REPORT ON INDUSTRIAL ATTACHMENT

AT M.M. Knitwear Ltd.

An Industrial Attachment
By
Md. Mizan Howlader

DEPARTMENT OF AMT
BGMEA University of Fashion & Technology
26, August 2016

Page 1 of 65

REPORT ON INDUSTRIAL ATTACHMENT

AT M.M. Knitwear Ltd.

An Industrial Attachment
By
Md. Mizan Howlader

ID: 122-421-0-45

Supervisor: Ms. Ishrat Jahan

Lecturer
DEPARTMENT OF APPAREL MANUFACTURE & TECHNOLOGY (AMT)

Submitted to the:
DEPARTMENT OF
APPAREL MANUFACTURE & TECHNOLOGY (AMT)
BGMEA University of Fashion & Technology
In partial fulfillment of the requirements for the award of the degree
Of
BACHELOR OF SCIENCE IN APPAREL MANUFACTURE & TECHNOLOGY
August 2016.

Page 2 of 65

Letter of Transmittal

August 24, 2016

Ms. Ishrat Jahan
Lecturer,
Department of AMT
BGMEA University of Fashion & Technology
Uttara, Dhaka, Bangladesh.

Subject: Submission of internship report.

Dear Madam,
Here in my internship reports that fulfills partial requirements for Degree of B.Sc in
Apparel Manufacture & Technology. It is very important for a student of Science and
Information to undergo a project/practical field of study.
I completed my internship report on A Industrial report at M.M Knitwear Ltd. In the
report, I have tried to accommodate my valuable comments & suggestions. In this
concern, if you need any further clarification, please email/call.
Thank you for your kind cooperation. Without your support, this internship report
would not have been completed. So I am submitting the final version of my internship
report and requesting your acceptance.

Regards,
Md. Mizan Howlader
ID: 122-421-0-45
Batch: 122 (AMT-4)

Page 3 of 65

DECLARATION

I hereby declare that, this Internship paper has been done under the supervision of Ms.
Ishrat Jahan, Lecturer, Department of AMT, BGMEA University of Fashion &
Technology. I also declare that neither this internship report nor any part of this
internship report has been submitted elsewhere for award of any degree.
Supervised By:

Ms. Ishrat Jahan

Lecturer,
Department of AMT
BGMEA University of Fashion & Technology
Uttara, Dhaka, Bangladesh.

Submitted By:
Md. Mizan Howlader
ID: 122-421-0-45
Batch: 122 (AMT-4)

Department of
Apparel Manufacture & Technology,
BGMEA University of Fashion & Technology

Internship Period:
Page 4 of 65

22nd June to 18th August, 2016

ACKNOWLEDGEMENT
Industrial training is very much essential just after finishing the theoretical course. It
is a great opportunity to take the challenge of doing something for a Apparel Student.
For this manner I am grateful to all helping me to do this program. I am grateful to
Almighty to give this opportunity to learn practical knowledge.

All praises belong to Allah, the creator of the Universe, the sustainer & to whom I
must return.
I would like to thank my honorable Head of the department, Dr. Mohammad
Sujauddin, Associate Professor, Head of the Dept. of AMT.
I would like to thank my honorable course teacher & supervisor Ms. Ishrat Jahan,
Lecturer, Department of AMT BGMEA University of Fashion & Technology for his
guidance, help and encouragement throughout the progress of the internship report. I
am very grateful for her kind advice and instructions.
I would also like to thank executives, senior executives and other officials of M.M.
Knitwear Ltd. for helping me to complete industrial training successfully. My
gratitude also goes to all the employees of M.M. Knitwear Ltd. for their sincere cooperation, support and valuable advices.
I would like to thank Mr. Shajal Kumar Saha, Sr. Merchandiser to giving me chance
under his Umbrella.

I would like to thank Md. Feruz Alam Mamun, Asst. Merchandiser to work with
him. He teaches me lots of things about merchandising profession.

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I also give thank some other person, Staffs who motivate us thoroughly and the other
people, who have made a significant contribution to make this report successful. Their
guide lines, suggestions & inspiration helped me a lot.

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EXECUTIVE SUMMARY

The Industrial Attachment is the most effective way for Apparel Manufacturing
student to be achieved the knowledge about the practical field of the Textile
Manufacturing. It brings an opportunity to all the learners to enrich their academic
knowledge by practicing with the experts of the practical field of textile.
M.M. Knitwear Ltd. is one of the major garments manufacturing organization in
Bangladesh. This organization increasingly reducing its rejection and rework rate inprocess and final garments in order to ensure product quality and delivery time as per
buyer requirement and increase profitability. MM will ensure sufficient training and
suitable work to increase productivity and skills of the employee.
In this report I tried to cover a short profile of M.M. Knitwear Ltd. and major
customers of M.M. Knitwear Ltd. and their different activities.
It is my pleasure that I had an opportunity to complete my two month internship at
M.M. Knitwear Ltd. which is one of the most modern industries of the country.

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TABLE OF CONTENTS
SL
NO

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9

CONTENTS
Cover Page
Submission Details
Letter of Transmittal
Declaration
Acknowledgement
Executive Summary
Table of Contents
Chapter One:
Introduction
General Discussion
Company Profile
The M.M. Knitwear Story
Quality Policy
Welfare Facilities
Buyers
Certification
Map
Layout of M.M
Chapter Two:
HR & Compliance
Introduction
Section Wise Manpower
Management Medium
Organgrams of Administration
Management System
compliance
Code of Conduct of SA 8000
Code of Conduct of BSCI
Code of WRAP

PAGE
NO
1
2
3
4
5
6
7

11
12
13
13
14
15
16
17
18
19
19
19
20
21
21
23
24
25

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3
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15

Chapter Three:
Different Departments
Different Departments
Chapter Four:
Knitting Division
Introduction
Types of Knitting
Organgram of Knitting Division
Knitting Division
Circular Knitting Unit
Flat Knitting Unit
Narrow Fabric Unit
Quality Control Unit
Summary
Chapter Five:
Dyeing & Finishing Division
Introduction
Flow Chart of Dyeing
Organgram of Dyeing & Finishing Section
List of Machineries
Raw Material for Dyeing
Grey Fabric
Finishing Section
Process Flow Chart of Finishing
Objective
Finishing Effects
Finishing Machinery
Function of The SLITTING Machine
Function of Squeezing/Dewatering machine
Function of Dry Machine
Function of STENTER Machine

26
27
27
28
28
29
30
30
30
30
31
31
32
33
35
35
36
36
37
37
37
37
38
38
38

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Chapter Six:
Testing
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9.1
9.2
9.3
9.4
9.5
10.1
10.2
10.3
10.4
10.5
10.6
10.7

Introduction
Types of Test in Laboratory
Stock Solution Preparation
Physical test
Chemical test
List of Machine in Laboratory
Quality Standard
Chapter Seven:
Garments Division
Sample Division
Cutting Section
Embroidery Section
Screen Printing Section
Sewing Section
Finishing
Office Staff
Quality Team
logistic team
Auditing Team
List of the Machines
Chapter Eight:
Quality Management System
Quality Policy
Quality Assurance Procedure
Inspection Area
Knitting Faults
Dyeing Faults
Finishing Faults
Problems Encountered in Dyeing
Process of Shade Matching
Chapter Nine:
Effluent Treatment Plant (ETP)
Effluent Treatment Plant (ETP)
Function
Required Chemical
Quality Checked
Process Flow Chart
Chapter Ten:
Maintenance & Utilities
Maintenance of Machinery
Types
Manpower setup for Maintenance
Maintenance of Dyeing Machine
Maintenance of Stenter Machine
Maintenance of Dewatering Machine
Dryer Machine

39
39
39
39
40
40
41
42
43
44
44
45
45
45
45
46
46
46
47
47
48
49
49
49
49
51
53
53
54
54
55
56
56
56
57
57
58
59
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10.8
10.9
10.10
10.11
10.12
11.1
11.2
11.3

Compactor Machine
Boiler Machine
Tools & Equipments
Utilities Services
Source of Utility
Chapter Eleventh
Conclusion
Conclusion
Limitation of the Report
Recommendation
References

59
60
60
61
61
62
62
62
64

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CHAPTER-01
INTRODUCTION

1.1. General Discussion

M.M. Knitwear Ltd. is 100% export oriented Knitting, Dyeing and Garments
composite unit. Since 2001 this industry is specialized in all kinds of knitted items. It
is housed in its own building surrounding an area of 3, 97,500 sq. ft. And 4,300
workers and stuff. The determination to achieve superior customer service and on
time delivery has earned MMKL recognition as an invaluable player and the desire to
succeed in customer satisfaction with every order makes the MMKL team even
stronger its these fundamental that keep this unit in the game and wining every time.

Figure 1.1: M.M. Knitwear ltd

Since the beginning MMKL has a very good reputation as a financially sound and
ethical business house. It has a long term association with selected factories, some of
them are certified in terms of social and quality compliance by worlds highest rating
bodies, and outstanding source capabilities. Thus MMKL has been able to prove itself
to be a reliable supplier for knit item in any style and design.

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1.2 Company Profile

1.2.1Management:

Md. Mofizul Islam : Managing Director.

Md. Maidul Islam : Director.
Md. Mamunur Rashid : Director.
Md. A.K.M.Shaheed Ahmed : Executive Director (Head office)
Md. Nurul Islam : Sr. General Manager
Md. Mohsin Ahmed : General Manager
Md. Abdul Haque : General Manager (Accounts)
Md. Monirul Islam : Deputy General Manager (Audit & HR)
Mamun Or Rashid : Deputy General Manager (Knitting)
Md. Abdul Hye Chanchal : Asst. General Manager (Marketing &
Merchandising)

1.2.2 Registered Name of the Company: M.M. Knitwear Ltd.

1.2.3 Name of Owner:
Md. Mofizul Islam (Managing Director)
Phone: (+88-01711-510764)
1.2.4 Contract Person:
Md. Abdul Hye (Chanchal)
AGM (Marketing & Merchandising)
Mobile: +88-01716-498856
Email: [email protected]
Md. Mahbub Alam
Manager, Marketing
Mobile: +88-01713-211453
Email: [email protected]
1.2.5 Factory Address:
Konabari, Nilnagar, Gazipur.
Phone No. +88-02-9297137, 9289027, 9297840
Mobile No. +88-01713-006740 (Director)
+88-01713-016641 (Director)
+88-01711-549008 (GM/Fty.)
1.2.6 Head Office Address:
Road # 10, House #16(3rd Floor),
Sector # 1, Uttara, Dhaka 1230,
Phone No. : 0088-02-8921471, 8950966, 8950969.
Fax No. : 0088-02-8922483,
E-mail : [email protected]
[email protected]
Page 13 of 65

1.2.6 Bank Name: United Commercial Bank Ltd.

Bangshal Branch,
Dhaka-1000,
Bangladesh.
SwWeft: UCBLBDDHBNG
My C/D A/C No: 21195
I envision MMKL to continue to develop so that it incorporates the latest technologies
available in manufacturing to accommodate large orders without unnecessary hassle
for my clients. My strength as a public company motivates us to create an
environment that provides jobs for my people with the capacity to grow as I do.
Consequently, M.M. Knitwear Ltd. has already gained support from many influential
figureheads in Bangladesh and are Ill on my way to becoming an industrial institution
in one of the worlds rising countries.
1.3 The M.M. Knitwear story
Year of establishment
: July2001.
Last year export turnover 2013
: 45.00 Million U.S Dollars.
Estimated turnover for year 2014 : 50.00 Million U.S Dollars.
Type of the Company

: 100% Export Oriented Composite \

Knitwear Industry
: Dyeing & Garments Manufacturer &
Exporter

Main Product

: Basic & Fancy T-Shirt, Polo Shirt,

: Ruggby Shirt, Tanktop, Knitted Jacket,
: Cut N Sewn Dress/Shorts, Long pant

Production Capacity
(Pcs/Day)

: If only Basic T-Shirt/Tops = 85,000

Total Factory Space

: If only Polo or Fancy Items = 45,000

: Average Styles = 70,000
: 3, 97,500 Sq.Ft.

1.4 Quality Policy:

Strive to achieve total customer satisfaction by exceeding customer expectation of
product quality, product performance, and delivery. Commit to implement of quality
systems, which conform to international standards. Make concept of continuous

Page 14 of 65

improvement synonymous with total quality management pay attention to detail and
strict adherence to buyers requirements in terms of quality and design.
1.5 Welfare Facilities:
Induction of workers Welfare committee aimed at improving workers morale,

job satisfaction and Attendance.

Canteen service.
Subsidized lunch for staff.
Free snacks for workers.
Full time free medical service provide by a professional doctor.
Provision for day care center for workers children, annual picnic.
Cultural function.

Page 15 of 65

1.6 Buyers:

Page 16 of 65

1.7 Certification:

Page 17 of 65

1.8 Map:

Figure 1.2: Road to Factory

Page 18 of 65

1.9 Layout of M.M:

4
1

Security office.

Administration office

:
:

Fabrics Store (Gr.Floor)+Knitting (2ndFloor+3rd floor), .

2
Human Resource Department (HRD)(4thFloor),

Merchandising section (5thFloor), garments(6th Floor 9th floor)

st
th
Yarn store (Gr. Floor)+
NTRY+Garment section(1 Floor 7 floor)

Fabric dyeing & finishing section.

Effluent Treatment Plant (ETP).

Generator house, Water Treatment Plant(WPT), Maintenance building.

E
X
I
T

Page 19 of 65

CHAPTER-02
HR & COMPLIANCE
2.1 Introduction:
The company has skilled administration, management and marketing team guided by
proficient, dexterous & experienced leaders of offer right solution for the consumers
with the right eminence & with the shortest lead-time for the export market in
director
Bangladesh. M.M. Knitwear ltd the Managing Director/Managing
Chairman who
controls the
entire factory. And the others respective department chief controls their department in
this factory.
Director, H R Dept.

2.2 Section Wise manpower:

Table 3.1: Total Manpower

Department

Accounts

Knitting
Deputy
Dyeing & Finishing,
Lab Officer
& QC Chief Egg.
Deputy Account
ETPs
Garments
Power, Boiler, Utility & Maintenance
Inventory
Administration
Electrical
Security
Others
Total
2.3 Management Assistant
Medium:
Accounts Officer

Intercom telephone
Fax
E-mail
Written letters & Papers
Oral
Senior

Sub assistant

Foreman

Manpower
150
Marketing 320
Store
Assistant Officer
General
Manager
10(ADMIN)
3590
50
10
77 Officer
SecurityAsst. Chief store Man
Mechanical
Officer
55 Assistant
Egg.
Manager (ADMI
44
4306
Sub assistant

Assistant
Security
Officer

Foreman

Asst. Officer

Ad

Store
Security
Havilder

2.4 In this below the organ grams of administration and the others department is
Junior
showing:
Medical Officer
.Security
Guard

Peon

Nurse

Page 20 of 65

officer
Assista

Foreman

Adm

Figure 3.1: Organgram

2.5 Management System

Buyer sample is send to G.M.

Matching is done by lab in charge.
Sample is prepared by dyeing master.
Sample is send to the buyer for approval.
Approved sample is returned and taken as STD. Sample for bulk production.
Asst. dyeing master gives responsibilities to production officer.
Page 21 of 65

Then production officer, with the supervisors start bulk production.

On line and off line quality check is done by lab in charge and asst. dyeing

master.
After dyeing finishing in charge controls the finishing process with the

supervision of production officer.

After finishing, the material is checked by dyeing master.
Finally G.M. checks the result with dyeing master and decision is taken for
delivery.

2.6 COMPLIANCE
2.6.1 Introduction:
Social Compliance / Social Accountability is an important parameter in international
business today, and buyers from major markets global markets, are increasingly
insisting on adherence to social compliance norms.
2.6.2 .Ethical Trading Practice:
M.M. Knitwear Ltd. recognizes that there are legal and cultural environments in
which factories operate. These ethical principles set forth the basic requirements of
Babylon factories in order to do business with its customers abroad.
M.M. Knitwear Ltd. makes ceaseless effort to promote best practices and continuous
improvement of ethical issues in all its manufacturing units. For easy access to the
issues, Babylon posted contents in the Notice Boards of factories in both Bangla and
English.
2.6.3 The issues are:
Laws & Regulation:
M.M. Knitwear Ltd. facilities operate in full compliance with the laws and regulations
of the jurisdictions in which they manufacture.
Employment Age:
Workers may not be younger than 18 years of age.
Forced Labor:

Page 22 of 65

M.M. Knitwear Ltd. facilities do not use involuntary or forced labor indentured,
bonded or otherwise.
Wage and Benefits:
MM facilities compensate their employees fairly by providing compensation packages
comprising wages and benefits that, at the very least, comply with legally mandated
minimum standards. Each employee is provided with a clear, written accounting for
each pay period. Employees are compensated for overtime according to local law.
Hours of Work:
M.M. Knitwear Ltd. facilities ensure employees Hours worked shall not, on a
regularly scheduled basis, exceed the legal limitations on regular and overtime Hours
in the jurisdiction in which they manufacture or 60 Hours per Week including
overtime. Except in extraordinary business circumstances, all employees are entitled
to one day off in every seven-day period.
Health and Safety:
M.M. Knitwear Ltd. facilities provide their employees with a clean, safe and healthy
work environment, designed to prevent accidents and injury to health arising out of or
occurring during the course of work. All MM facilities comply with all applicable,
legally mandated standards for workplace health and safety. All the workers and staff
enjoy free medical treatment. Company doctors are available full time.
Discrimination:
M.M. Knitwear Ltd. respects cultural differences, employment including hiring,
remuneration, benefits, advancement, termination and retirement based on ability and
not on belief or any other personal characteristics. MM facilities do not discriminate
on the basis of race, age, color, national origin, gender, religion, sexual orientation,
disability or similar factors.

Harassment:
M.M. Knitwear Ltd. facilities treat all employees with respect and dignity. Babylon
facilities do not subject employees to corporal punishment, physical, sexual,
psychological or verbal harassment or abuse.
Womans Rights:

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M.M. Knitwear Ltd. facilities ensure women workers receive equal treatment in all
aspects of their employment. Pregnancy test is not a condition of employment, and
pregnancy testing to the extent provided by MM facilities will be at the option of
the worker.
Monitoring and Compliance:
M.M. Knitwear Ltd. facilities maintain on site all documentation necessary to
demonstrate compliance with Global Compliance Principles. MM and its subsidiaries
undertake affirmative measures, such as announced and unannounced on-site
inspections of production facilities, to monitor compliance with Global Compliance
Principles. MM facilities allow customers representatives full access to production
facilities, employee records and employees for confidential interviews in connection
with monitoring visits.
2.7 Code of conduct of SA 8000 follow by M.M. Knitwear Ltd.:
1. Child Labor: No workers under the age of 15; minimum lowered to 14 for
countries operating under the ILO Convention 138 developing-country
exception; remediation of any child found to be working.
2. Forced Labor: No forced labor, including prison or debt bondage labor; no
lodging of deposits or identity papers by employers or outside recruiters.
3. Health and Safety: Provide a safe and healthy work environment; take steps
to prevent injuries; regular health and safety worker training; system to detect
threats to health and safety; access to bathrooms and potable water.
4. Freedom of Association and Right to Collective Bargaining: Respect the
right to form and join trade unions and bargain collectively; where law
prohibits these freedoms, facilitate parallel means of association and
bargaining.
5. Discrimination: No discrimination based on race, caste, origin, religion,
disability, gender, sexual orientation, union or political affiliation, or age; no
sexual harassment.

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6. Discipline: No corporal punishment, mental or physical coercion or verbal

abuse.
7. Working Hours: Comply with the applicable law but, in any event, no more
than 48 Hours per Week with at least one day off for every seven day period;
voluntary overtime paid at a premium rate and not to exceed 12 Hours per
Week on a regular basis; overtime may be mandatory if part of a collective
bargaining agreement.
8. Compensation: Wages paid for a standard work Week must meet the legal and
industry standards and be sufficient to meet the basic need of workers and
their families; no disciplinary deductions.
9. Management Systems: Facilities seeking to gain and maintain certification
must go beyond simple compliance to integrate the standard into their
management systems and practices.
2.8 Code of conduct of BSCI follow by M.M. Knitwear Ltd.:

Management Practice.

Documentation.

Working Time

Remuneration.

Child labor/Young Labor

Forced Labor/Discrepancy Measures/Prison Labor.

Freedom of Association and Collective Bargain.

No Discrimination.

Working Conditions.

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Health and Social Facilities.

Occupational Safety and Health.

Dormitories.
Environment

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2.9 Code of conduct of WRAP I follow by M.M. Knitwear Ltd.:

1. Compliance with Laws and Workplace Regulations
2. Prohibition of Forced Labor
3. Prohibition of Child Labor
4. Prohibition of Harassment or Abuse
5. Compensation and Benefits
6. Hours of Work
7. Freedom of Association and
8. Collective Bargaining
9. Health and Safety
10. Prohibition of Discrimination
11. Environment
12. Customs Compliance

Page 27 of 65

CHAPTER -03
Different Departments
To ensure smooth running of various activities, some departments are available they
are given bellow:
KNITTING SECTION:
1.Knitting
2.Inspection
KNIT DYEING SECTION:
1.Batch section
2.Store house for dyes & chemicals
3.Dye house
4.Dyeing & QC lab
5.Finishing
GARMENTS SECTION:
1.Merchandising
2.Sample
3.Production
MAINTENANCE:
1.Electrical
2.Mechanical
ACCOUNTS & COMMERCIAL SECTION
ADMIN SECTION

Page 28 of 65

CHAPTER-04
KNITTING DIVISION
4.1 Introduction:
Knitting is defined as the construction of fabric by interlocking loops of a single yarn
with the help of hooked needles. Each raw of such loops hanging from the one
immediately preceding it. Interloping consists of forming yarns into loops. The loops
are held together by the yarn passing from one to the next
Knitting may be done by hand or a machine. By hand, there are numerous styles and
methods. Flat knitting, which can be done on two straight needles or a circular needle,
produces a length of cloth, while circular knitting, which is done on circular or
double-pointed needles, produces a seamless tube.
4.2 Types of Knitting: There are two types
a. Warp Knitting.
b. Weft Knitting.
4.2.1 Warp Knitting:
In warp knitting, one or two yarn produce vertical column of loops and fabric is
produced in length way. Each loop in the horizontal direction is made from a different
thread and the no of threads used to produce such a fabric is at least equal to the
number of loops in horizontal raw. e.g. Net, Mesh fabric etc
4.2.2 Weft or Circular Knitting:
In a Weft knitted structure, a horizontal raw of loops can be made by using one thread
and the thread runs in horizontal direction. e.g. single jersey, rib, interlock etc

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4.3 Organ gram of Knitting Division:

AGM

PO

STORE INCHARGE

KNITTING MASTER

SUPERVISOR

FITTER MAN

FITTER MAN

OPERATOR

OPERATOR

Figure 4.1: Organ gram of knitting department

4.4 Knitting Division:

Figure 4.2: Knitting Machine

They are among the best knitting industries of Bangladesh and manufacture the best
quality Garments for my clients. Over the years there quality products and reputation
have created a strong business relation with the worlds famous clothing brands. They
use the latest technology and environment friendly production process to deliver the
best quality to my clients. My units are:
Page 30 of 65

4.5 Circular Knitting Unit:

They have a large circular knitting unit having 110 machines with 20GG, 24GG,
28GG cylinder and optimum attachment to produce all types of Weft knitted fabric.
Machines are Fukuhara, Fukuhama and Jiunn long branded. They also have 28
machines with open width take down and 05 engineering striper machine. List of
machines with diameter as bellow:
Table 4.1 List of Knitting M/C
Sl.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Name of Machine Dia Guage

S/J
16-20
24
S/J
21
24/28
S/J
22
24/28
S/J
23
24/28
S/J
24
24/28
S/J
25
24/28
S/J
26
24
S/J
27
24
S/J/FLEECE
28
24/20
S/J/FLEECE
29
24/20
S/J/FLEECE
30 24/20/28
S/J/FLEECE
32 24/20/28
S/J/FLEECE
34
24/20
S/J/FLEECE
36
24/20
S/J/FLEECE
38
24/20
S/J/FLEECE
40
24/20
S/J/FLEECE
42
24/20
RIB/INTERLOCK 30
18/24
RIB/INTERLOCK 32
18/24
RIB/INTERLOCK 34
18/24
RIB/INTERLOCK 36 16/18/24
RIB/INTERLOCK 38
18/24
RIB/INTERLOCK 40
18/24
RIB/INTERLOCK 42
18/24
RIB/INTERLOCK 44
18/24
ENG. STRIPE, S/J 30
24/20
ENG. STRIPE, S/J 34
24/20
RIB/INTERLOCK 36
24/20

Origin
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Japan
Japan
Japan

Nos
05
02
02
02
02
01
02
01
04
03
09
11
10
10
09
07
04
02
03
03
03
03
02
04
01
02
02
01

4.6 Flat Knitting Unit

Page 31 of 65

They have computerized flat knit machines branded around star, kauo heng, Jy lee
having jacquard option to produce different types of collar, Cuff and bottoms.
4.7 Narrow Fabric Unit:
They have a narrow fabric unit to produce better quality accessories of garments like
twill tape, dusting etc
4.8 Quality Control Unit:
They have a Ill equity quality control unit to product the best quality for my
customers.
Table 4.2: Quality Control Unit
1

Gray Inspection machine made by UZU from Taiwan

No

Yarn Length Tester (YLT) made by BARTHTEX form

8
0

s
No

GERMANY
Yarn Tension Tester Made by SCHMDT from GARMANY

2
0

s
No

Yarn Count Testing Machine Made For GARMANY

3
0

s
No

4.9 Summary:
Table 4.2: summary of Knitting
Total
Floor Space
Total Capacity
Manpower

158 sets
80,000 sq. feet
28,000 Kgs/Day (Average)20,000 Pw Collar/Day
(Average)20,000 Yds Tape/Day (Average)
390 personnel

Page 32 of 65

CHAPTER-05
DYEING & FINISHING DIVISION

5.1 Introduction
Dyeing means to color the whole fabric using different chemicals & dyestuff.
Although dyeing is a chemical operation, most of the simpler processes may be
carried out on the small scale by sensible people who have very little chemical
knowledge, nevertheless, following a set of instruction in ignorance of the reasons
behind their formulation is unlikely to lead to the deeper understanding of textile
coloration that is needed by professional people in the coloration industry.
Consequently this chapter has been included the working knowledge of chemistry.
5.2 Process flow chart of dyeing:
Grey fabric receive from knitting section

Batching

Select machine number

Fabric loading

Select production program

Pretreatment

Dyeing

After treatment

Fabric unloading
Flow chart 5.1: dyeing Department

Page 33 of 65

5.3 Organ gram of Dyeing & Finishing Section:

GM

PM

APM

SPO

Batch in charge

Finishing in charge

Lab
In charge

Sewing man

Lab technician

PO
Sewing man
APO
Squeeze
Supervisor

Turning m/c Operator

Operator
Dryer

Q.C. technician
Helper

Operator

Sr. Operator
Helper

Compactor Operator
Asst. Operator

Operator

Helper

Flow chart 5.2: Organ gram of Dyeing & Finishing Section

Page 34 of 65

5.4 List of Machineries:

Table 5.1: List of Machineries Dyeing & Finishing
Sl.

Name of the Machine

Capacity

Nos

Auto-detwisting Ballooning Squeezer

Air Turning Machine

Steam Boiler (:By N/Gas)

Air Compressor

Air Compressor

Air Compressor

7.5 M3/Min

1 sets Germany(Rollair)

Air Compressor

4.6 M3/Min

1 sets Germany(Rollair)

Compare

5 M3/Min

Sample Winch

15 Kgs/Batch 4 sets

China(Suntex)

10

Sample Winch

30 Kgs/Batch 2 sets

China(Suntex)

11

Sample Winch

10 Kgs/Batch

1 set

Bangladesh

12

Sample Winch

20 Kgs/Batch

1 set

Bangladesh

13

Sample Winch

50 Kgs/Batch

1 set

Bangladesh

14

Semi-Automatic Vertical Winch-1 chamber

100 Kgs/Batch 1 set Korea(Sungmoo)

15

Semi-Automatic Vertical Winch-1 chamber

150 Kgs/Batch 1 set Taiwan(Tongjeng)

16

Semi-Automatic Vertical Winch-2 chamber

200 Kgs/Batch 1 set Korea (Sungmoo)

17

Semi-Automatic Vertical Winch-1 chamber

300 Kgs/Batch 1 set Taiwan(Tongjeng)

18

Semi-Automatic Vertical Winch-3 chamber

300 Kgs/Batch 1 set Korea(Sungmoo)

19

Semi-Automatic Vertical Winch-4 chamber

400 Kgs/Batch 1 set Korea (Sungmoo)

20

Semi-Automatic Vertical Winch-1 chamber

120 Kgs/Batch 2 set

Fongs ( China )

21

Semi-Automatic Vertical Winch-2 chamber

200 Kgs/Batch 1 set

Fongs ( China )

22

Semi-Automatic Vertical Winch-2 chamber

400 Kgs/Batch 1 set

Fongs ( China )

23

Semi-Automatic Vertical Winch-3 chamber

600 Kgs/Batch 2 set

Fongs ( China )

24

Semi-Automatic Vertical Winch-4 chamber

800 Kgs/Batch 2 set

Fongs ( China )

70000 Kgs/Day 1 set

Origin/Brand
Turkey(Mersan)

12000 Kgs/Day 2 sets Korea(Dongnam)

10000 Kgs/Day 1 sets
8.5 M3/Min

UK (Cochran)

2 sets Germany(Rollair)

Air Compressor 2 sets Turkey(Dilgakiran)

1 sets

U.K

Page 35 of 65

Sl.

Name of the Machine

Capacity

Nos

25

Semi-Automatic Vertical Winch-1 chamber

900 Kgs/Batch 1 set Taiwan(Tongjeng)

26

Dms Ht Jumbo Jet Flow (HP Winch)

500 Kgs/Batch 1 set Turkey(Dilmenler)

27

Dms Ht Jumbo Jet Flow (HP Winch)

1500 Kgs/Batch 1 set Turkey (Dilmenler)

28

Dms Ht Jumbo Jet Flow (HP Winch)

1200 Kgs/Batch 1 set Turkey(Dilmenler)

29

Dms Ht Jumbo Jet Flow (HP Winch)

900 Kgs/Batch 1 set Turkey(Dilmenler)

30

Dms Ht Jumbo Jet Flow (HP Winch)

750 Kgs/Batch 1 set Turkey(Dilmenler)

31

Dms Ht Jumbo Jet Flow (HP Winch)

600 Kgs/Batch 1 set Turkey(Dilmenler)

32

Dms Ht Jumbo Jet Flow (HP Winch)

450 Kgs/Batch 1 set Turkey(Dilmenler)

33

Dms Ht Jumbo Jet Flow (HP Winch)

300 Kgs/Batch 1 set Turkey(Dilmenler)

34

Natural Gas Dryer Machine 3 Chamber

14000 Kgs/Day 1 no. Turkey(Dilmenler)

35

)Tubular Compactor (60

36

Pin chain compactor

37

RollerSun-Supper S
Tenter(98&8Chember)

10000 Kgs/Day 2 set

Korea(Ilsung)

38

Slitting Machine

12000 Kgs/Day 2 Set

Italy(Bianco)

39

Back Sewing TMS

40

Brush Sueding M/C

41

Brushsueding M/C

16000 Kgs/Day 1 set

6000-8000
Kg/D

3 set

Origin/Brand

USA(Tubetex)
Italy(Laffer)

60000 Kgs/Day 2 Set Turkey(Dilmenler)

700 kgs/Day

1 Set

Italy

1 Set

Italy

Page 36 of 65

5.5 Raw Material for Dyeing:

Raw material used in the dyeing section is:
1. Grey fabric
2. Dyes
3. Chemicals
5.6 Grey Fabric:
Following types of grey fabric are dyed:
Single jersey
Single jersey with lycra
Interlock
Interlock with lycra
ST Back Pique
DT Back Pique
Polo Pique
Single lacost
Double lacost
2T Fleece
2T Fleece with lycra
3T Fleece
3T Fleece with lycra
1 X 1 Rib
1 X 1 Rib with lycra
2 X 1 Rib
2 X 1 Rib with lycra
2 X 2 Rib
2 X 2 Rib with lycra
CVC
PC

Page 37 of 65

5.7 Finishing Section:

After fabric unloading from dyeing machine. Every required quality is checked by the
quality control. If all requirements are ok .then fabric is received by the finishing
section. 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.
5.8 Process flow chart of finishing:
Fabric Unload From Dyeing
Dyed Fabric from Dyeing Department

Shade check
Open width

Tubular form

De-watering

De-watering

Slitting

Drying

Stentering /Dryer

Calendaring & compactor

Open compactor

Final Inspection

Final Inspection

Packing
Delivery

Packing

Delivery
Flow chart 5.3: Process flow chart of finishing

5.9 Objective of finishing:

Page 38 of 65

Improving the appearance,luster, feel softness whiteness suppleness etc.

Improving the, which depends on the handle of the material & its, , fullness

etc.
Iaring qualities, non- soiling, anticrease, antishrink comfort etc .
Special properties for particular uses -water -proofing flame proofing etc .
Covering of the faults in the original cloth .
Increasing the Iight of the cloth .

5.10 Finishing effects:

Easy care .

Crease recovery.

Dimensional stability

Good abrasion resistance

Improved tear strength

Good sew ability

Soft or stiff handle

Shine or luster

5.11 Finishing Machinery:

In finishing section of M M Knitwear Ltd, the machines which are available are listed
below:

5.12

Slitter m/c(1 set)

Stenter m/c(1 set)
Detwisting m/c(2 set)
Natural Gas Dryer m/c(1 set)
Compacting m/c(4 set)
Air Turning m/c(1 set)
Calendering m/c(1 set)
Function of the SLITTING Machine:

Used to remove excess water after pretreatment and dyeing

To slit the tube fabric by the knife for opening of the fabric and ready for stentering
Delivered fabric increase free state
Before squeezing balloon is formed with the help of compressed air passing by a nozzle

or air sprayer
It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism

5.13 Function of Squeezing/Dewatering machine

Page 39 of 65

Reduce water from fabric

Fabric open from rope form

Dia/width control

Twisting and spirality control by twisting wheel

Apply chemical

Softening agent

Brightening agent

5.14 Function of DRY M/C:

Dry the fabric

GSM control

Shrinkage control up to 3-3.5%

75% dries at 150oC

5.15 Function of STENTER M/C:

Apply chemicals

Apply softener

Drying of fabrics

Width control

Curing of fabric

GSM control

Shrinkage control

Spirality control

Heat setting on cotton/ Lycra

Pigment dyeing

Bowing effect control

Surface coating

Heat setting

Page 40 of 65

CHAPTER-06
TESTING
6.1 Introduction:
Textile dyeing is combination of some series processes such as scouring , Bleaching ,
dyeing & after treatment which can be carried out at stages of fiber processing in
different forms like stable , yarn , fiber. Pretreatment is the preparatory process of
textile dyeing. It is also called the HEART OF DYEING.
6.2 Types of Test in Laboratory:
There in two types of test done in laboratory,
1. Physical Test
2. Chemical Test
6.3 Stock solution preparation:
In practice 1% stock solution is very common used in dying process. In Laboratory
work, 1.0 gm solid ( 100% concentration ) dyestuff / chemicals taken in a conical flax
& poured 100 ml of warm water ( 45 0c) to dissolve the reagent to make 1% stock
solution.
In the case of liquid ;
Take 10 ml liquid in a beaker; making it 100 ml by pouring necessary amount of
water is prepared 10% solution

6.4 Physical test

Yarn grade

Gsm test

Shrinkage test

Spirality test

Tensile test

Abrasion resistance

Pilling resistance
Page 41 of 65

Button strangth test

Lycra% determination

Crease resistance

6.5 Chemical Test:

colmy fastness properties

chemical solubilitytest

6.6 List of M/C in Laboratory:

Table 6.1: List of M/C in Laboratory
Sl
.
1

Name of the Machine

Spectra Flash Sf 600 Plus Spectro Photo Meter

(Data Color)
Infrared sample Dyeing Machine

Color Fastness to washing

Croc meter

Light box

Electric balance

Washing machine

Tumble Dryer

Perspire meter

10 Pilling Tester
11 Rota Wash
12 Electrolux Wascator
13 STD Front Tumble Dryer
14 Lab Oven & Incubator
15 PH Meter / Temperature Meter

Nos

Origin/Brand

1
set
2
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1

U.S.A
U.K
Korea
U.K
U.K
U.S.A
Italy
Italy
U.K
U.K

Page 42 of 65

16

Electronic Yarn Count System

set
1
set

6.7 Quality Standard:

Shrinkage: Should not exceed 4.

Wash Fastness:
Fastness to washing DIN EN ISO 20105 C 03: 60c : at least 4 -5.
Staining on Cotton, Polyester, Polyamide, Wool : at least 4.

Rubbing Fastness:
Fastness to rubbing DIN EN ISO 105 X 12: Dry at least 4 & It at
least3.

Color Difference, E: Should not exceed 1.

Page 43 of 65

CHAPTER-07
Garments Division
7.1 Sample division:
The style done by designer or developer.
Particular purchase order.

Sample is the specimen of any product.

Any revision to the style work.
Sample is a specimen or I can say a part which shows that the whole is look
like.
Conform with any specific requirement
7.1.1 Flow chart of sample department:
Sketch/design
(It is given by buyer for make sample and products are made according to that style of
designed)

Basic block
(Without any allowance)

Working pattern
(To make of garment according to design)

Sample making
(Sample is made by sample man)

Basic manufacturing difference

(Critical path is identify)

Approved sample
(Sample approved by buyer)

Costing
Page 44 of 65

Flow chart 7.1: of sample department

7.1.2 Sample type:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Development sample
Salesman Sample
Photo Sample
Approval Sample
Size set Sample
Mock up Sample
Pre-production Sample
Production Sample
Shipping Sample

7.1.3 Summary:

Floor Space : 4500 Sq.feet.

Machineries : 45 Machines + 1
Cutting Table + 2
Vacuum Iron+ 2
Inspection Table+ 1
Pattern Table.
Manpower : 60 Personnel working under the sample Manager separate Pattern
master

7.2 Cutting Section:

Cutting Table: 11 cutting table of (70-90 feet each) in fmy separate floors.
Floor Space: 40,000 sq. feet.
Total Capacity: 65,000 Pcs / Day (Average)
Manpower: 370 personnel

Page 45 of 65

7.3 Embroidery Section:

Figure 7.1: Embroider

3sets of Embroidery Machine with 20 head each ,

Brand : Barudhan, Japan
Floor space: 3,000 sq.ft.
Manpower : 28 Person

7.4 Screen Printing Section:

Figure 7.2: screen printing

In depended Print factory with 14 tables in 100feet in length. With Graphic
design and color Team.
Capacity: 35,000 pcs/Day in Avg.
Floor space : 22,000 sq.ft.
Manpower : 300 Person

Page 46 of 65

7.5 Sewing Section:

Four my floors of 6 lines each & three floor of 10-lines each.

Floor Space: 80,000 sq. feet.
Total Capacity : 70,000 Pcs/Day (Average)
Manpower: 3389 personnel.

7.6 Finishing Section:

Figure 7.3: finishing section

Two separate floors.

Floor space : 36,000 sq. feet
Total Capacity: 65,000 Pcs/Day (Average)
Manpower: 1065 personnel.

7.7 Office staff A large team of Technical personnel are directly working, assisting
the workers and Coordinating pattern, cutting, sewing, and quality, finishing-packing.
About 200 people are working as a supervisor, line chief, Floor in charge, section
manager.
7.8 Quality Team Independent quality team of 454 people is working to ensure
customers required quality standard. Factory regular AQL system is 2.5 but in certain
case it depends on customer requirement.
7.9 Logistic Team A team of 15 personnel working under the General Manager to
ensure proper and timely documentation to continue smooth procedure of Export
import , Banking and other logistic support.
Page 47 of 65

7.10 Auditing Team There is an Internal Auditing system is continuously going on

by the professional auditors. What are making everybody to be more careful,
responsible and minimizing wastage and process loss?
7.11 List of the Machines:
Table 7.1: List of sewing m/c
Sl.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Name of the Machine

Single needle Plain Machine
2-needle, 5-thread over lock
2-needle, 4-thread, over lock
2-needle, 4-thread, lap seam stitching
3-needle, 5-thread, chain stitch
1-needle Button Hole
1-needle Button Stitches
Snap button machine
Flat Lock Flatbed
Flat Lock Cylinder bed
Kansai Special (PMD)
Bar tack Machine
3 Thread over lock
Rib cutting machine
Cutting machine
Thread winder (Re-conning)
Heater less steam iron & Vacuum Table
Strapping Machine, TOYO
Thread Sucking Machine
Metal Detector (SainTex)
Cutting Layer
Boiler
Total

No. s
777
08
593
17
06
06
24
14
105
278
06
05
10
23
24
06
140 Sets
05
06
01
01
05
2085

Origin
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Taiwan
Japan
Japan
Japan
Japan
BD
Japan
Thailand
USA & China

CHAPTER-08
Quality Management System
8.1 Quality Policy:

Page 48 of 65

It is the policy of M.M. Knitwear Ltd. to produce quality dyed knit fabrics that meet
the customers expectations & needs. To implement this policy the top management of
Landmark Textile Mills Ltd. is committed to provide adequate Resource in terms of
good raw materials and trained personnel & continually improve / upgrade its
processes and systems. The quality control policy of Landmark Textile Mills Ltd. is
stated below

Leadership program from the top.

In-process quality control during manufacturing operation.
Evaluation programs in all areas of knitting, dyeing, cutting, sewing and

finishing.
Maintain chain of responsibility.
Follow strict stuffing, auditing and reporting.
Use inspection machines in required points.
Maintain standard AQL.
Sufficient lighting and sanitation.
Final inspection prior to packaging.
Meeting the appropriate expectations of clients.

8.2 Quality Assurance Procedure:

M.M. Knitwear Ltd. assures the quality of their products in the following three steps:

In laboratory.
In dyeing section
In finishing section

The quality assurance procedures are described below:

8.2.1 in laboratory:
Swatch card from buyer according to their requirement is received.
Recipe prediction for sample dyeing using CCMS.
Sample dyeing until matching with the swatch card. Acceptable color
difference is less than 1.
If matching is OK, then it is sent to the buyer for approval.
8.2.2 in dyeing section:
After approval from the buyer, sample dyeing is done in dyeing m/c, in
Page 49 of 65

dyeing shed & again matched with the approved sample.

If result is OK, then balk production is commenced.
During dyeing process, before the final acid wash, samples are taken and
checked for accurate shade matching.
After dyeing sample is collected & matching is done.
8.2.3 in finishing section:
Correctly dyed, after treated & matched fabrics are allowed for finishing.
By using a series of finishing machines correct width, softness & appearance are
maintained according to requirements.
Then sampling is done several times to test GSM, Shrinkage & fastness properties.
Finally fabric is inspected & prepared for delivery.
8.3 Inspection area:

Shade match of fabric

G.S.M.
Fabric diameter
Spirality
Shrinkage (%)
Length wise
Width wise
Wash fastness
Rubbing fastness
Faults
Dyeing faults
Knitting faults
Finishing faults

8.4 Knitting Faults

Hole
Slub
Needle mark
Stripe
Missing yarn
Contamination

8.5 Dyeing Faults

Uneven shade
Running shade
Fastness property
Dye spots and marks
Page 50 of 65

8.6 Finishing Faults

GSM variation
Spirality
Shrinkage control
Marks

8.7 Problems Encountered in Dyeing:

8.7.1 Uneven Dyeing
1. It can be caused due to rapid addition of dyes and chemicals. For this
purpose the dosing of soda ash should be maintained properly.
2. Pressure difference.
3. Over loading in the m/c.
4. Yarn lot mixing.
5. Improper control of temperature.
6. Less amount of leveling agent.
7. Improper pretreatment.
8.7.2 Uneven Shade in Rope to Rope
1. Improper rope length in each chamber.
2. Improper fabric flow speed in each nozzle.
8.7.3 off Shade
1. Improper M: L ratio.
2. Lower amount of auxiliaries.
3. Improper mixing of dyestuffs.
8.7.4 Dye Spots
This is most common fault caused by operator not correctly mixing and
thoroughly dissolving dyestuffs in the right amount of water.
8.7.5 Batch to Batch Shade Variation
If any of parameters of dyeing are changed then it will produce problems in batch to
batch consistency. In order to avoid this defect the following steps should be follow

Maintain the same liquor ratio.

Check that the fabric has the same dye affinity.

Use the same standard program procedures for each batch.

Page 51 of 65

Making sure that the operators add the right batch of chemicals at the same
time & temperature in the process.

Check the water supply daily especially ph, hardness & Na2CO3 content.

8.7.6 Crease Mark

Crease marks are produced due to the lower concentration of anti creasing
agent and improper cooling rate (defective cooling gradient). This is encountered by
increasing the concentration of anti creasing agent and proper adjustment of cooling
rate.
8.7.7 Running Marks
Running marks are frequently related to the material construction and are caused by
poor opening of the fabric rope.
1. Reducing the machine load and running at a slightly higher nozzle pressure, or
using the next largest available nozzle size, may also help.
2. Either pre setting or pre relaxation of the fabric before dyeing can avoid this
problem.
3. Running and crack marks can also be a result of incorrect process procedures. A
higher fabric speed, combined with slower rates of rinse and cooling will often correct
the problem.
4. Care should be taken to check that bath draining temperatures are not very high
especially viscose blends are involved.
5. Shock cooling of static material will also cause crack marks.
8.7.8 Intensive Foaming
In case of intensive foaming, which is caused when, the pumps try to pump a
mixture of air and water. This resets in the loss of nozzle pressure & floating of flake.
If the foaming is severe it is better to drop the bath & restart the process, after adding
an anti foaming agent to the new bath.
8.7.9 Patchy Dyeing
It is caused, if dye solution is not correct and also scouring is improper.
8.7.10 Miscellaneous Problems
Page 52 of 65

Batch to batch processing may vary due to the improper calculation of dyes and
chemicals and improper strength of salt soda and H 2O2 etc. Beside hardness of water
and caustic may lead to an improper shade.
8.8 Process of Shade Matching:
The required shade provided by the buyer is reproduced in the lab in lab
dyeing machine after the recipe prediction. The lab in-charge first uses the Computer
Color Matching System, to obtain the closest shade match recipe. Then he consults
the shade card and Pantone book to verify the obtained recipe. If he thinks that certain
changes in the recipe are necessary, he then alters the recipe according to his
experience. This recipe is used to dye a sample of 5 gm fabric in the lab dyeing
machine with following parameters.
a) Temperature and time
Cold Brand Reactive Dye - 65 c temp; 60 min
Hot Brand Reactive Dye - 98 c temp; 60 min
Turquoise Color (Cotton) - 85 c temp; 60 min
Polyester - 130 c temp; 30 min
b) M:L ratio
The samples are usually dyed using 1:10 ratio.
c) Pentone Book
Pentone Textile Color Selector
Total shade 1701
Color numbering system 6 digit + suffix
First two digits

11 to 19 ( range of lightness)

Middle two digits

01 to 64 ( range of hue)

Last two digits

01 to 64 ( range of chroma)

Page 53 of 65

Chapter-9
Effluent Treatment Plant (ETP)
9.1 Effluent Treatment Plant (ETP):
The effluent generated from different sections of a textile industry must be treated
before they are discharged to the environment. Various chemicals and physical means
are introduced for this purpose.
Capacity

80m3/ hr

Cost

Tk. 2.5 / m3

9.2 Function of different Unit of Biological Effluent Treatment Plant (E T P):

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

: 35 to 37 C

PH (Maximum)

: 6.5

Dissolved oxygen : 4 PPM

Sedimentation Tank / Biological feeding tank:
Treated water is over flowed from oxidation tank. Decolmyent is used here to destroy
the color of waste water.
Page 54 of 65

 Settling tank / Sedimentation Basin:

A tank or basin in which waste water is held for a period of time, during which the
heavier solids settle to the bottom and the lighter material will floats to the water
surface. In this tank sludge is immersed and the harmless water is discharge to ponds,
Land, river etc.
Sludge Thickener:
Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge. After
one hour of Polyelectrolyte dosing aeration is stopped and fresh water discharge to
drain when sludge is taken. The thickened sludge is transferred to the sludge thickener
bed.
Sludge Thickener bed:
Here sludge is dried which is used as good fertilizer as Ill as fuel of brick field. Sludge
is dried under the sunlight.
9.3 Required Chemical of Biological ETP:
Sulphuric Acid:
Function: Neutralize the waste water controlling the PH. It is auto dispensed in the
neutralization tank.
Polyelectrolyte:
Function: Used for sedimentation / sludge coagulation and also killing bacteria.
Antifoaming Agent:
Function: Used for reduction / controlling foam. It is used auto / manually in the
distribution tank.
De-colorant:
Function: Used for removing color. It is used auto / manually in the sedimentation
feeding tank.
Sodium Hypochlorite:
Function: It is used to kill the harmful bacteria. It is used in the biological oxidation
tank.
9.4 Product Quality Checked:

Biological Oxygen Demand (BOD)

Chemical Oxygen Demand (COD)
Total suspended solids (TSS)
Total dissolved solids (TDS)
Turbidity
Page 55 of 65

 Color
PH
etc.
9.5 Process Flow chart of Biological Effluent Treatment Plant:
Fabric Dyeing

Pumping and Screening

Acid Dosing

Homogenizing Tank

Distribution Tank
Antifoaming
Dosing
Biological Oxidation Tank

De-colorant
Dosing

Sedimentation Tank

Sludge Return Tank

Sludge Thickener

Polyelectrolyte Dosing

Dry Sludge

Filter Press

Dispose to Land Filling

Flow chart: Biological Effluent Treatment Plant

Page 56 of 65

CHAPTER - 10
MAINTENANCE & UTILITIES
10.1 Maintenance of Machinery
Maintenance of machinery is very essential mechanical effort for achieving smooth
running of different machines. Maintenance is a process by which equipment is
looked after in such a way that trouble free services and increased machine life can be
ensured and specific product quality required by the customers is sustained. On time
maintenance increase m/c lifetime & ensures trouble free services.
10.2 It has 2 types of Maintenance:
1. Break down maintenance
2. Routine maintenance
Maintenance

Routine Maintenance

Break Down Maintenance

Mechanical Maintenance
Electrical Maintenance
Mechanical Maintenance
Electrical Maintenance
Figure 10.1: maintenance
10.3 Manpower Setup for Maintenance
10.3.1 for electrical Maintenance: Per shift:
B Sc. Engineer - 1
Diploma Engineer - 1
Senior Technician 2
Junior Technician 4

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10.3.2 for mechanical Maintenance: Per Shift:

B Sc. Engineering - 2
Diploma Engineering - 3
Senior Technician 1
Junior Technician 4
10.4 Machine: Dyeing Machines
Table 10.1: Maintenance of Dyeing Machines
Sl.

Item needed to be checked & Serviced

No.
1.

Greasing of the winch bearing

2.

Complete cleaning of machine

3.
4.
5.
6.
7.

Cleaning of drain valves, replace seals if required

Checking of air supply filter, regulators, and auto drain seals
Cleaning of filter elements
Greasing of unloading roller bearings
Checking and cleaning (if required) of addition tank level indicator

8.

Checking the oil level of pump bearing and refill if required

9.
10.
11.

Checking the function of heat and cool modulating valves

Checking of all belts and belt tension
Check circulation, reel and other pumps

12.

Checking of all door seals

10.5 Machine: Stenter Machine

Table 10.2: Maintenance of Stenter Machine
Sl. No.

Item needed to be checked & Serviced

1.

Removal of gas burnt deposits from chains

2.

Checking of gas burners

3.

Cleaning of softener application unit

5.

Checking and cleaning of steam pipe lines

4.

Checking and cleaning of gas pipe lines

5.

Grinding of fabric gripping pins

6.

Cleaning of ventilation duct

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7.

Cleaning of m/c cabinet

8.

Checking of motors

10.6 Machine: Dewatering Machine

Table 10.3: Maintenance of Dewatering Machine
Sl. No.

Item needed to be checked & Serviced

1.

Cleaning of softener application unit

2.

Checking of rotating device of rotating trolley unit

3.

Checking of pneumatic pressure valves

4.

Checking and replacement (if necessary) of rubber pads of stretching

unit

5.

Checking of plaiting device

6.

Checking of speed regulating unit

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10.7 Machine: Dryer

Table 10.4: Maintenance of Dryer Machine
Sl. No.

Item needed to be checked & Serviced

1.

Checking of gas pipe lines

2.

Checking of gas burners

3.

Checking of belt conveyor system

4.

Checking of plaiting device

5.

Checking of speed regulating unit

6.

Cleaning of ventilation duct

7.

Cleaning of m/c cabinet

10.8 Machine: Compactor Machine

Table 10.5: Maintenance of Compactor Machine
Sl. No.

Item needed to be checked & Serviced

1.

Checking of Steam pipe lines

2.

Checking of pneumatic pressure valves

3.

Checking of belt conveyor system

4.

Checking of plaiting device

5.

Checking of speed regulating unit

6.

Checking and replacement (if necessary) of compacting shoe

7.

Cleaning of compacting shoe

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10.9 Machine: Boiler

Table 10.6: Maintenance of Boiler Machine
Sl.
No.

Item needed to be checked & Serviced

1.

Checking of gas pressure and gas supply line

2.

Dosing of softening chemicals to supply water

3.

Checking of all steam lines

4.

Cleaning of burner tank (after six month interval)

5.

Checking and replacement of valves

6.

Cleaning of feed water tank

7.

Checking and replacement of filters

8.

Cleaning of sight glass

10.10 Maintenance Tools and Equipments

Table 10.7: Maintenance Tools and Equipment
Sl. No. Maintenance tools/equipments
Functions
1.
Adjustable wrench
Used for setting nut & bolts
2.
Pipe Spanner
For pipe fitting
3.
Fixed Spanner for nut & bolts
Spanner
fitting
4.
Handle system for nut & bolt
Socket spanner
fitting
5.
Hammer
To apply load where required
6.
Screw driver
To release any screw
7.
Punch
Used to fit any worn out shaft
8.
Lock opener
To open the clip of bearing
9.
Hack saw
To cut any metallic thing
10.
Outside calipers
To measure outside dia
11.
Inside calipers
To measure inside dia
12.
Slide calipers
To measure very small dia
13.
Vernier scale
To measure very small dia
14.
Chain ton
To lWeft heavy load
15.
Welding machine
To join metallic parts
16.
Grinding machine
To make the smooth fabrics
17.
Tester
To test electric circuit
18.
Pliers
To grip anything & cut
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19.
20.

Avometer/Voltmeter
Steel tape

anything
To measure voltage
To measure length, width &
height

10.11 Utility Services Available

Electricity
Gas
Water
Compressed air
Steam etc.
Government Supply (PDB)
Electricity or Power
Factory's Own Generator
Air Compressor
Natural Gas
Steam Supply
Water
10.12 Source of Utility
The main Utility, which is used by M.M. Knitwear Ltd., is Natural gas. From
Natural gas generator produce electricity. From natural gas and electricity in associate
with mechanical and electrical apparatus, MM Knitwear Ltd Produce other Utilities
like water, steam, Compressed air etc.

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CHAPTER 11
CONCLUSION
11.1
Industrial attachment or, Industrial training is an essential part for textile education
because it minimizes the gap between theoretical and practical knowledge. These
Industrial training increases mine thought a lot about Apparel technology. It also helps us
to know a lot about industrial production process, machineries, and industrial
management and made me suitable for industrial life. Besides it gives us the first
opportunity to work in industry.
I have completed my industrial attachment from MM Knitwear Limited.
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 Ill educated and technically experienced manpower to get rid of
any defect in production process. It has also a good organizational hierarchy. At last, I can
say industrial attachment prepare us for the expected destiny of practical life.
11.2 Limitations of the report:
Because of secrecy act, the data on costing and marketing activities have not been
supplied.
I had a very limited time. In spite of my willing to study more it was not possible
to do so
Some points in different chapters are not included as these Ire not available.
It is not possible to hold the whole thing of a textile industry in such a small frame
as this report. So, try my hard to summarize all the information that I are
provided.

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11.3 Recommendations
Knitting production needs to increase as Ill as technical persons need to be
employed there?
More skilled labor should be used in a project and the overall efficiency will
increase.
Dyeing floor should keep always neat and clean. It kept It after unloading the
fabric from the dyeing machine specially, for Athena. Water must be swept time to
time.
During the transport of the fabric and during the loading of the m/c, fabrics get
soiled due to their drawing over the floor. This makes the fabric/part of the fabric
dirty. It may require more scouring/bleaching agent or may create stain.
Due to the pressure of higher production some times machine operators do not
maintain accurate time according to the actual process so that less quality product
is produced and may reject. So my suggestion is to increase machine and reduce
the pressure on the operator.
Should increase understanding between the top level personal and floor level
personal.
Finishing section need to be enlarged Ill as more technical persons need to be
employed there.
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.
In knitting and finishing section every workers should use mask to make protect
them from fly. Otherwise the exhaust air system should be more effective.
Workers are not interested to wear their gown & hand gloves.
In the Laboratory there is no technical person, a textile engineer may be employed
here.

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References:

1.
2.
3.
4.
5.
6.

www.google.com
www.mmKnitwear.com
www.slideshare.com
www.textiletoday.com
www.scholargoogle.com
www.eprothomalo.com

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