ACKNOELEDGEMENT

At first my gratefulness goes to Almighty Allah to give me strength and ability to

complete the industrial training and this report. You have made my life more beautiful. May
your name be exalted, honored and glorified.
Now I wish to take this excellent opportunity to think a lot of people who have assisted and
inspired me in the completion of my training period.
Md. Asif Hossain, Manager (Q.C), TEXEUROP (BD) LTD. to whom I am extremely
indebted for his tremendous support and guidance throughout my training period. Being
worked with him I have not only earned valuable knowledge but was also inspired by his
innovativeness which helped enrich my experience to a greater extent. His ideas and way of
working was truly remarkable.
I also express my gratitude to Mis:Kamrunnahar Sumi, Lecturer Europeain University of
Bangladesh(EUB) for his support.
I would like to thank the management of the TEXEUROP (BD) LTD. for giving me the
opportunity to do the industrial training successfully and also their valuable suggestions. My
deepest appreciation goes to Md. ShahidulAlamMozumder, General Manager (dyeing),
TEXEUROP (BD) LTD. for his permission to conduct my industrial training without which
it would be uncompleted. The generous support is greatly appreciated. I would also like thank
Production officer, senior production officer, Assistant dyeing manager, Assistant General
manager and other officials of Texeurop(BD) Ltd. for helping me to complete industrial
training successfully. My gratitude also goes to all the employees of Texeurop (BD) Ltd. for
their sincere co-operation, support and valuable advices.
Last but not least, thanks go to my precious family for their never ending love and inspire at
every stages of my life. Without their continuous support I realize that would not be a person
I am right now.

Page 1 of 75

1.

CONTENTS

CHAPTER

TITLE

PAGE NO.

01

Introduction

02

Project Description

4-8

03

Manpower Management

9-13

04

Machine Description

14-41

05

Raw Materials

42-48

06

Production Planning Sequences & Operations

49-74

07

Quality Assurance System

75-82

08

Maintenance

83-91

09

Utilities

92-102

10

Store & Inventory Control

103-106

11

Cost analysis

107-109

12

Marketing activities

110-113

CONCLUSION

114-115

Page 2 of 75

The term textile derived from the Latin word textiles and the France word texere,
meaning to weave, and it originally referred only to woven fabrics. It has, however, come
to include fabrics produced by other methods. Thus threads, cords ropes, braids, lace,
embroidery, nets and fabrics made by weaving, knitting, bonding, felting or tufting are
textiles. Some definitions of the term textile would also include those products obtained by
the papermaking principle that have many of the properties associated with conventional
fabrics. In addition to clothing and home furnishing, textiles are used for such industrial
products as filters to air conditioners, life rafts, conveyor belts, tents, automobile tires,
swimming costumes, safety helmet and ventilators.
From fiber to fabric, Texeurop (BD) Ltd. is truly integrated undertaking. The Texeurop (BD)
Ltd. has the capability to offer a complete product range for the export textile markets. The
goal of Texeurop (BD) Ltd. is to become the preferred partner for sourcing high quality
fabrics and clothing from Bangladesh with highly advanced technology and an emphasis on
developing local human resources. Texeurop (BD) Ltd. has the potential to make an
important contribution to the nations growing readymade garments export sector.
The nation behind the existing structure and future expansion of Texeurop (BD) Ltd. is to
capture value-added at each stage of the textile manufacturing process. Despite Bangladeshs
lack of indigenous cotton production capability, Texeurop (BD) Ltd. has leveraged
Bangladeshs labor cost advanced and export competitiveness to the maximum.

Page 3 of 75

1. LOCATION:
Page 4 of 75

Vogra, Joydebpur,Gazipur, Bangladesh.

Tel: +880-2-9261986, 9261988,9261993,9262163-4,9262701-2, Fax: +880-2-9261582
Website:www.texeuropbangladesh.com E-mail: info@texeuropbangladesh.com
1. SPONSORS:
Texeurop (BD) Ltd is a joint venture company in which there are four partners.
* Chairman & Managing director
: Md Abdul majid khan
* Director
: Md Ibrahim khalil
* Director
: MdMahfuzulhaque
*A major portion of project cost is financed by Dutch Bangla Bank Ltd.
1. PRODUCT :
a) Knitted grey fabrics : Plain single jersey(milange/lycra/PC/CVC) , Heavy Jersey, Polo
Pique, Single & Double Lacoste, Rib & Interlock, double jersey, Drop needle, 2/3 Thread
fleece (Brushed/ Un-brushed), Collar & cuff etc.
1. 100%Cotton
2. 100%Polyester
3. Grey melange (15% viscose + 85% cotton,
30% viscose + 70% cotton
10% viscose + 90% cotton
1% viscose + 99% cotton).
1. Polyester-Cotton blends.
b) Knit Garments: T-shirt, Polo shirt, Sweat shirt, Golf shirt, Cardigan, Jogging suit,
Short/Trouser, Legging, Fashion dress & Children wears etc.
1. PRODUCTION CAPACITY:
Knitting Section: 3-4 tons/day
Dyeing Section: 25 tons/day
Garments Section: 20,000 pcs/day.
1. FINAL PRODUCTS NAME:
T-Shirts, Polo Shirts, Ladies Wear, Hoody, Sports Wear, Tank Tops, Kids Wear, Jog suits,
Reversible garments etc.
1. PROJECT COST:
TK. 67 crores (approx.)

1. HISTORY OF THE PROJECT DEVELOPMENT:

Page 5 of 75

Texeurop (BD) Ltd. has been established with the objective and vision to satisfy the needs of
21st century of worldwide knit apparels markets from one stop service being committed to
One- time Delivery, Quality Assurance, Price Affordability and Social Accountability.
Basically Pantex garments factory was the mother textile at Narayangonj of Texeurop (BD)
Ltd. From which the factory was expanded with collaboration of European partner.
The project is located in vograjoydevpur under the district of Gazipur, about 25 km distance
from the HazratSahjalal (R:) International Airport Dhaka, Bangladesh. A well-developed
Road Communication is there to reach the factory from the Airport as well as from the Dhaka
City.
1. DIFFERENT DEPARTMENTS:
a) KNITTING SECTION:
1. Knitting
2. Inspection
b) DYEING SECTION:
1. Batch section
2. Dye house
3. Dyeing lab.
4. Quality control
5. Finishing
c) GARMENTS SECTION:
1. Merchandising
2. CAD
3. Cutting
4. Sample
5. Sewing Floor
6. Q.C. Dept.
7. Packaging.
d) MAINTENANCE SECTION:
1. Electrical
2. Mechanical
e) STORE SECTION:

a)
b)
c)
d)

1. General Store
2. Accessories Store
1. SUPPORTING DEPARTMENTS:
Personnel administration
HRD
Marketing
Procurement
Page 6 of 75

e) Finance and accounting

f) Security department
MAJOR CUSTOMERS:

1. S. Oliver
2. Poly Concept
3. American Eagle
4. Gerry Weber
5. US-Polo
6. ASSAN
7. Tom Tailor
8. C & A
9. Lerros
10. ELEVATE
11. Mustang Jeans
CERTIFICATIONS:

PHYSICAL INFRASTRUCTURE:
The mill is built in such a way that there is possibility for further expansion of the mill. The
structure such as mill, office buildings, record rooms, guardrooms & dining room etc. are
made of solid hard concrete & brick mtls. The main set up for m/cs are built of corrugated
Page 7 of 75

iron & iron sheet, transparent hard plastics with enough ventilation & scope for passing light
& air.
Total area of the industry
: 12500 sq Meter
Factory land area
: 10000 sq. Meter
Building
: 8 Storied.
Floor space (Knitting)
: 5000 SFT
Floor space (Dyeing & Finishing)
: 20,000 SFT

REMARKS:
Texeurop (BD) Ltd. is a modern textile industry. Every facility of a modern textile mill exists
in this factory. It has a no. of renowned buyers especially at Europe. So, Texeurop (BD) Ltd.
is getting popular throughout the textile sectors and its buyers.

Page 8 of 75

ORGANOGRAMS
1. ORGANOGRAM OF MANPOWER:
Chairman
Managing director
Director (admin)

Director (production)

1. ORGANOGRAM OF ADMINISTRATION:
Director
(Admin & HR)
Manager
(account)

Manager
(Store)

Manager
(Admin / HR)
Store
keeper
Account
Officer
Asst.
Accountant

Asst. Store
keeper

Helper
HR
officer

Security
officer

Admin officer

1. ORGANOGRAM OF PRODUCTION:
Page 9 of 75

Compliance
officer

IT
executive

Director
(Production)
GM
(Dyeing)

AGM
(Dyeing)
Manager
(Quality)

Manager
(Knitting)

GM
(Operation)

Manager
GMmaintenance AGM
(Maintenance)
garments

ManagerMerchandising

Manager
Sr. Merchandiser
Jr. Merchandiser
Asst./Trainee Merchandiser

Asst.
Asst. Manager
Asst.
Manager
Manager
Senior P.O.

Incharge

Asst.
Manager

Senior P.O.

Supervisor
P.O
Operator
Operator

Operator

Operator

Technician

Different Helpers

MANAGEMENT SYSTEM
Page 10 of 75

Manager
Cutting/Sewing
Officer

1. INTERNAL COMMUNICATION SYSTEM:

1. Intercom telephone
2. Written letters
3. Fax
4. Oral
5. Cell Phone
6. SHIFT CHANGE:
There are three shifts in this factory and each shift is of eight hours. Shift is changed after a
week on Saturday.
Shift Change for worker of Security:
A Shift 06:00 - 14:00
B Shift 14:00 - 22:00
C Shift 22:00 - 06:00
General shift 09:00 - 18:00
1. RESPONSIBILITIES OF PRODUCTION OFFICER:
From getting an order of upper level all responsibilities are on the production officers.
They work with a troop of operators, helpers, fitters etc. to finish the production in due time.
In the meantime production officers bear all hazards, problems. They have to explain to the
manager for any type of production hamper. So, all production activities and its success
depend on the production officers.
1. Job Alignment of P.O & S.P.O:
Job title: Production officer & Senior Production officer
Report to: Production Manager
Purpose:
1. To control shift according to the plan made by the production manager
2. Territory: Dyeing section (major) Batching and Finishing section (minor)
Role within the organization:
Responsible for own shift production with a good quality and minimum time.
Environment:
Production officer has to work under huge stress. He has to work in acute heat under physical
& mental pressure. Also he has to work in acute heat all the year round.

Job Description of Production Officer:

Report To: Sr. production officer
Duties & Responsibilities:
1. Overall supervision of dyeing, finishing production.
Page 11 of 75

2.
3.
4.
5.
6.
7.

Batch preparation & PH check.

Dyes & chemical requisition issue & check.
Write fabrics loading & loading time from m/c.
Program making, sample checking, color management.
Control the supervisors, operator, asst. operator & helpers of dyeing m/c.
And also any other work as & when required by the management.

Job Description of Sr. Production Officer:

Report To: P.M (production)
Job Summary:
To plan, execute & follows up the production activities & control the quality production with
related activities.
Duties & Responsibilities:
1. Overall supervision of dyeing, finishing production.
2. Checks the different log books of different areas & report to management.
3. Checks the sensitive parameters of different machine for smooth dyeing.
4. Checks out the plan to control the best output from supervisor & workers.
5. To trained up & motive the subordinates how to improve the quality production.
6. Maintenance of machine & equipment. Any other works& when required by the
management.
7. Control the supervisors, operator, asst. operator & helpers of dyeing m/c.

1. 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.

1. INTRODUCTION:
Texeurop (BD) LTD. is an integrated computerized company. It has total 20 dyeing machines
among of them 10 machines are known as sample dyeing machine on the basis of their
production capacity. The machines are controlled by high skilled operators. On the other hand
Knitting section contains 18 machines, among of them 13 are circular knitting machine and
another 5 are flat bed machines.
KNITTING MACHINE DESCRIPTION
Process requirements:
In Texeurop (BD) Ltd. three types of machines are used for producing and inspecting knitted
fabrics.
These are:Page 12 of 75

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

2) Flat knitting Machine (Cuff & Collar).
3) Fabric inspection machine
And the whole knitting section is divided in four sections,
1. Circular knitting section
2. Flat knitting section
3. Fabric inspection section
4. Store section
Total no of machine at a glance:
M/C Type
Number of Machine
Single jersey
07
Rib
Fleece
Flat bed (Cuff)
Flat bed (Collar)
Twill Tape
Warping M/C
Fabric Inspection M/C

Grand Total
38
M/C

05
06
05
10
03
01
01

1. Circular Knitting Section:

This section contains 13 circular knitting machines. Circular knitting machines are of
different types, made by different manufacturer and also have different specifications. In this
section body fabric for knitted garments is produced. The different specifications of different
machines are given one after another
Specification of circular knitting machine:
M/C
No.
01
02
03
04
05
06
07
08

Brand

Model

Origin

Type

Dia.(inch)

Gauge
16 G
17 G

No. Of
Needle
1507 T
1800 T

No. Of
Feeder
60 F
60 F

Monarch
JIUNN
LONG
JIUNN
LONG
ORIGIO
JIUNN
LONG
JIUNN
LONG
JIUNN
LONG
JIUNN
LONG

LDR
JLD

Japan
Taiwan

Rib
Rib

30
30

JLD

Taiwan

Rib

34

18 G

1920 T

68 F

JO
JLS

Italy
Taiwan

S/J
S/J

30
24

28 G
24 G

2640 T
1812 T

72 F
72 F

JLD

Taiwan

Rib

36

24 G

2040 T

72 F

JLS

Taiwan

S/J

28

24 G

2112 T

84 F

JLS

Taiwan

S/J

25

24 G

1872 T

75 F

Page 13 of 75

09
10
11
12
13
14
15
16
17
18

ORIGIO
JIUNN
LONG
JIUNN
LONG
JIUNN
LONG
GoangLih
GoangLih
GoangLih
GoangLih
LISKY
LISKY

JO
JLS

Italy
Taiwan

S/J
Rib

30
34

24 G
18 G

2220 T
1920 T

72 F
68 F

JLS

Taiwan

S/J

23

24 G

1740 T

69 F

JLS

Taiwan

S/J

30

24 G

2256 T

90 F

GLF
GLF
GLF
GLF
LFS
LFS

Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan

Fleece
Fleece
Fleece
Fleece
Fleece
Fleece

30
30
30
30
30
30

20 G
20 G
20 G
20 G
20 G
20 G

1860 T
1860 T
1860 T
1860 T
1885 T
1885 T

84 F
84 F
84 F
84 F
96 F
96 F

Fig: Circular Knitting Machine

2. Flat Knitting Section:
Generally collar, cuff of knitted garments is produced in this section. In this section there are
5 flat knitting machines, all of them are same type and also have same specification. The
specification of all machines is given below.
Specification of flat knitting machine (Collar):
M/C No.
01
02
03
04
05
06
07
08
09

Brand
MATSUYA
MATSUYA
MATSUYA
MATSUYA
MATSUYA
MATSUYA
MATSUYA
MATSUYA
MATSUYA

Model
M-100
M-100
M-100
M-100
M-100
M-100
M-100
M-100
M-100

Origin
China
China
China
China
China
China
China
China
China
Page 14 of 75

Gauge
14 G
14 G
14 G
14 G
14 G
14 G
14 G
14 G
14 G

Prodn./hr
20 PCS.
20 PCS.
20 PCS.
20 PCS.
20 PCS.
20 PCS.
20 PCS.
20 PCS.
20 PCS.

10

MATSUYA

M-100

China

14 G

20 PCS.

Fig: Flat Knitting Machine (Collar)

Specification of flat knitting machine (Cuff):

M/C No.
01
02
03
04
05

Brand
JY LEH
JY LEH
JY LEH
JY LEH
JY LEH

Model
JL- 6 colour
JL- 6 colour
JL- 6 colour
JL- 6 colour
JL- 6 colour

Origin
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan

Spec.
Single Carriage
Single Carriage
Single Carriage
Single Carriage
Single Carriage

3.Twill Tape Section:

M/C No.
01
02
03
04

Type
Warping m/c
Twill tape m/c
Twill tape m/c
Twill tape m/c

Brand
Dong Guan
Dong Guan
Dong Guan
Dong Guan

Model
WMC-302
KYF-8/30
KYF-8/30
KYF-8/30

Origin
China
China
China
China

Tape Width

1. Cloth Inspection:
In cloth inspection section one machines is available. Specification of these machines is given
below.
Type
Manufacturer name
Country
Model No

: Cloth Inspection Machine

: Uzu fabric Inspection
: Thailand
: UZ 900.31
Page 15 of 75

Fig: Fabric Inspection M/C

1. Basic element of knitting:

2. Needle.
3. Sinker.
4. Cam.
5. Types of needle
In general there are three types of needles.
1. Bearded needle.
2. Latch needle.
3. Compound needle.
According to the Butt position Latch needle are four types:-

1. One butt latch needle

2. Two butt latch needle
3. Three butt latch needle
4. Four butt latch needle
1. CAM:
Cams are the devices which convert the rotary m/c drive into a suitable reciprocating action
for the needles or other elements.

Page 16 of 75

Types of cam: Two type of cam

1. Engineering cam
2. Knitting cam

Knit cam
Miss cam
Tuck cam

Function of CAM: The function of cam is as follows:

1. To produce motion to needles.
2. To drive the needles.
3. Formation of loops.

Sinker:
This is secondary primary knitting element. It is a thin metal plate with an individual and
collective action approximate at right angles from the hook side between adjoining needles.
Function of sinker:
It may one or more of the following functions dependent upon the
machines knitting action and consequent sinker shape and movement.

The functions of Sinker are:

1. Loop formation.
1. Holding down.
1. Knocking over.

Sinker
Page 17 of 75

1. Others Equipments Used In Knitting Section:

2. GSM cutter
3. Electronic balance

1. Terms and definition of knitting:

Course A horizontal row of loops formed by the needles during one knitting cycle
Wale A vertical column of loops formed by a single needle
Loop- It is a basic unit consisting of a loop of yarn meshed at its base with previously basic
unit. Knitted loops are arranged in rows and columns roughly equivalent to the warp and weft
of woven structures termed Wales and courses respectively
Stitch- The smallest dimensionally stable unit of al knitted fabric is stitch. It consists of a
yarn loop which is held together by being intermeshed with another stitch or other loop.
Stitch length - Stitch length is a length of yarn which includes the needles the needle loop &
half the sinker loop on either side of it. Generally the larger stitch length, the more extensible
& lighter the fabric & the poorer the cover, capacity & bursting strength.
Steps should be taken to change stitch length.
1.
2.
3.
4.
5.

Check the S.L of the m/c prevailing.

Change the diameter of VDQ pulley.
Set of the position of carriage.
Set the speed of take- up roller
Maintain the optimum yarn tension.

Stitch Density -Courses per inch (CPI) Wales per inch (WPI)
M/c Gauge - A number of needles per unit length in the knitting m/c, measured as the
number of needles in one inch. This measure determines the number of Wales per unit length
in the knitted fabric.
1. Essential elements of JIUNN LUNG Knitting m/c:
2. Creel
3. Yarn guide
4. Tensioner
5. Feeder
Page 18 of 75

6. Needle
7. Cam box
8. Cam& sinker
9. VDQ Pulley
10. Base plate
11. Take up roller
12. Body
13. Auto stopper
Creel: - Which is used to place the yarn cone, from where the yarn is supplied to m/c,
through pipe.
Yarn Guide: - Which is used to guide the yarn, Yarn guide is necessary for maintaining
proper tension on yarn during kitting.
Yarn Tensioned: - Yarn tensioned is requiring to proper gripping of yarn by needle.
Feeder: - Feeder is directly related to the production. E.g. if no. of feeder is high then
production will be high and vice versa.
Cylinder: - Cylinder is an important part of knitting m/c through which needles are set.
During selection of knitting m/c for specific types of knitting cylinder gauge is an important
parameter.
Needle: - The main part of knitting m/c is needle, without needle it is impossible to knit
garments. In knitting m/c there are many types of needle may be used, like letch needle,
bearded needle, compound needle but latch needle are very popular in knitting.
Cam box: - Cam box is used to hold the cam according to the fabric design. Knitting cams
are arranged according to the design, e.g. arrangement of knit, tuck & miss cam.
Sinker: - Sinker is essential for knitting garments. Sinker is used to hold & support the thread
during the loop formation. In knitting different shape of sinker is used.
VDQ Pulley: - VDQ pulley is very important in maintaining proper stitch length.
VDQ pulley is positive then increase stitch length and decrease GSM. VDQ pulley is
negative then decrease stitch length and increase GSM.
Base plate: - Base plate is circular shaped body, on which cylinder is situated.
Take-up roller: - Take-up roller is used to take the cloth by roller.
Page 19 of 75

1. Typical knitting calculations:

The calculations which are frequently used in the knitting section are discussed below:

1. Gauge (G): Number of needles per inch.

2. Total needles: Machine diameter Gauge3.416.
3. Feeders of Single Jersey: Machine diameter3.
4. Feeders of Double Jersey: Machine diameter2.
5. Non tech Calculation of Single Jersey:

6. Non tech Calculation of Double Jersey:

1. Production Calculation (kilograms):

Production formula:
Kg/hour
Example: Let,
Dia. = 32"
Gauge = 24
RPM = 18
Yarn count = 30s/1
Feeder = 120
SL = 2.85
Production =?

We know, Production=
kg/hour
Page 20 of 75

=
kg/hour
= 149 kg/hour

1. DYEING MACHINE DESCRIPTION:

List of Machines
Department

Batch

Machine type
Fabric inspection m/c

No. of machine
01

Turning m/c
Overlock m/c
Lab Dip Machine

02
03
04

Electric pipette
Electric Balance
Electric Iron
Sample Dryer
GSM Cutter
Light Box
Washing m/c
Data Color (spectrometer)
Computer
Printer
PH meter

02
02
01
01
01
01
01
01
02
01
01

Winch m/c (Env. Temp.)

Winch m/c (High Temp.)
Computer
Light Box
Slitting m/c

09
12
02
01
02

Squeezer
Hydro Extractor
Stenter
Dryer

01
01
03
02

Grey Fabric Store & inspection

Dyeing
Lab

Dyeing Floor

Finishing Floor

Page 21 of 75

Washing

Tube Compactor
Open Compactor
Suiding m/c
Calender
Brushing m/c
Washing m/c

02
02
01
01
02
08

Tumble Dryer
Hydro Extractor

06
01

1. SPECIFICATION OF DIFFERENT MACHINES:

1. MACHINES IN LAB:
Data color machine
With increasing pressure for smaller production lots, shorter time to market and intricate
blends, the only way to optimize time, recipe development and production is to have a broad
knowledge
base taken directly from dyers themselves. Data color is a unique solution that uses
the knowledge of the experts in your company to help you manage dyeing recipes and entire
processes. It automatically creates or specifies the best production recipe for any color, dyed
on a specific fabric and for a particular customer. It manages hundreds of different production
recipes by relevant dyeing requirements.
MACHINE SPECIFICATION:
Standard features include the following:
1. Pulsed xenon light source
2. Multiple aperture sizes to accommodate samples of different sizes
3. Automated specular port
Optional features including the following:
1. Automated aperture detection
2. Automated zoom lens
3. Automated, adjustable ultra-violet filters for measuring fluorescent samples
4. Adjustable UV Filter
5. Option Transmission Option
6. Vertical Mount Option
Electrical/Environmental Requirements
Power : 85 to 264 VAC, 47 to 63 Hz, 80 VA peak, 35 VA typical
Absolute Operating Environment
5C to 40C, 20-85% RH, non-condensing
Interfaces Serial: RS232 9600/115200 baud (shipped at 19200 baud)

Page 22 of 75

USB: 1.1 or higher

Fig: Delta Pass in Data Color

Fig: Data Color Machine

Dyeing pot: 250 & 450 ml

Sample Dyeing machines: there are 4 m/cs in the lab.
Labdip m/c 1:
Capacity
: 24 pots (250 ml)

Model
Brand
Origin

: HS-24

: F&P
: China

Labdip m/c 2:
Capacity
: 24 pots (250 ml)
Model
: HS-24
Page 23 of 75

Brand
Origin

: F&P
: China

Labdip m/c 3:
Capacity
: 24 pots (450 ml)
Model
: HS-24
Brand
: F&P
Origin
: China

Fig: Lab dip Machine

Labdip m/c 4:
Capacity
: 24 pots (450 ml)
Model
: HS-24
Brand
: F&P
Origin
: China

Fig: High Temperature Winch Dyeing M/C

Page 24 of 75

Fig: Environmental Temperature Winch Dyeing M/C

1. Different Finishing Machinery
01. Hydro extractor m/c:
GUOHANG, China.
Rpm: 700-746(max).
Extraction% : 60%(apprx.)
Use: Loose structure fabric like rib, interlock etc.

Fig: Hydro extractor m/c

02. Slitting m/c:
Bianco, Italy.
Function:
1. To cut the tubular fabric for opening.
2. To check the fabric fault.
3. Rubber pressure roller removes a slight amount of water.
4. Softener can be at the tank.
Page 25 of 75

5. Utility Used: Air, Water, Electricity.

6. Main points:
7. Speed : 100 m/min.
(For single jersey fabric line speed is maintained as 5 m/min.
For other fabric line speed is maintained as 1 m/min.)
1. Production capacity: 7 tons/day

Fig: Slitting m/c

03.Open squeezer:
Bianco, Italy.
Main parts:
1. Squeeze roller(dewatering)
2. Over feeding roller(to delivers as per feed)
3. Folding device(to delivers the fabric in folded form)
4. Softener tray.(to impart soft finish)

Utilities used:
1. Electricity.
2. Compressed air.
Padder pressure: 4.5-5 bar.

04. Squeezer:
Bianco, Italy.
Main parts :
1. Revolving platform.
2. J-box squeezer.
3. Deatering unit.
4. Stretching unit(for adjusting dia.)
5. 1st tank to remove dust, hairy fiber etc.
Page 26 of 75

6. 2nd tank to apply different chemical finishes like flame retardant, softener, fixer.

7. Speed: 80 m/min(max)
8. Pressure of 1st padder : 3
9. Pressure of 2nd padder : 4-5
10. Water extraction%: 36-40%

05. Dryer m/c:

DILMENLER, Turkiye.
Function:
1. To dry the fabric properly.
2. To dry the fabric without tension.
3. To gain the finished GSM.
4. Specially used for lycra, piping, twill tape, Rib collar.
5. Main parts:
1. Heat chamber.(3)
2. Burner.(3)
3. Blower.(6)
5. Synthetic blanket.
6. Folding device.
1. Utility used:
2. Steam
3. Electricity.
4. Steam pressure: 5.5 Kg/sq.cm(78 psi) at 155C
5. Speed: 45 m/min(max)
6. Blower Speed: 230 rpm(max)

O6.Tube Compactor:
TUBE-TEX, America.
Functions:
1. To minimize the shrinkage.
2. Overfeed given to achieve the finished gsm.
3. Hairy Fibers can be removed to improve the handle.
4. Spirality& Boeing can be minimized.
Features:
Maximum line speed : 100 m/min.
Maximum dia.
: 62".
G.S.M
: Maximum 20% increase after compacting.
Page 27 of 75

Shrinkage
: 5%(max)
M/c temperature
: 95C
Production capacity : 7 tons per day.
Utility used:
1. Gas.
2. Electricity.
3. Steam.
Sensor position:
1. On the stretcher.
2. After compacting unit.
3. On the conveyor.

07. Stenter m/c (7 chamber):

M/C No. : 01
Company
Model
Type
Capacity
Origin

: UNITECH
: 316
: Roller Padder
: 10,000 KG
: ITALY

M/C No. : 02
Company
Model
Type
Capacity
Origin

: UNITECH
: 316
: Roller Padder
: 10,000 KG
: ITALY

M/C No. : 03
Company
Model
Type
Capacity
Origin

: IL SUNG
: 8 GP
: 2800 mm
: 10,000 KG
: KOREA

1.
2.
3.
4.

For Lycra fabric Heat setting is available only.

Width is set in such a way so that it gives the required GSM & shrinkage.
Suitable for open compactor.
Course and wales become align and even distribution by Mahlo in the feed side i.e to
minimize Bais& Boeing problem.
5. For Rib Fabric blower speed is less due to its loose structure.
6. 14 burner, 7 chamber,14 blower.
Page 28 of 75

7. In case of heavy fabric temp 210C and for light fabric it is 180-190C.
8. Over feed speed is maintained as per delivery speed so that it can give the desired
quality.
9. Temperature control depends on shade condition.
10. Glue is used along the selvedge to prevent curling.
11. Two set of padders with tank are used to apply chemical finishes & squeezing.
12. Padder pressure must be controlled carefully.

Controlling points:
1. Fabric speed.
2. Fabric width.
3. Temperature.
4. Over feeding speed.
Utility used:
1. Gas.
2. Electricity.
3. Steam.

1. Settings:
Fabric type Over feeding (%)
Single jersey 65%
Rib
50%
Interlock
55%
Lacoste
50%

Temperature (C)
140-150
170-190
160-170
145-150
Page 29 of 75

Speed (m/min)
20-30
20-30
20-30
20-30

Blower Speed
60
35-45
40-45
45-55

T.C

60%
190
1. For heat-setting overfeed % is kept 20%.
2. For heat-setting temp. is kept 180-185C
3. If Overfeed% (High)
tension (Less)

20-30

40-50

Shrinkage (Less) GSM (High)

08. Open compactor :

FERRARO, Italy.
Functions:
1. To impart dimensional stability.
2. To provide better cohesion.
3. To obtain required width and G.S.M.
Main parts:
1. Heated cylinder(steam)
2. Steaming device.
3. Blanket.
4. Teflon roller.
5. Over feed %: up to 50%.
6. Steam pressure: 5-6 bar.
Machine specification:
1. Brand name: Ferraro
2. Type/model no: COMPTEX-RE 2800.
3. Company: Italy
4. No of motor: 08
5. Over feed = 35%
6. Machine speed =80 m/min.
7. Temperature range: 100C -1500C
8. Maximum width 86 inch
9. Minimum width 36 inch
10. Left over feed: -20% to +20%
11. Right over feed: -20% to +60%
12. Front over feeding cylinder: -20% to +60%
13. Production Capacity : 24 tons/day
14.

Page 30 of 75

Special finishing machine

2. Sueding/pitch Finish
1.

A sueder is sometimes referred to a s a sander since the machine consists of one or more rolls
covered with sand paper as the abrasive. Fabrics traveling over these rolls develop a very
Low pile and the material's surface can be made to feel like suede leather. The hand will
depend on the fiber composition, the filament count in the yarn and the intensity with which
the fabric is worked.
Filament fabrics can be made to feel like a spun fabric and all fabrics will have a softer hand.
It also known as pitch finish or carbon finish.
Tasks:
1. To develop soft feeling at the face side.
2. To increase the aesthetic properties on the garments
3. To provide warm feeling to the garments.
M/C quantity : 01
1. Brand :Unitech- Santalucia
2. Model: 10 GS X 1952
3. Origin-Italy
4. Normal Current - 96 Amp.
5. No of Counter-Pile :03
Setting Point :
1. Taker -in- Tension (14 K/g)
2. Drum Tension (47 K/g)
3. Fabric Return Tension (15 K/g)
4. Plaiter Tension (14 K/g)

Page 31 of 75

1. Raising/ Brushing m/c:

Tasks:
1. To provide warm and smooth feeling.
2. To satisfy the buyer needs like heavy, medium & light brushing.
Machine specification:
1. Brand name: I KVANG M/C Works Ltd.
2. Type/model no: RG2-200
3. Country: Taiwan
4. No of motor: 04
5. Speed of main drum: 50 rpm
6. Production Capacity: 2 tons/day
7. Utility: Electricity, Compressed air

Washing Sectors M/C:

Task:
1. Washing m/c is used to do normal wash in Garments.
2. It used to create special effect in Garments.
3. Tumble Dryer is used to dry Garments.
Page 32 of 75

1. TESTING LAB MACHINES:

1. Pilling Box:
This Machine is used to create pill by rotation in fabric.
1. Pilling Assessment Viewer:
It is used for view the condition of pilled fabric & help to take decision about
pilling properties of fabric.
1. Crock Master:
It is used to crocking in the fabric due to find out the color fastness of sample.
1. Light Fastness Tester:
It use light (UV) to cheek the light fastness properties of sample.
1. Light Box:
It used to compare the shade% with idol in different light source (i.e. daylight 65).
1. Perspiration Tester:
It is used to measure the fastness due to perspiration.
1. Washing Machine:
It is used to wash fabric & help to measure Srinkage%.
1. Dryer:
It is used to dry sample after various wet test.
1. Bursting Tester:
Measure the bursting properties of fabric.

Fig: Pilling Box

Fig: Pilling Assessment Viewer

Page 33 of 75

Fig: Light Box

Fig: Light Fastness Tester

Fig: Crock Master

Fig: Bursting Tester

Fig: Perspiration Tester

Fig: Washing Machine

1. PRINTING SECTIONS MACHINE:

1. Rotary Screen Printing Machine
Brand
: JI LONG
Origin
: China
Model
: 200
Capacity
: 6-Head, 6-Screen, Attach drying System.
Blanket
: 20m (length), 78inch (width).
Speed
: 5-80m/min.
Production Type: Allover Print (AOP) & Burnout Print (BOP).
Page 34 of 75

1. Annual Requirements of Dyes :

The annual requirement of Dyestuffs, Chemicals & Auxiliaries was not determined as
necessity of these are assessed by volume of production. Annual requirement of dyes &
chemical depend on the order of production. But for various reasons such as improper
weighting, carelessness of operators, hydrolysis of dyes, uneven process control, wrong
recipe formulation, incorrect batching, improper storage facilities& for different unwanted
expenditure , extra dye consumption increased dye & chemical requirement.
1. Sequence of operation(Dyeing):
Lab dip approved
Grey fabric inspection
Batching
Scouring & Bleaching
Enzyme (If required or buyer requirements)
Dyeing
Bath Drain
Cold Wash
Neutral With Acetic Acid
Soaping
Fixing (If required )
Softening

1. Lab dip making procedure:

Standard swatch/pantone from buyer collection

Page 35 of 75

Select appropriate combination of dyes and making recipe with required fabric from available
reference or data color
Making stock solution as per respective dyes and chemical
pipeting by manually or digitally from
stock solution according to dye percentage and liquor
.ratio (M : L)
Dyeing in machine by keeping exact parameter as per shade percentage and dyestuff
(Migration and fixation)
Washing (cold, hot, chemical)
Drying & ironing
Enquiry light source matching shade with standard
If not ok need correction
If ok, submit to buyer
Taking approval from buyer
Check the recipe from approved shade
Go to bulk production according to correct recipe

1. Example of a colored sample preparation in lab:

Buyer: Lerros,Order sample

Page 36 of 75

(Delta in data color (getting recipe)

Colorshade%
R/b red RX =0.072.1
R/B red 3GX = 0.078.2 total shade%= 0.15
[for 1 no. stock sol.=0.5%,for 2 no. stock sol =1%[from chart in lab
[salt 20 g/l, soda 4g/l [from chart
Sample wt = 5gm
M:L = 1:10
Unit for 5gm sample from stock color amount: l
R/b red RXcc 0.72 = 5/ (5*0.072)=
R/B red 3GXcc 0.39= 1/ (5*0.078)=
Total amount of color =1.11 cc
Salt = (20*5)/25 = 4cc
Soda = (4*5)/10 = 2cc
For salt, here in lab 25% stock sol previously prepared soda10% stock sol. previously
Prepared we have to take total liquid 50 ml, when dye+ salt +soda exceeds 50ml or near 50ml
then salt have to take as solid. Without these normally taken as liquid. for a very little amount
stock sol. prepared taken as solid is difficult for test.
(Labelling agent =1cc from 1% stock sol. (used in lab sequestering agent =1cc () total liquid
50cc
cc 40.89 = (1+1+2+4+1.1)-so additional water =50
.now put the recipe in pot then put it to the m/c
60 temp 40 min for migration and 60 temp. 1 hour for fixation finally it comes

Page 37 of 75

1. Production Parameters :
Process
Scouring -Bleaching
Enzyme Wash
Enzyme Deactivation
Reactive Dyeing (Light Shade)
Reactive Dyeing (Dark Shade)
White Shade
Turquoise color dyeing
Polyester dyeing
Softening Water

Temp. (C)
98
55
70
60
60
98
80-90
130
40

Time (min)
60
60
10
60
60
20
90
45
45

1. Grey Fabric Inspection :

In grey fabric inspection the available faults are
1. Hole/Loop
2. Needle breaking
3. Neaps, Thin & Thick places
4. Needle mark
5. Sinker Mark
6. Yarn problem
7. Bar/Stripe
8. Wheel mark
9. Oil mark
10. Foreign Fiber
11. Hair
12. Lycra drop
13. Contamination

Batching:
Page 38 of 75

pH
11.5-12
4.5-5
10.2-10.8
10.9-12
10.5-11.5
10.9-12
4.5-5
4-5

M : L ratio
1:8
1:8
1:6
1:6
1:6
1:6
1:6
1:6

Batching preparation is the process where inspected grey fabrics are divided into different
batches with reasonable quantity according to machine capacity, nozzle number in order to
make them suitable for the further operation In batching. It must be carefully observed that
each Nozzle of a machine contains equal length of fabric. After batching some fabrics are
tuned to backside to minimize the risk of faulty dyeing.
Following are the fabrics those are tuned back by turning machine:
Single Jersey
1. Single Jersey
2. Locoest (Single & Double)
3. Fleece(if asked)
1. Sequence of Batching :
Grey fabric divided into batches
Batches divided nozzle wise according to length & Dia.
1. Instrument used:

1.
2.
3.
4.
5.

Turning m/c
Plaiting m/c
Weighting m/c
Back sewing m/c
Over-lock m/c

1. Information checked:
1.
2.
3.
4.
5.
6.
7.
8.

Order No
Color
Yarn Count
Yarn lot
Yarn brand
Knitting factory
Machine No
Roll No

1. Pre-treatment:
1. For scouring & bleaching at first the fabric is loaded on to the bath.
2. Required amount of water is taken to the bath.
Page 39 of 75

3. Wetting Agent & Anti creasing Agent is added.

4. Scouring Agents (Caustic/Soda) & Stabilizer are added by the aid of dosing when the
temperature reaches at 50 C.
5. H202 is added by the aid of dosing system for 5'.
6. Temperature is raised to 98 C & the process is carried for 6O'
7. The liquor are drained at 80 C.
8. After that chemical wash & enzyme wash are done.
1. Curves for Pre-treatment: Scouring & Bleaching:

98C (60')
80C
60C (5')
2C/min
Room Temperature
1. Anti-creasing
2. Wetting Agent
3. Sequestering Agent
4. Antifoam
5. Stabilizer
6. Soda
7. Caustic

H2O2

Cold

7
Cold

5'

5'

1. Chemical Wash:
80C (15')
60C (5')
Room Temperature

1) Oxalic Acid
2) Peroxide Killer
Page 40 of 75

Cold Wash

Cold Wash

5'

5'

1. Dyeing Light /Medium Shade:

Dyeing Bath Preparation:
1. Auxiliaries are added at 50 C.
2. Salt added by dosing system ( time : 10-20') .
3. pH maintained at 6.5-7.
4. Color dosing at 60C for 20'.
Exhaustion & Fixation:
1. After 30' soda ash added by dosing for 30-35' .
2. pH checked & maintained at 10.5
3. Dye bath is kept at 60 C for 40-60'.
4. After every 10' the sample is checked fixation occurs during this time.
5. Rinse for 10' & the bath is drained.
Neutralization:
The material should be neutralized to remove alkaline condition at room temperature by acid
wash for 15 min & rinsing will be carried on for 10 min.
Soaping:
o Then soaping agent is added & temperature raised to 90C-100C for 10 min.
o The bath is cooled 7 rinsed for 10 min.
o Dye bath temperature then cooled to 60 C.
Softening:
Softener is applied to soften the fabric as well as it improves the hand feel. The material is
treated at 60C for 20 minutes. Then rinsing again & material unload.
1. Procedure of Dark shade:
At first the bath is set at 50C & takes the right volume of water in the dye bath.
Required amount of wetting agent is added.
Caustic soda is added & second heat command 60C & stabilizer is added also.
H202 is dosed & 10' runs.
Page 41 of 75

Temperature raised to 100 C & run the material for 30'

Cooling the bath at 75C & bath is drained.
At 90 C the material is run for 15 minutes
Cooling the bath to 75C to drain
Add Acetic Acid to neutralize the whole bath of fabric & run time is 20'
Rinse the fabric for 5' & bath is drained.
New water from reserved is taken & pH should be 4.5-5
Enzyme is injected to the bath. Run time is 60' at 55C

Temp. Raised to 70C & run time 10' & then drain
Again new water is taken & dosing of glubar salt for 20' & pH should be check
(pH =7)
Color dosing for 30' at 50C
Soda is added by dosing for 40'at 50C
Then raise the temp. & run the fabric for 35-60'.At this time after every 10' the sample is
checked.
Rinse the material for 10' & bath is drained.
At room temp. Acid treatment is done for 20'& rinse the material for 5'
Soaping is done at 90C for 10 min & bath is drained.
Fixing agent is added at 50C & run time is 20' & bath is drained
Softening is done at 60C for 20'& is drained.
Finally the fabric is unloaded.
White Shade:
Page 42 of 75

At first Scouring bleaching chemicals are added to the bath & they are treated at 98C for 60'
Temperature is lowered at 80C & OBA is added. Run time is 10'.
Temperature is raised to 98C & Run time is 20'.
Then enzyme treatment is applied & then softening occurs
Dyeing Curve:
60C for 60'
Room temperature

Cold Wash
5'

1. Auxiliaries
2. Salt
3. Color dosing
4. Soda dosing

4
Cold Wash
5'

Cold Wash
5'

Stripping:
1. First of all these two chemicals are taken & treated with fabric in cold temperature for
30min. (Soda ash =0.5 g/L Bleaching powder =0.5 g/L Then Direct drain is done)
2. After that some other chemicals named below are treated at 98C for 45 min.
3. Anticreasing Agent =0.3 g/L Leveling Agent =0.3 g/L Wetting Agent =0.3 g/L Caustic
soda =1-2 g/L
4. After that 3-5 g/L Reducing Agent is taken and treated at 80C for 10'. Then Direct
Drain is done.
5. After that half or full scouring takes place
6. Lastly fabric is treated by acetic acid.
Stripping for white:
1. First of all these two chemicals are taken & treated with fabric in cold temperature for
30 min. Soda ash =0.5 g/L, Bleaching powder =0.5 g/L Then Direct drain is done.
2. After that these two chemicals are taken & treated with fabric at 98C for 60 min.
Hydrose =1-2 g/L, Caustic Soda =1-2 g/L
3. Lastly fabric is treated by acetic acid.
Machine Wash:
Page 43 of 75

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

Run 20' at 110C
Run 10' at 95C
Run 10' at 80C
Run 10' at 60C
Run 10' at 40C
Drain
FINISHING:
Textile finishing, in a restricted sense, is the term used for a series of processes to which all
bleached, dyed, printed & certain grey fabrics are subjected before they are put to market.
OBJECTIVE OF FINISHING:
1. Improving the appearance, luster, whiteness etc.
2. Improving the feel, which depends on the handle of the material & its
softness, suppleness, fullness etc.
3. Wearing qualities, non- soiling, anticrease, antishrink comfort etc .
4. Special properties required for particular uses -water -proofing flame proofing etc .
5. Covering of the faults in the original cloth .
6. Increasing the weight of the cloth .
FINISHING EFFECTS:
1.
2.
3.
4.
5.
6.
7.
8.

Easy care
Crease recovery
Dimensional stability
Good abrasion resistance
Improved tear strength
Good sew ability
Soft or stiff handle
Shine or luster

SEQUENCE OF OPERATION:

For Open fabric:

Page 44 of 75

Slitting
Stenter( Softener used )
Compactor
For tubular fabric:
Padder (Softener used)
Drying
Compactor
FINAL INSPECTION REPORT:
For final inspection, Inspection table & Inspection m/c is used.
The 4-point system is given belowSize of Defect
Less than 3 inches
3-6 inches
More than 6- 9 inch
More than 9 inch
Size of holes & openings1 inch or less
More than 1 inch

1.
2.
3.
4.

Penalty point
1
2
3
4

2
4

Some general rules of the inspection areNot 1 meter of cloth is penalized more than 4 points.
Cloth is inspected on face side only unless specified.
If the total defect parts per 100 yards of fabric are 40 or more the fabric will be
rejected. But it may be changed according to buyers requirements.

1. Ratio Between Salt & Soda according to shade % :

For All Colors
Shade %
Salt/Soda
<.09
10/2
.10-.20
15/3
.20-.40
20/4
Page 45 of 75

.40-.80
.80-1.20
1.20-1.60
1.60-2.50
2.50-3.50
3.50-4.50
4.50-5.50
5.50 to above

25/5
30/6
40/10
50/12
60/15
70/17
78/18
80/20

For Drimarine Colors

Shade %

Salt/Soda

<.05
<.05 -.10
10 - .30
.40 - .60
.60 - 1.0
1.0-1.50

10/2
15/3
. 20/4
25/5
30/6
40/10

Color Mixing Temperature for most commonly Used Dyestuffs:

These dyes are soluble at 60C-70C
Reactive Orange ME-2RL
Reactive Black HFGR
Reactive Red ME4BL Reactive G.Yellow MERL Reactive Black B
Reactive Black GR
Reactive Black WNN Reactive Navy Blue ME2GL
All Turquoises color are soluble at 80C Temperature
1. Operations Involved In Apparel Section:
1. Sample Making Sequence and Description

Flow Chart of Sample Making

Page 46 of 75

Garments Design or Sketch (Manually or Computerized)

Basic Block (Manually or Computerized)

Working Pattern (By Machine)

Sample Garments (Manually)

Problem of Production or Production Related Matter

Costing.............................................. ..................................Send to Buyer

Approved Sample

Production Pattern (By Hand or Computer)

1. Briefly Discuss:
Design or Sketch:
It is nothing but one kind of engineering art including all measurement of particular
style.
Basic Block:
It is an individual component of garments without any design or style.
Working Pattern:
To make pattern for a particular style with net dimension.
Sample Garments:
The garment which is needed for bulk production is called sample garments.
Problem of Production or Production Related Matter:
Page 47 of 75

Production related problems should be eliminated in this step.

Approved Sample:
The sample which is approved by buyer is called approved sample.

Send to Buyer:
When all process are done, then the garments are sent to buyer.
Production Pattern:
To make pattern for a particular style with net dimension along with allowance.
Factors Upon Which Pattern Making Depends:
2. Skill.
3. Technological knowledge
4. Analysis of design and
5. Experience of garments making.
1. Areas / Sequence in Garment Manufacturing
On industrial basis there are certain areas or sequence through which garments are
manufactured.
Design / Sketch:
In the garment manufacturing the first step is designing the sketch for the dresses that have to
be prepared. For this purpose the designer first draw several rough sketches in the sketch
book. The designer does not go for details at this moment but he rather let his creativity flow
on the paper and he draws many sketches. Later these sketches are analyzed by a panel of
designers. They finally select few out of them. These few sketches are rendered in detail
separately or in the form of a single collection. The designer also draws working drawings
along with the sketch. Working drawings are flat drawing of the sketch and it help pattern
maker in understanding the patterns involved in the construction.
Pattern Design:
The pattern maker now develop first pattern for the designs in any one standard size. This is
made by pattern drafting method and the purpose of making this pattern is to create the
sample garment for test fit.
Sample Making:
The first patterns are sent to the sewing unit for assembling them into garment. This is
usually stitched on calico or muslin which is an inferior quality of fabric and it reduces cost.
Page 48 of 75

This sample is constructed to analyze the pattern fit and design too. After the sample garment
is stitched it is reviewed by a panel of designers, pattern makers and sewing specialists. If any
changes have to be made they are made at this time.
1. Quality Control Flow Chart:
Yarn receiving
Sample Knitting
Batching
Dyeing (Check shade & Faults of dyeing)
Dewatering & Untwisting
Drying (Check diameter, Pretreatment, Shrinkage Spirality and GSM)
Compacting
Final inspection
If sample OK go for bulk production
1. Quality Control in Grey Fabric Inspection:
Some Points Are Needed To Maintain For High Quality Fabric:
a) Brought good quality yarn.
b) Machines are oiled and greased accordingly.
c) G.S.M, Stitch length, Tensions are controlled accurately.
d) Machines are cleaned every shift and servicing is done after a month.
e) Grey Fabrics are checked by 4 point grading system.
List of Equipments:
In this factory this is the list of equipments to assure quality:1) Inspection m/c # 1
2) Scissors
3) Electronic balance
4) GSM cutter
5) Indication sticker
6) Measuring tape

Page 49 of 75

Quality Assurance Procedure:

1) Body & Rib Inspection:
All rolls are kept in front of the inspection m/c time to time and are inspected over the
inspection m/c visually in a pre-set speed against light. For any major or minor faults like
thick-thin, bare mark, fall out, contamination, fly, holes, oil lines, needle line, slubsetc are
recorded in inspection report to classify the fabric based on the four point system.
2) Collar & Cuff Inspection:
Collar& cuff are inspected visually under the light box, any major or minor faulty collar/cuff
like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc.
properly counted and recorded.
1. Quality Standard:
Texeurop(BD)Ltd. maintains the ISO: 9002 standard in case of quality. They also posses
SGS &Oekotex certificate Therefore, the four point system is followed to inspect the body &
rib fabric. The defects found and points given against are recorded in the inspection sheet.
Following table shows the four point grading system followed by inspection at
Texeurop(BD)Ltd.
Four point grading system
Size of defects
3 inches or less
Over 3 inch but not over 6 inch
Over 6 inch but not over 9 inch
Over 9 inch

Penalty
1 point
2 point
3 point
4 point

Hole <1 inch

Hole >1 inch

2 points
4 points

The following formula is used for determining points/100 sq. yds. in a roll of a fabric:Points/100 sq. yds. = (0.08*Roll points*A.GSM) / Roll wt. in Kg
Grading calculation based on Points:
Points Grade
Up to 10 points
A
10-20
B
20-30
C
30- 40
D
Above 40
Reject

Page 50 of 75

Following faults and results are shows common body and rib faults and response by
inspection section at Texeurop(BD)Ltd.:Rejection criteria for body & ribs
No.
Faults
1.
Needle mark
2.
Stripe
3.
Barre mark
4.
Contamination & fly
shed 1
point is assigned
5.
Slubs
6.
Thick thin place
7.
Pin holes
8.
Wrong design
9.
Mixed yarn
10.
Sinker mark
11.
Missing yarn
12.
Holes
13.
Oil line/stain
14.
Chemical
15
Dirt stain
16.
Crease line
17.
Uneven tension

Response
Major needle line is rejected
Major needle line is rejected
Rejected
Approved for color but for white

1 point
Reject
1 point
Reject
Discuss with manager
Major sinker mark is rejected.
Use 4 point
Do
Do
Do
Do
Do
Discuss with manager

Following table shows common collar and cuff fault and response taken by inspection section
at Texeurop(BD)Ltd.:Rejection criteria for collar & cuff
No.
Faults
Response
1.
Wrong ply
Reject
2.
Hole
Reject
3.
Needle line
Reject
4.
Slubs
Reject
5.
Wrong design
Reject
6
Fly & contamination
Acceptable for color but not for white
7.
First round problem
Reject
8.
Uneven tension
Discuss with manager
9.
Missing yarn
Reject
10.
Crease line
Reject
11.
Rust line
Reject
12.
Oil stripe
Reject
Page 51 of 75

13.
14.

Thick-thin
Wrong tube

Reject
Reject

1. Quality Control in Dyeing And Finishing:

The Texeurop(BD)Ltd assures the quality of the products of dyeing section in the following
three steps:
1. In laboratory
2. In Dyeing section &
3. In Finishing Section
Procedures are described below.
In laboratory:
1. Swatch card from buyer according to their requirement
2. Recipe prediction for sample dyeing
3. Sample dyeing until matching with swatch card
4. Fastness & other tests of the fabric or yarn are done here.
In dyeing section:
1. According to the buyers sample, sample dyeing is done in sample dyeing machine in
dyeing shed & again matched with the approved sample.
2. If result is OK, then bulk production.
3. During dyeing, samples are taken until accurate shade matching.
4. The interval may be 30-40 minutes.
5. After dyeing sample is collected after softening matching is done. Last of all, sample
is collected after fixation & matched.
6. Then allowed the fabrics to be finished.
In finishing section:
1. By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
2. Then sampling is done for several times to test GSM, Shrinkage & fastness properties.
Finally fabric is inspected & prepared for delivery.
Quality Standard:
Texeurop(BD)Ltd follows the quality standard: ISO-9002:2000, It also possess SGS
andoekoTex certificate. So it maintains SGS and OekoTex requirements.

List of Equipments:In the Quality Assurance Department the followings equipment are used Page 52 of 75

1. KERN Electronic Balance

2. Iron
3. Ahiba Nuance Lab. Dip Dyeing Machine
4. Digital Pipette
5. Creda Dryer
6. Rota Wash
7. Crock Meter
8. Incubator
9. Spectra Photometer with software (Data Color)
10. PH meter
11. GSM cutter
1. Tests
There are two types of tests are done in Quality Assurance Department. They are
1. Physical Tests
2. Chemical Tests
Physical Tests:
1. GSM test
2. Shrinkage test
3. Spirality test
4. Abrasion resistance
5. Lycra% determination
6. Crease resistance
Chemical Tests:
1. Fastness to washing
2. Fastness to light
3. Fastness to actual laundering
4. Fastness to water
5. Fastness to Perspiration
1. Fabric Inspection:
The inspection of fabric is a procedure by which the defects of fabric are identified and fabric
is classified according to degree or intensity of defects. The fabric inspection is done for both
grey and finished fabric.

Grey Fabric Inspection:

Grey fabric inspection is performed according to 4-point system.
Finished Fabric Inspection:
Page 53 of 75

4 point numbering system is followed for finished fabric inspection. Defects found in the
final inspection:
1. Uneven shade
2. Oil spot
3. Neps
4. Crease mark
5. Machine Stoppage mark
6. Listing
7. Line mark
8. Pick missing
9. Double yarn
10. Dead cotton
11. Bowing
12. Fly yarn contamination
Inspection checking points:
1. Enzyme quality.
2. Hand feels on fabric surface
3. Uneven on fabric surface
4. Running shade on fold to fold.
5. Color spot on fabric surface
6. Softener spot on fabric surface
7. Oil spot on fabric surface.
8. Bowing line
9. Bias on Grid line
10. Line mark on fabric surface
11. Dia. variation in one roll fabric surface
12. GSM of fabric against required GSM
13. Needle mark or slit mark
14. Pin mark on fabric surface
15. Sinker mark
16. Crease mark
17. Dia. mark
18. Neps, contamination, thick & thin place.
19. Patta problem
20. Stripe bowing
21. Fabric elasticity
22. Fabric strength
23. Brush quality
24. Suided/piece finish quality
25. Color fastness to wash and water
26. Rubbing fastness to dry and wet
27. Shrinkage and Spirality.
Page 54 of 75

SHRINKAGE TEST CALCULATION:

Before wash-After wash
Shrinkage % =

X 100
Before wash

Spirality test calculation:

S = (S1+S2) / 2
Spirality = (S/ L)*100. Suppose,
S1 = The right side distance of the specimen from the stitch line after wash.
S2 = The left side distance of the specimen from the stitch line after wash. L = Length before
wash
1. Remarks:
The Texeurop(BD)Ltd always aware about the quality of the product. The quality of the
product is always approved by the buyer. They follow the quality standard: ISO - 9002:2000,
SGS &Oekotex requirements. The Texeurop(BD)Ltd is well equipped for checking the
quality of the product. They sent the quality report to the buyer time to time/batch to batch.

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

for provision of a condition of machines, buildings and services that will permit uninterrupted
implementation of plans requiring their use.

1. Objectives Of Maintenance:
1. To keep the factory-plants, equipment, machine tools etc. in an optimum working
conditions.
2. To ensure specified accuracy to products and time schedule of delivery to customers.
3. To keep the down time of machines to the minimum thus to have control over the
production program.
4. To keep the production cycle within the stipulated range.
5. To modify the machine tools to meet the augmented need for production.
6. To improve productivity of existing machine tools and to avoid sinking of additional
capital.
Page 55 of 75

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

factory overheads.
8. To prolong the useful life of the factory, plant and machinery, while retaining their
acceptable level of accuracy of performance thus avoiding or propounding incurring
of heavy capital expenditure involved in their replacement.
1. Maintenance of Machinery:
Preventive maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time
inspection/checking of facilities to uncover conditions that may lead to production break
downs or harmful description.
Breakdown maintenance:
In this case repairs are made after the equipment is out of order & it cannot perform its
normal functions.

Routine maintenance:
Maintenance of different machines are prepared by expert engineer of maintenance
department. Normally in case of dyeing machine Maintenance after 30 days complete
checking of different important parts are done.
Economic Consideration of Maintenance:
1.
2.
3.
4.
5.
6.

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

It improves product quality.
It ensures less time to produce a specific product.
It improves machine accuracy.
It maintains a long life of the machine.
No chance of back order.

Maintenance Flow Chart:

Head of Maintenance

Technician
Page 56 of 75

Assistant

Manpower Set-Up for Maintenance

A Shift
6 AM - 2 PM
B Shift
2 PM - 10 PM
General Shift
9AM - 6 PM
1. FUNCTIONS OF MAINTENANCE PERSONNEL:
Inspection or Check-Ups:
1. External inspections: Watching and detecting defects form abnormal sound,
vibration, heat, smoke etc. when machine is in operation.
1. Internal inspections: Inspection of parts such as gears, bushes, bearings, tolerances
in the parts etc. when machine is under pre-planned shutdowns.
1. Inspections of important machines: Machines, which can disrupt whole of the
production, are delicate and require much time for the repair. Attentions are given for
inspection of these machines and schedule for inspection, cleaning lubrication are
done rigidly.
2. Inspections of ordinary machines: Frequency of inspection of ordinary machines is
kept as low as they do not affect the production.
Lubrication: Mechanical components like gears, bearings, bushes and other friction surfaces
etc. Give good performance for long periods when they are systematically lubricated.
Systematic lubrication means the application of right type of lubricants at the right time, at
right place and in right quantity. For lubrication, a lubrication schedule should be prepared
and that should be followed strictly. Here lubrication is done whenever is needed.
Planning and scheduling: Every preventive maintenance work should be pre-planned in
detail on the basis of the analysis done on the past records. A scheduled programmed thus
prepared should be followed strictly. Thus programmed should be in detail specifying the
point-requiring daily, weekly, monthly, and half yearly or yearly attention.
Records and analysis: Good record keeping is essential for good maintenance, as it helps in
for casting maintenance. For this purpose following records are generally maintained:
Page 57 of 75

1.
2.
3.
4.
5.
6.
7.
8.

Operation manual
Maintenance and instruction manual
History Cards and History Registers
Spares Procurement Registers
Spare Procurement Register
Inspection Register
Log books
Defect Register etc.

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

essential for the maintenance personnel. Hence the technicians and supervisors are trained to
carry out maintenance, inspection and repaired in a systematic way.
Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for
considerable time and thus it affects considerable loss of production. Hence it is essential to
keep the spare parts so as to avoid loss of production.
The following tasks are generally d on e du ring maintenance:
1.
2.
3.
4.
5.
6.

Inspections & check ups

Lubrications
Planning & scheduling
Record analysis
Training of the maintenance crew
Collection or purchase of spares

1. Maintenance schedule of the different machines:

Boiler Maintenance Schedule:
Daily:
1. Check gas pressure
2. Maintain log sheet
3. Chemical dosing

Weekly:
1. Check all steam line
2. Fire quality of boiler
Monthly:
Page 58 of 75

1.
2.
3.
4.

Check all steam line

Fire quality of boiler
Gas consumption report
Burner clean

Quarterly:
1. Burner clean
2. Economizer clean
3. Feed tank clean
4. Chemical tank clean
5. Sight glass clean
Half yearly:
1. Burner clean
2. Feed tank clean
3. Chemical tank clean
4. Economizer clean
5. Replace gasket
6. Replace valve
7. Check gas line & filter & pressure
Yearly:
1. Overhauling of boiler
2. Chemical cleaning of boiler
3. Safety valve test
4. Economizer clean
5. Feed tank clean
6. Chemical tank clean
7. Burner clean
8. Check safety valve setting
9. Replace valve & gasket
10. Boiler inspection by authority
Dyeing m/c maintenance Schedule
Daily:
1. Check belt tension
2. Check steam or water system & air supply
3. Check chemical pump
4. Machine clean
Weekly:
1. Bearing & belt check
2. Check leakage of air, steam & Water line
3. Greasing bearing points
Page 59 of 75

4. Add gland packing at pump

Monthly:
1. Greasing bearing points
2. Replace bearing points (if required)
3. Gasket check
4. Clean steam trap
5. Lubricating all chemical pump
Quarterly:
1. Replace belts
2. Repairing of pulley, shaft & bearing housing
3. Painting m/c & pipe line
4. Clean steam trap
5. Replace seals (if leakage)
6. Change gasket of steam of water lines
Half yearly:
1. Replace belts
2. Repairing pulley, shaft & bearing housing
3. Painting m/c, pipe line
4. Replace seals
5. Machine body repairing
Yearly:
1. Machine overhauling
Hydro extractor Maintenance schedule:
Daily:
1. Machine clean
2. Belt checking
Weekly:
1. M/c clean
2. Belt clean
3. Greasing & lubricating of all points

Monthly:
1. M/c clean
2. Check gear oil quality
Quarterly:
1. Change of gear oil
Page 60 of 75

2. Belt change
Half yearly:
1. Change of gear oil
2. Belt change (if required)
Yearly:
1. Machine overhauling

Tensionless Dryer Maintenance Schedule:

Daily:
1. Check belt tension
2. Check steam supply & air system
3. Machine clean
Weekly:
1. Check fabric drying quality
2. Greasing bearing points
3. Clean air filter & regulator
Monthly:
1. Clean radiator & m/c cabinet
2. Greasing bearing points
3. Clean air filter and regulator
Quarterly:
1. Replace belt
2. Replace gear oil
3. Duct clean
Half yearly:
1. Check roller condition
2. Greasing & lubricating all points
Yearly:
1. Machine overhauling
Tumble Dryer Maintenance schedule:
Daily:
1. Check belt
2. Steam leakage area
3. M/c clean
Page 61 of 75

Weekly:
1. Heat exchange clean
2. Greasing & lubricating of all points
3. Belt check
4. M/c clean
Monthly:
1. Filter clean
2. Steam trap clean
Quarterly:
1. Replace belt
2. Replace gear oil
3. Duct clean
4. Gasket & valve change
Half yearly:
1. Gasket & valve change
Yearly:
1. Machine overhauling
Stenter m/c Maintenance schedule:
Daily:
1. Check belt tension
2. Check Steam supply & air system
3. M/c clean
Weekly:
1. Check fabric quality
2. Greasing bearing points
Monthly:
1. Greasing bearing points
2. Clean air filter & regulator
3. Clean steam trap
Quarterly:
1. Replace belts
2. Replace gear oil
3. Painting m/c & pipeline of the total system
4. Replace seals
Page 62 of 75

Half yearly:
1. Check roller condition
2. Greasing & lubricating of all points
3. Check bearing condition
Yearly:
1. Machine overhauling

1. Remarks:
The maintenance department of Texeurop( BD) Ltd. is well equipped. It has sufficient
maintenance manpower including mechanical and electrical engineers. They do the
maintenance of the m/c during the Eid vacation. Otherwise, they do the breakdown
maintenance. To increase the lifetime of the machineries and ensure the proper running
of the machinery.
Production and profit are closely related. In order to get quality final product it needs fresh
raw materials as well as effective manpower and machinery in good condition. Utility in
conjugation with the three Ms plays an important role to maximize the production as well as
the profit.
1. GAS:
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section (Boiler- for heating water) from the
main line of the TITAS GAS LTD.
1. COST OF DIFFERENT UTILITIES:
Electricity cost:
REB =3.8 TK / KW-HR
Gas generator = 1.80 TK / KW-HR
Gas cost:
4.94 Tk/m for boiler
3.66 Tk/m for generator
4.5 Tk/m for domestic purpose
Steam cost:
4.30 Tk. per kg fabric.
Page 63 of 75

1. THE EFFLUENT TREATMENT PLANT:

The Texeurop (BD) Ltd. has well organized Effluent treatment plant. Normally the effluent
generated from different sections of a textile mill must be treated before they are discharged
to environment. Various chemicals & physical means are introduced for this purpose. The
effluent treatment plant in Texeurop (BD) Ltd is chemical biological combination process.

Objects:
This process is provided for treating the effluents of dyeing, printing, finishing, weaving
& thus allow to discharge effluent as per by World Bank dept. of environment of Bangladesh.
Capacity
:
40 tons/ hr.
Cost
:
Tk. 6 / Littre
10 lac BDT spend per month in ETP.
Requirement of discharge effluent as per World Bank:
PH
BOD
COD
SS
TDS
Color

:6-8
: < 50
: < 250
: < 100
: Not stated
: Clear

Chemical used:
1.
2.
3.
4.

Ferrous Sulphate.
Lime.
Polyelectrolyte.
HCl

Chemical using procedure:

-

80 Kg Ferrous sulphate is mixed with 1000L water.

50 Kg Lime is mixed with 1000L water.
1 Kg Polyelectrolyte is mixed with 1000L water.

Product Quality Check:

Following chemical tests are carried out to check the quality:
- BOD
- COD
- Total suspended solids
Page 64 of 75

- Total dissolved solids

- Color
- PH
Typical Output of the Plant:
Raw effluent color
Raw effluent pH
Treated effluent color
Treated Effluent pH
Treated Effluent Temp
Treated effluent BOD
Treated effluent BOD

Black/deep purple
10
Light greenish
6-6.5
380C
175-200
60-100

Flow Chart of Effluent Treatment:

Raw effluent
Equalization Tank
Page 65 of 75

Flash mixing Tank

Flocculation tank
Tube settler tank-1
pH correction channel
Bacteria reactor-1
Bacteria reactor-2
Tube settler tank-2
Filter feed sump
pH Check
Sludge of Tube settler
Sludge thickening plant
Centrifuge platform.

1. Remarks:
As the new project Texeurop (BD) Ltd, but it has vast utility systems. There is a skill
manpower group of engineers and other technical staffs to look after these utility services.
They have to remain aware of solution on a great sense of responsibility for any type of
problem due to utility supply.

Introduction :
Inventory is planning and execution involves participation by most of the fundamental
segment of business sales, production, purchase, finance and accounting. Inventory is a wider
Page 66 of 75

sense is defined as any idle resource of an enterprise however it is semi-finished packing

spares and other stocked in order to meet an expected demand or distribution.
1. OBJECTIVES OF INVENTORY CONTROL:
1) Financial activities:
a) To save amount of investment
b) To know the cash position
2) Property Protection:
a) Preventable waste
b) Insurable damage
c) Unauthorized use
3) Operating:
a) To obtain the best overall balance between production and inventory carrying cost.
b) To minimize losses
c) To avoid stock out and to keep inventory holding costs in costs in balance.
Scope of Inventory Control:
- Raw materials
1. Dyes store.
2. Other chemicals.
3. Grey fabrics.
- Finished fabric.
- Spare parts.
- General store:
1. Capital equipment.
2. Accessories.
3. Stationary.
4. Maintenance parts.
Frequency of Inventory Update:
1. Monthly inventory control
2. Annual inventory control

INVENTORY PROCEDURE
1. Bin Card
2. Store Requisition
3. Store Ledger Account
Page 67 of 75

4.
5.
6.
7.

Daily Inspection & Package Report

Monthly Stock & Consumption Report
Monthly L/C wise Delivery Report
Received Delivery & Balance Stock

1. Inventory Control System for Raw Materials:

Dye store & other chemicals store
1. Both of these are received by the store in charge.
2. First he sends these to quality in-charge for inspection. If they are found to be of
required quality then they are taken to store by the storekeeper.
3. Store in-charge supplies these when required and records the date, type of material,
quantity and section in which supplied, in his register book.
Grey fabric store
1. Grey fabric is usually stored in another storeroom, which is separate from dyeing
shade.
2. Grey fabric is first sent to the QC department for quality assurance and then taken to
the storeroom.
3. Grey fabric is received by fabric store in-charge.
4. He supplies the fabric as per requirement and records the date, type of material,
quantity and section in which supplied, in his register book.
At present the grey fabrics store of Texeurop (BD) LTD. containing the following types of
fabrics1. Single jersey.
2. 1x1 Rib.
3. 2x2 Rib.
4. 2x1 Rib.
5. Mlange.
6. Pique.
7. Single jersey (with Lycra attachment)
8. 1x1 Rib (with Lycra attachment) etc.
9. Single lacost
10. Double lacost
11. Fleece
12. Terry Fleece
13. Interlock
14. Wafel
Stages of Grey Fabric Inventory Control:
1. After knitting production.
2. Grey inspection.
Page 68 of 75

3. Warehouse.
4. Batch preparation.
5. Dye house.
Inventory Control System for Finished fabric:
1. Finished fabric from the compactor or stenter goes to inspection team. Here
inspection is done by a four points system.
2. Required GSM, width (diameter), shrinkage, spirality, wash fastness, rubbing fastness
etc are tested from the lab before packaging.
3. After finishing the fabric is kept in package before their transfer to the garments
department.
4. It is controlled by the finishing in-charge who keeps a list of total finished product. He
also keeps a list of delivery products.
5. He supplies the fabric as per requirement and records the date, type of material,
quantity and section in which supplied, in his register book.
Stages of Finished Fabric Inventory Control:
1. Finishing section.
2. After final inspection.
3. Warehouse.
Others:
There is a central store at Texeurop (BD) Ltd. In that store the various types of forms, papers;
stationary & other necessary goods are kept.
Inventory Control System for Spare Parts:
1. Spare store officer keeps the spare parts in store and makes a list of spare parts.
2. If the spare parts are little in stock he gives requisition to maintenance manager.
3. Maintenance manager gives requisition to head office. Head office imports spare parts
or buys from local market as per requirement.
4. As new spare parts arrive to store officer, he receives and catalogues them.
5. He supplies the spare parts as per requirement and records the date, type of material,
quantity and section in which supplied, in his register book.

1. Remarks:

Page 69 of 75

Texeurop(BD)Ltd. has individual stores for raw materials, finished goods and spare parts.
The store of dyestuff and chemicals are not so clean. There is not enough space to store the
finished goods. It requires increasing the store area.
1. Introduction:
Costing system mainly describes how the cost of the final product is fixed by the
company/beneficiary. So Costing is a process by which the setting price of a product is
calculated. It is a very important task for a factory which runs for business purposes. And it is
also strictly followed in the Texeurop (BD) Ltd. Costing of the products considering the raw
materials expenditure, salary and wages of officers and workers, distributions and
advertisement expenses etc. All direct and indirect expenses are needed to be considered
during costing. It is determined by a team of accountants with advice and consultancy of
executive director.

The following points are considered for costing any dyed product in Texeurop (BD) Ltd.
1.
2.
3.
4.
5.
6.
7.
8.
9.

Total cost of yarn

Cost of fabric Production
Total dyes & chemical cost
Total utility cost
Salary
Payment
Transport cost
Miscellaneous cost
Government cash incentive

Price of the Product:

Generally price of product is determined by the required profit adding to the total expenses.
So,
Price of products= (Direct expenses + Indirect expenses + Factory Overhead) + profit
Price Range of Different Products:
T-Shirt = $0.75 - $4.50 /Pcs
Polo Shirt =$2.00 - $6.50 /Pcs
Kids Wear ==$0.75- $2.15 /Pcs

1. DIFFERENT SECTION CHARGE OF DIFFERENT FABRICS:

Knitting Charge of Different Fabrics:
Page 70 of 75

Fabric nameCharge per kg (Tk)

1. Single Jersey
2. Lycra Single Jersey
3. Single locust
4. Double lacost
5. Rib
6. Rib with Lycra
7. Interlock
8. Fleece

09
30
16
16
17
30
25
22-25

Dyeing Charge of Different Fabrics:

Name of fabric processCharge per kg(Tk)
White with Enzyme
White without Enzyme
Avg. color with Enzyme
Avg. color without Enzyme (Light& med.)
Deep shade with Enzyme (Black)
Deep shade without Enzyme (Black)
Only wash (Tubular)
Only wash (Open)
Double dyeing (Face & Back)

35
30
85
75
110
95
25
45
115

Finishing Charge of Different Fabrics:

Name of fabric processCharge per kg(Tk)
Slitting only
Stenter only
Compacting only
Stenter + Compacting
Stenter + Compacting+ wash
Tube Compacting

5
25
15
35
50
10

1. Costing Of the Product:

Let price of yarn is $ 3.00/ kg.
Process loss of yarn for knitting (10%) = $0.30
Knitting fabric cost = $3.30
Cost of dyes & chemicals = $2.50
Process loss for dyeing (12%) = $0.30
Page 71 of 75

Dyed fabric cost = $ 6.10

Packing cost = $0.05
Production cost of fabric=$6.15
Fabric price (with 25% margin) =$7.79
Fabric consumption/ doz. =(Body length + Sleeve length) x Chest length x 2 x GSM x12 /
10000000
Garments specification (For a particular garment): Body length=78 cm
Sleeve length=33 cm Chest length=62 cm GSM=210
Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000
= 3.469 kg
Fabric consumption/ doz. (with 10% wastage) = 3.816 kg
Body fabric cost / doz. =$(7.79x 3.816)
= $29.73
Cost of collar& cuff/ doz.= $ 4.00
Cost of Trims=$ 2.25
Cost of Trims (with 5% Process loss) = $2.36
Production Cost of Garments/ doz.=$36.09
Garments Price/ doz. (with 25% Profit) =$45.12
1. Remarks:
Proper Costing is very important for a productive factory. Without proper costing all
production will go to vain. Because a factory cannot reach to its goal without achieving good
profit and good profit is not possible without proper costing. So costing should be done by a
group of intelligent, experienced, highly qualified personnel. Every Factory has some rules
and regulations. Texeurop (BD) Ltd. did not provide us all the documents of costing, because
its confidentially. So this Chapter is not so sufficient to analyze the costing of product.
1. Introduction:
As Texeurop (BD) Ltd. is a 100% Export oriented industry no product can be marketed at the
local market. The goods produced at this factory are exported at different countries of the
world. Texeurop (BD) Ltd. has a number of renowned buyers. Following are the important
buyers of Texeurop (BD) Ltd.
1.
2.
3.
4.
5.
6.
7.
8.
9.

S. Oliver
Tom Tailor
J.C. Penny
Lerros
Street One
Innovation Club
Gerry Weber
US Polo
ASSAN
Page 72 of 75

10. Elevate
11. American Eagle
12. Mustang
13. Polyconcept
14. H & M
15. C & A
Following are the different local Buyer whose provide Sub-contracts for Texeurop (BD) Ltd.
1. Teba Group
2. Pantex and Scarlet (Garments industry of Texeurop (BD) Ltd.)
3. Epic Group
4. Islam Group
5. Hi-Fashion
6. Matrix
7. Needle touch
8. Brine Knit
9. Razzak Textile
10. Dip Knit
1. Product Label:
There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemical cleaning, drying conditions
etc.
2) Size Label: It contains size of garments.
3) Composition Label: It contains the fabric composition of different fibre type.
4) Decorative Label: Decoration is as buyer or consumer choice wise.
1. Package Size & Label Market:
Package size & label differs from buyer to buyer. The Package size & label are prepared
according to the buyer requirements. Normally the following package sizes are used: 60 x 40 x 40 cm.
58 x 33 x 44 / 43 / 42 cm.
58 x 33 x 25 cm.
58 x 33 x 13 / 16 / 18 cm.
LOCAL MARKET:
Texeurop (BD) Ltd. is 100% export oriented mill. So there is no local market involved in it.
But the knitting section takes some sub-contact for knitting an amount of fabrics from their
given yarn.

Importing Countries:
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There are some countries which are importing goods from Texeurop (BD) Ltd. which are
given below1. United State of America
2. England
3. France
4. Germany
5. Italy
6. UK
1. Manpower of Marketing:
Marketing is the important department of any industry or institution to describe the features
of the products to the buyer & to communicate with the buyer. Almost ten marketing officers
and ten others workers act under the Executive Director.

CONCLUSION:
We have completed our industrial attachment successfully by the grace of Allah. Industrial
attachment sends us to the expected destiny of practical life. The completion of the three
months Industrial attachment at Texeurop (BD) Ltd. we have got the impression that factory
is one of the most modern export oriented knit composite complex in Bangladesh. Though it
was established only a few years ago, it has earned very good reputations for its best
performance over many other export oriented textile mills.
During our training period, talking with the clients of this mill we knew that the mill is
fulfilling the countrys best export oriented white finished fabric as well as very good colored
fabric due to its modern machinery & good management system.
Mill is settled with utility to give all convenient supports to the productions for twenty-four
hours. It had self-power generator system to satisfy total power consumptions of the mill. We
are enough fortunate that we have got an opportunity of having a training in this mill. During
the training period we are received co-operation and association from the authority full &
found all man, machines & materials on appreciable working condition. All stuffs & officers
were very sincere & devoted their duties to achieve their goal. There are some suggestions
from us within our limited knowledge.

Some Suggestions:

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1. The m/c stoppage time should be analyzed and minimized. The maintenance should
be carried out when the m/c is out of action (wherever possible) and routine
maintenance should be carried out regularly.
2. There should be a yarn-dyeing project.
3. Sitting arrangement of production officers should be improved.
4. There should be textile engineers for the finishing, merchandising and garments
section.
5. The dyeing floor is watery most of the time: it should be cleaned all the time.
6. Knitting capacity need to be increased to meet the dyeing production continuously.
7. To increase overall efficiency, more skilled labor should be used in a project.

Limitations of the Report:

1. We didnt have the opportunity to work in the lab So in spite of having the facility, we
could not get the chance to learn about it.
2. Because of secrecy act, the data on costing and marketing activities has not been
supplied in details.
3. In spite of our limited time, we could not study in detail.
4. Some of the points in different chapter are not described as these were not available.
5. The whole process is not possible to bind in such a small frame as this report, hence
our effort spent on summarizing them.

LASTLY:
We tried our best to collect all necessary information but it is true that within this short period
it is quite impossible to achieve 100% success but as a whole this industrial training was a
satisfactory one and once again wed would like to thank the authority of Texeurop (BD) Ltd.
as well as our honorable teachers far their altruistic help and advice. We are fortunate enough
that we have got an opportunity to have training in this mill. During the training period we
have received enough co-operation and association from the authority and found all
personnel. All stuffs and officers were very sincere and devoted their duties to achieve their
goal.

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