Report on

Industrial Attachment
With

Cotton Club (BD) Ltd. (Knit Composite) and Mondol Knitwear Ltd.
Mondol Group of industries
Jarun (South), Kashimpur, Gazipur & Surabari, Kasimpur, Gazipur

Submitted to
Nasif Chowdhury
Senior Lecturer
Department of Textile Engineering
City University

Prepared By:
Name ID Batch
Md. Sabber Hossain Sakib 13334149 25th
Md. Shohan Rahman 13334019 25th
Md. Imran Hossan 13334493 25th

i
 ACKNOWLEDGEMENT

Firstly we would like to thank the Almighty Allah for giving us patience to conclude our
internship program & finally this industrial attachment. Preparing the internship report
based on “Fabric Manufacturing Technology (Knitted Fabric)”, we have understood that it
is very difficult to find out the basic and fundamental aspects of Fabrics Manufacturing are
largely distant from the theoretical bookish knowledge. We express our heartfelt gratitude
to Md. Abdul Mannan Mondol (Director) for his Permission in completing internship at
Cotton Club (BD) Ltd. We are so much thankful to Md. Asaduzzaman, (General Manager)
Mondol knitwear’s Ltd. for helping us as our supervisor in the mill. Special thanks to Mr.
Aminul Islam Sharker (DGM Cotton Club (BD) Ltd.) for his cordial support during the
period of internship. And special thanks to Md. Rahat Islam (senior engineer) for his kind
help in internship period.
We are very grateful and deeply indebted to our respected teacher Md. Arifuzzaman,
Coordinator of Textile Department, City University. For his continuous support,
encouragement, suggestion, guidance and constructive criticism to get through the
industrial training. We would like to pay our liberated gratitude to our honorable
supervising teacher, Nasif Chowdhury (Senior Lecturer, Textile Department, City
University), who guided us in every sphere we marched in preparing the report. Without
his cordial supervision it would be almost impossible to prepare such a large report.
We thank the management of Cotton Club (BD) Ltd & Mondol Knitwear’s Ltd. for giving
us the opportunity to undergo Industrial Training there. Thus all in all it can be said that
without their help it would not be possible for me to prepare this internship report. So we
would like to convey thanks notation to all who directly or indirectly contributed and
inspired me time to time in preparing the report.
Our gratitude also goes to all the employees of Cotton Club (BD) Ltd & Mondol Knitwear’s
Ltd. for their sincere co- operation, support and valuable advice which they have provided
us during the training of two months.

Page | ii
 EXECUTIVE SUMMARY

MONDOL KNITWEAR’S LTD & COTTON CLUB BD LTD are one of the leading
Company in Bangladesh and is going from strength to strength since its inception. By
observing the factory existing condition and employees behavior to one other, their fasted
and quality production and organization structure, we was led to believe that the company
is very centralized.

The factory is consisted with some well-equipped departments and these are Knitting,
Dyeing, Printing and Garments Departments. The factory faces good competition from
their competitors which motivates them to work harder to achieve their objectives and
goals. The organization uses the multiple departmental bases and according to the
management this base is the most appropriate.

While surveying the organization we found that the factory provides comfortable working
conditions, friendly co-workers, efficient management and status and from the factory
management part, they have made ensure the world class accommodation, amenities,
services, facilities without any doubt.

Page | iii
 DECLARATION

We thereby that, this industrial internship has been done by us under the supervisor, Nasif
Chowdhury Senior Lecturer, Department of Textile Engineering, City University. I also
declare that neither this report nor any part of this report has been submitted elsewhere for
award of any degree or B.Sc in Textile Engineering.

Supervised By:
Nasif Chowdhury
Senior Lecturer
Department Of Textile Engineering
City University.

Submitted By:

Name ID Batch
Md. Sabber Hossain Sakib 13334149 25 th

Md. Sohanur Rahman 13334019 25th

Md. Imran Hossain 13334493 25th

Page | iv
 Overview
This report is organized in the following order:

Part A: Introduction:

This part explains the Purpose, Scope and Limitation. It also gives an introduction
to the Company, Cotton Club (BD) Ltd., including its background, Company Profile,
research goals and university partnerships. This part also summarizes the
background information of the ‘Industrial Attachment Training Program’ as well as
the students’ responsibilities. This part contains two chapters.

Part B: Training Research and Implementation & Attachment Conclusion

This part discusses the training and research done by the students, as well as the results of
the implementation. This part is arranged according to the different division of the factory.
It contains twelve chapters.

This part gives the overall conclusion of the industrial attachment and further
recommendations for improvement. This also includes the bibliography and references used
by the students. It has two chapters.

Page | v
 Table of Contents

Part A. Introduction
Chapter Name of the Topic Page
No. No.
Chapter-01 Training Background 02-04
Chapter-02 Project Description 05-13

Part B. Training Research and Implementation & Attachment

Conclusion

Chapter Name of the Topic Page

No. No.
Chapter-03 Man-Power Management 15-24
Chapter-04 Duties & Responsibilities of Different working 25-29
Personnel
Chapter-05 Machine Description 30-36
Chapter-06 Raw Materials 37-41
Chapter-07 Knitting Section 42-62
Chapter-08 Dyeing Section 63-68
Chapter-09 Printing Section 69-73
Chapter-10 Garments Section 74-84
Chapter-11 Effluent Treatment Plant(ATP) 85-91
Chapter-12 Maintenance 92-96
Chapter-13 Decision & Conclusion 97-99

Page | vi
Page | vii
 Part A
Introduction

Page | 1
Chapter One

Training Background

This chapter begins with explaining the purpose of the report; followed by its scope and
limitations. It ends by mentioning the students’ responsibilities in training program and
institution partnership with the company.

Page | 2
1.1 Background Training Program
After successfully completing the B.Sc. in Textile Engineering course from City University
every student have to take part in two month long Industrial Attachment Training Program.
For this training program the students are divided into several groups and the groups of
students are sent to the large and famous Textile Industries for practical training. This bears
100 marks of the syllabus.

1.2 Purpose
The Industrial Attachment program fulfills part of the requirement in pursuing the degree
of Bachelor of Applied Science (B. Sc in Textile Engineering) in City University. This
report serves to summaries the activities and experiences gained with Cotton Club (BD)
Ltd & Mondol Knitwear’s Ltd.

1.3 Scope and Limitations

During the industrial attachment training, we, a group of four students of City University
were involved in training through the whole factory. This report will only cover parts of
the project, which were done by the students. The experience gained during the attachment
had helped the students to fulfill the objectives of the attachment.
However, due to unforeseen circumstances, the commencement of the attachment was
delayed. This resulted in a shortage of time for the completion of the project. Therefore,
this report will be limited to the stages of implementation prior to the date of reporting.
Further work and research that done after the date of reporting is not described fully in this
report. The emphasis of this report will be on the research done by the students, in addition
to the experience that they gained during the attachment. Frequent references will be made
with regards to these concepts.

Page | 3
1.4 Students’ Responsibilities

With the four years education in the institution students gain much theoretical knowledge.
For the fulfillment of B.sc in Textile Engineering course the Industrial Attachment Training
program plays a vital role. It gives the students a lot of practical knowledge and introduces
with the factory environment. In this training program the students has much
responsibilities. They have to learn about all the process going on in the factory, all the
machineries used, faults and remedies in the different sections, administrations, utilities,
costing of the products. Finally students have to make a report on whole program.

1.5 Institution Partnerships

Cotton Club (BD) Ltd & Mondol Knitwear’s Ltd has an extensive network of relationships
with selected departments in leading academic institutions in Bangladesh, and invests
considerable resources to support them. They are important to City University Engineering
College because it shares with the academic community a concern to foster innovative
research, and to develop the skills and experience of the people involved in its generation
and transfer. Over the past 10 years CCL has built up a portfolio of programs to encourage
collaboration with universities across a broad spectrum of mutually beneficial activities.
Every year CCL hosts about 10 students of PTEC who work as internee to gain industrial
internee to gain industrial experience for their academic qualifications.

It is hoped that this relationship will be increased day by day

Page | 4
Chapter Two

PROJECT DESCRIPTION

This chapter will give a brief introduction on the history of Cotton Club (BD) Ltd., the
attached company, Factory profile, No. of Employers and workers, their responsibilities,
Organogram of different sections of the factory and Head office, types of production and
marketing, etc.

Page | 5
MONDOL KNITNEAR’S LTD

Page | 6
2.1 History
Mondol Knitwear’s Ltd & Cotton Club Ltd established in the year 2006, the quality
standards and is engaged in manufacturing of all kinds of knitted fabrics & garments. Under
the profound guidance of their mentor Haji Abdul Majid Mondol (Chairman of Mondol
Group, established in 1991), their company has gained an immense success and has earned
goodwill with twenty years of experience in the garments industries. The Chairman is
guiding their team with his wide experience and skill. Their product is made using top
quality yarn that is procured from reliable sources across world. They make use of world
class in-house infrastructure and modern machines as well as simple hand tools that helps
in producing high quality fabric in large volumes and varieties. They are dedicated to offer
timely delivery of goods and services at affordable prices.

2.2 Mission

Mondol Group mission is to enrich the quality of life of people through responsible
application of knowledge, skills and technology. That’s why Mondol Knitwear’s & Cotton
Club Ltd. is committed to the pursuit of excellence through world-class products,
innovative processes and empowered employees to provide the highest level of satisfaction
to its customers.

2.3 Vision
Mondol Group will endeavor to attain a position of leadership in each category of its
businesses.
Mondol Knitwear’s Ltd & Cotton Club BD Ltd are the part of this group so their vision is
same.

2.4 Values

 Strong work force that ensures quality finished fabric.

 Talented designers

Page | 7
2.5 Major Competitor

Cotton Club & Mondol Knitwear’s Ltd company are a fully export oriented company so
they have face both local and international competition locally. There are many company
compete with the Cotton Club ltd company those are India, Pakistan, Koria, Thailand,
China and in locally beximco, DBL Group, Anlima Group, Jalima Group, Square Textile,
Robin Tex ,ACS Textile.etc.

2.6 General Information of Factory

2.6.1 Cotton Club BD Ltd

Registered Name of Company : Cotton Club (BD) Ltd.

Type of the Company : 100% Export Oriented Knitting, Dyeing &

Garments Composite.

Name of the Owner : Haji Abdul Majid Mondol

Contract Person : Md. Hasanuzzaman

(Manager, HR, Admin and Compliance),
hr@cclbd.com

Phone No. : 88-02-9298645-6, 9298732-4,

Fax : 88-02-9298647

E-mail : zubayer.mondol@gmail.com

Web : www.cclbd.com

Corporate Office : Siaam Tower (Level 9th & 10th)

Plot#15, Dhaka Mymensingh Road.
Sector#3 Uttara Model Town.
Uttara Dhaka-1230, Bangladesh.
Phone: 8955000-2, 8955004
Fax: 8955005

Year of Establishment : 2006

Total Floor Space : 26,500 sq. ft. /per floor. (Eight Stored)

Page | 8
Last 3 years’ turnover of Cotton Club BD Ltd:

Year 2014 2015 2016

Amount in USD 51.3 59.2 65

2.6.1.1 Google Map Location and Satellite View

Page | 9
2.6.2 Mondol Knitwear’s Ltd

Registered Name of Company : Mondol Knitwear’s Ltd.

Type of the Company : Subcontract of all kinds of Knit Fabrics

Name of the Owner : Haji Abdul Majid Mondol

Contract Person : Md. Asuduzzaman

(General Manager, Mondol Knitwear’s Ltd)
az@cclbd.com

Phone No. : 88-02-9298647-9, 9298735-8,

Fax : 88-02-9298647

E-mail : zubayer.mondol@gmail.com

Web : www.mondol.com

Corporate Office : Siaam Tower (Level 9th & 10th)

Plot#15, Dhaka Mymensingh Road.
Sector#3,Uttara Model Town.
Uttara,Dhaka-1230, Bangladesh.
Phone: 8955000-2, 8955004
Fax: 8955005

Year of Establishment : 2006

Total Floor Space : 26,500 sq. ft. /per floor. (Eight Stored)

Page | 10
Last 3 years’ turnover of Mondol Knitwear’s Ltd:

Year 2014 2015 2016

Amount in USD 49.1 56.2 61

2.6.2.1 Google Map Location and Satellite View

Page | 11
2.7 The Eight (8) Identified Areas

2.7.1 Cotton Club BD Ltd

1. Child labor
2. Forced labor
3. Health & Safety
4. Freedom of assembly/ Right to collectively bargain
5. Discrimination
6. Disciplinary practices
7. Working hours
8. Remuneration/ Compensation

Page | 12
2.7.2 Mondol Knitwear’s Ltd

1. Child labor
2. Forced labor
3. Health & Safety
4. Freedom of assembly/ Right to collectively bargain
5. Discrimination
6. Disciplinary practices
7. Working hours
8. Remuneration/ Compensation

Page | 13
PART B

Page | 14
Chapter Three

MAN-POWER MANAGEMENT

Page | 15
3.1 Board of Directors of MONDOL GROUP LTD

Alhaz Abdul Mozid Mondol Chairman

Md. Abdul Momin Mondol Managing Director

Md. Zubayer Mondol Director

Alhaz Abdul Mannan Mondol Director

3.1.1 Cotton Club BD Ltd, Staffs of all section

Page | 16
3.1.2 Cotton Club BD Ltd, Workers of all section

3.1.3 Total Man-power of Cotton Club BD Ltd

Page | 17
3.1.4 Cotton Clout (BD) Ltd. Staffs of all sections

3.1.5 Cotton Clout (BD) Ltd. Workers of all sections

Page | 18
3.1.6 Total Manpower of Cotton Club (BD) Ltd.

3.1.7 Grand Total

Page | 19
3.2 ORGANOGRAM

3.2.1 Organogram of Head Office

Page | 20
3.2.2 Organigram of Admin & Production

Page | 21
3.2.3 Organogram of Knitting Division

Page | 22
3.2.4 Organogram of Dyeing Division

Page | 23
3.2.5 Organogram of Garments Division

Page | 24
Chapter FOUR

Duties and Responsibilities of Different

Working Personnel

Page | 25
4.1 Managing Director

 Responsibilities

 Make policy and ensure effective implementation.

 Check and approve company budget & ensure proper utilization.
 Arrange all resources as necessary & ensure proper utilization.
 Monitor & audit of all ongoing functions.
 Check, analyze & review reports & data for continual improvement plan.
 Make plan for sales, marketing & procurement and monitor all respective issues.

4.2 Director
 Responsibilities

 Implement policy & strategy of sales & marketing & ensure available work orders
as per the requirement of the company policy.
 Provide updated information of both local and global commercial functions to all
member of the merchandising team so that they can make procurement plan
accordingly.
 Monitor both merchandising and commercial activities.
 Analyze, review and update of customer requirements.
 Prepare raw material procurement plan & production schedule.
 Ensure sending of complete order file before 07 days of bulk production.
 Monitor production status, ensure in time pre-shipment inspection and in time
delivery.
 Reports to Managing Director & Chairman

Page | 26
4.3 General Manager

 Responsibilities

 Making Decision about implementation of planning.

 Making decision for purchasing raw materials, machines and equipment, spare part.
 Observing the production rate and giving necessary instruction to increase
production.
 Employing skilled efficient personnel in different section.
 Monitor both merchandising and commercial activities.
 Monitor production status, ensure in time pre-shipment inspection and in time
delivery.

4.4 Deputy General Manager

 Responsibilities

 Making decision about production amount, style, process, machines and equipment
used.
 Maintaining the time schedule of order and shipment.
 Giving direction to the junior officer
 Reporting to the GM

4.5 Manager

 Responsibilities
 L/C Import Operation:
 Identification of gaps & getting clarification.
 Ensuring necessary amendments.
 Operate all other function regarding L/C as per necessity of customer,
company and supplier

Page | 27
  Export operation & preparation of relevant documents.
 Custom and other relevant activities.
 C & F operation.
 Accountable to Chairman.

4.6 Assistant Manager (Production)

 Responsibilities

 Monitor daily in line operation & take following step to ensure balanced production
 Re-adjustment of Production/ Operator layout
 Re-adjustment of working time.
 Inter section linking with proper feedback
 Waste Control
 Abide by the company’s social compliance.
 Accountable to Manager (Production).

4.7 Production officer

 Responsibilities

 To collect the necessary information and instruction from the previous shift for
the smooth running of the section.
 To make the junior officer understand how to operate the whole production
process.
 To match the production sample with the target shade.
 To identify the faults of production an report to the PM/GM for necessary
action.
 To execute the overall floor work.

Page | 28
4.8 In-charge
 Responsibilities

 Support marketing & sales section with following activities:-

 Develop new design with decent make up.
 Relevant technical information.
 Consumption of raw material.
 Support procurement section with the following:-
 Detail analysis of PO/Contract sheet, determination of order requirement,
identification & clarification of gaps.
 Preparation of approval sample & detail checklist with relevant technical
information
 (consumption, measurement, Sketch & critical quality point of raw
material)
 Preparation of photo sample & swatch card.
 Distribution complete order (along with following) files before 07 days of bulk
production:-
 Contract or Order sheet.
 Quality breakdown.
 Makeup/Style detail
 Measurement chart
 Sketch/placement of accessories.
 Stitching detail.
 Garment sample (Approve by Customer)
 Washing and Embroidery Instruction.
 Fabric & accessories swatch card (Mentioning fabric face-back)
 Master Pattern set.
 Reports to (Merchandising & Commercial)

Page | 29
Chapter FIVE

MACHINE DESCRIPTION

Page | 30
5.1 Machine Details of Each Section (Cotton Club BD Ltd)

5.1.1 Knitting Machines:

Name Of Machines Manufacturer Country Quantity

Circular Knitting Machine Tayu China 05 Sets
Circular Knitting Machine Jiunnlong Taiwan 22 Sets
Rib/Interlock Jiunnlong / Tayu Taiwan 12 Sets
Single Jersey Fukuhara Japan 06 Sets
Total 45 Sets

5.1.2 Dyeing Machines:

Name of Machines Manufacturer Country Quantity

Dyeing Machine
Dilmenler Cap 11000 Kgs. Turkey 11 Sets
Flying Yang Cap 30 Kgs. China 03 Sets
Dyeing Finishing & Batch
Machinery
Relax Dryer (Tube) Dilmenler Turkey 01 Set

Relax Dryer (Open) Dilmenler Turkey 01 Set

Squeezer Mersan Turkey 02 sets

Steam Setting Dong Nam Korea 02 Nos.

Compactor Tube-Tex USA 02 Sets

Page | 31
Compactor (Open Width) Dilmenler Turkey 01 Set

Turning Machine Mersean Turkey 01 Set

Turning Machine Dong nam , S Korea 02 Sets

Sang.Ho

Setting Dilmenler Turkey 01 Set

Dryer Machine Tube Euroasiatic Germany 01 Set

Hydro China China 02 Sets

Washing Machine Hazinhongfa China 02 Sets

Tumble Dryer Machine Hazinhongfa China 02 Sets

Tumble Dryer Machine F&P China 02 Sets

Tumble Dryer Machine China China 02 Sets

Inspection Machine UZU Thailand 02 sets
Lap Machinery
Lab Dip Machine
Washing Machine
Dyer Machine Rapid Taiwan 03 Sets
Yarn Count M/C Tromin, Aristom Italy 02 Sets
Crock Meter M/C Peramount UK 1 Set
Twist Tester M/C Peramount India 1 Set
Peramount India 1 Set
Peramount India 1 Set
Total Machine 49 Sets

Page | 32
5.1.3 Sewing Cutting & Finishing Machine

Name of the Machines Manufacturer Country Quantity

Plain Machine
Auto Trimmer Plain Machine-Brother Japan 390 Sets
Button Hole Machine-Brother Japan 14 Sets
Button Stitch Machine-Brother Japan 20 Sets
Bar Tuck Machine-Brother Japan 4 Sets
Snap Button UZU China 12 Sets
Overlock Machine

Overlock Machine Pegasus Japan 286 Sets

PMD Kansai Japan 5 Sets
Automatic Fabric & Thread Trimmer Pegasus

Other Machineries

Auto CAD Winda Japan 162 Sets

Cutting m/c RMKM China 1 Set
Rib Cutting m/c Dino Japan 16 Sets
Fushing m/c Hasima Taiwan 12 Sets
Mini Spotty m/c PMD Japan 2 Sets
Metal Ditector m/c Hasima Hong Kong 6 Sets
Strapping m/c UZU China 10 Sets
Cloth Inspection m/c UZU Thailand 6 Sets
Thread Winding m/c UZU China 6 Sets
Pre Cutting m/c Kansai Japan 4 Sets
Smoking m/c Kansai Japan 2 Sets
Feet of the Arm Brother Japan 2 Sets
Button Pull Test m/c Imada Co. Ltd. Japan 1 Set
Stem Iron Sewoong Korea 136 Sets
Total Machine 1100 Sets

Page | 33
5.1.4 Embroidery & Printing Machinery

5.1.5 Power & Utility

Page | 34
5.2 Machine Details of Each Section (Mondol Knitwear’s Ltd)

5.2.1 Knitting Machine

Machine Total M/C Gauge Feeder Needle RPM Rotation Origin Produc
name M/C Dia number (max) ed
Fabric
Fukahma Single
02 21”,22” 24 81,84 1584 60 Taiwan Jersey

Clock & Taiwan S/J,

Pailung 82 17”-48” 18-28 42-218 1284- Anticlock Rib,
5136 wise Interlo
ck

Fukuhara 21 30”-38” 18,24 42-76 Anticlock Japan Auto

2268- wise Stripe
4056 S/J
Tayu 95 16”-42” 18-28 48-126 Anticlock China S/J,
1280- wise Rib,
6336 Interlo
ck
Fleeze
Jiunn- 40 16”-42” 16-24 90-160 1872- Anticlock Taiwan .S/J
Long 6048 wise Rib
Interlo
ck

Mayer & Open

CIE 13 30”-38” 24,28 96-123 2268- German Width
3312 S/J
Lisky Fleece
08 17”-40” 18-24 51-88 1272- Anticlock Taiwan S/J,
4512 wise Rib/
interlo
ck

Page | 35
 S/J,
U Masa 12 18”-36” 18,24 54-84 1354- Anticlock Taiwan Rib/
5424 wise interlo
ck
S/J,
Year 09 23”-42” 18-28 68-126 1728- Taiwan Rib/
China 6240 interlo
ck
S/J,
Sang 08 24”-44” 18,24 korea Rib/
Yang interlo
ck

5.2.2 Machines

Machine Type Quantity(Pieces) M/C Dia

Single Jersey 278 16-46
Rib Machine 51 26-44
Auto Strip 46 30-38

Flat Bed 274 40-80

Inspection 24
Total Machine 673

Page | 36
Chapter Six

RAW MATERIALS

Page | 37
6.1 For Knitting

6.1.1 Important Yarn

Receive From Count Blend Ratio

(Name of spinning mills)

80s/1, 60s/1,

Nahar (India) 40s/1 CB/CP 100%

Zaber 30s/1 BC 100%

Zaber 40s/1 CW 100%

Zaber 50s/1 Comb 100%

Zubair 30s/1, 40s/1 CW 100%

Zubair 40s/1, 50s/1 CB/CP 100%

Talha 16s/1, 20s/1, CTN 100%

24s/1

Talha 30s/1 KW 100%

Yasmin 16s/1, 30s/1, PC 50%+50%

24s/1, 38s/1,

45s/1, 50s/1

Yasmin 40s/1, 45s/1, CW 100%

58s/1, 70s/1

Yasmin 45s/1, 46s/1 PC 65%+35%

Page | 38
 40s/1, 45s/1,

Yasmin 50s/1 CVC 60%+40%

Yasmin 49s/1 Comb 100%

Sufia 20s/1, 45s/1 CTN 100%

Sufia 30s/1 KC 100%

Sufia 45s/1 CVC 100%

Ashik 9s/1 CTN 100%

Ashik 16s/1 CTN 100%

Z&Z 10s/2, 16s/1 CTN 100%

Z&Z 36s/2 CVC 60%+40%

Noman Tex 30s/2 CW 100%

Noman Tex 40s/2 CB/CP 100%

Zaber 32s/2 CW 100%

Square 20s/2 CTN 100%

Mytas 20s/2 CTN 100%

R.K. 20s/2 TC 35%+65%

R.K. 20s/2 CB/CP 100%

R.K. 60s/2 CTN 100%

R.K. 20s/2 CW 100%

Mimtex 40s/2 COMB 100%

Mimtex 60s/2 CP/CB 100%

Tamij 80s/2 CP/CB 100%

Paramount 40s/1 CVC 60%+40%

Page | 39
 Paramount 20s/1 CVC 60%+40%

Paramount 40s/1 PC 50%+50%

Paramount 20s/1 CTN 100%

Paramount 40s/1 CB/CP 100%

Mohi Tex 30s/1 CTN 100%

Mohi Tex 30s/2 CW 100%

6.2 Raw Material of Sizing

6.2.1 Chemical name
 Jet size 105
 Jet size 210
 Penetrose 50
 Pinitex
 Glysofill soft
 Acry size
 PVA

6.2.2 Raw Material of Dyeing

 Whitening agent
 Wetting agent
 Fixing agent
 Detergent
 Silicon
 Stiffering agent
 Water proofing agent

Page | 40
 De-foaming agent
 Enzymes
 Caustic soda
 Soda ash
 Acetic acid
 Oxalic acid

Page | 41
Chapter Seven

Knitting Section

This chapter begins with the fundamentals of knitting, then it goes with different types of
fabrics produced in the Cotton Club and machines used for preparation of those and
specification, manufacturing country and uses. Here different knitting terms, notation of
fabric with cam arrangement are briefly discussed. This chapter ends with the faults of
knitting and their remedies.

Page | 42
7.1 Definition of Knitting Technology

Knitting is the interlocking of one or more yarns through a series of loops. The length wise
columns of stitches, corresponding to the warp in woven cloth, are called Wales; the cross
wise rows of stitches, corresponding to the filling in woven cloth, are called Courses,
Filling Knits (Weft Knits) are those fabrics in which the course are composed of a single
strand of yarn, while warp knits are those in which the Wales are composed of single strand
of yarn. Gauge corresponds to the yarn in a woven fabric, and is defined as the number if
needles of yarns in half inches of cloth. The higher the gauge, the more compact and finer
is the cloth

7.2 Organogram of Knitting Section

General Manager

Knitting Manager

Production Officer

Knitting Master

Asst. Knitting Master

Shift In charge

Supervisor

Operator

Helper

Page | 43
7.3 Types of Raw Materials

Yarn:
 Combed Yarn
 Cotton + Modal
 Cotton + Viscose
 Carded Yarn

Spun Yarn: 100% Polyester

Lycra: In vista, Made in Singapore

7.4 Sources of Yarn for Knitting

Name of the spinning Mills Location

Arif Knit Spinning Ltd. Gazipur

The Delta Spinning Kashimpur Gazipur

Square yarn ltd. Kashimpur Gazipur

Bengol NFK Textile Gazipur

NRG Spinning Mills Gazipur

Prime Textile Pagla Narayngong

AA Kader synthetics Narayngong

Shirin Spinning Ltd Shreepur, Gazipur

Malek Spinning Mymensingh

Aman Cotton Fabrics Ltd Mowna

Page | 44
7.5 Classification of Knitting Section

 Flat Knitting section

 Circular Knitting section
 Fabric inspection section

7.6 Machine Profile

Brand name Origin Machine Machine Fabric Fabric Machine

structure Dia Dia GSM gauge
64’’
U.MASA Interlock 32’’ 200 24
Open
70’’
Year Chaina China 1X1 Rib 36’’ 180 18
Open
54’’
Jiunn Long Waffle 38’’ 175 18
Tube
64’’
Jiunn Long 2X1 Rib 30’’ 220 18
Open
Double
Year Chaina China 20’’ 27.5’’ 195 24
Pique

French
U.MASA 29’’ 64’’ 210 24
Terry

Single
Ta-Yu Thailand 32’’ 64’’ 140 24
Jersey

PRECISION Single
36’’ 96’’ 190 24
FUKUHARA Lacost

Twisted
58’’
Year Chaina China Single 36’’ 200 24
Open
jersey

PRECISION Double 64’’

32’’ 200 24
FUKUHARA Lacost Tube

Page | 45
7.7 Process Flow Chat of Knitting

Sample Fabric

Design Analysis

Machine Selection

Set the Machine according to Specific Design

Yarn in Cone Form

Feeding the Yarn Cone in the Creel

Feeding the Yarn in the Feeder

Tension Device

Knitting

Withdraw the rolled fabric and Weighting

Inspection

Numbering

Page | 46
7.8 Knitting Cam Arrangement

Page | 47
Page | 48
Page | 49
Page | 50
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Page | 52
7.9 Description of Production Process

In every mill there maintains a sequence in production processing. It is also followed in

this mill where we were in industrial attachment. The process sequences are in list below:

 Firstly knitting manager gets a production shit from the merchandiser as according
as consumer requirements then he informs or orders production officer about it.
 Production officer informs technical in charge & knows about machine in which
the production will be running.
 Technical in charge calls for leader of mechanical fitter troops, they two take
decision about machine for production considering machine condition, production
capacity, maintenance complexity etc.
 Production officer with experienced mechanical fitter adjusts required stitch length
& grey GSM for required final GSM.
 Supervisor checks daily production regularity & make operator conscious about
finishing tin due time.

Page | 53
  Operators operate machine in high attention as if there were no faults in the fabrics.
If he thinks or sure about any fabrics faults then he calls for the mechanical fitters
in duty. Mechanical fitter then fixes it if he can or he informs technical in charge.
Then he comes in spot.
 After required production & final inspection in 4- point system, they sent in dyeing
section.

7.10 Production Parameters

 Machine diameter
 Machine RPM
 No. of feeds or feeders in use
 Machine Gauge
 Count of yarn
 Required time (m/c running time)
 Machine running efficiency

7.11 Production Calculation

Production/shift in Kg at 100% efficiency:

RPM X No. of feeder X No. of Needle X SL
= ------------------------------------------------------------
3527.80 yarn count

Production/shift in meter:
Course / min
= -----------------------
Course / cm

RPM X No. of feeder X 60 x 12 X efficiency

= -------------------------------------------------------
Course / cm X 100

Page | 54
 Fabric width in meter:
Total no. of Wales
= --------------------------------
Wales / cm X 100

Total no. of needle used in knitting

= -------------------------------------------------
Wales/ cm X 100

7.12 Different Parts of Knitting Machine

Creel: Creel is used to place the cone.

Feeder: Feeder is used to feed the yarn.

Tensioning device: Tensioning device is used to give proper tension to the yarn.

VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch
length.

Guide: Guide is used to guide the yarn.

Sensor: Sensor is used to seen & the machine stops when any problem occurs.

Take up roller: Take up roller is used to take up the fabric.

Page | 55
7.13 Some Figure of Different of Knitting Machine

Figure: Knitting Circular Machine

Figure: Knitting Circular Machine

Page | 56
 Figure: Knitting Circular Machine

7.14 Some Common Knitting Faults

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.

Page | 57
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.

 Bent needle should be changed.

3. Star mark:

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.

4. Drop Stitches:

Causes:

 Defective needle.
 If yarn is not properly fed during loop formation i.e. not properly laid on to
the needle hook.
 Take-down mechanism too loose.

Page | 58
  Insufficient yarn tension.
 Badly set yarn feeder.

Remedies:

 Needle should be straight & well.

 Proper feeding of yarn during loop formation.

5. 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.

6. Pin hole:

Causes:

 Due to break down or bend of the latch, pin hole may come in the fabric.

Remedies:

 Change the needle.

Page | 59
7. Fly dusts:

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.

8. Yarn contamination:

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.

Page | 60
9. Patta:

Causes:

 Yarn count variation.

 Yarn tension variation.

Remedies:

 Proper yarn count & tension should be maintained.

Remarks:

 For dark color & plain single jersey patta very sensitive. But in case of
derivatives of single jersey, rib &interlock light patta considerable.

10. Lycra out & tension variation of Lycra:

Causes:

 Breakage of Lycra yarn & uneven tension of Lycra.

Remedies:

 To maintain uniform tension.

11. Yarn Miss:

Causes:

 Yarn breakage due to any reason and not pass through the yarn guide. It
may be occur for tension variation.

Remedies:

 Yarn guide and tensioner must be used.

Page | 61
12. Lycra and cotton mixed:

Causes:

 Lycra yarn twisted with cotton yarn.

Remedies:

 Correct the lycra path.

 Clear the yarn guide.

Page | 62
Chapter Eight

DYEING & FINISHING

Page | 63
8.1 Organogram of Finishing Section
General Manager (Dyeing & Finishing)

Asst. Manager

Sr. Executive

Production officer

Shift in charge

Floor in charge

Supervisor

Operator

Helper

8.2 THE OBJECTIVES OF FINISHING ARE GIVEN BELOW

 To improve the attractiveness and service ability of the textile materials.

 To accentuate/inhibit some natural characteristics on the textile materials such as
softening, de-lustering, brightening etc.
 To change the surface characteristics of textile materials.
 To impart new characteristics/properties of textile materials such as flame retardant,
water repellent or water proof finishes.
 To increase life and durability of textile materials.

Page | 64
  To set the fabric, so that it can be maintained its shape and structure.
 To set the chemicals into the textile materials.
 To meet up specific end uses.

8.3 TYPES OF FINISHING

Chemical finishing
 Chemical reaction of auxiliaries with fibers.
 Application of the handle modifying products/additives.

Mechanical Finishing
 Mechanical treatment with m/c.

8.4 FINISHING EFFECTS:

 Easy-care.
 Crease recovery.
 Dimensional stability.
 Good abrasion resistance.
 Improve tear resistance.
 Good sew ability.
 Soft or stiff handle.
 Shine or luster.

8.5 LIST OF DYEING FINISHING MACHINE IN CTTON CLUB (BD)

LTD

Page | 65
Machine Brand Name Machine Name Work
No.

01 METSA Turning m/c Fabric Turn

02 BIANCO Sliting m/c Tube to Open
03 BRUCKNER Stenter m/c Fabric Dry
04 TUBE TEX Tube Compacting m/c Dia, Gsm, Shinkage
05 LAFER Open Compacting m/c Dia, Gsm, Shinkage
06 DIMENLER Dry m/c Dia, Gsm, Shinkage
07 BIANCALANI Shinkage control m/c Shinkage Control
08 BIANCALANI Tumble Dry m/c Dia, Gsm, Shinkage
09 MERSAN Squizer m/c Prepare for Dry
10

8.1 Fig: Open Compacting Machine

Page | 66
8.2 Fig: Tube Compacting Machine

8.3 Fig: Squeezer Machine

Page | 67
8.6 Process Sequence of Finishing for knitted Jersey Fabric in cotton club
is as follows

Page | 68
Chapter Nine

PRINTING SECTION

This chapter begins with the brief discussion on printing and different methods and styles
of printing. Here screen preparation process, chemical used for printing are also briefly
discussed. Different printing processes used in Cotton Club are mentioned with recipe and
process sequence. At the end of this chapter, common faults of printing are showed.

Page | 69
9.1 Textile Printing

Printing is another part of wet processing technology. Printing is carried out after pre-
treatment of fabric or after dyeing of the fabric. Printing is carried out for producing
attractive designs on fabric or other materials. The printing is described as localized dyeing
i.e., dyes or pigments are applied locally or discontinuously to produce the various
attractive designs on fabric. The main objectives of printing are the production of attractive
designs with well defined boundaries made by the artistic arrangement of a motif or motifs
in one or more colors. Printed fabrics are well protected from friction and washing if dyes
or pigments are applied properly on fiber. A strong bonding is formed between dyes and
fiber. At the initial stage of printing, this printing work was done by hand but day by day
this style is changing by utilizing different modern techniques. Now different types of critical
printing is done very easily by the bless of modern science.

9.2 Steps in Textile Printing

Textile printing is carried out in different steps, such as:

1. At first, fabrics should be pre-treated before printing.

2. Printing paste must be prepared by using printing ingredients; printing
performance depends on a well printing paste.
3. Then, making an impression of the print paste on the fabric by using any of the
printing methods, which is required.
4. After that, drying is carried out on printed fabric.
5. Steaming is carried out on printed fabric for fixing the printing paste on the
fabric.
6. At last, printing fabrics are neutralized by the after-treatment process.

Page | 70
9.3 Styles of Printing

There are three different styles of printing. Such as:

1. Direct style of printing
2. Discharge style of printing:
a) White discharge
b) Color discharge
3. Resist style of printing:
a) White resist
b) Color resist

9.4 Methods of Printing

Printing is carried out with different instruments. Different methods are use to produce
impression on fabric. Methods of printing differ on the demand of user. Also it depends on
the materials type and type of purpose of end product use. The following methods can be
applied for textile printing operation. They are as follows:

1. Block Printing
2. Burn-out Printing
3. Blotch Printing
4. Digital printing
5. Duplex Printing
6. Engraved Roller Printing
7. Electrostatic Printing
8. Flock Printing
9. Ink-jet Printing
10. Jet Spray Printing
11. Photo Printing
12. Rotary Screen Printing
13. Screen Printing (Flat Screen)
14. Stencil Printing

Page | 71
 15. Spray Printing
16. Transfer Printing
17. Warp Printing
18. Special Methods (Tie dyeing and Batik Printing)

9.5 Different Types Printing in Cotton Club

a. Pigment printing
b. Rubber printing
c. Discharge printing
d. Plastic sol/ High-density printing
e. Flock printing
f. Foil printing
g. Glitter printing
h. Emboss / Pub printing
i. Burnout printing
j. Transfer printing
k. Afsan Printing
l. Spray Printing

9.6 Flow Chart of Printing Section

Art work receive from buyer

Make film for screen by designer

Make screen for sample

Color standard receive from buyer for matching color

Recipe maintain to register

Page | 72
 Strike off send to buyer for approval

Approved strike off received from merchandiser

Bulk cut panel receive from cutting

Send to lab for wash report

Recipe receive from sample section

After receiving wash report start bulk production

Quality control check

Delivered to garment input section

Page | 73
Chapter Ten

GARMENTS SECTION

This chapter begins with introduction of different machines used in garments section,
different types of sewing. Here there is a brief discussion on pattern making and fabric
cutting. Then it briefly discusses making procedure of Trousers and Polo Shirt. This chapter
ends with the sewing threads and apparel defects and remedies.

Page | 74
10.1 Garments Manufacturing
Garments are the final achievement of textile processing, which started from fiber as a raw
material of finished goods. After completing spinning, weaving, wet processing; the materials
are ready for apparel manufacturing. Apparel is made generally from dyed or printed fabrics.
The process of making a garment according to the pattern, desired design and style is called
garment manufacturing.

10.2 Flow Chat of Apparel Manufacturing

Garments are produced in a line of sequence, which is either manually controlled or

computerized. Anyhow, the sequence of a garment manufacturing is as follows:

Design/ Sketch
↓
Pattern Design
↓
Sample Making
↓
Production Pattern
↓
Grading
↓
Marker Making
↓
Fabric Spreading
↓
Fabric Cutting
↓
Sorting/ Bundling
↓

Page | 75
 Sewing / Assembling
↓
Pressing/ Finishing
↓
Final Inspection
↓
Packaging
↓
Dispatch to Buyer or Retailer

10.3 Machine Specification

Name of m/c: Plain machine.

Brand name: Juki.
Origin Japan.
Model: DDL-9000 SS
Needle type: DB×1
Stitch type: Lock stitch.
Motor type: Servo motor.
Rpm: 400-4000

Name of m/c: Overlook machine.

Brand name: Juki
Origin: Japan.
Model: MO-3914, TO-42.
Needle type: DC×1, DC×11, DC×14.
Stitch type: Chain stitch.
Motor type: Servo motor.
Rpm: 400-8000

Page | 76
Name of m/c: Flat lock machine.
Brand name: Juki.
Origin: Japan.
Model: MF-7823, U-10-B-56.
Stitch type: chain stitch.
Motor type: clutch motor.
Rpm: 2600

10.4 Pattern Construction

In garments making; different types of modern equipments are added for ensure the quality
of the products. Day by day; man wants to design their pattern by the modern system. For
this man introduced CAD and Digitizing system for making the pattern design. This system
also decrease the rate of defects of garments.

Pattern is created Cotton Club (BD) Ltd. by two ways:

1. Manual Method
2. Directly by CAD

10.5 Fabric Cutting in Garments Industry:

In garments industry; a garments is made by assembling different parts of fabric by sewing.

Different apparel accessories also sew in sewing section. After spreading of fabric, cutting
operation is performed. This fabric cutting is done in cutting section. Incorrect cutting can
make various garment faults.

Page | 77
10.6 Process Flow Chart of Fabric Cutting

Fabric Spreading
↓
Marker placing at the top
↓
Fabric cutting
↓
Sorting
↓
Numbering and checking
↓
Parts replacing
↓
Bundling
↓
Input to sewing section

10.7 Production Procedure of Trouser Sewing

Trouser or Jeans are the newest fashion of the world. Most of the people in most of the
states are interested to wear jeans Pant. Different types of jeansare manufactured in the
apparel industry. Various types of finishes are applied to the jeans product to increase its
popularity. Any types of defects can be the cause of rejection of the product, for this reason
extra care is required to maintain in every stages of the manufacturing.

Page | 78
10.8 Sewing sequence of Trouser is given below:

Number matching back & front pant

↓
Back rise & Front rise joint
↓
Pocket facing joint with pocket part by over lock m/c
↓
Pocket part sewing by over lock m/c
↓
Pocket tracing joint by plain m/c
↓
Top stitch pocket with pocket facing
↓
To sin Zigzag (pocket Rolling)
↓
Pocket marking by catalog & scissor
↓
Number matching pocket & body part
↓
Pockets tuck (2 end side of the pocket)
↓
Pocket joint with the body part
↓
Pocket top sin (Zig Zag)
↓
Back & front matching (number)
↓
Side sewing of the trouser
↓
Side top sin (Zig Zag )

Page | 79
 ↓
In side sewing by over lock
↓
Elastic tuck for waist belt
↓
Eye lot at middle point of the belt
↓
Rib tucks sewing for belt
↓
Elastic cutting at size wise
↓
Elastic + Rib (belt) tuck
↓
Belt surfacing
↓
Belt & body tuck

10.9 Production Procedure Polo-Shirt

Polo-Shirt is one of the stylist apparels in the world. This type of shirt could be made of
cotton or synthetic fibers. Its sewing operation is done with great care. It is near similar to
T-Shirt. After passing the cutting section, different cut parts are assembled in the sewing
section by sewing operation.

Page | 80
10.10 Sewing operation of the Polo-Shirt is done as the following sequence.

Lining joint with collar part by heat pressing

↓
Collar marking for open stitch
↓
Collar inside open stitch
↓
Collar marking
↓
Collar ¼ top sin
↓
Collar cutting
↓
Band Rolling
↓
Band joint with Collar
↓
Band top sin 1/6
↓
Placket lining
↓
Placket marking
↓
Placket Rolling
↓
Placket joint
↓
Placket top sin 1/6
↓
Placket Pattern top sin

Page | 81
 ↓
Placket pattern top sin 1/6
↓
Box Sewing
↓
Pocket Rolling
↓
Pocket iron
↓
Pocket marking
↓
Pocket joint with body
↓
Yoke joint with back part
↓
Yoke ¼ top sin
↓
Back & front part matching number
↓
Solder joint
↓
Solder top sin
↓
Collar marking
↓
Collar & body number matching
↓
Collar joint with body part
↓

Collar top sin in jointing point

Page | 82
 ↓
Sleeve marking
↓
Sleeve over locked
↓
Sleeve Rolling
↓
Sleeve pair matching
↓
Sleeve & body matching
↓
Sleeve body tuck
↓
Sleeve joint with body part
↓
Sleeve marking for batch
↓
Sleeve batch joint (left & right side)
↓
Body marking for batch
↓
Batch joint with body part
↓
Label make
↓
Label Iron
↓
Main label joint in back side
↓
Sleeve opening tuck
↓

Page | 83
Body hem sewing
↓
Care label sewing
↓
Side joint
↓
Band tuck
↓
Band tape joint
↓
Band top sin
↓
Sleeve chap tuck
↓
Inspection

Page | 84
Chapter Eleven

EFFLUENT TREATMENT PLANT

(ETP)

Page | 85
11.1Introduction

In this industrialized age, environmental pollution is a matter of great concern. surface

water pollution is one of the elements of environmental pollution. Chemical processing
industries especially textile processing industries are claimed to produce huge emuent to
discharge in our rivers. A complex mixture of hazardous chemicals both organic and
inorganic is discharged into the water bodies from all these industries, usually without
treatment. It is well known that textile mills consume large volume of water for various
processes such as sizing, desizing, scouring, bleaching, mercerizing, dyeing, printing,
finishing and washing. Due to the nature of various chemical processing of textiles, large
volumes of wastewater with numerous pollutants are discharged every day. In Bangladesh
most of the industrial units are located along the banks of the rivers and they do not use
Effluent Treatment Plant (ETP for wastewater. As a consequence, industrial units drain
effluent directly into the rivers without consideration of the environment. setup an effluent
treatment plant is mandatory for a factory today. Authority gives no permission of
electricity and gas connection to a new factory without ETP.

Flow Chart 30m3/hr

PH 8-14

BOD 400-600 PPM

COD 1000-1200 PPM

TSS 200-500 PPM

TDS 3000-6000 PPM

Oil & Grease 30-60 PPM

Color Dark Mixed

Temperature 600C

Page | 86
11.2 Outlet Effluent Parameters (Bangladesh Standard)

Flow Chart 30 m3/hr

PH 7-8
BOD <50 PPM
COD <250 PPM
TSS <100 PPM
TDS <2000 PPM
Oil & Grease <10 ppm
Colour Clean
Temperature <300C

11.3 Process Flow Chart

Raw Effluent

Screening

Pre-Treatment

Equalization
&
Skinning

Coagulation

Flocculation

Primary-Treatment
Neutralization

Sedimentation

Page | 87
 Biological Sludge Dewatering

Secondary-Treatment

Outlet to River/Drain Sludge Drying

11.3.1 Pre-Treatment

11.3.1.1 Screening

The raw waste water (Raw Effluent) from the process of the plant would be first screened
through a manual bar screen strainer channel, where all particles with dia 5mm as well as
small pieces of the fiber and floating suspended matters like polythene paper, polythene
bags, rags and others materials removed by bar screen net. The bar screen consists of
parallel rods or bars and is also called a bar rack. These devices are used to protect
downstream equipment such as pumps, lines, valves etc. from damage and clogging by
rags and other large objects. The bar screen is cleaned manually by means of rakes. The
screening is disposed of suitably after they are de-watering. The screened clean effluent
flows by gravity to an equalization tank.

11.3.1.2 Equalization and Skimming

The raw waste water from the screen chamber is collected in the equalization tank, where it is
equalized with respect to its characteristics and homogenous flow and an uniform pollution load
as well as to make bacteria acclimatized the waste water is stored in a tank. High speed bottom
fixed aerating device which blows air through the waste at a rate about 0.1 CUF of air per gallon
of effluent. The rising air tends to coagulate the grease and oils and cause them to rise to the
surface where they can be removed by a scraper mechanism. Besides, in order to accomplish a

Page | 88
proper equalization of both varying loading and flocculating pH values. The equalization tank is
designed for hydraulic retention time of around 6 hours. A substantial part of the COD will also
be removed by the dissolved air flotation process.

11.4 Primary Treatment

11.4.1 Coagulation & Flocculation

The homogenized effluent is than pumped to a Flash mixing tank followed by a

flocculation tank. Where added coagulants like lime (Calcium Hydroxide) and Ferrous
sulfate (FeSO4) for coagulation of the total dye particles. The basic idea of adding
coagulant is to bring together all the suspended and dye particles so that they can precipitate
out in a flash mixing and coagulation mechanism. Adequate quantity of poly electrolyte
polymer solution are dosed to enhance the process of color removal by the flocculation
process

11.4.2 Precipitation and Sedimentations Tube Settler-1

The flocculated effluent is taken by natural gravity in to the tube settler-1 from flocculation
tank for precipitation of dye sand suspended particles. The flocs formed a removed in the
downstream tube settler-1 by the help of tube settler media. The effluent will further now
by overflow system to a pH correction tank where requisite quantity of acid will be dosed
and pH will be adjusted as per the requirement.

11.4.3 PH Correction

The overflow effluent from tube settler-l tank is than by gravity the connection channel for ken in
to the PH neutralization.33% HCI acid is dosed for neutralizing the pH from around 10 to 7. The
pH correction channel is designed for hydraulic retention time of around 10 minutes and is
provided with slow speed agitator for thoroughly mixing of waste with acid A pH indicator is
installed in the tank for measuring the pH (optional).

Page | 89
11.5 Secondary Treatment

11.5.1 Biological Reactor 1 & 2

The neutralized effluent is taken by gravity in to the biological treatment aeration tank for
treatment of organic matter to reduce BOD/COD aerobically. The biological reactor is
designed on extended aeration principle. The aeration is provided with fixed type surface
aerator for providing the required oxygen for the biological degradation of BOD and COD.
The air is supplied by means of the bubble diffusion.

11.5.2 Tube Sattler- 2

After aerobically treatment effluent flows by gravity to the tube settler-2, the biological
solids generated are removed from the tube settler 2 by the help tube settler media.

11.5.3 Filter Feed Pump

The effluent tube settler 2 overflow in to the pressure sand filter and activated ca from filter
feed pump to the pump. From here the disinfected effluent is pumped by means of the
pressure sand to the level switch in pressure sand filter. The pump is normally operated in
automatically with interlock the filter pump.

11.5.4 Pressure Sand Filter

The effluent is pumped to the pressure sand filter. The filtration takes place in the
downward mode. The filter is filled with a layer of graded sand media supported by a layer
of graded gravel. The suspended matter in the effluent is filtered out in this unit, the effluent
is then flown into the activated carbon filter.

Page | 90
11.5.3 Activated Carbon Filter

The filter effluent from the pressure sand filter flows into the activated carbon fiber. In this
unit to the feed flow is downward through a layer of granular activated carbon filter in
which dissolved organics in the effluent are absorbed.

11.5.4 Treated Effluent Tank

The effluent from the activated carbon filter is collected in the treated tank. From this sump
the final treated effluent is disposed off. As indicated before, this effluent is utilized for
backwashing the pressure sand filter and activated carbon filter units.

11.5.5 Sludge Treatment

The sludge generated in tube settler-1, tube settler-2 and biological reactor is taken to a
sludge sump and pumped to a sludge thickener where sludge is concentrated. The thickened
sludge from the thickener shall be pumped to sludge drying bed for de-watering. The de-
watered sludge is formed into cake by natural dry or a centrifuge. The dried cake will be
disposed in a tank. The overflow from the sludge thickener will be flow back to
equalization tank for further treatment.

Page | 91
Chapter Twelve

MAINTENANCE

Page | 92
12.1 Maintenance of Machinery

The machineries used in textile wet processing should be subjected to scheduled

maintenance
Activities for their optimum performances at their following points:
 Routes of different utilities like water, stem, gas, electricity, compressed air, etc.
 Dyestuff & chemical dosing system.
 Drainage system of waste water, color & chemical.
 Driving arrangement of different machineries.
 Power transmission to different machineries.
 Fabric guiding system through the machineries.
 Cleanliness of machine parts.

12.2 Maintenance Schedule:

 Perform visual inspection

 Check bearing.
 Clean & grease.
 Inspecting all sides.
 Clean & oiling.
 Cleaning of drain valves
 Checking of all electrical wires.
 Checking of circuit breaker, magnetic contractors.

Page | 93
12.3 Maintenance Tools & Their Equipment

The most important maintenance tools that are used frequently are tabulated

Maintenance Tools Function

Grease Lubrication
Tread Tape Joining of broken metallic parts
Cutting Disc For cutting pipes, rods.

Glove Valve Fitting from stem line

Maintenance Tools Function
Union Fittings for water, steam line.
Union Elbow Fittings for water, steam line.
Cutting oil Lubrication
Gear oil Lubrication
Hydraulic oil Lubrication
Oil Gun Oil Application
Spanner Tightening of nut bolts
Master Range Tightening of nut bolts
Flat Screwdriver Screw tightening & loosening
Star Screwdriver Screw tightening & loosening
Hacksaw blade Cutting
Hacksaw Frame Cutting
Spray gun WP40 Spaying a chemical named WP40 that
lubricates bearings.
Drill Machine Drilling to make holes
Grinding Machine Grinding

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12.4 Boiler Machine Maintenance 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
 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

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  Safety valve test
 Economizer clean
 Feed tank clean
 Chemical tank clean
 Burner clean
 Check safety valve setting
 Replace valve & gasket

12.5 Remarks:
 As maximum machines are new, so they need a few maintenance that is the
breakdown maintenance.

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Chapter Thirteen

DECISION & CONCLUSION

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13.1 Decision

Mondol Knitwear’s Ltd & Cotton Club (BD) Ltd. is one of the most versatile business
conglomerates in the private sector in Bangladesh. These two companies are committed to
the best human workplace practices. Their goal is to continuously improve their Human
resource policies and procedures through education, training, communication and
employees involvement. Right from inception the policy of the company has been to
provide total customer satisfaction by offering quality knitted fabric in time with an
objective to up the quality and the value of merchandise to meet the manufacturing to
quality and promote delivery. These companies decided to integrate the manufacturing
process in a planned manner. Over the year the entire process has been integrated by
importing sophisticated machinery from world-renowned manufacturers. According to
their capacity they have an enriched production team which is very rare in other factories
of Bangladesh. The working environment of this factory is very cordially & friendly. All
of the learners. The goal of these companies are to get high production & to maintain the
quality of the product at a minimum cost. There is no non-woven m/c in this factory. But
it is able to produce all types of knit structure. There is no person to input the self-shade of
different types of lot every-day in the spectrophotometer but for accuracy of the recipe, it
is very important to input the self-shade of different lot of dyes in a regular basis.

13.2 Conclusion

There is large difference between the theoretical knowledge and practical experiences. This
is truer in case of the study of Textile Engineering. Industrial attachment or, Industrial
training is an essential part for textile education because it minimizes the gap between
theoretical and practical knowledge. This Industrial training increases our thought a lot
about textile technology. It also helps us to know a lot about industrial production process,
machineries, and industrial management and made us suitable for industrial life. Besides it
gives us the first opportunity to work in industry. So we can say industrial attachment
prepare us for the expected destiny of practical life.

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We have completed our industrial attachment from Mondol Knitwear’s Ltd. & Cotton
BD Ltd.
During our two-month long industrial training at these companies. We got the impression
that this factory is one of the modern export oriented dyeing knit garments industry of our
country. This factory does not compromise in case of quality. So, they have established on-
line and off-line quality control of each product. Besides, they also use the good quality
yarn, dyes and chemicals in their production process. Due to this, it has earned a “very
good reputation” in foreign market for its quality product over many other export oriented
textile mills. It has very well educated and technically experienced manpower to get rid of
any defect in production process. It has also a good organizational hierarchy.

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