Industrial Attachment Report Padma Poly Cotton Knit Fabrics Ltd.

CHAPTER-01
INTRODUCTION
Dept. of Textile Engineering, MBSTU
Page 1
INTRODUCTION
By means of practical knowledge its not possible to apply the theoretical knowledge in the
practical field. For any technical education, practical experience is almost equal important in
association with the theoretical knowledge.
The industrial attachment is the process, which builds understanding, skills and attitude
of the performer, which improves his knowledge in boosting productivity and services.
University education provides us vast theoretical knowledge as well as more practical
attachment, in despite of all these industrial attachment helps us to be familiar with technical
support of modern machinery, skill ness about various processing stages.
It also provides us sufficient practical knowledge about production management, work
study, efficiency, industrial management, purchasing, utility and maintenance of machinery and
their operation techniques etc. the above mentioned cannot be achieved successfully by means of
theoretical knowledge only. This is why it should be accomplished with practical knowledge in
which it is based on. Industrial attachment makes us reliable to be accustomed with the industrial
atmosphere and improve courage and inspiration to take self-responsibility.
Textile education cant be completed without industrial training. Because this industrial
training minimizes the gap between theoretical and practical knowledge and make us accustomed
to industrial environment. I got an opportunity to complete two-months long industrial training at
Padma Poly Cotton Ltd, which is a 100% export-oriented composite Knit Dyeing Industry. It has
well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate
knitting and knitwear manufacturing.
Page 2
1.1 OBJECTIVE OF INDUSTRIAL ATTACHMENT
B. Sc in Textile Technology is the combination of theoretical knowledge along with the practical
experience. We as the Graduates of Textile Technology must acquire adequate practical
knowledge to coup up with the challenge that we will face in future. This is the why the
Industrial Training has been included in our academic curriculum.
The main objective of this training is to comprehend our theoretical knowledge along with the
practical knowledge. It also enables us to orient ourselves with the practical environment that we
will work in future. We systematically learned about various steps of Fabric
manufacturing. Moreover we knew about the man management technique. We also learned about
merchandising and buyer co-ordination.
Page 3
1.2 LOCATION OF MILL
Page 4
1.3 GENERAL INFO ABOUT MILL

Table 1 Company Profile
Name of the mill :
Padma PolyCotton Knit Fabrics Limited
Status :
Private Limited Company
Type :
Knit composite mill.
Year of establishment :
1995 Year
Year of starting production :
1995 Year
Address: Factory:
131 Tejgaon Industrial Area, Dhaka.
Head Office:
5, Rajuk Avenue,Dhaka-1000
Tel: 9460917-20. Fax: 880956204
Email: Padma@bd.com
100% cotton
100% polyester
Raw Materials:
a) Spun
b) Filament
100% Viscose
95% cotton 5% lycra
95% polyester 5% lycra
95% viscose 5% lycra
60% cotton 40% polyester
50% polyester 50% sulcool
48% cotton 48% modal 4% lycra
Production Capacity:
a) Knitting Section
a) 8 Ton/Day
Page 5
b) Dying Section
b) 25 Ton/day
c) Cutting Section
c) 65000 Pcs/day
d) Sewing Section
d) 60000 Pcs/day
e) Printing Section
e) 60000 Pcs/Day
f) Embroidery Section
f) 35000 Pcs/Day
g) Garment Washing Capacity
g) 15000 Pcs/Day
Yearly Turnover:
2 Million US dollar per year(approx.)
Different Departments:
a) Knitting Section
Knitting section
Inspection
b) Dyeing Section
Batch section
Dyeing lab.
Dyeing section
Quality control
Finishing
c) Garments Section
Cutting
Sewing
R.N.D. / Sample
Finishing & packing
Quality Control
I.E.N. & planning
Store
Page 6
d) Merchandising & Marketing
e) Maintenance Section
Electrical
Mechanical
f) Store Section
Supporting Departments
Security department
HRD
Marketing
Procurement
Finance and accounting
Personnel administration
Total Manpower:
Over 700
Major Customers:
Sub-Contracts from different Industries
Page 7
CHAPTER-02
Manpower Management
Page 8
2.1 TOP MANAGEMENT ORGANOGRAM
Page 9
2.2 SHIFT CHANGE
Three shifts (A, B, C): each of 8 hours
1. A Shift: 6 A.M to 2 P.M.

2. B Shift: 2 P.M. to 10 P.M
3. C Shift: 10 P.M. to 6 A.M
General Shift: 9 A.M to 8 P.M.
Office Time : 9 AM to 5 PM
2.3 RESPONSIBILITIES OF HR
Man Power Planning.

Man Power recruitment.
Man Power Selection.
To monitor Performance of Management.
To Observe Disciplinary cases.
To look after the welfare of worker.
To handle Grievances of worker
Page 10
2.4 JOB DESCRIPTION AND RESPONSIBILITIES:
Title : Supervisor
Dept. /Section : Knitting/Dyeing

Report to : Shift Incharge
Job summary: To guide the operator and helpers working at the production unit, motivation the
workers when necessary, Check the materials list whether they are at the right quantity or not.
Title : Shift Incharge
Dept. /Section : Knitting/Dyeing

Report to : Production Officer
Job summary: To follow the workers movement, To maintenance the production sequence,to
check the sample at certain time interval, To set programs for the supervisions.
Title : Production Officer
Dept/Section : Knitting/Dyeing
Report to : Manager
Job summary: To plan, execute & follows up the production activities & control the quality
Production with related activities.
Title : Manager
Report to : General Manager
Page 11
Job summary: To plan for the sequence of production, To arrange necessary raw material for
the production, to follow up the production and give solution to the production problems, To
supervise the personal working under him.
Title : General Manager
Report to : Director and Chairmen
Job summary: To plan,apply and administrative function, To set up the price for the product, To
deal with the buyer and merchandiser .
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
Page 12
CHAPTER-03
Research & Development &
planning Department
Page 13
3.1 WORKING PROCEDURE OF R & D
Party
R & D (Approval Sheet)
Planning
Knitting (Knit of the fabric)

Quality control
Dyeing
Quality Control (Shade matching)
Finishing
Finishing Inspection
Delivery to Party
Page 14
3.2 WORKING PROCEDURE PLANNING DEPARTMENT
R & D (Approval Sheet)
Knitting M/C Select
Batching Plan for Dyeing
Dyeing M/C Program
Finish Priority Program
RFD (Ready for Fabric Delivery)
On Time Fabric Delivery
Page 15
CHAPTER-04
Machine Description
Page 16
Knitted structures are progressively built up from row of intermeshed loops. The newly feed yarn
converted into a new loop in each needle hook. The needle then draws a new loop head first
through the old loop, which remains from previous knitted cycle. The needles at the same time
release the old loop so that they hang suspended by their heads from the feet of the new loops
whose heads are still held in the hook of the needles.
A cohesive knitted loop structure is thus produced by a combination of the intermeshed needle
loops and yarn that passes from needle loop to needle loop.
Padma PolyCotton Knit Fabrics Limited is well equipped modern export oriented industry. It has
high quality machinery with large production. There are 2 types of machine in this industry.
These are: Circular knitting machine
Single jersey machine

Double jersey machine
Flatbed machine (cuff & collar).
Page 17
4.1 MACHINE AT A GLANCE

Table 2: Number of Machines
Machine type
Machine name
Total no
Single jersey
28
Double jersey
14
Collar , cuff
33
Circular knitting machine
Flat knitting machine
Page 18
4.2 LAYOUT OF THE 1ST FLOOR OF KNITTING SECTION
Page 19
4.3 MACHINE SPECIFICATION OF 1ST FLOOR

Machine-01
Machine Name
: Orizio-01
Machine Type
: Single Jersey
Machine dia
: 26
Machine gauge
: 24
Feeder
: 84
Origin
:Italy
Machine-02
Machine Name
: Orizio-02
Machine Type
: Single Jersey
Machine dia
: 26
Machine gauge
: 24
Feeder
: 84
Origin
: Italy
Machine-03
Machine Name
: Orizio-03
Machine Type
: Single Jersey
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-04
Machine Name
: Orizio-04
Machine Type
: Single Jersey
Page 20
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-05
Machine Name
: Orizio-05
Machine Type
: Single Jersey
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-06
Machine Name
: Orizio-06
Machine Type
: Lycra Rib
Machine dia
: 30
Machine gauge
: 18
Feeder
: 60
Origin
: Italy
Machine-07
Machine Name
: Orizio-07
Machine Type
: Lycra Rib
Machine dia
: 30
Machine gauge
: 18
Feeder
: 60
Origin
: Italy
Page 21
Machine-08
Machine Name
: Orizio-08
Machine Type
: Fleece
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-09
Machine Name
: Orizio-09
Machine Type
: Single Jersey
Machine dia
: 20
Machine gauge
: 20
Feeder
: 96
Origin
: Italy
Machine-10
Machine Name
: Orizio-10
Machine Type
: Single Jersey
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-11
Machine Name
: Orizio-11
Machine Type
: Single Jersey
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Page 22
Machine-12
Machine Name
: Orizio-12
Machine Type
: P/Interlock
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-13
Machine Name
: Orizio-13
Machine Type
: P/Interlock
Machine dia
: 30
Machine gauge
: 24
Feeder
: 96
Origin
: Italy
Machine-14
Machine Name
: Orizio-14
Machine Type
: P/Interlock
Machine dia
: 30
Machine gauge
: 22
Feeder
: 96
Origin
: Italy
Machine-15
Machine Name
: Orizio-16
Machine Type
: Rib
Machine dia
: 36
Machine gauge
: 18
Feeder
: 72
Origin
: Italy
Page 23
Machine-16
Machine Name
: Orizio-17
Machine Type
: Lycra Rib
Machine dia
: 30
Machine gauge
: 18
Feeder
: 96
Origin
: Italy
Machine-17
Machine Name
: Baso-6
Machine Type
: Fleece
Machine dia
: 32
Machine gauge
: 20
Feeder
: 102
Origin
: China
Machine-18
Machine Name
: Baso-7
Machine Type
: Fleece
Machine dia
: 35
Machine gauge
: 24
Feeder
: 108
Origin
: China
Machine-19
Machine Name
: Mayer & Cie-1
Machine Type
: Fleece
Machine dia
: 30
Machine gauge
: 20
Feeder
: 96
Origin
: Germany
Page 24
Machine-20
Machine Name
: Mayer & Cie-2
Machine Type
: Fleece
Machine dia
: 30
Machine gauge
: 20
Feeder
: 96
Origin
: Germany
Machine-21
Machine Name
: Mayer & Cie-7
Machine Type
: Rib
Machine dia
: 36
Machine gauge
: 20
Feeder
: 62
Origin
: Germany
Machine-22
Machine Name
: Terrot-17
Machine Type
: Single Jersey
Machine dia
: 22
Machine gauge
: 24
Feeder
: 70
Origin
: Germany
Machine-23
Machine Name
: Terrot-25
Machine Type
: Single Jersey/Heavy Jersey
Machine dia
: 24
Machine gauge
: 20
Feeder
: 70
Origin
: Germany
Page 25
Machine-24
Machine Name
: Terrot-26
Machine Type
: Single Jersey
Machine dia
: 34
Machine gauge
: 24
Feeder
: 108
Origin
: Germany
Machine-25
Machine Name
: Terrot-27
Machine Type
: Lycra Rib
Machine dia
: 34
Machine gauge
: 18
Feeder
: 60
Origin
: Germany
Machine-26
Machine Name
: Terrot-28
Machine Type
: Rib
Machine dia
: 36
Machine gauge
: 18
Feeder
: 34
Origin
: Germany
Machine-27
Machine Name
: Terrot-29
Machine Type
: Lycra Rib
Machine dia
: 30
Machine gauge
: 18
Feeder
: 54
Origin
: Germany
Page 26

3220G
3818G
3424G
J-02
L-03
J-03
3624G
J-04
3424G
J-05
3220G
L-02
2824G
J-01
3424G
P-01
3624G
P-02
3624G
P-03
4224G
P-04
4018G
P-05
Inspection m/c
4.4 LAYOUT OF THE 2ND FLOOR OF KNITTING SECTION
J=Jiahao P= Pai Lung L= Lisky
Page 27
4.5 MACHINE SPECIFICATION OF 2ND FLOOR

Machine-28
Machine Name
: Pailung-1
Machine Type
: Single Jersey
Machine dia
: 34
Machine gauge
: 24
Feeder
: 102
Origin
: Taiwan
Machine-29
Machine Name
: Pailung-2
Machine Type
: Fleece/Terry
Machine dia
: 36
Machine gauge
: 24
Feeder
: 108
Origin
: Taiwan
Machine-30
Machine Name
: Pailung-3
Machine Type
: Single Jersey
Machine dia
: 36
Machine gauge
: 24
Feeder
: 108
Origin
: Taiwan
Machine-31
Machine Name
: Pailung-4
Machine Type
: Single Jersey
Page 28
Machine dia
: 42
Machine gauge
: 24
Feeder
: 126
Origin
: Taiwan
Machine-32
Machine Name
: Pailung-5
Machine Type
: Double Jersey
Machine dia
: 40
Machine gauge
: 24
Feeder
: 80
Origin
: Taiwan
Machine-33
Machine Name
: Lisky-1
Machine Type
: Fleece
Machine dia
: 40
Machine gauge
: 24
Feeder
: 80
Origin
: Taiwan
Machine-34
Machine Name
: Lisky-2
Machine Type
: Fleece
Machine dia
: 40
Machine gauge
: 24
Feeder
: 80
Origin
: Taiwan
Page 29
Machine-35
Machine Name
: Baso-1
Machine Type
: Single Jersey
Machine dia
: 28
Machine gauge
: 24
Feeder
: 84
Origin
: Taiwan
Machine-36
Machine Name
: Baso-2
Machine Type
: Single Jersey
Machine dia
: 34
Machine gauge
: 24
Feeder
: 102
Origin
: Taiwan
Machine-37
Machine Name
: Baso-3
Machine Type
: Double Jersey
Machine dia
: 38
Machine gauge
: 24
Feeder
: 76
Origin
: Taiwan
Machine-38
Machine Name
: Baso-4
Machine Type
: Single Jersey
Machine dia
: 36
Machine gauge
: 24
Feeder
: 108
Origin
: Taiwan
Page 30
Machine-36
Machine Name
: Baso-5
Machine Type
: Single Jersey
Machine dia
: 30
Machine gauge
: 24
Feeder
: 90
Origin
: Taiwan
Page 31
4.6 MACHINE LAYOUT OF COLLAR,CUFF SECTION
Page 32
4.7 MACHINE SPECIFICATION OF COLLAR,CUFF

SECTION
Machine Type
Company
Brand name
Gauge
Origin
Name
Fully
Matsuya
Automatic
Corporation
Total no of
machine
G 14
Japan
19
Flying Tiger
G 14
Taiwan
G 14
Japan
Saehwa loom
Korea
Flat bed
knitting
machine
Computerized
Sheng Meel
Flat Bed
machine
knitting
manufacturing
machine
limited
Computerized
Shima Seiki
Flatbed
manufacturing
knitting
limited
machine
Tape Making
Saehwa
Machine
Precision
Machine
Company
Page 33
4.8 LAYOUT OF THE DYEING FLOOR
Page 34
4.9 MACHINE SPECIFICATION OF DYEING FLOOR

DYEING MACHINE:
M/C # 1: MCS
TYPE
: MCS , Water flow , high temp. m/c
Origin
: Made in Italy
Capacity
: 800 kg
m: l
: 1:6
M/C # 02: THEN
TYPE
: Air flow, high temp. m/c
Origin
: Made in Germany
Capacity
: 800 kg
m: l
: 1:7
M/C # 03: Brazzole
TYPE
: MCS , Water flow
Origin
: Made in Italy
Capacity
: 1500 kg
m: l
: 1:6
M/C # 09: Brazzole

TYPE
: MCS , Water flow , high temp. m/c
Origin
: Made in Italy
Capacity
: 1200 kg
m: l
: 1:5
Page 35
M/C # 10: Khung Yang
TYPE
: Water flow, low temp. m/c
Origin
: Made in Korean
Capacity
: 30 kg
m: l
1:7
M/C # 11: AK
TYPE
: Water flow, low temp. m/c
Origin
: Made in Korean
Capacity
: 1200 kg
m: l
: 1:8
FINISHING MACHINES:
M/C # 01: Corino

TYPE
: DMS 07 Fabric Centrifuge m/c
Origin
: Made in Germany
Total Power
: 16.12 kw
Capacity
500 kg
Function
Squeezing of fabric
Page 36
M/C # 02: Bianco

Origin
Made in Italy
Type
Tessli m/c
Function
Slitting & Squeezing of fabric
Origin:
Made in Italy
Function
Sliting of fabric
M/C # 03:Bianco
M/C # 04:Ferraro
Orizin
: Made in Germany
Capacity
: 600
Function
: Dia, GSM, Shrinkage control, Calendering
M/C # 05:Xetma Vollenweider

Origin
: Made in Italy
Capacity
: 1200 kg/ 12 hour
Funtion
: Brushing.
M/C # 06: Bianco

STENTER M/C
Temp
250C(lycra temp high)
Capacity
1ton/shift
Speed
7m/min(maximum 16-22)
Page 37
4.10 DETAILS ABOUT SOME MACHINES

CIRCULAR KNITTING MACHINE
Circular knitting m/cs. are widely used throughout the knitting industry to produce fabric.
This m/c can be built in almost any reasonable diameter and the small diameter of up to
five, which are used for wear.
Machine for outerwear and under wear may vary from 12 inch to 60 inch in diameter
according to manufactures requirement. This m/c can be used either as fabric or for
making garments completely with fancy stitch. Latch needles are commonly employed in
all modern circular m/c because of their simple action and also their ability to process
more types of yarns.
Plain circular m/c uses only one sets of needles, circular rib m/c uses two set of needles i,
e, Cylinder needle and Dial needle, the interlock circular knitting m/c also uses two sets
of needles by needles are long and short respectively for both dial and cylinder, that is
why multiple design and thick fabric can be produce with that m/c. That m/c is also
called double Jersey m/c.
M/c. Gauge needle/inch (varies according to diameter)

Needle Type Latch
Needle bed type Single cylinder, Double cylinder, Cylinder & Dial,
long or short needles for cylinder and dial.
Two principle operation exist:

1. English system Where the cams and yarns strands revolve by needle and fabric
take down is stationary.
2. American system Where the needles and fabric take down revolves by cams
and yarn strands are stationary.
Page 38
Page 39
IMOPORTANT EQUIPMENT OF CIRCULAR KNITTING M/C
1. Start/Stop/Inch Buttons: Complete set of easily accessible start/stop/inch buttons at

top in each leg.
2. Ratchet Lever: Permit hand movement of the M/C.
3. Auto Stop Motion: Automatic three stages 24v yarn motion, positive feed tapes &
knitting zone. Indicator lamps are on individual stop motions & on the main control
panel. While the yarn is broken we can find the location which is broken as well as to
repair, meanwhile the motor can break and stop operation at once to keep the security of
M/C.
4. Free Standing Side Creel: With an active reserve package for each feed.
5. Auto Counter: Two shift revolution with display counter with predetermined stop, to
settle freely the weight or yardage of fabric.
6. Variable Speed Drive With m/c Brake: Transistor inverter provided for free
controlled, the process of V.S. motor-drive from slow operation to normal operation is
quite & fast break to prevent damages in case of needles or yarn breakage.
7. Fabric Take-up System: With variable speed control by a belt drive set can be
adjusted the speed for different course of fabric-constant and uniform fabric tension.
8. Safety Guard Switch: Machine cannot be started with guards open; this guards have
reinforced fiberglass window for easy fabric inspection.
Page 40
9. Auto Lubrication: The automatic central pressurized oil sprayer can be adjusted at
cycling time and quantity to make cylinder, dial, sinker rings cam, needles and sinkers
lubricated enough, besides it has the function cooling and clearing.
10. Auto-line Removal System: Three fans on each rotating arm for clearing off any
dust of creel and knitting zone.
Page 41
PARTS OF CIRCULAR KNITTING MACHINE
Knit cam
Miss Cam
Tuck Cam
Sinker
Page 42
MAIN ELEMENTS OF CIRCULAR KNITTING MACHINE:

1. Needle
2. Cam
3. Sinker
Needle: The fundamental element of construction of knitted fabric is the knitting

needle. Needle is the hooked metal part which is used for the formation of loops.
The needles are the most important stitch forming elements. During yarn feeding,
the hook is opened to release the retrained old loop & to receive the new loop
which is then enclosed in the hook. They are displayed vertically up & down and
are mounted into the tricks or cuts of the knitting cylinder. All kinds of knitting
needle should have the system to make a new loop and return back to the old loop.
There are three types of needle namely:
i.
Latch needle
ii.
Spring bearded needle, and
iii.
Compound needle
hook
latch
stem
butt
Fig: Needle [latch needle]
Page 43
Sinker: Sinker is the second knitting element. It is a thin metal plate within an
individual or collective action operating approximately at right from the hook side
between adjacent needles. It may perform one or more of the following functions
dependent upon the machines action and related sinker shape and movement.
iv.
Loop formation
v.
Holding down
vi.
Knocking over
1=Butt,2=Butt breadth,3=Height of shank,4=Buldge,5=Neb,6=Length of

neb,7=Throat angle,8=Sinker platform height,9=Breadth of lower
shank,10=Clearance,11=Throat
Fig: sinker.
Cam: Cam are the third primary knitting elements which cover the rotary
machine drive into a suitable reciprocating action for the needles and other
Page 44
elements. The cams are carefully profiled to produce precisely timed movement
and dwell periods. The drive transmitted and adapted via cam followers, leavers,
pivots and rocking shafts. One complete revolution of the driving shaft is
equivalent to one knitting cycle.
There are mainly two types of Cams:
i. Engineering cams
ii. Knitting cams: 3 Types.
a. Knit cam
b. Tuck cam
c. Miss cam
Fig: Cam
Page 45
CHAPTER-05
Raw Materials
Page 46
5.1 INTRODUCTION
Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in continuous production and for high quality fabric. Padma Poly Cotton Knit Fabrics
Limited Takes yarn as its raw materials for its initial production of knitted fabrics to make
garments. It is dependent on different spinning mills of home and abroad to collect different
types of yarn as it requires. It also needs dyestuffs for use in wet processing unit.
5.2 RAW MATERIAL FOR KNITTING(YARN)
Type of yarn
Count (depend on GSM)
Cotton
20S, 22S, 24s, 26s, 28s, 30s, 32s, 34S, 40S
Polyester
72 D,75 D, 100 D
Lycra yarn
20D, 40D
Grey Mlange (5%, 10%, 15 %)
24S, 26S
PC (65%Polyester & 35% cotton)
24S, 26S, 28S, 30S
CVC
24S, 26S, 28S, 30S
5.3 SOURCES OF YARN

1. Pacific Cot spin Ltd. (India)
8. Youth Spinning Mills Ltd
2. Contermann Peipers (India) Ltd.
9. MSML Textiles Mills Ltd
3. Padma (1, 2) Beximco Ltd.
10. UTAH Spinning Mills Ltd.
4. Shameem Composite Mills Ltd.
11. OTTO Spinning Mills Ltd.
5. Shohagpur Textiles Mills.
12. Comilla Spinning Mills Ltd.
6. Welspur Syntex Ltd.(India)
13. Keya Spinning Mills Ltd.
Page 47
7. Square Textiles Mills Ltd.
14. Toplon Hyosung Corporation.
5.4 RAW MATERIALS (DYESTUFFS)
Generic
Name
Source
Black-S-MAX
Bezema
Blue-S-FR-150%
Blue-SLF
Blue-S-MAX
Blue-S-GLD-150%
Cosmos-S-MAX
Navy-SLF
Orange-S-MAX
Red-S-2B
Red-S-2B-150%
Bezective
Red-SGT
Red-SLF
Red-S-MAX
Rubine-S-MAX
Scarlet-S-2GF
Yellow-S-3R-150%
Yellow-SLF
Yellow-S-MAX
Yellow-V-5GL
Bluton
BVBI
CHT
Skaywhite BVB
Blue-HGN
Ciba
Brill blue-NF-G
Page 48
Red-NF-R
Cibacron
Scarlet-NF-6G
Yelloe-F-4G
Yellow-FN-2R
Black-CC-R
Dychufix
Blue-CC
Blue-S-BB
Blue-SE-2R
Dianix
Dianix blue-ER-150
Navy-CC
Red-EFB
Rubine-CC
Turquise-CC
Yellow-E-3GE
Yellow-S-EG
Disperse
Blue-XFT
Dychufix
Blue-2R-H-WT
Black-XFT
Crimson-XFT
D-Red-XFT
Orange-HWT
Red-XFT
Rubine-HWT
Scarlet-HWT
Scarlet -XFT
Dychufix
Blue-BR-XF_150%
Dychufix
Brill-Yellow-4GL-150%
Navy-Blue-EC
Red-EC
Page 49
Leavafix
Amber-CA
Dyestar
Blue-CA
Red-CA
Yellow-CA
Remazol
Blue-BB-133%
Dyestar
Blue-HRD
Blue-RR
Brill-Blue-RSPL
Brill-Yellow-3GL
Red-RR
T-Blue-G-133%
Page 50
5.5 RAW MATERIALS (CHEMICALS)

Generic
Name
Ablu
Ablusoft-AC-720
Ablutex-AP-750HC
Ablutex-BBV
Boiler
Nalco-450
CHT
Felosan-NOF
Meropan-CIT
Meropan-Red
Polyavin-3000
Saravid-VP-174
Clariant
Antioxidant-M
Destofil-LC
Diresul-Antioxidant-M-Liq
Ladiquest-1097
Sandozin-EH
Cognis
Adalin-11
Adasil-SME
Cottoclarin-114
Dyapol
Dyapol-ECO
Effluent
Ferrous-Sulphate-(Feso4-7H2o)
Hydrochloric-Acid(HCL)
Lime
Polymer
Sodium-Hypo-Chloride(NaOCl)
Urea-Fertilizer
Jintex
Jinlev-CL-225
Page 51
Jinsofter-BSK
Jinsofter-FS(Flakes)
Jinsofter-ME
Jinsofter-WCS(Flaks)
Jintex-CPS
Jintex-Stab
Zschimmer
Setavin-PK
Zetafix-2000
Zetafix-R-(WER)
Page 52
CHAPTER-06
Analysis of Fabric
Page 53
M/c Name: Terrot-20
M/c GG: 23 24 GG
Fabric
S. length : 2.85
: Single jersey
G.G.S.M : 135
F. Dia.
: 60 cm (tube)
F.G.S.M : 160
: 26s /1 CB pacific L- 083
Yarn
SAMPLE
NOTATION DIAGRAM
NEEDLE ARRANGEMENT
CAM SETTING
3
4
N.B:
= Knit stitch
3= Three butt needle
= Knit cam
4= Four butt needle
Page 54
M/c GG: 30 20 GG
M/c Name: Orizio-09

Fabric
: Fleece
S. length : S/4.20 + B/4.80 + Loop/1.44
G.G.S.M : 210/215
F.G.S.M : 280
Yarn
: 30s /1 CD padma L- 3071 + 24s /2 P.C padma L-11
SAMPLE
CAM SETTING
1
2
3
4
NEEDLE ARRANGEMENT
N.B:
= Miss cam
1= One butt needle
= Knit cam
2= Two butt needle

4= Four butt needle
Page 55
Fabric
: Double Lacoste
SAMPLE
CAM SETTING
NOTATION
DIAGRAM
NEEDLE ARRANGEMENT
3
4
N.B:
= Knit stitch
= Tuck stitch
4= Four butt needle
= Tuck cam
= Knit cam
Page 56
M/c GG: 36 18 GG
M/c Name: Orizio-16

Fabric
: 1 1 Rib
S. length : 2.75
F. Dia.
G.G.S.M : 156/160
: 75 (open)
F.G.S.M : 210
: 26s /1 CB pacific L- 2629
Yarn
SAMPLE
c

NEEDLE ARRANGEMENT
1
N.B:
1
2
= Knit cam
1 = One butt needle
2 = Two butt needle
1
2
Page 57
M/c GG: 36 18 GG
M/c Name: Orizio-16

Fabric
: 2 2 Rib
S. length : 1.75
F. Dia.
G.G.S.M : 200
: 47 (open)
F.G.S.M : 260
Yarn
: 26s /1 CB padma L-2631
SAMPLE
CAM SETTING
NEEDLE ARRANGEMENT
N.B:
= Knit cam
L = Long butt needle
C= Cylinder
D= Dial
Page 58
M/c Name: Interlock -
M/c GG: 30 22 GG
Fabric
S. length : 2.85
: Plain Interlock
G.G.S.M : 160/165
F. Dia.
F.G.S.M : 190/200
Yarn
: 26 (tube)
: 40s /1 CB CLC
SAMPLE
CAM SETTING
NEEDLE ARRANGEMENT
N.B:
= Knit cam
= Miss cam
H = High butt needle
C= Cylinder
L = Low butt needle
D= Dial
Page 59
6.1 FAULTS, CAUSES & THEIR REMEDIES IN KNITTING

1. Hole Mark
Causes:
Holes are the results of yarn breakage or yarn cracks.
During loop formation the yarn breaks in the rejoin of the needle hook.
If the yarn count is not correct on regarding structure, gauge, course and density.
Badly knot or splicing.
Yarn feeder badly set .
Remedies:
Yarn strength must be sufficient to withstand the stretch as well as uniform.
Use proper count of yarn.
Correctly set of yarn feeder.
Knot should be given properly.
2. Needle Mark
Causes:
When a needle breaks down then needle mark comes along the fabrics.
If a needle or needle hook is slightly bends then needle mark comes on the fabrics.
Remedies:
Needle should be straight as well as from broken latch.
Page 60
3. Sinker Mark
Causes:
When sinker corrode due to abrasion then sometimes cannot hold a new loop as a
result sinker mark comes.
If sinker head bend then sinker mark comes.
Remedies:
Sinker should be changed.
4. Star
Causes:
Yarn tension variation during production.
Buckling of the needle latch.
Low G.S.M fabric production.
Remedies:
Maintain same Yarn tension during production.
Use good conditioned needles.
5. Drop Stitches
Causes:
Defective needle.
If yarn is not properly fed during loop formation i.e. not properly laid on to the needle
hook.
Page 61
Take-down mechanism too loose.

Insufficient yarn tension.
Badly set yarn feeder.
Remedies:
Needle should be straight & well.

Proper feeding of yarn during loop formation.
Correct take up of the fabric & correct fabric tension.
Yarn tension should be properly.
6. Oil stain
Causes:
When oil lick through the needle trick then it pass on the fabrics and make a line.
Remedies:
Ensure that oil does not pass on the fabrics.
Well maintenance as well as proper oiling.
7. Rust stain
Causes:
If any rust on the machine parts.
Remedies:
If any rust on the machine parts then clean it.
Proper maintenance as well as proper oiling.
Page 62
8. Pin hole
Causes:
Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies:
Change the needle
9. Grease stain
Causes:
Improper greasing
Excess greasing
Remedies:
Proper greasing as well as proper maintenance
10.
Cloth fall- out
Causes:
Cloth fall- out can occur after a drop stitch especially when an empty needle with an
empty needle with closed latch runs into the yarn feeder and remove the yarn out of
the hook of the following needles.
Page 63
Remedies:
Make sure all the latches of needle are closed with feeding yarn after a drop stitch.
11.
Barre:
Causes:
This fault comes from yarn fault.
If different micro near value of fiber content in yarn.
Different lusture, dye affinity of fiber content in yarn.
During spinning different similar classes of fiber is mixed specially in carded yarn &
these fibers have similar characteristics.
In draw fame different similar classes sliver is mixed and make one sliver.
Remedies:
We can use this fabric in white color.
12. Fly dust:

Causes:
In knitting section too much lint is flying to and fro that are created from yarn due to
low twist as well as yarn friction. This lint may adhere or attaches to the fabric
surface tightly during knit fabric production.
Remedies:
Blowing air for cleaning and different parts after a certain period of time.
By cleaning the floor continuously.
By using ducting system for cleaning too much lint in the floor.
Over all ensure that lint does not attach to the fabric.
13. Yarn contamination
Page 64
Causes:
If yarn contains foreign fiber then it remains in the fabric even after finishing,
If lot, count mixing occurs.
Remedies:
By avoiding lot, count mixing.
Fault less spinning.
14. Yarn Faults:

Neps.
Slubs.
Yarn count variations.
Thick/Thin place in yarn.
Hairiness.
6.2 COUNTS ARE USED IN CIRCULAR AND FLAT

KNITTING MACHINE
Needle hook has to take yarn to convert it into a loop and finally latch has to close the
needle hook so that loop is properly held by the needle hook and ultimately this helps in
passing new loop through the previously held loop. It is clear from this explanation that
there should be a proper balance between needle hook size and the thickness of the yarn
or filament. If the yarn is thicker than needle hook then there will a chance that needle
hook will not able to hold this loop and consequently there will be a small hole in the
fabric. If the situation is reverse, means yarn is thinner than the size of the needle hook
then the fabric produced will look like a net. Both situations are not wanted. This
situation demands a balance between needle hook size and count of yarn. It is worth to
Page 65
note that needle hook size depends upon the machine gauge. Every time knitter has to
decide about the yarn count. There are many ways for the selection of proper count. In
the following lines we will discuss most common methods to select count for different
machines of different gauge. It is also important to note that selection of yarn counts also
depends upon the machine manufactures and type of machines, like, single and double
knit machine. However a general guideline will be given below.
For single Jersey Knitting Machine

Suitable count = G*G/18
for an example: Machine Gauge-24 then the suitable yarn count for this knitting machine
will be = 24*24/18=32S
Double Jersey knitting machine

Suitable count= G*G/8.4
For example: Say machine Gauge of a double knitting machine is 18, then the suitable
count for this machine will be=18*18/8.4=38S
Flat knitting machine:

Suitable yarn counts for flat knitting machine are 24S, 26S, 28S,30S,34S,40S etc
Page 66
CHAPTER-07
Production Planning Sequence and

Operation
Page 67
7.1 PRODUCTION SEQUENCE FOR LAB

PRODUCTION
Referance recipe
Stock solution
preparation
Pipeting
Raise temp up to
600c and run for 20
min
Take dye solution,

sample and salt in
the jar and set the
dyeing machine
Sample measuring
Add soda as
recommended in
the recipe. Then
run for further 60
min at the same
temp
Unload and wash

in cold water
Hot wash for 5 min

at 800c with PS-60
Squeeze and dry
Wash in cold water
Available Stock Solutions:
Red 0.1%, 0.5%, 1.0%, 2.0% (very common)
Yellow 0.1%, 0.5%, 1.0%, 2.0% (very common)
Blue - 0.1%, 0.5%, 1.0%, 2.0% (very common).
Page 68
Preparation:
To prepare 0.1% Stock solution, it is necessary to mix 0.1 g dye and 100 cc water.
To prepare 0.5% Stock solution, 0.5 g dye stuff is mixed with 100 cc water.
To prepare 1.0% & 2.0% Stock solution similar procedure is followed.
To prepare 10% Stock solution of Soda ash, 10 g Soda is mixed with 100 cc water.
Depth of shade:
Padma Poly Cotton Ltd. produces 0.5% to 5% shade for the goods.
Calculation:
Usually following calculations are as followed Recipe% Sample Weight
** Dye Solution =
(cc).
Stock solution %
Recipe(g/l) Liquor
** Salt =
(Gram per liter, g/l)

1000
Recipe (g/l) 100 Liquor

** Soda Solution =
(cc).
(1000 Stock solution %)
Sample calculation for 0.5% shade

Sample wt. = 5 mg
Material liquor ratio = 1: 10
Total liquor (5 10) = 50 cc
5 0.5%
Dye solution required =
= 2.5 cc
1%
Page 69
50 25
Salt solution required =
20 10
= 6.25 cc
50 10
Soda ash solution required =
20 10
= 2.5 cc
Water required {50 - (2.5 + 6.25 + 2.5)} = 38.75 cc
Working procedure
All ingredients had taken according to the recipe into the pot of sample dyeing machine.
At a room temperature, the material had run then after 10 min started to rise the temperature at
1C/ min. to get 60C temperature. For performing the required dyeing temperature, it took 30
min. The material had dyed at 60C for 45 min. then the temperature reduced at room
temperature within in 10 min. The fabric washed in cold water & then the material was washed
in 1 gm/l soap solution (liquor ratio 1:20) at 90C temperature for 15 min. Then after rapidly
cold washing, the material was dried & preserved
Page 70
7.2 PRODUCTION SEQUENCE FOR BULK

PRODUCTION
Process Flow chart of scouring bleaching:
Machine filling
with water
Chemical
(Sequestering,
Wetting,
Anticreasing)
Dozing at 500c
Run time
10 min
NaOH dozing
(20min)
Raise temp. at
600c
H2O2 Dozing
(15min)
Raise temp.
at 1100c
Run time
20 min
Cooling at 950c
Run time 10
min
H2O2 Killler
Dozing (10min)
Rinse at 800c
(pH Check)
Cooling for 550c
Acid wash
20 min
Drain
Page 71
Process flow chart of enzyme:
Machine filling with water
Acetic acid dozing
Run for 10 min. at 500C

(pH check)
Raise temp. at 550C
Dozing enzyme
Raise temp. at 700c
Run for 10 min at 700c
Drain
Page 72
Process flow chart of white dyeing:
Raise temp. at 550C
Chemicals dozing
Run time 10 min.
OBA dozing (10min)
Raise temp. at 80 0C
Run time 15 min.
Cooling at 550C
Rinse for 5 min.
Drain
Page 73
Process flow chart of turquoise method (color dyeing):
Machine filling
with water
Raise temp. at
600C
Chemical dozing
(Sequestering,
Wetting,
Anticreasing)
Run time
10 min.
Dyes dozing
(25 min)
Run time
10 min.
Salt dozing
(10 min)
Run time
20 min
Soda dozing
(20 min)
Run time
40 min.
Raise temp. at
800C
Run time
10 min.
Cooling at
600C
Rinse
Drain
Page 74
Process flow chart of soaping:
Raise temp. at 600C
Acetic acid dosing (10 min)
Run time 10 min.
Rasie tmp. at 950C
Chemicals dozing (10 min)
Run time 10 min.
Cooling at 700C
Rinse
Drain
Page 75
Process flow chart of softening:
Raise temp. at 500C
Chemicals (Softener) dozing
Run time 30 min.
Drain
Page 76
CHAPTER-08
Effluent Treatment
Page 77
8.1 EFFLUENT TREATMENT PLANT (ETP)

The effluent generated from different sections of a textile industry must be treated before
they are discharged to the environment. Various chemicals and physical means are introduced for
this purpose.
Capacity
40m3/ hr
Cost
Tk. 2.5 / m3
8.2 PROCESS FLOW CHART OF BIOLOGICAL

EFFLUENT TREATMENT PLANT
Fabric Dyeing
Pumping and Screening

Acid Dosing
Homogenizing Tank
Distribution Tank
Antifoaming
Biological Oxidation Tank
De-colorant
Sedimentation Tank
Sludge Return Tank
Polyelectrolyte
Sludge Thickener
Dosing
Dry Sludge
Filter Press
Dispose to Land Filling
Page 78
8.3 FUNCTION OF DIFFERENT UNIT OF BIOLOGICAL

EFFLUENT TREATMENT PLANT (ETP)
Screening unit:
It works like a filter. By filtering waste water, it removes threads, pieces of fabrics, small
metal pieces etc. In this unit a rotating brush is used for clean the pores if screen. The brush
rotates periodically.
Storage and homogenization tank:
Different waste water from varies process is stored and makes a homogeneous mixture by
mixing different concentration of waste water.
Neutralization tank:
Neutralization of waste water is performed by dosing 98% H2SO4 as required to control
the pH of waste water PH range 6.5 to 7.5.
Distribution tank:
It distributes the water to the biological oxidation tank. Continuous aeration is supplied
here. Antifoam is dosed here to control the foaming in the oxidation tank.
Biological oxidation tank:
It is the heat of E T P. The entire harmful chemicals are damaged here by breaking their
bonds. This is done by bacteria. To ensure the proper function work and growth of bacteria, few
conditions must be maintained.
Temperature
: 35 to 37 C
PH (Maximum)
: 6.5
Dissolved oxygen
: 4 PPM
Page 79
Sedimentation tank / biological feeding tank:

Treated water is overflowed here from oxidation tank. Decolourent is used here to
destroy the color of waste water.
Settling tank / sedimentation basin:
A tank or basin in which waste water is held for a period of time, during which the
heavier solids settle to the bottom and the lighter material will floats to the water surface. In this
tank sludge is immersed and the harmless water is discharge to ponds, Land, river etc.
Sludge thickener:
Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge. After one
hour of Polyelectrolyte dosing aeration is stopped and fresh water discharge to drain when sludge
is taken. The thickened sludge is transferred to the sludge thickener bed.
Sludge thickener bed:
Here sludge is dried which is used as good fertilizer as well as fuel of brick field. Sludge
is dried under the sunlight.
Page 80
8.4 REQUIRED CHEMICAL OF BIOLOGICAL ETP

H2SO4:
Neutralize the waste water controlling the PH. It is auto dispensed in the neutralization
tank.
Polyelectrolyte:
Used for sedimentation / sludge coagulation and also killing bacteria.
Antifoaming agent:
Used for reduction / controlling foam. It is used auto / manually in the distribution tank.
De-colorant:
Used for removing color. It is used auto / manually in the sedimentation feeding tank.
Sodium hypochlorite:
It is used to kill the harmful bacteria. It is used in the biological oxidation tank.
8.5 PRODUCT QUALITY CHECKED

1. Biological Oxygen Demand (BOD)
2. Chemical Oxygen Demand (COD)
3. Total suspended solids
4. Total dissolved solids
5. Color
6. pH etc.
Page 81
8.6 REMARKS
Waste water from processing industries e g. Dyeing , Printing , Finishing and washing
causes great harmful effect on our environmental, As a result agricultural land loses its fertility,
natural water becomes polluted aquatic life is destructive and crops are damages.
So, it is important to control ETP plan.
Page 82
CHAPTER-09
Quality Assuarance
Page 83
9.1 QUALITY ASSURANCE
Quality assurance is defined as all those possible planned and systematic actions necessary to
provide adequate confidence than a product or service will satisfy given requirements for quality.
The Quality Assurance Department is assigned to maintain consistently uniform quality of the
material in process and various stages of manufacturing.
9.2 OBJECT OF QUALITY CONTROL

Specification test
Raw materials control
Process control
Process development
Product testing
Research
9.3 QUALITY ASSURANCE SYSTEM

Quality assurance procedure may be divided into two major parts:
Online quality control
Offline quality control
Page 84
9.4 YARN QUALITY
check the quality by yarn test method( suitable for white color or dark color)
check the yarn count( thick/thin, slub, neps, contamination, patta, hariness)
9.5 KNITTING QUALITY

Working Area of ON Line Quality Control:
At the knitting production stage check the every fabric quality by online quality person. Also
check the program sheet with the knit card (like buyer, order, yarn count, machine diameter,
gauge, stitch length, yarn lot etc.)
a) On line circular knit:
Function:
Design & shade approval.

Yarn & m/c evaluation.
QC parameter checking.
Body& Rib Inspection.
b) On line flat knit:
Function:
Design & shade approval.

Yarn & m/c evaluation.
Page 85
QC parameter checking.
Collar & cuff. Inspection.
a) Grey inspection:
Function:
100% Fabric Inspection.

Fabric transfer to store.
Area cleaning.
Co-ordination & reporting.
b) On line finishing:
Function:
100% Fabric Inspection.

Problem Identification.
Problem Rectification.
Fabric Transfer for reprocesses.
9.6 RESPONSE TO FAULTS
Following response is to be taken:

Faults
Response
Grey inspection
Inform yarn supplier & knitting department.
Knitting fault
Inform knitting Department
Finishing fault
Inform Finishing Department
Page 86
Working Area of OFF Line Quality Control:
After knitting, check the grey fabric by inspection machine .find out the knitting fault & mark by
marker pen. Make a report sheet (on 4 point system).
9.7 LIST OF EQUIPMENT FOR QUALITY CONTROL
The list of equipments to assure quality:-
Inspection m/c.
Electronic balance
GSM cutter.
Measuring tape.
Scissors.
Indication sticker.
Following faults are detected & identified in final inspection for body:
A) Penalty points legends:
H= Hole
OS= Oil Stain
CS= Chemical stain
RS= Rust Stain
GS= Grease Stain
MS= Missing Yarn
Page 87
DS= Drop Stitch
D= Dirt Stain
MarkUT= Uneven Tension
S= Stripe
OL= Oil Line
TT= Thick & Thin Yarn
S= Slubs
SM= Sinker Mark
FL= Fly Contamination
MY= Mixed Yarn
YC= Yarn Contamination
BE= Birds Eye
WD= Wrong Design
BR= Barre Mark
PH= Pin Holes
B) Faulty appearance:
US= Uneven shade
N= Neps
CR= Crease Mark
HR= Hairy
MS= Machine stoppage
NL= Needle Line
BR= Barre mark
CM= Crumple
DC= Dead Cotton
BW= Bowing
Besides roll to roll and meter to meter variation is checked.
Page 88
9.8 QUALITY ASSURANCE SYSTEM
Padma PolyCotton Knit Fabrics Limited maintains the ISO: 9002 standard in case of quality.
Therefore, the four points system is followed to inspect 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 the Padma PolyCotton Knit Fabrics Limited.
Length of defects
Penalty point
3 inches or less
Over 3 inch but not over 6 inch
Over 6 inch but not over 9 inch
Over 9 inch
Hole
Penalty Point
1 inch or less
Over 1 inch
Total defect points per 100 square yards are calculated. And upto 40 points fabric is accepted.
Page 89
CHAPTER-10
Maintenence Management
Page 90
10.1 OBJECTIVE OF MAINTENENCE
To keep the factory plants, equipments, machine, tools in an optimum working

condition.
To ensure specified accuracy to product & time schedule of delivery to customer.
To keep the down time of machines to the minimum thus to have control over the
production program.
To keep the production cycle within the stipulated range.
To modify the machine tools to meet the need for production
10.2 TYPES OF MAINTENCE
Maintenance
Preventive
Maintenance
Electrical
Maintenance
Mechanical
Maintenance
Break Down
Maintenance
Mechanical
Maintenance
Electrical
maintenance
Page 91
10.3 PREVENTIVE MAINTENANCE
Preventive Maintenance is a predetermined routine activity to ensure on time inspection /

checking of facilities to uncover conditions that may lead to production break downs or harmful
depreciation.
10.4 ROUTINE MAINTENANCE

Routine maintenance usually denotes those activities of maintenance which are bare minimum to
ensure efficient working of machines. These activities have to be performed according to
predetermined frequencies which are based on technical and quality considerations
Routine maintenance tasks followed in the factory:Daily work
Motor sound checking

Auto line checking
Positive feeder checking
Oil line checking
Airline checking
Take up roller checking
Every 15 days
Gear box checking

All bearing checking
Page 92
All bearing greasing

Panel board cleaning
Fan filter cleaning
Checking all control panels
Lubrication of all motor bearing
All cable terminal tighten
10.5 MAINTENANCE TOOLS & EQUIPMENTS

Adjustable Wrench
Use :
To set different type of nutsand bolts
Tightening & loosening of nuts & bolts.
Double Head Spanner

Use :
To set nuts and bolts.
Single Head Spanner

Use :
To set nuts and bolts.
Page 93
T-Type L-Key
Use :
Use to fitting cam boxAnd other m/c parts.
Allen-Key
Use :
Use to fitting cam boxAnd other m/c parts.
Pin setter
Use :
To hold small m/c parts.
T-Type L-Key
Use :
To fitting cam box and other m/c parts.
Flat Screw Driver

Use :
To fitting varies type screw.
Page 94
I- Type L-Key
Use :
To fitting cam box and other m/c parts.
Hammer
Use :
To beat metal part.
To reshape machine parts.
Cutting-Pliers
Use :
To cut metal wire.
Long Nose-Pliers
Use :
To hold and set m/c parts
In thin or narrow space.
Multi-Pliers
Use :
To hold m/c parts,
Cut metal wire,
Set nuts and bolts
Page 95
CHAPTER-11
Utility services
Page 96
11.1 UTILITY REQUIRED IN PADMA POLYCOTTON

KNIT FABRICS LTD.
Utility is a very big factor in case of any industry. In textile industry there are various types of
utility has to be present for the smooth running of the operations. In case of any textile
processing industry following types of utility are very much necessary like;
Utility required in Padma PolyCotton Knit Fabrics ltd. textile industry are:
1. Electricity
2. Water
3. Steam
4. Compressed air
11.2 SOURCES OF UTILITY

Electricity: Government supply and Factory own generator.
Steam: Boiler
Water: Pump
Compressed air: Compressor
Gas: TITAS GAS LTD.
Page 97
11.3 MACHINES FOR UTILITY SERVICES

Power generator: In Padma PolyCotton Knit Fabrics Limited There are four power generator
present and three of them run by diesel fuel and the remaining one run with gas fuel.
Name
ENGINATOR
MODEL:
VHP-7100-GSID
MODEL:
1000
RPM:
415/240
VOLTS:
410/24 hours
Air Compressor:
In order to compress the air and to raise its pressure Air compressor is used. The air compressor
sucks air from the atmosphere, compress it and then deliver the same under a high pressure to a
storage vessel. From the storage vessel it may be conveyed by the pipeline to a place where the
supply of compressed air is required. Padma PolyCotton Knit Fabrics limited does have five
compressors
Machine no
BRAND
KEISER
KEISER
LG
KEISER
ORIGIN
Germany
Germany
Germany
UK
SERIAL
4511922
4511922
6M37021558H 1824
SSRML50
POWER
30KW
30KW
55KW
CAPACITY
3bar
3bar
5m3/min
11bar
8bar
Page 98
CHAPTER-12
Cost Analysis
Page 99
12.1 INTRODUCTION
Costing is a very important task for a factory which runs for business purposes.
And it is also strictly followed in the Padma Poly Cotton Knit Fabrics Limited. 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 is
done in this factory. It is determined by a troop of accountants with advice and
consultancy of executive director.
12.2 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
12.3 COSTING OF THE PRODUCT

Here we collect some cost sheets which help us to know the costing systems:
PADMA POLY COTTON KNIT FABRICS LTD.
Utilization and Cost Sheet

Buyer
L/c #
Rainbow Express S.L.
Date
8144656001000201
L/C Value
21/09/2003
USD 90.500
Page 100
Article
100% cotton Pique PFD 200-
Order No.
&
220 GSM
Order Qty :
50,000 pcs
Ship Date
25th October 2003 (as per
Fabric
2030PD, 2029PD &2031 PD
: & Single Jersey PFD 180 GSM

:
Licence)
A) Yarn Requisition #82
SL
Yarn Description
Yarn
Quantity(kgs) Unit Price in
Count
Total Amount in
USD
USD
01.
100% cotton Pique
Ne 26/1
12700.72
2.35
29,846.69
02.
100% Cotton S/J
Ne 24/1
8164.72
2.35
19187.092
TOTAL
= 20865.44
= 49033.78
B) Accessories
SL#
Item Description
Quantity
Unit Price in USD
Ttl Amount
(USD)
1.
Sewing Thread
600.00 cone
2.20
2.
Composition Label
883.33 Doz
0.10
3.
Composition Label
883.33 doz
0.16
4.
Main Label
883.33 doz
0.300
5.
Size Label
891.67 doz
0.05
6.
Care Label
883.33 doz
0.260
7.
Horn Button
26.00 GG
12.00
8.
Eyelet
3666.67 doz/set
0.07
9.
Size label
2229.17 doz
0.05
10.
Composition label
2208.17 doz
0.26
11.
Care label
2208.17 doz
0.10
12.
Care & Composition label
1337.5 doz
0.35
Page 101
13.
Horn Button
28 GG
3.75
14.
Gum Tape
80 roll
0.55
19.
Scotch Tape
75 roll
0.20
20.
Interlining
18 roll
15.00
21.
Poly bag (Blister)
437.5 doz
0.45
22.
PP Belt
10 roll
7.00
23.
Metal clip
9 box
0.520
24.
Shoulder Tape inch
326.67 yds
1.55
25.
Zipper(Half)
Pcs
26.
Sewing Ticket
Doz
27.
Carton
1300 pcs approx.
28.
Mobilon Tape
Doz
29.
Single Poly
Doz.
30.
Tissue Paper
Doz
31.
Spot Lifter
pcs
32.
Size Label
2229.17 Doz
1.30
0.05
TOTAL =
7,000.93
Page 102
PADMA POLYCOTTON KNIT FABRICS LTD

Inter Office Correspondence
OVER HEAD SHEET
Buyer : Rainbow
L/C # : 8144656001000201
A) Knitting Charge :
SL
Description
Quantity(kgs)
Unit Price in USD
Amount in USD
01.
Pique
12700.72
0.31
3,937.22
02.
Single Jersey
8164.72
0.17
1,388.00
03.
1x 1 Rib
504.00
0.31
06.
Interlock
0.35
07.
Fleece
0.45
Total =
5,325.17
B) Dyeing Charge :
SL #
Description
Quantity (kgs)
01.
Dark Shade
0.55
02.
Medium Shade
0.45
03.
Light Shade
0.35
04.
White
0.20
05.
Wash
06.
Brushing
20865.44
Unit price in USD
0.15
Amount in USD
3,129.82
0.27
Charge
Total =
3,129.82
Page 103
C) Making Charge :
SL#
Description
Quantity (doz)
Unit Price in USD
Amount in USD
01.
Polo shirt
2083.33
5.00
10,416.65
02.
Short Slv T-
2083.33
2.00
4,166.66
Total =
14,583.31
Shirt
PADMA POLY COTTON KNIT FABRICS LTD.

Inter office Correspondence
Estimated Requirement of Dyes & Chemicals
Buyer :
Rainbow
L/C# :
8144656001000201
Order#:
2030PD,2029PD & 2031PD
L/C Value:
USD 90,500
Item :
Short Slv T-Shirt & Polo Shirt
Order Qty:
50,000 Pcs
Fabric:
100%cottonS/J 180 GSM&100%cotton
Reqd. Yarn: 10284 Kgs
pique 200-220
SL# List of Dyes & Chemicals
Reqd. Qty
Unit
Total
(kgs)
Price(USD)
Amount(USD)
Citamol BL
ALBATED FFC
120.00
5.50
660.00
Cibafluid C
600.00
1.70
1,020.00
4.24
Page 104
Sirrix 2UD
2.13
Sandopur RSK
2.96
Alcosperse AD
5.15
Drimizen R2R
Oxalic Acid
0.90
Sapamine FPS
1.65
10
Hydruce
1.10
11
Tinoci Arite CBB
12
Ammunium Sulphate
0.25
13
Formic Acid
1.00
14
Acetic Acid
570.00
1.05
15
Caustic Soda
665.00
0.60
598.50
16
Hydrozen peroxide
665.00
0.60
399.00
17
Glober Salt
0.20
399.00
18
Soda Ash
0.25
19
Setamol BL
1.18
20
Invadin Da
240.00
2.90
21
Invatex CS
240.00
1.60
696.00
22
Invatex PC
240.00
1.90
384.00
23
Cibacron Navy W-BT
7.30
456.00
24
Cibacron Yellow H-2G
19.70
25
Cibacron Red FN3G
20.40
26
Sun White BYB
17.27
27
Cibacron Red H-B 150%
14.50
28
Cibacron Scarlet F3G
27.50
29
Cibacron Brilliant Blue FNG
21.00
30
Cibacron Yellow FN2R
16.60
31
Cibacron Yellow WR 200%
13.70
32
Tricon Blue SE 2BT
16.20
575.00
240.00
2.80
1,610.00
1.70
408.00
Page 105
33
Tricon Yellow SE4GT
10.56
34
Tricon Red EFBN-T
11.57
35
Tricon n.Blue SE-EXNT
8.80
36
Ratnafix G.Yellow MERL
9.63
150
37
Ratnafix Red ME-6BL 150
9.26
38
Naka Nlack US
2.13
39
TaifoxBlack VS-BT 133
5.93
40
Traicon Black BSD-T
6.95
41
Forcon Brilliant Red SRGL
27.78
42
Taisoft ABN
3.14
43
Taifix Briliant Blue RTSPC
21.37
Total =
6,630.50
12.4 REMARKS
Costing is as important as production for a productive factory. Without proper costing all
production curriculums will go to in vain. Cause, a factory cannot reach to its goal without
achieving good profit and good profit is not possible without skillful costing. Seeing the
improvement of Padma Poly Cotton Knit Fabrics Limited day by day, we can assume that it
follows the right and proper way of costing with skillful technical persons.
Page 106
CHAPTER-13
Marketing activities
Page 107
13.1 CONSUMER OF THE PRODUCTS

Marketing activities are done in this mill, Padma Poly Cotton Knit Fabrics Limited by a skillful
team of marketing officers under the Executive Director. Here are the details of marketing
activities.
The mill has a great number of renowned and international consumers. Following are some
regular consumers:
1) Tom Taylor
2) Sara Lee
3) I.C. Company
4) Rainbow
13.2 PRODUCT LEBEL

There are following lebels used by this mill:
1. Care Lebel: It contains washing in hot or cold water, chemical
cleaning, drying
conditions etc.
2. Size Lebel: It contains size of garments.
3. Composition Lebel: It contains the fabric composition of different fibre type.
4. Decorative Lebel: Decoration is as buyer or consumer choice wise.
13.3 PACKAGE SIZE & LEBEL

Most common sizes are
S - Small
M - Medium
L - Large
XL - Extra large
XXL - Very very large
Page 108
13.4 LOCAL MARKET
Padma Poly Cotton Knit Fabrics Limited 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. But some of the yarn is also imported.
Importing countries:
This mill relates to the countries for yarn importing, they are
1) India
2) Korea
13.5 MANPOWER
Almost ten marketing officers and ten others workers act under the Executive Director.
13.6 DUTIES & RESPONSIBILITES OF MARKETING

OFFICERS
Executive director takes order from the buyer and gives order the marketing officers
troops to produce a cost sheet.
Marketing officers are known the amount and design of product.
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.
Page 109
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.
13.7 REMARKS:
Marketing activities are very important tasks for a productive factory. In this mill there
having highly qualified marketing officers. As a result, the mill rises up day by day.
Page 110
CHAPTER-14
Conclusion
Page 111
14.1 CONCLUSION
We have completed our Industrial Training successfully by the grace of Allah.
Industrial Attachment sends us to the expected destiny of practical life. Padma Poly Cotton Ltd.
is a well know factory in the textile field of Bangladesh. The completion of the two months
industrial attachment at Padma Poly Cotton Ltd. gave us the inspiration that factory is one of the
appropriate destiny to implement the theoretical knowledge. From this industrial attachment we
got the details idea about the factory environment, production process, total management, store
& inventory process, maintenance, utility etc.
Padma Poly Cotton Ltd. is well equipped and the working environment is excellent. The relation
between top management to bottom level is so nice.
We are lucky to get the opportunity of having training in this mill. The factory runs by a number
of efficient Textile Engineers, Skilled technical & Non-technical persons. All the Textile
Engineers, technical & Non-technical persons are very sincere, co-operative and helpful. We
wish good luck of them and also for this factory.
It was really a productive practical learning besides our four year academics, so we wish we will
be able to implement our learning and methodological knowledge successfully in the textile
industry and the betterment of the economy of our country.
Page 112

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CHAPTER-01

Dept. of Textile Engineering, MBSTU

Dept. of Textile Engineering, MBSTU

1.1 OBJECTIVE OF INDUSTRIAL ATTACHMENT

Dept. of Textile Engineering, MBSTU

1.2 LOCATION OF MILL

Dept. of Textile Engineering, MBSTU

1.3 GENERAL INFO ABOUT MILL

Name of the mill :

Padma PolyCotton Knit Fabrics Limited

Private Limited Company

Knit composite mill.

Year of starting production :

131 Tejgaon Industrial Area, Dhaka.

Tel: 9460917-20. Fax: 880956204

95% cotton 5% lycra

95% polyester 5% lycra

95% viscose 5% lycra

60% cotton 40% polyester

50% polyester 50% sulcool

48% cotton 48% modal 4% lycra

Dept. of Textile Engineering, MBSTU

g) Garment Washing Capacity

2 Million US dollar per year(approx.)

Dept. of Textile Engineering, MBSTU

d) Merchandising & Marketing

Sub-Contracts from different Industries

Dept. of Textile Engineering, MBSTU

Dept. of Textile Engineering, MBSTU

2.1 TOP MANAGEMENT ORGANOGRAM

Dept. of Textile Engineering, MBSTU

2.2 SHIFT CHANGE

Three shifts (A, B, C): each of 8 hours

1. A Shift: 6 A.M to 2 P.M.

General Shift: 9 A.M to 8 P.M.

Man Power Planning.

Dept. of Textile Engineering, MBSTU

2.4 JOB DESCRIPTION AND RESPONSIBILITIES:

Dept. /Section : Knitting/Dyeing

Title : Shift Incharge

Dept. /Section : Knitting/Dyeing

Title : Production Officer

Dept. of Textile Engineering, MBSTU

Title : General Manager

Dept. of Textile Engineering, MBSTU

Dept. of Textile Engineering, MBSTU

3.1 WORKING PROCEDURE OF R & D

Knitting (Knit of the fabric)

Dept. of Textile Engineering, MBSTU

3.2 WORKING PROCEDURE PLANNING DEPARTMENT

R & D (Approval Sheet)

Knitting M/C Select

Batching Plan for Dyeing

Dyeing M/C Program

Finish Priority Program

RFD (Ready for Fabric Delivery)

On Time Fabric Delivery

Dept. of Textile Engineering, MBSTU

Dept. of Textile Engineering, MBSTU