Gasket cutter For gasket cutting

23. File To smooth the rough surface

Maintenance Procedure :

Normally preventive maintenance is done here. During maintenance procedure

following points should be checked :

Maintenance of knitting machine/flat knitting machine:

SL.

No.

Items need to be checked & Serviced

1. Check and tightening all motor terminals.

2. Check and clean pressure sensor and tightening terminals

3. Clean the ventilation fans of panel board and circular fan on top of

machine.

4. Check and clean the interfacing and data cables.

5. Check and tightening the proximity switch terminals.

6. Inspection, cleaning and tightening all the terminals in the panel.

7. Check and tightening limit switch, safety door guard and the

emergency switch.

8. Functional test of the yarn detector.

Maintenance of Dyeing machine machine:

(Mechanical)

Serial no.

Item need to be checked & serviced

1 Grease the winch bearing

2 Complete cleaning of machine

3 Cleaning of drain valves, replace scales if required

4 Check air supply filters, regulators, and auto drain seals

5 Clean filters element and blow out

6 Greasing of unloading roller bearings

7 Checking of oil level and bolts of unloading roller

gearbox

8 Checking of unloading roller coupling and packing


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9 Checking and cleaning of main vessel level indicator

10 Check the oil level of pump bearing and refill if required

11 Check the function of heat and cool modulating valves

12 Check all belts and belt tension

13 Check all door seals

Maintenance of Dyeing machine :

(Electrical)

Serial no.

Items needed to be checked and serviced

1 Check & clean fluff and dirt at al motor fan covers

2 Check all motors terminals

3 Check main panels (by using compressed air)

4 Check panel cooling fan & clean it filter

5 Clean main pump inverter and its cooling fan

6 Check all circuit breaker, magnetic contractors and

relays

7 Check current setting of all circuit breaker & motor

over loads

8 Visual checking of all power & control cables

9 Check all pressure switches

10 Check DC drive of neel motors

11 Check calibration of main vessel

12 Check calibration of all additional tank

13 Check all pneumatic solenoids

14 Check calibration of heating / cooling

15 Check setting of tangle sensor

16 Check setting & operation of lid safety switches

17 Check all emergency switches

18 Check all indicating lamps

19 Check all on / off switches

20 Check all signal isolators

21 Check key pad & display of controller

22 Check proximity switches

Maintenance of stenter machine :

(with mahalo arrangement)


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SL.

No.

Items need to be checked & Serviced

1. Check and tightening all motor terminals and clean the motor fan

(30days).

2. Check activity of wide and sensor and pneumatic regulator.

3. Check and clean pressure sensor and tightening terminals

4. Clean the A/C ventilation fans of panel board

5. Check the fan and the heat sink o the inverters in the panel board.

6. Check and tightening the edge sensors.

7. Check and tightening the photo sensor terminals.

8. Check and tightening the safety light barrier and tightening the

terminals.

9. Inspection, cleaning and tightening all the terminals in the panel.

10. Check and tightening limit switch, safety door guard and the

emergency switch.

The following tasks are generally done during maintenance:

Inspections & check ups

Lubrications

Planning & scheduling

Record analysis

Training of the maintenance crew

Collection or purchase of spares

Maintenance schedule of the different machines:

Boiler Maintanance Schedule:

Daily:

Check gas pressure

Maintain log sheet

Chemical dosing

Weekly:

Check all steam line

Fire quality of boiler

Monthly:

Check all steam line

Fire quality of boiler

Gas consumption report

Burner clean


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90 P a g e

Quarterly:

Burner clean

Economizer clean

Feed tank clean

Chemical tank clean

Sight glass clean

Half yearly:

Burner clean

Feed tank clean

Chemical tank clean

Economizer clean

Replace gasket

Replace valve

Check gas line & filter & pressure

Yearly:

Overhauling of boiler

Chemical cleaning of boiler

Safety valve test

Economizer clean

Feed tank clean

Chemical tank clean

Burner clean

Check safety valve setting

Replace valve & gasket

Boiler inspection by authority

Dyeing m/c maintenance Schedule

Daily:

Check belt tension

Check steam or water system & air supply

Check chemical pump

Machine clean

Weekly:

Bearing & belt check

Check leakage of air, steam &

Water line

Greasing bearing points

Add gland packing at pump

Monthly:


Replace bearing points (if required)

Gaskrt check

Clean steam trap


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Lubricating all chemical pump

Quarterly:

Replace belts

Repairing of pulley, shaft & bearing housing

Painting m/c & pipe line

Clean steam trap

Replace seals (if leakage)

Change gasket of steam of water lines

Half yearly:

Replace belts

Repairing pulley, shaft & bearing housing

Painting m/c, pipe line

Replace seals

Machine body repairing

Half yearly:

Replace belts

Repairing pulley, shaft & bearing housing

Painting m/c, pipe line

Replace seals

Machine body repairing

Yearly:

Machine overhauling

Hydro extractor Maintenance schedule:

Daily:

Machine clean

Belt checking

Weekly:

M/c clean

Belt clean

Greasing & lubricating of all points

Monthly:

M/c clean

Check gear oil quality

Quaterly:

Change of gear oil

Belt change

Half yearly:


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Change of gear oil

Belt change (if required)

Yearly:

Machine overhauling

Tensionless Dryer Maintainance Shedule;

Daily:

Check belt tension

Check steam supply & air system

Machine clean

Weekly:

Check fabric drying quality


Clean airfilter & regulator

Monthly:

Clean radiator & m/c cabinet


Clean air filter and regulator

Quarterly:

Replace belt

Replace gear oil

Duct clean

Half yearly:

Check roller condition

Greasing & lubricating all points

Yearly:

Machine overhauling

Tumble Dryer Maintainance schedule:

Daily:

Check belt

Steam leakage area

M/c clean

Weekly:

Heat exchange clean


Belt check

M/c clean

Monthly:


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Filter clean

Steam trap clean

Quarterly:

Replace belt

Replace gear oil

Duct clean

Gasket & valve change

Half yearly:

Gasket & valve change

Yearly:

Machine overhauling

Stenter m/c Maintainance schedule:

Daily:

Check belt tension

Check Steam supply & air system

M/c clean

Weekly:

Check fabric quality


Monthly:


Clean air filter & regulator

Clean steam trap

Quarterly:

Replace belts

Replace gear oil

Painting m/c & pipeline of the total system

Replace seals

Half yearly:

Check roller condition


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Check bearing condition

Yearly:

Machine overhauling

Remarks:

The maintenance department of Texeurop(BD)Ltd. is well equipped. It has

sufficient maintenance manpower including mechanical and electrical engineers.

They do the maintenance of the m/cs during the Eid vacation. Otherwise, they do

the breakdown maintenance. To increase the lifetime of the machineries and

ensure the proper running of the machinery.


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Chapter-VIII


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Production and profit are closely related. In order to get quality final product it needs fresh

raw materials as well as effective manpower and machinery in good condition. Utility in

conjugation with the three M’s plays an important role to maximize the production as well as

the profit.

Available Facility Of Utility

UTILITY Source

Electricity PDB & Generator

Gas TITAS

Compressed air Compressor

Steam Boiler

Water Natural Water by pump

Functions of Utility

Utility ensures power supply by generator.

Utility ensures water supply by pump.

It ensures steam by boiler.

It ensures compressed air handling by vacuum planning system.

It provides fuel and gas supply.

It provides workshop facilities.

ELECTRICITY

Texeurop (BD) Ltd. has two generators for power supply to ensure continuous dyeing &

knitting operation and help to fulfill their target production in garments. Gas generator is

widely used because of lower production cost.

Specification of generator:

Generator-1:

Type Gas Generator

Manufacturer Bangla cat

Manufactured Country USA

Year of Construction 2005

Rated Power Prime

Capacity 1030 KW

Effeciency 90%

Voltage 440


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97 P a g e

Frequency (Hz) 50 Hz

Rotating Speed (RPM) 1500

No of pump 2

Gas pressure 14 psi (9 psi minimum)

Oil required 6-7 litre/day

Cylinder No 16

Gas consumed 5 lac in BDT

Generator-2:

Type Gas Generator

Manufacturer Bangla cat

Manufactured Country USA

Year of Construction 2005

Rated Power Prime

Capacity 1600 KW

Effeciency 90%

Voltage 440

Frequency (Hz) 50 Hz

Rotating Speed (RPM) 1500

No of pump 2

Gas pressure 14 psi (9 psi minimum)

Oil required 9-10 litre/day

Cylinder No. 16

Gas consumed 6 lac in BDT

Besides these two generator, Texeurop(BD)Ltd has 10 KW national power grid electric

connection.

Power consumption of different sections:

In Dyeing floor : 700-750 KW

Knitting floor :5.5 KW/machine

In garments :450 KW.

WATER

Texeurop(BD)Ltd has own source of water from deep tube well by a submersible pump.

Water treatment plant:

Water Softening Method – Base Exchange Process

Depth of each pump: 500 ft

Production capacity : (of deep tube well)

Pump-1: 175-200 m3/hr with 50-55 hp


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Pump-2: 150 m3/hr with 38-42 hp

Delivery of Soft water :

Pump-1: 150 m3/hr

Pump-2: 100 m3/hr

Required water – Average less than 200 m3/hr

Hardness of unprocessed water: 80-130 ppm

Hardness of processed water: 0-5 ppm

Total project cost : 143 lac

WATER SUPPLY DETAILS: There are two deep tubes well for supplying water in the

factory. This unit collects water from the under ground and supplied into Oxidation tank of

40ft diameter and 16 ft depth. Then water taken into Sand filter by a pump and then to the

Resin filter. SODIUM XEOLITE is used as Resin. For dyeing section 02-05 ppm hardness is

maintain. This collecting water is reserve in reserve tank and then supply everywhere in the

factory by the booster pump.

Back wash: It is done to remove the waste from the filter(sand or resin) and it is given

for 1 hour.

Salt wash: When the desired hardness of water cant be found then a salt wash is done

Here a salt solution is poured into the resin filter for 15 min during that time the valve of

sand filter remain closed. After 15 min the valve is open and then normal and salt water

mixed and come through resin filter. Then hardness measured is time to time until desired

hardness is found.

Hrdness Test Method: Procedure:

1. Take 100 ml of samle water in a beaker.

2. Add 5 ml (NH)4 Cl Buffer solution.

3. Pour 1-2 drops of Erichrome black T solution.

4. Finally titrate it against EDTA (0.01M) solution.

Calculation:

1 ml of 0.01 M EDTA = 1 mg

Total hardness = volume of EDTA * 10 ppm.

100 ml sample are taken. But for ppm sample will be 1 litre, so the result will be 100 times

more.

STEAM SUPPLY:

Texeurop[(BD)Ltd use two boiler to supply steam for different operation where it is

necessary.

Specification of boiler:

Boiler -1:

Type of Boiler: Fire tube boiler

Company name: Cleaver & books


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99 P a g e

Model : CB700600150

Country: USA

Max. working Pressure: 150(PSI)

Running working pressure: 100 psi

Capacity:10 ton steam/hr

Actually produce: 9.4 ton/hr

BTU/HR : NAT

Heating surface: 3000 sft

Vapour Production capacity: 20700lb/hr

Electricity Required: 25 KW

Boiler-2:

Type of Boiler: Fire tube boiler

Company name: Cleaver & books

Model : CB400600150

Country: USA

Max. working Pressure: 150(PSI)

Running working pressure: 100 psi

Capacity:10 ton steam/hr

Actually produce: 9.4 ton/hr

BTU/HR : NAT

Heating surface: 3000 sft

Vapour Production capacity: 20700lb/hr

Electricity Required: 25 KW

Power Supply:

3 phase

Frequency: 50 Hz

Volts: 415 volts, 54 amp

Min.circuit ampacity: 61.5 amp

Max. rating of circuit protection; 216 amp

Blower motor: 20Hp

Air compressor: 7.5 hp

Oil heater: 7.5 KW

Control circuit: 120V, 1 phase, 50 hz,

Oil pump motor: 415 V, 3 phase, 50 hz, 1.8 amp.

Source of water in Boiler : Soft water from water treatment plant are used in this two

fire tube Boiler

Chemicals used: Ther are two chemicals are used in boiler for removing scaling. And this

chemicals are dosed with soft eater into the boiler throughout 24 hours by drop.

Chemicals are-

Protector 2001 (scale inhibitor for boiler)

Eraser 1001 (water scale inhibitor)

- Approximately 16 lac BDT has been invested in this two Boiler.


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100 P a g e

COMPRESSED AIR SUPPLY:

Compressor is mainly used to deliver compressed air to different section as

required. In Texeurop(BD)Ltd .There are two compressors are used to produce and

deliver compressed air to different section.

Specification of compressor:

No of compressor: 02

Manufacturer: ATLAS copco Airpower

Origin: Germany

Type: GA55C

P max. : 10 bar,145 psi, 1 MPa

P motor: 55KW, 75 hp

n motor: 2975 r/min

Air pressure: 08 bar( For factory)

Max pressure: 10 bar

Air suck: 5.83m3/min

- Temperature of compressor should not exceed 100 C

- Normal temperature: 94-98 C

- No of Reservior: 1

- capacity of Reservior: 1000 L

- 30% of total produced compressed air is used in Dyeing floor and others are

used in Knitting and garments.

GAS: The source of Gas is TITAS GAS LTD.

The gas is supplied to gas generator or different section (Boiler- for heating water) from the

main line of the TITAS GAS LTD.

COST OF DIFFERENT UTILITIES:

Electricity cost:

REB =3.8 TK / KW-HR

Gas generator = 1.80 TK / KW-HR

Gas cost:

4.94 Tk/m³ for boiler

3.66 Tk/m³ for generator

4.5 Tk/m³ for domestic purpose

Steam cost:

4.30 Tk. per kg fabric.


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THE EFFLUENT TREATMENT PLANT:

The Texeurop(BD)Ltd. has well organized Effluent treatment plant. Normally the

effluent generated from different sections of a textile mill must be treated before they are

discharged to environment. Various chemicals & physical means are introduced for this

purpose. The effluent treatment plant in Texeurop(BD)Ltd is chemical biological

combination process.

Objects: This process is provided for treating the effluents of dyeing, printing, finishing,

weaving & thus allow to discharge effluent as per by World Bank dept of environment of

Bangladesh.

Capacity : 40 tons/ hr

Cost : Tk. 6 / Litre

10 lac BDT spend per month in ETP.

Requirement of discharge effluent as per World Bank:

PH : 6 – 8

BOD : < 50

COD : < 250

SS : < 100

TDS : Not stated

Colour : Clear

Chemical used:

1. Ferrous Sulphate.

2. Lime.

3. Polyelectrolyte.

4. HCl

Chemical using procedure:

- 80 Kg Ferrous sulphate is mixed with 1000L water.

- 50 Kg Lime is mixed with 1000L water.

- 1 Kg Polyelctrolyte is mixed with 1000L water.

Product Quality Check: Following chemical tests are carried out to check the quality:

- BOD

- COD

- Total suspended solids

- Total dissolved solids

- Colour

- PH


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Typical Output of the Plant: Raw effluent colour Black/deep purple

Raw effluent pH 10

Treated effluent colour Light greenish

Treated Effluent pH 6-6.5

Treated Effluent Temp 380C

Treated effluent BOD 175-200

Treated effluent BOD 60-100

Flow Chart of Effluent Treatment :

Raw effluent

Equalization Tank

Flash mixing Tank

Flocculation tank

Tube settler tank-1

pH correction channel

Bacteria reactor-1

Bacteria reactor-2

Tube settler tank-2

Filter feed sump

Sludge Separation: Sludge of Tube settler

Sludge thickening plant

Centrifuge platform.

Remarks: As the new project Texeurop (BD) Ltd, but it has vast utility systems. There is a

skill manpower group of engineers and other technical staffs to look after these utility

services. They have to remain aware of solution on a great sense of responsibility for any

type of problem due to utility supply.

pH Check


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CHAPTER – IX


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Introduction : Inventory is planning and execution involves participation by most of the fundamental

segment of business sales, production, purchase, finance and accounting. Inventory is a

wider sense is defined as any idle resource of an enterprise how ever it is semi-finished

packing spares and other stocked in order to meet an expected demand or distribution.

OBJECTIVES OF INVENTORY CONTROL:

1) Financial activities:

a) To save amount of investment

b) To know the cash position

2) Property Protection:

a) Preventable waste

b) Insurable damage

c) Unauthorized use

3) Operating:

a) To obtain the best overall balance between production and

inventory carrying cost.

b) To minimize losses

c) To avoid stock out and to keep inventory holding costs in costs

in balance.

Scope of Inventory Control:

- Raw materials

Dyes store.

Other chemicals.

Grey fabrics.

- Finished fabric.

- Spare parts.

- General store:

Capital equipments.

Accessories.

Stationary.

Maintenance parts.

Frequency of Inventory Update:

1. Monthly inventory control

2. Annual inventory control


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Inventory Procedure

Bin Card

Store Requisition

Store Ledger Account

Daily Inspection & Package Report

Monthly Stock & Consumption Report

Monthly L/C wise Delivery Report

Received Delivery & Balance Stock

Inventory Control System for Raw Materials:

Dye store & other chemicals store

Both of these are received by the store in charge.

First he sends these to quality in-charge for inspection. If they are found to be of required

quality then they are taken to store by the storekeeper.

Store in-charge supplies these when required and records the date, type of material,

quantity and section in which supplied, in his register book.

Grey fabric store

Grey fabric is usually stored in another storeroom, which is separate from dyeing shade.

Grey fabric is first sent to the QC department for quality assurance and then taken to the

storeroom.

Grey fabric is received by fabric store in-charge.

He supplies the fabric as per requirement and records the date, type of material, quantity

and section in which supplied, in his register book.

At present the grey fabrics store of Texeurop (BD) LTD.containing the following

types of fabrics-

Single jersey.

1x1 Rib.

2x2 Rib.

2x1 Rib.

Melange.

Pique.

Single jersey (with Lycra attachment)

1x1 Rib (with Lycra attachment) etc.

Single lacost

Double lacost

Fleece

Terry Fleece

Interlock


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Stages of Grey Fabric Inventory Control:

After knitting production.

Grey inspection.

Warehouse.

Batch preparation.

Dye house.

Inventory Control System for Finished fabric: Finished fabric from the compactor or stenter goes to inspection team. Here inspection is

done by a four points system.

Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness

etc are tested from the lab before packaging.

After finishing the fabric is kept in package before their transfer to the garments

department.

It is controlled by the finishing in-charge who keeps a list of total finished product. He

also keeps a list of delivery products.

He supplies the fabric as per requirement and records the date, type of material, quantity

and section in which supplied, in his register book.

Stages of Finished Fabric Inventory Control:

Finishing section.

After final inspection.

Others: There is a central store at Texeurop (BD) Ltd. In that store the various types of

forms, papers; stationary & other necessary goods are kept.

Inventory Control System for Spare Parts: Spare store officer keeps the spare parts in store and makes a list of spare parts.

If the spare parts are little in stock he gives requisition to maintenance manager.

Maintenance manager gives requisition to head office. Head office imports spare parts or

buys from local market as per requirement.

As new spare parts arrive to store officer, he receives and catalogues them.

He supplies the spare parts as per requirement and records the date, type of material,

quantity and section in which supplied, in his register book.

Remarks:

Texeurop(BD)Ltd. has individual stores for raw materials, finished goods and spare parts.

The store of dyestuff and chemicals are not so clean. There is not enough space to store

the finished goods. It requires increasing the store area.


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CHAPTER-X


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Introduction: Costing system mainly describes how the cost of the final product is fixed by the company/benificiar.

So Costing is a process by which the setting price of a product is calculated. It is a very important

task for a factory which runs for business purposes. And it is also strictly followed in the Texeurop

(BD) Ltd. Costing of the products considering the raw materials expenditure, salary and wages of

officers and workers, distributions and advertisement expenses etc. All direct and indirect expenses

are need to be considered during costing. It is determined by a team of accountants with advice and

consultancy of executive director.

Costing Of the Product

The following points are considered for costing any dyed product in Texeurop (BD) Ltd.

Total cost of yarn

Cost of fabric Production

Total dyes & chemical cost

Total utility cost

Salary

Payment

Transport cost1

Miscellaneous cost

Government cash incentive

Price of the Product: Generally price of product is determined by the required profit adding to the total

expenses. So,

Price of products= (Direct expenses + Indirect expenses + Factory

Overhead) + Required profit

Price Range of Different Products:

T-Shirt = $0.75 - $4.50 /Pcs

Polo Shirt =$2.00 - $6.50 /Pcs

Kids Wear ==$0.75- $2.15 /Pcs

Knitting Charge of Different Fabrics:

Fabric name Charge per kg

(Tk)

1. Single Jersey 09

2. Single Jersey with Lycra 30

3. Single locust 16

4. Double lacost 16

5. Rib 17

6. Rib with Lycra 30

7. Interlock 25


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8. Fleece 22-25

Dyeing Charge of Different Fabrics:

Name of fabric process Charge per kg(Tk)

White with Enzyme 35

White without Enzyme 30

Avg. color with Enzyme 85

Avg.color without Enzyme (Light& med.) 75

Deep shade with Enzyme (Black) 110

Deep shade without Enzyme (Black) 95

Only wash (Tubular) 25

Only wash (Open) 45

Double dyeing (Face & Back) 115

Finishing Charge of Different Fabrics:

Name of fabric process Charge per kg(Tk)

Slitting only 5

Stenter only 25

Compacting only 15

Stenter + Compacting 35

Stenter + Compacting+ wash 50

Tube Compacting 10

Costing Of the Product:

Let price of yarn is $ 3.00/ kg.

Process loss of yarn for knitting (10%) = $0.30

Knitting fabric cost = $3.30

Cost of dyes & chemicals = $2.50

Process loss for dyeing (12%) = $0.30

Dyed fabric cost = $ 6.10

Packing cost = $0.05

Production cost of fabric=$6.15

Fabric price (with 25% margin) =$7.79

Fabric consumption/ doz. =

(Body length + Sleeve length) x Chest length x 2 x GSM x12 /10000000

Garments specification(For a particular garment):

Body length=78 cm

Sleeve length=33 cm

Chest length=62 cm


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110 P a g e

GSM=210

Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000

= 3.469 kg

Fabric consumption/ doz. (with 10% wastage) = 3.816 kg

Body fabric cost / doz. =$(7.79x 3.816)

= $29.73

Cost of collar& cuff/ doz.= $ 4.00

Cost of Trims=$ 2.25

Cost of Trims (with 5% Process loss) = $2.36

Production Cost of Garments/ doz.=$36.09

Garments Price/ doz. (with 25% Profit) =$45.12

Remarks:

Proper Costing is very important for a productive factory. Without proper costing all

production will go to vain. Because a factory cannot reach to its goal without achieving good

profit and good profit is not possible without proper costing. So costing Should be done by a

group of intelligent, experienced, highly qualified personnel. Every Factory has some rules

and regulations. Texeurop (BD) Ltd. did not provide us all the documents of costing,

because its confidentialty.So this Chapter is not so sufficient to analyze the costing of

product.


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CHAPTER- XI


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Introduction: As Texeurop (BD) Ltd. is a 100% Export oriented indutry no product can be marketed at the

local market.The goods produced at this factory are exported at different countries of the

world. Texeurop (BD) Ltd. has a number of renowned buyers. Following are the important buyers

of Texeurop (BD) Ltd.

Okaidi

Obaidi

J.C. Penny

Lerros

Street One

Vert Baudet

O.B.S

Innovation Club

Gerry Weber

TK International

Bluhm Klon

Primark

Multiline

H & M

Walmart

MMC

Following are the different local Buyer whose provide Sub-contracts for Texeurop (BD) Ltd.

Teba Group Pantex and Scarlet (Garments industry of Texeurop (BD) Ltd.) Epic Group Islam Group Hi-Fashion Matrix Needle touch Brine Knit Razzak Textile Dip Knit

Product Label:

There are following labels used by this mill:

1) Care Label: It contains washing in hot or cold water, chemical cleaning, drying

conditions etc.

2) Size Label: It contains size of garments.

3) Composition Label: It contains the fabric composition of different fibre type.

4) Decorative Label: Decoration is as buyer or consumer choice wise.

Package Size & Label Market:Package size & label differs from buyer to buyer. The Package

size & label are prepared according to the buyer requirements. Normally the following package sizes

are used: -

60 x 40 x 40 cm.

58 x 33 x 44 / 43 / 42 cm.

58 x 33 x 25 cm.

58 x 33 x 13 / 16 / 18 cm.


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LOCAL MARKET: Texeurop (BD) Ltd. is 100% export oriented mill. So there is no local market involved in it. But the

knitting section takes some sub-contact for knitting an amount of fabrics from their given yarn.

Importing Countries: There are some countries which are importing goods from Texeurop (BD) Ltd. which are given

below-

United State of America

England

France

Germany

Italy

UK

Manpower of Marketing:

Marketing is the important department of any industry or institution to descibe the features

of the products to the buyer & to communicate with the buyer. Almost ten marketing officers

and ten others workers act under the Executive Director.

Marketing Strategy:

At Texeurop (BD) Ltd. senior marketing officers, merchandiser & higher officials deal

with the buyer. There are some fixed buyers of the industry. The buyers give their orders

continuously all over the year. The marketing officers & the merchandisers communicate

with the buying houses to collect the orders.

By the understanding of both side the rate & the order quantity are fixed.

A well defined marketing strategy has the following characteristics:

o Good quality

o Low price or competitive price

o Prompt service

o Good commitment

o Good business communication

Duties & Responsibilities Of Marketing Officer:

Job summery:

Market search

Market development

Customer’s motivation

Production follow up

Technical assistance of customer

Dealing with the buyer & convince the buyer is the main duty of marketing officer. A

marketing officer also has some other duties. The main duties & responsibilities of a

marketing officer are given bellow-

Executive director takes order from the buyer and gives order the marketing

officer’s troops to produce a cost sheet.

Marketing officers are known the amount and design of product.


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They collect the sample from the buyers and send to knitting and dyeing section.

Knitting section adjusts the amount of total yarn and knitting conditions and

dyeing sections adjust the amount of dyes and chemicals. They send a rough

calculation to the marketing section.

Marketing officers adjust the amount of garments accessories with the help of

their own experiences and their knowledge. They also take help of garments in

charge.

Finally, they adjust their cost sheet after consulting with the Executive Director

and copy several pieces of the cost sheet.

Basically the responsibilities & duties of marketing officer begins from getting order of

buyer & ends after sending goods to the buyer. So, he should be always smart, energetic &

sincere to work.

Merchandising

Garment merchandising is a complicated and detail oriented job. If this task can be

performed successfully & properly then it will bring both money and reputation for the

industry. But when a merchandising department of an industry fails it will be a great threat

for the existence of industry. For this reason the merchandiser of textile industry must be

highly qualified, well trained and experienced.

In the Texeurop (BD) Ltd. fully skilled and experienced personnel run the merchandising

section. After receiving an order, the merchandiser with the help of pattern master calculates

the total consumption of fabric. Then according to the cost detail sheet and the price

mentioned by the buyer costing is done. After the price is negotiated with the buyer order is

placed to the suppliers of raw material and accessories.

The manufacturing factory as per the requirement suppliers the fabric and a ledger is

maintained regularly to assess the production status. The accessories such as label, button,

zipper, sewing thread, packing materials are collected from outside [sometime mentioned by

the buyer] through back-to-back L/Cs. The merchandising department also looks for the

sources for procuring yarns to produce fabric.

Merchandising section monitors the production status regularly and ensures timely delivery

of the shipment.

REMARKS: Marketing activities are very important tasks for a productive factory. A well-planned

marketing strategy can help an industry to meet its goal. In this mill, there having highly

qualified marketing officers. As a result, the mill is getting more order from the buyers


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CHAPTER- XII


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Conclusion: We have completed our industrial attachment successfully by the grace of Allah.

Industrial attachment sends us to the expected destiny of practical life. The completion of the

two months Industrial attachment at Texeurop (BD) Ltd. we have got the impression that

factory is one of the most modern export oriented knit composite complex in Bangladesh.

Though it was established only a few year’s ago, it has earned “very good reputations” for its

best performance over many other export oriented textile mills.

During our training period, talking with the clients of this mill we knew that the mill is

fulfilling the country’s best export oriented white finished fabric as well as very good

colored fabric due to its modern machinery & good management system.

Mill is settled with utility to give all convenient supports to the productions for twenty-four

hours. It had self-power generator system to satisfy total power consumptions of the mill.

We are enough fortunate that we have got an opportunity of having a training in this mill.

During the training period we are received co-operation and association from the authority

full & found all man, machines & materials on appreciable working condition. All stuffs &

officers were very sincere & devoted their duties to achieve their goal.

There are some suggestions from us within our limited knowledge

Some Suggestions:

The m/c stoppage time should be analyzed and minimized. The maintenance should be carried

out when the m/c is out of action (wherever possible) and routine maintenance should be

carried out regularly.

There should be a yarn-dyeing project.

Sitting arrangement of production officers should be improved.

There should be textile engineers for the finishing, merchandising and garments section.

The dyeing floor is watery most of the time: it should be cleaned all the time.

Knitting capacity need to be increased to meet the dyeing production continuously.

To increase overall efficiency, more skilled labor should be used in a project.

Limitations of the Report:

We didn’t have the opportunity to work in the lab (except one girl). So in spit

of having the facility, we could not get the chance to learn about it.

Because of secrecy act, the data on costing and marketing activities has not

been supplied in details.

In spite of our limited time, we could not study in detail.


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Some of the points in different chapter are not described as these were not

available.

The whole process is not possible to bind in such a small frame as this report,

hence our effort spent on summarizing them.

Lastly:

We tried our best to collect all necessary information but it is true that within this short

period it is quite impossible to achieve 100% success but as a whole this industrial training

was a satisfactory one and once again wed would like to thank the authority of Texeurop

(BD) Ltd. as well as our honorable teachers far their altruistic help and advice. We are

fortunate enough that we have got an opportunity to have training in this mill. During the

training period we have received enough co-operation and association from the authority and

found all personnel. All stuffs and officers were very sincere and devoted their duties to

achieve their goal.


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Documents

Internship Report at Texeurope (BD) Ltd. by Azad