Sheikh Kamal Textile Engineering College, Jhenaidah

Aruakandi, Madhupur, Jhenaidah.

INDUSTRIAL ATTACHMENT REPORT

At

Fakir Apparels Ltd.

Enayethnagar, Fatullah, Narayongonj

Submitted By :

Md. Liton Mia

ID: J201714001
Department : Apparel Engineering

Supervised By :

Shariful Islam
Foreman
Sheikh Kamal Textile Engineering College
Sheikh Kamal Textile Engineering College, Jhenaidah
Apparel Engineering

Course Code: AE 416

Course Title: AE Industrial Attachment

Supervising Teacher’s approval

………………………..…………….

Supervisor: Shariful Islam

Foreman
Sheikh Kamal Textile Engineering College
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Acknowledgement

At first we would like to express our heart-felt thanks to Almighty ALLAH for his
kind blessing for complete of this internship report successfully.

A warm felicitation goes for me to acknowledge the people who hold the desirability for
encouraging, praising, assisting, and believing me on what I have worked through my
internship period in Fakir Apparels Ltd.

I would like to extend thanks to Our Honorable Teacher Firoz Khandakar ( Principal , Sheikh
Kamal Textile Engineering College ) not only for his tremendous academic support , but also for
giving us so many wonderful opportunities and logistic supports to do this project .

I would like to thanks Shariful Islam, Foreman, Sheikh Kamal Textile Engineering
College , for providing support during my internship

We would like to thank the 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 us a lot.
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Executive Summary

The Industrial Attachment is the most effective way for Textile Engineering 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.

It is our pleasure that we had an opportunity to complete our two month internship at
Fakir Apparels Ltd., which is one of the most modern industries of the country.

In Bangladesh, there are different types of Textile industries producing high-quality

textile and apparel products. Fakir Apparels Limited is one of them. It is Knit
Composite Garments Manufacturer & Exporter

They have Different types of latest Knitting, Dyeing, Cutting, Sewing, and Finishing
machines supplied by primarily Japan, Taiwan, U.K, U.S.A., China.

In this report we tried to cover a short profile of FAL and major customers of Fakir
Apparels Ltd. and their different activities.

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TABLE OF CONTENTS

CHAPTER NAME: PAGE NUMBER:

Chapter 1: Information about Factory 1- 11

1.1 Introduction 2
1.2 History of the Factory 2
1.3 At a Glance 3
1.4 Site Direction from Dhaka 4
1.5 Key product 6
1.6 Key Fabrics 6
1.7 Key Customers Top- 5 7
1.8 Different Major Departments 9
1.9 Organogram 9
1.10 Clients 10
1.11 Certificates 11

Chapter 2 : Knitting 12-27

2.1 Knitting Structure 13

2.2 Knitting Layout 14
2.3 Machine List of Knitting Section in FAL 15
2.4 Organogram and Process Flowchart 15
2.5 Types of Knit Fabrics 16
2.6 Types of Yarn Using in FAL 16
2.7 Knitting Machine Parts with Figure 17
2.8 Knitting Parameters 18
2.9 Machine Gauge or Needle Gauge 18
2.10 Quality Check 18
2.11 Floor Data Collection 20
2.12 Specification of Machines in Knitting Section 22

Chapter 3: Batch 28 -28

Chapter 4: Lab Section 29-34

4.1 Physical Lab Test Name 29

4.2 Different Types of Test Equipment for Physical Test 30
4.3 Analytical Lab 31
4.4 Color Lab 31

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Chapter 5: Dyeing Section 35-56

5.1 Introduction 35
5.2 Theory of Dyeing 35
5.3 Dyeing in Fakir Apparels Ltd 36
5.4 Dyeing Floor Layout 37
5.5 Dyeing Machine Capacity 38
5.6 Fabrics Used for dye in Fakir Apparels 38
5.7 Duties and Responsibilities 39
5.8 Raw Materials for Dyeing 39
5.9 Dyeing Machines in Fakir Apparels Ltd 42
5.10 Scouring, Bleaching and Enzyme Wash 43

Chapter 6: Washing 57-59

6.1 Introduction 57
6.2 Objectives 57
6.3 Process Flowchart 58
6.4 Types of Wash used in Washing Section 58

Chapter 7: Sample Section 60-65

7.1 Sample 60
7.2 Flowchart of Sample Department 60
7.3 Sample Type 62
7.4 The Details attached to the Garments Sample 62
7.5 Pattern Making 63
7.6 Maker Section 63
7.7 Fabric Spreading 64

Chapter 8:Cutting Section 66-71

8.1 Introduction 66
8.2 Cutting Flowchart 66
8.3 Factors affect the Cutting Process for fabrics are as follows 67
8.4 Different Types of Cutting Machine 67
8.5 Features of Cutting Machines 67
8.6 Factors involved in Cutting Fabrics 70
8.7 Working principle of Straight Knife as Cutting accessories 70
8.8 Different Types of Fabrics Fault 71

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Chapter 9: Embroidery Section 72-74

9.1 Introduction 72
9.2 Process Flowchart 73
9.3 Types of Embroidery 74
9.4 Common Faults in Embroidery 74

Chapter 10: Printing Section 75-77

10.1 Flowchart of Printing 75

10.2 Types of Printing 75
10.3 Common Print Defects 76
10.4 Major causes of Print Defects 76
10.5 The Basic of Printing 77

Chapter 11: Sewing Section 78- 91

11.1 Introduction 78
11.2 Flowchart of Sewing 78
11.3 Sewing Machine used 79
11.4 Stitch used for Sewing 80
11.5 Sewing Machine Description 82
11.6 Machine Wise Sewing Thread Consumption 85
11.7 Different Types of Seam Description 85
11.8 Different Types of Sewing Fault 86
11.9 T- shirt Manufacturing Process 87
11.10 Pierce Pant Manufacturing Process 87
11.11 Manufacturing process of suit shirt 88
11.12 Hoodies Manufacturing process 88
11.13 The Steps of 5s 90
11.14 8 Wastes of lean 90
11.15 Stitch and its type 90

Chapter 12: Finishing Section 92-97

12.1 Garments Finishing 92

12.2 Process Flowchart of Garments Finishing 92
12.3 Work flow in the Finishing room 93
12.4 Machine Description of Finishing 93
12.5 General Rules of spot Removing 94
12.6 Flowchart of Garments Inspection 94
12.7 Pressing or Folding 96
12.8 Assortment 96

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Chapter 13: Quality Control Development 98-100

13.1 Introduction 98
13.2 Objectives of Quality Control 98
13.3 Finish Fabrics Inspection 98
13.4 Quality Management System 99
13.5 Acceptable Quality Label(AQL-2.5) 99
13.6 Online Quality Assurance Test 99
13.7 Offline Quality Assurance Test 100

Chapter 14: Merchandising 101-103

14.1 Introduction 101

14.2 Why Merchandising 101
14.3 Responsibilities 102
14.4 Elements of Merchandising 102
14.5 Benefits of Merchandising 103

Chapter 15: Store and Inventory 104-104

15.1 Cases of maintain Inventory 104

15.2 Scope of Inventory Control 104
15.3 Frequency of Inventory Control 104
15.4 Store Capacity 104

Chapter 16:ETP( Effluent Treatment Plant) 105- 105

Chapter 17: Industrial Engineering Department 106-107

17.1 Introduction 106

17.2 Calculation 106

Chapter 18:Supply Chain Management 108-109

18.1 Method of Purchasing Raw materials 108

18.2 Procedure of Import Goods 108
18.3 List of Trims and Accessories 108

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Chapter 19: Impact of Internship 110-112

Chapter 20: Conclusion 113-113

Chapter 21: References 114-114

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Chapter 1: Information about Factory

Contact & Address:

Fakir Apparels Ltd.

Head Office & Factory Address A-
127-138, 142-145, B-501-503
BSCIC Hosiery Industrial Estate
Enayethnagar, Fatullah, Narayangonj
Tel: 880-2-7671684-5, 7671300,
7672660-61
Fax: 880-2-7671301
Web: http://www.fakirapparels.com

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1.1 Introduction:

This competitive world of technology wants a student who possesses theoretical and practical
knowledge. I learned about theoretical and practical knowledge on different textile sections during
my study. However, industrial training expands the knowledge of engineering students and gives a
real-world environment. This will help a student prepare before joining a workplace. I got an
opportunity to complete my industrial training at Fakir Apparels Ltd with a 40 working days time
duration. It is a 100% export-oriented composite industry situated at Enayetnagar, Fatullah,
Narayangonj, Bangladesh. It consists of a well-established facility that facilitates knitwear
manufacturing and woven sewing. They are planning to open a weaving department to attract more
foreign buyers. The purpose of industrial training is to flourish the theoretical knowledge with
industrial knowledge and learn about different techniques methods used for industrial production. In
these 45 days of industrial training, I have learned about Knitting, Batching, Dyeing, Fabric
Finishing, Lab, Cutting, Printing Section, Embroidery, Industrial Engineering, Sewing, Washing,
Garments Finishing, Supply Chain, Merchandising.

1.2 HISTORY OF THE FACTORY

Sixteen Years is not a long time for a garment factory to grow up and avail one of the
top positions, but Fakir Apparels is an exception. The companies who lead the
knitwear number one export sector of the country. Fakir Apparels Ltd. is one of them.
The company had a brand identity for themselves in the RMG sector.

Fakir Apparels started its expedition in 1998 with most comprehensive and strategic
planning supported by sophisticated machinery, latest technology. Skilled
workmanship, substantial marketing, proper discipline and consistent effort from all,
the company entered into the global market.

This company comprises of ultra modern plants related to garments industry such as
independent knitting, dyeing, sewing, finishing and packaging with sufficiently
supportive backward linkage facilities. A huge 10 storied building located in BSCIC,
Narayangonj, and one hour drive from Capital city Dhaka.

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1.3 AT A GLANCE:

• Established: 1998
• Turnover: USD $119 Million (2020)
• Units Shipped: 52 Million units (2020)
• Manpower: 12,000 employees (2020)
• Total Daily Production: 1,80,000 Piece
• Total Area: 13,20,000 square feet
• Production capacity (Knitting): 28 ton per day
• Production capacity (Dyeing): 40 ton per day
• Total Sewing Line: 139
• Total Sewing Machine Used: 3673
• Products: Knits, Outerwear & Sports
• Knit Vertical Integration: Yarn to Style composite
• Final Inspection system: 4 point system

Factory Mission
Our purpose is to generate shareholders value by delivering quality products at the
right time in the most cost effective ways. We will realize this mission by setting the
highest standards in individual and organization performances in the industry and
continuously rewarding achievements.

Factory Vision
Fakir Apparels Ltd's vision is to be Garment Makers to the Best Brands across the
Globe. One of the Top 3 in Bangladesh. We have a tailored vision to be the best in
whatever we do, exceeding customer expectations in quality, value, and service.

Factory Values
 Passionate
 Caring
 Innovative
 Courageous
 Accountable

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1.4 SITE DIRECTION FROM DHAKA

Courtesy: Google Maps

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Construction of Fakir Apparels Ltd

Courtesy: Google Maps

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1.5 KEY PRODUCT

1.6 KEY FABRICS:

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1.7 KEY CUSTOMERS-TOP 5:

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H&M C&A Tom Tailor s.Oliver .Star

2%
8%
12%

19% 59

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1.8 DIFFERENT MAJOR DEPARTMENTS:

To ensure smooth running of various activities, some departments are given

bellow:

1. Knitting department:
a. Knitting
b. Inspection

2. Knit dyeing department:

a. Batch section
b. Store house for dyes & chemicals
c. Washing
d. Quality Control

3. Garments department:
a. Merchandising
b. Cutting
c. CAD Section
d. Sewing
e. Embroidery
f. Sample
g. Printing
h. Packaging
i. Color Lab
j. Dyeing Section
k. Finishing & Delivery

1.9 ORGANOGRAM

The organogram of the administration is as follows:

Organogram of Administration Organogram of

Operation
Chairman Senior manager
↓ ↓
Managing director Assistant manager
↓ ↓
Director Production officer

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↓ ↓
Executive director Shift in charge
↓ ↓
General Manager Supervisor
↓ ↓
Deputy General Manager Senior operator
↓ ↓
Assistant general manager Operator
↓ ↓
Production manager Assistant operator
↓
Helper

1.10 Clients:

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1.11 CERTIFICATES:

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Chapter 2: Knitting
The term knitting describes the technique of constructing textile structures by
forming a continuous length of yarn into columns of vertically intermeshed
loops. It relies heavily on the availability of fine, strong, uniformly spun
yarn. The term ‗knitting‘ dates from the mid-sixteenth century, earlier words
such as the Saxon ‗cnyttan‘ and the Sanskrit ‗nahyat‘ being less precise,
indicating that knitting, probably evolved from sources such as the
experience gained by knotting and Coptic knitting.

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2.1 Knitting Structure:

Knitted structures are progressively built-up from row after row of
intermeshed loops. The newlyfed
yarn is converted into a new loop in each needle hook. The needle then draws
the new loop
head first through the old (fabric) loop, which it has retained from the
previous knitting cycle. The needles, at the same time, release, (cast-off or
knock-over) the old loops so that they hang suspended by their heads from the
feet of the new loops whose heads are still held in the hooks of the needles.
A cohesive knitted loop structure is
thus produced by a combination of
the intermeshed needle loops and
yarn that passes from needle loop to

needle loop.

Figure: Knitting Structure

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2.2 Knitting Layout:

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2.3 Machine List of Knitting Section in FAL:

Machine Name Machine Quantity

Circular Knitting(Single Jersey) Machine 100 (37 used for Terry)
Circular Knitting(Rib) Machine 17
Engineering Stripe Machine 02
V-bed Knitting Machine 10
Grey Fabric Inspection Machine 7

Knitting section is divided in four sections

• Inspection section
• Flat knitting section
• Circular Knitting section
• Store section
2.4 Organogram and Process Flow Chart

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2.5 Types of Knit Fabrics:

In Fakir Apparel they produce Weft knit Fabric .There are two types of weft knit fabric.
They are:
• Single Jersey
• Double Jersey

Single Jersey: Double Jersey:

 Plain S/J  Interlock
 Lycra S/J  1×1 Rib

 Polo pique  2×2 Rib

 Single Lacoste  2×1 Rib

 12×4 Rib
 Fleece
 Drop Needle
 Lycra fleece Rib
 Terry  Lycra rib
 Variegated
Rib

2.6 Types of Yarn Using in FAL:

 Card  Melange
 Combed  Siro
 Compact  Vortex
 Linen  Inject
 Polyester  PL
 Viscose  (Polyester Linen)
 Lyocell  Lurex
 Tencel  Spandex/Lycra
 Modal
 CVC
 PC

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2.7 Knitting Machine Parts with figure :

o Sinker
o Ring
o Feeder
o Sinker Box
o Cylinder
o Needle Box
o Leg
o Wheel
o Gate
o Roller
o Gear Box
o VDQ pulley
Knitting Floor o Handle
o Shaper
o Fan
o Power Board
o Motor
o Needle

Circular Knitting Machine

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2.8 Knitting Parameters:

• loop structure
• loop/stitch length
• CPI
• WPI
• GSM
• Shrinkage
• Spirality
• Fabric width
• Dimensional
• Stability

2.9 Machine Gauge or Needle Gauge:

The number of needles present in one inch of a needle bed is called machine
gauge. It is denoted by G or E.
Yarn Count GSM
30 S 150
28 S 160
Single Jersey 26 S 170
24 S 180
24 Gauge
22 S 190
20 S 200
18 S 210
When we use lower than 18 Count, we use 20 Gauge Machine.
Fabric Type Gauge
Rib Fabric 18 Gauge
Fleece Fabric 20 Gauge(For 2 Thread)
24 Gauge(For 3 Thread)
Interlock 24(Regular)
28 (Special Case)

2.10 Quality Check:

Considerable Points to produce knitted Fabric:
When a buyer orders for fabric then they mention some points related to
production & quality.
Before production of knitted fabric, these factors are needed to consider. These are follows:
2. Type of fabric or design of fabric
3. Fabric composition
4. Finished G.S.M
5. Yarn count

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6. Type of Yarn (combed or carded)

7. Diameter of fabric Stitch length

4 Point system:
4 Point system for fabric inspection is widely used in apparel industry for fabric quality
inspection. To use this system, you have to know following things.
8. Fabric inspection method or preparation
9. Criteria of giving penalty points based on defects and defect length.
10. Calculation method of total penalty points for total defects found in a fabric roll or than
11. A Check sheet or format for recording data
12. Knowledge of different types of defects (how a defect looks and its appearance)
Criteria for giving penalty points:
Size of Defect Penalty Points
Length of defects in Fabric (Either Length or width)
up to 3 inches 1
3 inches < 6 inches 2
6 inches < 9 inches 3
> 9 inches 4
Holes and Openings(Largest dimension)
1 inch or less 2
Over 1 inch 4

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2.11 FLOOR DATA COLLECTION:

Fabric type GSM Yarn count Stitch length M/c Finished

dia x width
Gauge

Plain 115 40/1 2.54 30x2 33‖

8 Tube
Single 135 30/1 2.68 36x2 72‖
4 Open
Jersey 150 28/1 2.75 36x2 74‖
4 Open
160 26/1 2.70 36x2 62‖
4 Open
Lycra H.F.L 32/1+20D 2.85 30 64‖
190 X28 0PEN
Single F.F.L 30/1+40D 2.98 30 64‖
250 X28 0PEN
Jersey 190 32/1+20D 2.85 30 64‖
X28 0PEN
160/65 32/1 2.7 30 43‖
X24 TUBE
210/20 22/1 2.72 28 76‖
X24 OPEN

Single 210/20 22/1 2.75 25 35.5‖TU

X24 BE
Lacoste 220 22/1 2.75 24 66‖
X24 OPEN
220 22/1 2.75 25 66‖
X24 OPEN
215/20 24/1 2.64 32 46‖
X24 TUBE
Lycra 210 28/1+40D 2.85 26 66‖
s/lacost X24 OPEN
160/65 30/1 2.65 30 43‖
X24 TUBE

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Double 160/65 30/1 2,65 28 41‖
X24 TUBE
lacost 160/65 30/1 2.58 30 43‖
X24 TUBE
160/65 30/1 2.52 30 43‖
X24 TUBE
175 34/1 2.54 40 37‖
X18 TUBE
200 30/1 2.52 38 74‖
X18 OPEN
200 30/1 2.64 38 37‖
X18 TUBE
1 X 1 RIB 200 30/1 2.54 38 68‖
X18 OPEN
200 32/1 2.54 38 41‖
X20 TUBE
200 28/1 2.58 38 74‖
X18 OPEN
220 28/1 2.52 38 68‖
X18 OPEN
1X1 Lycra 280 28/1 +70 2.85 34 32‖
X18 TUBE
Rib 380 34/1+70D 3.10 36 34‖
X16 TUBE
2X2 300 24/1 3.3 40 24‖
X18 TUBE
RIB 380 20/1 3.42 40 24‖

X18 TUBE
2X2LYCRA 340 24/1 +70D 3.45 36X1 22‖
RIB 8 TUBE

Pique 220 20/1 2.78 26X2 37‖

4 TUBE
260 30/1 +75D+26/2 K-4,B-3,L-1.5 30X2 68‖
0 OPEN
Fleece 280 34/1 +75D+20/2 K-3.5,B- 30X2 68‖
3.25,L-1.6 0 OPEN
270 32/1+12/1 K-4,B-3.3,L- 30X2 74‖
1.6 0 OPEN

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300 32/1 +12/1 K-4.1,B-3.3,L- 30X2 74‖
1.6 0 OPEN

Lycra 260 30/1+70+26/1+20D K-4,B-3.1,L- 30X2 68‖

1.5 0 OPEN
fleece 260 30/1+70D+26/1+20D K-4,B-3,L-1.5 30X2 OPEN
0

2.12 SPECIFICATION OF MACHINES IN KNITTING SECTION:

Machine no : A01 Machine no: Machine no :A03

Machine type : Single A02 Machine type : Single
jersey Machine type: Single jersey knitting m/c
Circular knitting m/c jersey Circular knitting Brand name : JIUNN
Brand name : JIUNN m/c LONG MACHINE CO.
LONG MACHINE CO. Brand name : JIUNN LTD.
LTD. LONG MACHINE CO. Origin :
Origin : LTD. Taiwan
Taiwan Origin : No of needles :2544
No of needles : 3000 Taiwan No of feeders :102
No of feeders : 120 No of needles :2712 Gauge 24
Gauge 24 No of feeders :108 Diameter :34˝
Diameter : 40˝ Gauge 24
Diameter :36˝

Machine no :A04 Machine no :A13 Machine no :A12

Machine type: Single Machine type: Single Machine type : Single
jersey circular knitting jersey jersey
m/c Circular knitting m/c Circular knitting m/c
Brand name :JIUNN Brand name : Brand name : JIUNN
LONG MACHINE CO. JIUNN LONG LONG MACHINE CO.
LTD. MACHINE CO. LTD. LTD.
Origin : Origin : Origin :
Taiwan Taiwan Taiwan
No of needles :2400 No of needles :2136 No of needles :2756

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No of feeders :96 No of feeders :76 No of feeders :80
Gauge 24 Gauge 18 Gauge 18
Diameter :32˝ Diameter :38˝ Diameter :40˝

Machine no :A11 Machine no :A10 Machine no :A09

Machine type: Single Machine type: Rib Machine type : Single
jersey circular knitting Circular knitting m/c jersey circular knitting
m/c Brand name : m/c
Brand name : JIUNN JIUNN LONG Brand name: JIUNN
LONG MACHINE CO. MACHINE CO. LTD. LONG MACHINE CO.
LTD. Origin : LTD.
Origin : Taiwan Origin : Taiwan
Taiwan No of needles :2484 No of feeders :90
No of needles :2136 No of feeders :88 Gauge 24
No of feeders :76 Gauge 18 Diameter :30˝
Gauge 18 Diameter :44˝
Diameter :42˝

Note:
 A16,A07,A14,A15 no. machines are similar to A02 no. machine
 A04 no. machine is similar to A08 no. machine
 A05,A06 no. machines are similar to A01 no. machine

Machine no Machine no : B02 Machine no : B04

:B Machine type : Single Machine type : Single
01 Machine type : jersey jersey
Single jersey circular knitting m/c circular knitting m/c
circular knitting Origin : Taiwan Origin :
m/c Origin: Taiwan Taiwan Brand name:
Brand name: JIUNN
Brand name: JIUNN LONG JIUNN LONG
MACHINE CO. LTD. LONG MACHINE CO.
LTD. MACHINE CO. LTD.
No of needles
:19 No of needles Dia. : 30˝
68 No of feeders :76 :21 Gauge 24
Gauge 24 12 No of feeders :84 No. of feeders 90
Diameter :26˝ Gauge 24 no of needle: 2256
Diameter :28˝
Machine no : B06 Machine no : B10 Machine no :B12
Machine type : Single Machine type : Single Machine type : Single
jersey jersey jersey
circular knitting m/c circular knitting m/c circular knitting
Origin : Origin : m/c Origin :
Taiwan Taiwan

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Brand name: JIUNN LONG Brand name: JIUNN LONG Taiwan
MACHINE CO. LTD. MACHINE CO. LTD. Brand name: JIUNN
No of needles No of needles LONG MACHINE CO.
:24 :21 LTD.
00 No of feeders :96 36 No of feeders No of needles
Gauge 24 :10 :22
Diameter :32˝ 2 Gauge 20 62 No of feeders
Diameter :34˝ :10
8 Gauge 20
Diameter :36˝
Machine no : B13 Machine no : B15 Machine no : B16
Machine type :Single jersey Machine type : Single Machine type :Single
circular knitting m/c jersey jersey
Origin : Taiwan circular knitting circular knitting m/c
Brand name: JIUNN LONG m/c Origin : Origin :
MACHINE CO. LTD. Taiwan Taiwan Brand name:
No of needles Brand name: JIUNN LONG JIUNN
:24 MACHINE CO. LTD. LONG MACHINE CO.
00 No of feeders :96 LTD.
Gauge 28
No of needles :2712

Diameter :32˝ No of needles No of feeders

:25 :1
44 No of feeders 08 Gauge 24
:10 Diameter :36˝
2 Gauge 24
Diameter :34˝

Machine no : B17 Machine no :B25 Machine no :B27

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Machine type: Single jersey Machine type : Single Machine type: Single
circular knitting m/c jersey jersey
Origin : circular knitting m/c circular knitting
Taiwan Origin : m/c Origin :
Brand name: JIUNN LONG Japan Brand name: Taiwan
MACHINE CO. LTD. FUKUHARA Brand name: JIUNN
No of needles No of needles LONG MACHINE CO.
:28 :18 LTD.
80 No of feeders 84 No of feeders :90 No of needles
:11 Gauge 20 :30
4 Gauge 24 Diameter :30˝ 00 No of feeders
Diameter :38˝ :12
0 Gauge 24
Diameter :40˝

Machine no : B29 Machine no : B30 Machine no : B38

Machine type :Single jersey Machine type : Single Machine type :Rib
circular knitting m/c jersey circular knitting machine
Origin : Taiwan circular knitting Origin :
Brand name: JIUNN LONG m/c Origin Germany
MACHINE CO. LTD. :
Brand name:MAYER
No of needles Taiwan
:31 AND CIE
Brand name: JIUNN LONG
68 No of feeders MACHINE CO. LTD. No of needles
:12 :16
No of needles
0 Gauge 24 :33 96 No of feeders :66
Diameter :42˝ 12 No of feeders Gauge 18
:13 Diameter :30˝
2 Gauge 24
Diameter :44˝
Machine no :C07 Machine no : C05 Machine no : C04
Machine type : Rib Machine type :Rib circular Machine type : Rib
circular knitting m/c knitting m/c circular knitting m/c
Origin: Taiwan Origin : Taiwan Origin : Taiwan
Brand name: JIUNN Brand name: JIUNN LONG Brand name: JIUNN LONG
LONG MACHINE CO. MACHINE CO. LTD. MACHINE CO. LTD.
LTD. No of needles :1800 Dia. : 42˝
No of needles :2040 NoNo
of of
feeders
feeders :72 Gauge
:64 18
Gauge: 18
Diameter :36˝ Gauge 18 No. of feeders :84 No of
Diameter :32˝ needle : 2376

Machine no : C03 Machine no : C01 Machine no :C08

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Machine type: Rib Machine type : Rib Machine type : Interlock
circular knitting m/c circular knitting m/c circular knitting m/c
Origin : Origin : Taiwan Origin :
Taiwan
NBrand name: JIUNN Brand name: JIUNN LONG Taiwan
oLONG MACHINE CO. MACHINE CO. LTD. Brand name: JIUNN LONG
t LTD. No of needles :2136 MACHINE CO. LTD.
eNo of needles :2256 NoNo
of of
feeders
feeders :80 Gauge
:76 18
No of needles :2880
: Diameter :40˝ Gauge 18 No of feeders :72
 C Diameter :38˝ Gauge 24
0 Diameter :38˝
9
,

C
1
0 no. machines are similar to C07no. machine
 C06 no. machine is similar to C05 no. machine
 C02 no. machines are similar to C01 no. machine
 C17,C11,C13 no. machines are similar to C16 no. machine

Specification of Auto stripe machine:

Machine Brand name No. of Gauge Diameter Mfg. Model

no. needle (Inch) country
C19 FUKUHARA 2268 24 34 JAPAN VX-
R8Y3RE
C18 FUKUHARA 2245 18 34 JAPAN V-FY6

Auto rib striper

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Auto S/J striper

Remarks:
All the machines are well arranged and availability of sufficient
spaces among the machines facilitates the movement of personnel
and smooth production.

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Chapter 3: Batch

―A group of units of products of the same type, structure, color and finish,
class and composition, manufactured under essentially the same
conditions and essentially at the same time, and submitted at any one time
for inspection and testing.‖
Types of Batching:
 Solid batch
 Ratio batch

Proper batching criteria

 To use maximum capacity of existing dyeing Machine.

 To minimize the washing time or preparation

time & Machine stoppage time.
 To keep the no. of batch as less as possible for same
shade.

 To use a particular Machine for dyeing same shade.

Machine used in the batching:

 Back sewing Machine: Used to form tube

fabric form from open fabric.
 Reverse sewing Machine: Used only for single jersey

 fabric to replace the back part with front part in dyeing of critical shade.

𝐁𝐚𝐭𝐜𝐡 𝐐𝐮𝐚𝐧𝐭𝐢𝐭𝐲 𝐅𝐢𝐧𝐢𝐬𝐡𝐞𝐝 𝐃𝐢𝐚 𝐐𝐮𝐚𝐧𝐭𝐢𝐭𝐲

Batch Calculation:
𝐓𝐨𝐭𝐚𝐥 𝐐𝐮𝐚𝐧𝐭𝐢𝐭𝐲

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Chapter 4: LAB Section

4.1 Physical Lab test name:

• Dimensional Stability
• Color Fastness to Wash
• Color Fastness to Perspiration
• Color Fastness to saliva
• Yellowing
• TCI Pilling
• BATCH CARD
• Yarn Twist Test
• Yarn Strength Test
• Yarn evenness test
• Bursting Test
• Abrasion Test
• Drape Test
• Shrinkage Test
• Special Property Test

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4.2 Different types of test equipment for physical test:

1. Equipment name: Busting strength tester

Brand name: James Heal
Model: 1440
Process: mechanical

2. Equipment name: ICI Pilling tester

Brand: SDL ATLAS
Process: mechanical

3. Equipment name: Tumble Pilling tester

Brand: James Heal
Process: mechanical

4. Equipment name: Thermohygraph

Process: temperature and humidity test ( mechanical)

5. Equipment name: Color fastness to rubbing

Brand: James Heal
Process: mechanical

6. Equipment name: Digital weighting balance

Process: mechanical

7 .Equipment name: GSM cutter

Process: mechanical

8. Equipment name: Midi martindale Pilling tester

Process: mechanical
Brand: James Heal

9. Equipment name: Wrap Red machine

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Brand: MAG
Process: mechanical

10. Equipment name: yarn twist tester

Process : mechanical

Pilling Test Machine

Bursting Test Machine

4.3 Analytical Lab:

• pH Test
• Nickel Test
• Corrosion Resistance Test
• Fiber Composition Test
• Polyester Remove Test

4.4 Color Lab:

The color lab is the heart of the factory for dyeing. Lab dip development is done in the
dyeing lab. We know from the previous article that lab dip is a particular garment style
containing many shades of the fabric color that the buyer is asked to have to be sent to
the buyer for approval before further production. The higher precision lab can aid
easily to achieve the goal of the dyeing mill. Before bulk production, a swatch of fabric

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test dyed to hit a color standard. It is a process by which the buyer is supplied swatch
is matched with the percentage of the varying dye in the laboratory with or without the
help of

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a spectrophotometer. For doing all tests, different equipment is used in the dyeing lab.
In this article, I will discuss the different aims of the dyeing lab, the working process of
the dyeing lab, and the different types of machines used in the dyeing lab.

• Process Flowchart

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Machinery
• C.C.M. (Computer color matching) Software used: Color i7

• A.G.S. Macbeth Spectralight-III

• 2 Roll laboratory padder [Vertical + Horizontal] by Mathis

• Laboratory steamer by Mathis

• Dispenser by Tecnorama

• Infrared (I.R.) Lab Dyeing Machine

• High-Temperature Lab Dyeing Machine

• Oscillation Dyeing Machine

• Lab Jig Dyeing Machine

• Gyro-Wash

Automatic Dipensing Machine (Dyes)

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Chapter 5: Dyeing Section
5.1 INTRODUCTION:

The objective of dyeing is the uniform coloration of the mass of fibers constituting the
material,
usually to match a pre-specified color. Any significant difference in color from that
requested by the customer, and any unevenness of the color of a fabric, will be
immediately apparent. Many factors can influence the final color appearance.
These include fiber characteristics such as the luster, denier, and staple length, texture,
and cross-section, as well as the cloth construction. Since a client‘s colored sample is
rarely of the same material as that to be dyed, dye house laboratories devote
considerable time to dyeing trials aimed at developing recipes to reproduce the
desired color on the given goods. Coloration of a textile material is achieved in a
number of different ways:
 Direct dyeing, in which the dye in the aqueous solution in contact with the
material is gradually absorbed into the fibers because of its inherent
substantively

 Dyeing with a soluble precursor of the dye, which forms an insoluble

pigment deep within the fibers on treatment after dyeing

 Direct dyeing followed by chemical reaction of the dye with appropriate

groups in the fiber;

 Adhesion of the dye or pigment to the surface of the fibers using an

appropriate binder.

All of these methods but the last require that the fibers, at some stage, absorb the dye,
or an appropriate precursor, from an aqueous solution. This process is essentially
reversible. Note, however, that precipitation of a pigment and reaction with the fiber
are irreversible chemical processes.

5.2 Theory of Dyeing:

Dyeing theory covers a wide range of subjects mainly in the area of physical
chemistry. As for all theory, the aim is to provide a set of hypotheses that explain
the behavior of known dyeing systems, and which are capable of predicting what will
happen in a new situation. Dyeing theory has many qualitative aspects that are useful
in explaining practical dyeing, but the physico-chemical measurements on dyeing
processes that provide quantitative data are often far removed from actual dyeing
practice. Some of the subjects included in dyeing theory are:

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1. The state of dyes in solution and in the fiber during and after dyeing
2. The rates of dyeing processes and how these are influenced by mass-
transfer of dye from the bath solution to the dye–fiber interface, and by
diffusion of the dye from the interface into the fiber
3. The phenomena occurring at the dye–fiber interface such as dye
molecule adsorption and the effects of surface potentials
4. The nature of the interactions between dye and fiber molecules, which
are the origin of substantively
5. The treatment of dyeing as a thermodynamic equilibrium and its
description in terms of thermodynamic variables
6. The theory of fiber structure and how this influences dyeing
rates and equilibrium.

5.3 DYEING IN FAKIR APPARELS LTD.:

In Fakir Apparels Ltd. dyeing process mainly occurs in discontinuous process. That‘s
why here process is very easy and can be described with easy manner. Here order is
mainly comes for knitted fabric dyeing like single jersey, double jersey, Lycra single
jersey, terry or locust fabric, mainly produced from cotton or polyester. That‘s why
here mainly two dyes are used.
2. Reactive dyes for Cotton
3. Disperse dyes for Polyester.
Besides this pigment dyeing is done for garment dyeing.

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5.4 Dyeing Floor Layout :

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5.5 Dyeing Machine Capacity:

Machine Number Capacity in KG Machine Number Capacity in KG

Machine Number : 1 750 Kg Machine Number :10 1500 Kg
Machine Number : 2 750 Kg Machine Number : 11 1500 Kg
Machine Number : 3 750 Kg Machine Number : 12 1500 Kg
Machine Number : 4 500 Kg Machine Number : 13 1000 Kg
Machine Number : 5 500 Kg Machine Number : 14 1000 Kg
Machine Number : 6 500 Kg Machine Number : 15 1000 Kg
Machine Number : 7 500 Kg Machine Number : 16 750 Kg
Machine Number : 8 250 Kg Machine Number : 17 250 Kg
Machine Number : 9 1500 Kg

5.6: Fabrics Used For Dye In Fakir Apparels:

• Single Jersey
• Single Jersey with
• Polo Pique
• Waffle
• Single Lacoste
• Double Lacoste
• Lycra
• Fleece
• Rib
• Rib with Lycra
• Variegated Rib
• Interlock

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Fabric unloading

5.7 Duties & Responsibilities:

• Overall supervision of dyeing, finishing production Checks the different log books of
different areas & report to management.
• Checks the sensitive parameters of different machine for smooth dyeing.
• Checks out the plan to control the best output from supervisor & workers.
• To trained up & motive the subordinates how to improve the quality production.
• Maintenance of machine & equipment. Any other works & when required by the
• management.
• Control the supervisors, operator, asst. operator & helpers of dyeing Machine.

5.8 RAW MATERIALS FOR DYEING:

Reactive dyes:

Sunsol Black EPHC 1000 $ 4.70

Sunfix Yellow S3R 1500 $ 4.70
Sunfix Red S3B 150% 1500 $ 7.50

Sunfix Navy SBF 1000 $ 4.00

Sunsol Black B 1000 $14.50
Sunfix Yellow SN2R 500 $18.55
Sunfix Red SN2BL 500 $20.65
Sunfix Blue SNR 1000 $ 8.50

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Sunfix Yellow SPR 100 $ 7.50
Sunfix Red SG 75 $20.50
Sunfix Blue SBRN 1000 $ 9.62
Sunfix Red MFD 200 $ 5.65
Sunfix Yellow MF-3RD 1500 $ 5.00
Sunfix Yellow SPD conc 2000 $ 5.00
Sunfix Red SPD 2000 $ 7.30
Sunfix Navy SPD 2000 $ 8.90
Sunfix Yellow S4GL 150% 300 $18.50
Sunfix Yellow SF 50 $18.50
SunfixBlu SF 50 $14.60
Sunfix Red SF 100 $ 5.50
Sunfix Red S2B 50 $18.20
Sunfix Scarlet S2G 50 $ 8.60
Sunsol Violet 5R 50 $10.50
Sunsol Blue R Special 300 $10.50
Sunsol Turq Blue G 266% 150 $ 7.55
Sunsol Orange SRN 50 $ 7.95
Sunsol Yellow SRN 100 $ 8.65
Sunsol Red SBN 100 $16.50
Sunsol Blue BB 133% 100 $12.10
Sunsol Blue SRN 100 $ 7.20
Bezaktive Black S Max 4000 $ 6.80
Bezaktive Red S3B 500 $ 7.80
Bezaktive Yellow S3R 500 $ 7.80
Bezaktive Red SLF 100 $23.20
Bezaktive Orange SRL 200 $11.30
Bezaktive Turquoise Blue 200 $ 6.00
Bezaktive Blue SGLD 600 $17.20
Besaktive Blue SLF 150 $17.20
Bezaltive Yellow SLF 150 $11.80
Bezaktive Yellow S8G 100 $12.80
Bezaktive Black SLF 1000 $15.50
Bezaktive Navy SLF 500 $20.70

Disperse dyes:

Disperse Yellow 8GFF200%

Taicron Black HWTECO

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Taicron Black WW-GST
Taicron Blue2RHWT
Taicron Blue EACT
Taicron Blue XFT
Taicron Bril BlueSE-GLT
Taicron Deep Red XF-T
Taicron Golden yellow WRST
Taicron Navy Blue HWT
Taicron Navy Blue XF-T
Taicron Red E-ACT

CHEMICALS:

Acid buffer Anticreasing Anti foam Basic Cationic

chemicals softner
Eulysin S Ac-200 Antifoam AFJ Acetic acid Belfasin 44
cone
Merapen KP Biavin-109 Kappasol Caustic soda
AF2000
Breviol PAM- Gluber salt
N
Detergent Kappavon CL Fixing Agent Hydrogen Levelling
peroxide agent
E.WetWell Primasol Jet Albafix ECO Soda Ash Kappaquest
A41
Foryl BGL Rucolin JES Fixos FDR Lekol SN
Kappawet Hydrocol Sun Levegal RL
BOS
Rucozen NZA KappafixGG100
Rucozen Lamfix -L
WBL
Wetto NOF
Neutralizer Non ionic OBA for cotton Peroxide Killer Levelling

softner (Polyster)
Heptol DBL Perapret F- Kappaphor-ME Pk-20 Croscolor
PEB PLD
Heptol EMG Tubingal- Syno white 4BK Verolan NBO Satavin
1112 SUE
Neutracid Tuboblanc HV- Visco color
NVM S3

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Tuboblanc Rub
Tuboblanc –
EBF
Tuboblanc-
HAPD
Ultraphor -PFA
Enzyme Sequester Resin Silicon Softner Soaping
HDL160 AntisilConz Condensole- Adasil ME Avolan IS
FAM
Retrocell Plx Chelate DBC Fixapret F-ECO Antipil Jet Cyclanon
xc
–W
Chemsoft Lurotex Kappasoft BD DSP-1250
MAK-P TX2504
Kappaquest – Perapret Kappasoft – Setamol
FE Booster SM WS
Securon-540 Polyavain-LPE
Ultratex S
Stabilizer Stripping Utility
agent
Contavan GD Dyapol ECO Biocide LF2
Stagen B Meropan- Biocide TS15
RED
Sodium Common salt
Hydrose
Sodium
hypocloride

REMARKS:
Fakir Apparels ltd. uses best quality raw materials. It produces fabrics
from best quality yarn. They use the best quality dyes like
REMAZOL, REACTRON, REACTIVE, TERACIL etc. During the
time of using dyestuff

they give importance upon the quality of dyes than the price of the
dyes and chemicals.

5.9 DYEING MACHINERIES IN FAKIR APPARELS LTD.:

In Fakir Apparels ltd there mainly two types of machines .One is winch dyeing
and another is jet dyeing machines. There are two floors or two section of
dyeing. Such as

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Dyeing floor 1: This floor consists of 13 machines of well equipped high-tech

such as ATYC from Spain, THIES from Germany, FONGS from China, and
AK from Taiwan.

Dyeing floor 2: This floor also consists of 9 machines including sample dyeing
machine with mentioned company made. Here total capacity 25000 kgs/day.

Dyeing Floor -01

SL Brand Origin Capacity(kg) Max.Temp

1 ATYC SPAIN 300 135
2 ATYC SPAIN 600 135
3 ATYC SPAIN 600 135
4 ATYC SPAIN 900 135
5 Fong's CHINA 1000 98
6 Fong's CHINA 1000 98
7 AK TAIWAN 200 98
8 AK TAIWAN 200 98
9 Fong's CHINA 1500 98
10 Fong's CHINA 1500 98
11 Thies Germany 480 98
12 Thies Germany 300 98
13 Thies Germany 700 98
S2 ATYC SPAIN 80 135
S3 Fong's CHINA 100 130
S4 Fong's CHINA 30 130
S5 Fong's CHINA 30 130
S6 Fong's CHINA 12 130
S7 Fong's CHINA 12 130

©Daffodil Intern

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Fig: New Machine (ATHENA 2) appointed in floor 2 in Fakir Apparels

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5.10 SCOURING, BLEACHING, ENZYME WASH:

Scouring-bleaching is carried out in the same bath and at the same time

simultaneously.

Bleaching is not carried out for black shade.

Scouring is carried out for every type of shade.

Scouring-Bleaching chemicals:

Agent Brand g/l used

Wetting agent Sandoclean PCLF 1

Alkali Caustic soda 2

Ant creasing agent Romapon 173 .5

H O
Bleaching agent ² ² 2

Stabilizer Stab.soft 0.5

Acid Acetic 2
aci
d

(Neutralization)

Firstly the fabric is load on to

the bath. Required amount of
water is taken to the bath.
Wetting agent i.e. PCLF, & anticreasing agent i.e.Romapon is added.
Steam pipes are on & scouring agents (i.e., caustic soda/soda

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ash) added by the aid of dosing when the temperature

When thetemperature reaches at then stabilizer is added.

Then H202is added by the aid of dosing system in 10 mins
and the material is run for 10-15 mins to reach the temp.

carried out for 30 mins depending on the requirements.

The liquors are the drained at

ENZYME WASH:

To remove hairiness from the material.

This treatment can be done before dyeing & after dyeing.

Sometimes double enzyme treatment occurs if buyer

wants.

The fabric knitted with carded yarn always requires enzyme

wash for obtaining combed effect by biopolishing. This

process is very sensitive to PH (4-5) & temperature.

Cotton dyeing:

Shade% Dye selection Temp.

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Light shade (<0.5%) Drimarine 60

Medium shade(0.5-1.5%) Reactive 60-65

Deep shade(>1.5%) Reactive 60-65

Turquish shade Reactive 70-80

 Deep shade: Navy, Red, Black, Green, etc.

 Medium shade: Khaki, Yellow, Blue, Orange, Olive, Royal, etc.

 Light shade: Sand, Beige, Stone, Pink, Rose, Purple, Rose petal, etc.

 Sensitive shade: Red, Black, and Turquish.

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Chapter 6: Washing
6.1 Introduction:

The process by which we remove dust, dirt, germs, and impurities from completed apparel
and get some washing effect as per buyer requirement is known as apparel washing. With
the change of time, human choice, demand, garment design, and fashion are changing very
quickly. To meet the demand of users, garment manufacturers are adopting new processes
and technologies. Therefore, garment washing is an important technology to modify
appearance, outlook, comfortability, and fashion.

6.2 Objectives:

• To remove dust, dirt, waste materials, impurities, germs, and harmful

materials from garments.
• To remove sizing materials from garments
• To get various fading/washing effects as per buyer demand.
• To change the appearance of garments.
• To increase the brightness of garments.
• To increase smoothness and make the garments soft and handy.

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6.3 Process Flowchart:

6.4 Types of Wash Used in Washing Section:

Mainly washing is divided into two major classes- wet

and dry. Various types of washing are given below

 Normal wash
 Rinse wash
 Silicone wash
 Pigment wash
 Caustic wash
 Acid wash
 Bleach wash
 Stonewash
 Enzyme wash
 Super white
 Perlite wash
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 Antique wash
 Oil wash
 Panel wash
 Wrinkling
 Sandblasting

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Chapter 7: Sample Section
7.1 SAMPLE:

 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 we can say a part which shows
that the whole is look like.
 Conform with any specific requirement
 Sample is the physical form of design.

7.2 FLOW CHART OF SAMPLE DEPARTMENT:

Sketch/de
sign
(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

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appoved
sample
(Sample approved by buyer)

Costing

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.

Problem of Production or Production Related Matter:

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 is done, then the garments are sent to buyer.

Production Pattern:
To make pattern for a particular style with net dimension along with allowance.

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7.3 SAMPLE TYPE:

1. Development sample
2. Salesman Sample
3. Photo Sample
4. Approval Sample
5. Size set Sample
6. Mock up Sample
7. Pre-production Sample
8. Production Sample
9. Shipping Sample

7.4 The Details Attached to the Garment Sample:

After the confirmation of order, each sample sent to the buyer has the following
details attached to it, with the help of a tag. It contains the details pertaining to both,
what the buyer has demanded and what supplement fabric/trim etc they have used (if
applicable).

 Ref no.
 Color
 Fabric
 Composition
 Description
 Quantity
 Style no/ Size
 Store

There may be a separate sampling department in a company. But as the

merchandiser is the person who is interacting with the buyers regarding
samples and other requirements, this sampling department will work under the
supervision of merchandising department. Also as the samples are to be made
according to the buyers‘ price ranges and quality levels, merchandiser has to

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advise sampling department suitably.

In the sample section there are different types of department need to

be overcome for sampling. The entire department thoroughly
discussed in following:

7.5 PATTERN MAKING:

Pattern is the one of important element of a design. In a garment industries there are
two type of pattern uses based on their capability. Mostly big companies are use CAD
(Computer aided design) as well as little companies‘ uses manual pattern. In FAL use
CAD also manual pattern in some cases. Basically INVESTRONICA Software uses
here. There are 10-12 high skilled pattern masters working here.

7.6 MARKER SECTION:

In FAL marker is made both manual system & automatic system. In computer aided
marker FAL use INVESTRONICA software. In manual marker making process,
marker man use pattern paper to draw different garments parts in marker paper.

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Fig: Marker making machine (Plotter M/C)

7.7 FABRIC SPREADING:

Fabric spreading is very important part of the production process because it is

basic for obtaining a high quality final product. Spreading is the process of
unwinding large rolls of fabric onto long, wide tables in preparation for cutting
each piece of a garment. The number of layers of fabric is dictated by the
number of garments desired and the fabric thickness. Fabric Spreading
Machines are used for bulk production.

Objectives of spreading process:

 Understanding the process of fabric spreading

Factors affecting spreading
 Face and nap of the fabric

Number of plies depends on:

 Capacity of the cutting machine

 Volume of production.
 Type of fabric itself (rough or slippery).
 Thickness of fabric.

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Types of Fabric Spreading:

The spreads can be of two basic types:

1. Flat spreads- all plies are of the same length.

2. Stepped spreads- this as the name suggests, is built up in steps, with all the
plies in one step having the same length. A stepped spread is generally used
when the quantities to be cut precludes the use of a flat spread. The cut order
plan details the colors and ply lengths for a stepped spread, if it is needed.

Ideal Lay height of Cutting

Heavy Weight 4-5" 5-4"

Med Weight 3-4" 3-3.5"

slights Weight 2.5- 2-

3" 2.25"

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Chapter 8 : Cutting Section

8.1 Introduction:
Cutting is the major operation of the cutting room, when the spread fabric is
cut into garment components. Of all the operations in the cutting room this is
the most decisive, because once the fabric has been cut, very little can be done
to rectify serious mistakes. Cutting can be done manually using powered
knives or by computer-controlled system.

8.2 Cutting Flow Chart:

Fabric received

Cabric relaxation

Original sample received

Pattern making

Marker making

Fabric spreading

Marker placing

Cutting

Numbering and country sticker

Cut pannel check

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Replace cut pannel

Bundling

Send to print / embroidery if required

Sewing input

8.3 Factors affect the cutting process for fabrics are as follows:
 Nature of fabric (grain line shade, twill etc.)
 Thickness of fabric.
 Design characteristics of finished garment.
 Machines and tables used.

8.4 DIFFERENT TYPES OF CUTTING MACHINE:

1. Straight knife cutting m/c,

2. Band knife cutting m/c,
3. Round knife cutting m/c,
4. Die-cutting m/c,
5. Notcher cutting m/c,
6. Drill cutting m/c,
7. Computer-controlled knife cutting m/c,
8. Laser beam cutting m/c,
9. Water Jet cutting m/c,
10. Plasma torch cutting m/c.

8.5 Features Of Cutting Machine:

1. Straight Knife Cutting Machine:
Features of Straight Knife Cutting M/C:

 Here, the knife is driven by using electric power.

 Straight edge is mostly used in the straight knife.
 Here, blade stroke varies from 2.5 to 4.5 cm.
 During cutting, the grinding wheel helps to sharpen the cutting knife.
 Blade edge: straight edge, wave edge, saw edge, serrated edge
 This type of knife can cut heavy fabric i.e. canvas

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
2. Band Knife Cutting Machine:
Features of Band Knife Cutting M/C:

 This type of knife consists of a series of three or more pulleys that are powered by an
electric motor.
 The band knife blade is normally narrower than the straight knife.
 Here, the cutting knife is endless in shape and also flexible.
 It is one kind of sawmill cutter.

3. Round Knife Cutting Machine:

Features of Round Knife Cutting M/C:

 Some key elements of round knife fabric cutting machines are base plate, electric motor,
circular blade, etc.
 The band knife blade is circular.
 Band knife blade diameter ranges from 6 to 20cm.
 This type of blade is driven by electric power

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4. Computer Controlled Knife Cutting Machine:

Features of Computer Controlled Knife Cutting M/C:

 The computer-controlled knife cutting method provides the most accurate possible cutting
at high speed.
 Here, the cutting knife is very hard and oval-shaped.
 During cutting, the marker is not needed to put over the fabric lay.
 A cutting blade is made of stainless steel.
 The sharpness of the knife is also high here.
 This type of fabric cutting machine followed the CAD (computer-aided design) system.
 The cutting knife itself moves according to the direction of the computer program.

5. Laser Beam Cutting Machine:

Features of Laser Beam Cutting M/C:

 In the case of laser beam fabric cutting machines, the cutting head is controlled by a
computer.
 Here, the fabric is cut at a speed of 13m per minute.
 In the case of this cutting process, the fabric is cut by a ray of light in a very fine spot using
a laser.
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 When the ray falls on a material, it generates heat on the material, and the cutting process
is done by vaporization.
 The radius of the spot of light is 0.25 mm which is highly powerful.

8.6 Factors involved in Cutting Fabrics:

Factors affect the cutting process for
fabrics are as follows:-

 Nature of fabric (grain line shade, twill etc.)

 Thickness of fabric.
 Design characteristics of finished garment.
 Machines and tables used.

8.7 WORKING PRINCIPLE OF STRAIGHT KNIFE AS CUTTING ACCESSORIES:

The Working Principle of Straight Knife of Garment Manufacturing which is

used on Cutting Section is as below-
1. Firstly, switch on this cutting machine.
2. Then, place the cutting machine at any corner of the table.
3. Then switch on the blade.

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4. Then the operator moves the machine by hand through the stationary
fabric layers and cut along marker lines until finish the marker.

8.8 Different type of fabric fault:

1. Knot
2. Slub
3. Holes
4. Spot
5. Thick & Thin Places
6. Dirt & Stains
7. Oil stain
8. Missing yarn

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Chapter 9 : Embroidery Section
9.1 Introduction:

Embroidery is an embellishment process in the field of garments production. After

cutting has been done, the cut panels are sent to the embroidery department, and as per
the design supplied by the buyer, the authority finalizes the design, and then bulk
production begins. It is the craft of decorating fabric or other materials using a needle
to apply thread or yarn. Embroidery may also incorporate other pearls, beads, quills,
and sequins. In modern days, embroidery is usually seen on caps, hats, coats, blankets,
dress shirts, denim, dresses, stockings, and golf shirts. Embroidery is available with a
wide variety of thread or yarn colors. The basic techniques or stitches of the earliest
embroidery are chain stitch, buttonhole or blanket stitch, running stitch, satin stitch,
cross-stitch. Those stitches remain the fundamental techniques of hand embroidery
today.

Embroidery floor

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9.2 Process Flowchart:

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9.3 Type of Embroidery:

9.4 Common Faults in Embroidery:

• Stitch Gap

• Color Missing

• Fabric Grin/Gapping
• Poor Stitch Balance
• Fabric Damage
• Thick or Thin Embroidery

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Chapter 10: Printing Section
10.1 Flow chart of printing:

Bulk cut panel received from cutting

Fabric preparation

Impress on fabric

Drying the printing fabric

Fixation by curing

Washing and soaping

Finally dry

Delivery

10.2 Types of Printing:

 Rubber printing  Volcanic printing

 Foil printing  Discharge print
 Pigment printing  Puff print
 Metallic printing  Plastisol print
 Flock printing  Crack print
 Photo printing  Sticker/transfer print
 Burnout printing  Reflective Print
 Glitter Printing
 Silicon printing
 High density printing

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10.3 Common Print Defects:

 Measuring fault
 Print missing
 Wrong color
 Hand feel not correct
 Color migration problem
 Not Properly Attach

10.4 Major Causes of Print Defects:

 Screen & print body are not in same axis

 Irregular wash of screen frame
 Wrong color recipe
 Insufficient drying of previous color
 Inaccurate composition of fixture
 Improper heat & pressure
 Dirty environment

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10.5 The Basic Ingredients of Printing are as follows:

 Dyestuffs and Pigments.

 Thickener.
 Acid or alkali or acid liberating agents.
 Carrier or swelling agents.
 Solvents or solution acids or dispersing agents or humectants.
 Antifoaming agents or de-foaming agents.
 Wetting agents.
 Catalyst or oxygen carrier.

Printing Section

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Chapter 11 :Sewing Section

11.1 Introduction:
This is the main assembly stage of the production process, where sewers stitch fabric
pieces together, and a garment is assembled. Computerized sewing machines (costly),
can be programmed to sew a specific number of stitches to perform a standard
operation, such as setting a zipper or sewing a collar.

11.2 Flow chart of sewing:

Production,Preparation and Process

Collect duplicate counter sample

Floor PP meeting

Cut panel received

Randomly cut panel check

Part matching

Line layout

Bulk production (follow SOP)

Process QI

All reports making

End table QI check

Good audit randomly

Garments sucking

Counting and sizing

Send to finishing

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11.3 Sewing Machine used:

• Single Needle Lock Stitch Machine
• Overlock Sewing Machine
• Flatlock sewing machine
• Button Attaching Machine
• Feed off the Arm
• Button Hole Machine
• Bartack machine
• Zigzag sewing machine
• Multi-needle chain stitch machine
• Double needle lock stitch machine

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11.4 Stitch Used for sewing:

 Back tack
 Backstitch
 Basting stitch (US)
 Blanket stitch
 Blind stitch
 Buttonhole stitch
 Chain stitch
 Cross-stitch
 Catch stitch
 Darning stitch
 Embroidery stitch
 Hemstitch
 Overcast stitch
 Pad stitch
 Pick stitch
 Running stitch
 Sailmakers stitch
 Slip stitch
 Stoating
 Straight stitch
 Tack
 Tent stitch
 Topstitch
 Whipstitch
 Ladder stitch

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fig : SEWING SECTION

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11.5 Sewing Machine Description:

1. Single Needle Lock Stitch Machine

This machine makes lock stitches (stitch class 301). Lock stitches are formed with one needle thread
and one bobbin thread. This is a widely used sewing machine and used for sewing stitch class 301.
Basic to computer-controlled version is available in this machine category.

Purpose: Single needle lock stitch machines are used for joining two or multiple fabric plies together.
The machine is used to sew lightweight, medium weight, and heavy materials.

2. Overlock Sewing Machine

Overlock machines are available in 3 threads, 4 threads and 5 threads over edge sewing. An overlock
machine can form various types of stitches like stitch class 503, stitch class 504 and stitch class 512.

Purpose: This machine is used for serging garment panels (for example: trouser panels serging) and
for overedge stitch. These types of machine are mostly used in knitted garment sewing for overedge
stitch. Like side seam stitch of a t-shirt is done using an overlock machine.

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3. Flatlock sewing machine

machine is called a cover-stitch sewing machine. Flatlock sewing machines normally come with 2-3
needles. For the bottom cover stitch machine 2 needle threads pass through the material and inter
loop with 1 looper thread with the stitch set on the underside of the seam. Flatlock sewing machine
form stitches like Stitch class 406.
Usage of these machines: Flatlock machines are used for hemming sleeve and bottom of the knits
products. A cover-stitch machine can be used in any part of the garment for decorative purpose

4. Button Attaching Machine

A special machine used only for stitching button in a garment. different sizes of button can be
attached in same the machine by changing the settings.

5. Bartack machine
Bartack stitch is made to reinforce the seam and garment component. Like in belt loop joining and at
the bottom of side pocket opening bartaking is done.

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6. Button Hole Machine

This machine is used for making buttonholes on garments. Buttonholes can be made with different
stitch densities. Like in Shirts, Trousers, and Polo Shirts etc.

7. Zigzag sewing machine:

This machine is used for zigzag stitching. Used in bra manufacturing, jacket manufacturing.

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11.6 MACHINE WISE SEWING THREAD CONSUMPTION (FOR 1"STITCH):

Machine wise sewing thread consumption per inch are gives in bellow:
Machine No. of needle Thread consumption
per inch

Plain 1 2.5”
Plain 2 5”
Over lock 3 16”
Over lock 4 18”
Over lock 5 21‖
Bar tack ----------- 7‖---8‖
Button hole stitching ----------- 6‖—7‖ normally per
hole

Button attaching 2 hole ---------- 4‖ per button

Kanshai Stitching ---------- 4‖ per one needle

11.7 DIFFERENT TYPES OF SEAM DESCRIPTION:

Superimposed Seam (SS):

The superimposed seam is achieved by two or more separate pieces of

together. This is the one of the most common method of seaming.

Lapped Seam (LS): Lapped seam is made with two or more pieces of fabric
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overlapping each other. LS commonly, but not always, have one ply of fabric
fold under itself for a finished edge.

Bound Seams (BS): Bound seam is made to finish and edge of a garment. A
common example of this would be a neckline of a Crew T.

Flat Seam (FS): A flat seam is constructed by having two pieces of fabric
meet precisely at their edges. A cover stitch is used to sew the two pieces of
fabric together.

Edge Finished Seams (EF): This seam is used to prevent the edges of the
fabric from rolling or curling. Primarily used for knit fabrics and is suitable for
straight or curved seams and edges.

Ornamental Seam (OS): This seam is made using machines with zigzag
capability. It is used on a plain seam on woven or knit fabric.

Stitch Defects Seam Appearance Defect

Loose Stitches Puckers
Poorly formed stitches Twists
Crowded stitches Plaits
Tight stitches Undulations
Crooked stitches Run-off (raised seams)
Skipped stitches Raw edges exposed (felled seams)

11.8 DIFFERENT TYPE OF SEWING FAULT:

 Skip/ Drop stitch

 Uneven stitch
 Over stitch
 Joint stitch
 Raw edge
 Tension loose
 Broken stitch
 Puckering
 Run off stitch

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11.9 T-Shirt Manufacturing Process:

1. Both part sticker match and sleeve and body sticker match (manual)

2. Both shoulder join and trim (O/L)

3. Rib tack and fold (S/N)

4. Neck join (O/L)

5. Back neck piping (F/L)

6. Back neck top stitch with label (S/N)

7. Sleeve joining (O/L)

8. Side seam with care label (O/L)

9. Bottom hem,sleeve hem (F/L)

10. Trimming

11.10 Pierce pant manufacturing process: Jogging

1. Pocket making (OL4T)

2. Pocket join with body (single needle)

3. Pocket side tuck ( single needle)

4. Side Seam (OL4T)

5. Side top stitch (flat lock)

6. In Seam ( OL4T)

7. Button hole making (first stitch then make hole)

8. Waist belt join with elastic ( OL4T)

9. Leg elastic join (OL4T)

10 .Main label, care label and size label joining (SNLS)

11. Waist band elastic pressure

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12. Waist top stitch ( kansai)

13. Leg elastic hemp ( flat lock )

14 .In Seam bartack

15 .Trimming ( use to cut extra thread)

11.11 Manufacturing process of suit shirt:

1. Cut panel gathering

2. Shoulder join and trim (OL4T)

3. Shoulder top stitch ( flat lock cylinder bed)

4. Rib tuck and folding( single needle lock stitch)

5. Neck join (OL4T)

6. Back neck to stitch

7. Sleeve join (OL4T)

8. Arm hole top stitch ( flat cylinder bed)

9. Side Seam both side

10. Bottom hem join

11. Cuff hem join ( OL4T)

12. Bottom hem top stitch( FLCB)

13. Cuff hem top stitch( FLCB)

11.12 Hoodies Manufacturing process:

1. Body insert and hood and body sticker match (manual)

2. Pocket hem join (S/N)

3. Zipper facing overlock, trim and fold (O/L)

4. Pocket join with body

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5. Both shoulder join (O/L)

6. Sleeve join (O/L)

7. Arm hole top stitch (F/L)

8. Side seam (O/L)

9. Join care label

10. Cuff join (O/L)

11. Zipper facing join with bottom rib (S/N)

12. Bottom rib join (O/L)

13. Zipper join with right side (S/N)

14. Zipper join with left side (S/N)

15. Zipper facing join with right side (S/N)

16. Zipper facing join with left side (S/N)

17. Hood uppor 2 and lower 2 part join (O/L)

18. Hood upper and lower 2 part join with loop (O/L)

19. Drawstring hole (button hole)

20. Hood channel top stitch (F/L)

21. Hood run stitch with body (S/N)

22. Hood join with body (O/L)

23. Back tape piping (F/L)

24. Back tape top stitch with main, size label join (F/L)

25. Zipper top stitch both side (S/N)

26. Drawstring insert

27. Drawstring fixing tack (S/N)

28. Pocket position bartack (bartack m/c)

29. Trimming

30. Suckering

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11.13 The steps of 5s:

1. Sort :

Remove unnecessary items from each area.

2. Set in order :

Organize and identify storage for efficient use.

3. Shine :

Clean and inspect each area regularly.

4. Standardise :

Cleanliness resulting from regular performance of the first 3 S.

5. Sustain :

Discipline to perform the first 4 S.

11.14: 8 wastes of lean :

*Defects

*Excess processing

*Over production

*Waiting

*Inventory

*Transportation

*Motion

*Non utilized talent

11.16 Stitch & its types:

Stitch : A stitch is defined as a loop of thread or yarn used to close a fabric.

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Classification of stitch:

Chain stitch ( Class 100)

Hand stitch (Class 200)

Lock stitch (Class 300)

Multi thread stitch ( Class 400)

Over edge stitch (Class 500)

Covering chain (Class 600)

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Chapter 12: Finishing Section

12.1 Garments Finishing:

Garment finishing through wet processing is responsible for adding beauty to the
garment. Proper finishing could provide better look to the garment, change the feel
of the fabric and bring about a change to the texture of the fabric. There are various
types of finishes like peach finish, anti-microbial finish, wrinkle free finish, aroma
finish, UV guard finish, acid wash, enzyme wash, etc.

12.2 PROCESS FLOW CHART OF GARMENT FINISHING:

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12.3 WORK FLOW IN THE FINISHING ROOM:

As mentioned earlier, workflow in the Finishing Department is shown here for

reference:

 Eliminate micro-dust and residual thread from the garment

 Press/iron garments as specified by buyer or as per requirements
 Fold the garments as required by customer
 Fix necessary tickets (Price tickets) or tags (hang tags), etc to the garments
at this stage
 Insert garments into poly bags
 Divide garments as per size and color (assortment)

12.4 Machine Description of finishing section (Fakir Apparels Ltd.):

Machine Numbe
r
1. Steam iron 029

2. Metal detector 02

3. Thread sucker 03

Finishing capacity: 1000 pcs/hr (approximately)

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12.5 The General Rules of Spot Removing:

 The longer a stain remains, the tougher it is to remove.

 Always treat a stain before laundering.

 Blot gently — never rub; and don't ever blot with hot water.

Stain Removal:

STAIN TYPE USED CHEMICAL

(COMMERCIAL NAME)
1. Oil stain Spot lifter
2. General stain Thinner
3. Termeric stain MRS
4. Ink stain MR
5. Glue stain(Polymer based ) Heat gun

6. Rust stain Markvill

7. Print mark Printvill

Ironing:

Ironing is the use of a heated tool (an iron) to remove wrinkles

from fabric. The heating is commonly done to a temperature of 180–
220 °Celsius, depending on the fabric. Ironing works by loosening
the bonds between the long-chain polymer molecules in the fibers
of the material. While the molecules are hot, the fibers are
straightened by the weight of the iron, and they hold their new shape
as they cool. Some fabrics, such as cotton, require the addition of
water to loosen the intermolecular bonds.

12.6 FLOW CHART OF GARMENT INSPECTION

Confirmation of Quantity
↓
Confirmation of
accessories
↓
Size specification inspection
↓
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In side Inspection
↓
Out side Inspection
↓
Final Inspection
↓
Packing

Size Specification inspection:

After confirmation of accessories all pieces are checked as per size

specification based on the instruction sheet which is given by the buyer side. If
any measurement problem is noticed then we check the original sample and
inform the buyer same time.

In Side Inspection:

At this stage garment is checked from reverse side to ensure that there is no
fabric defect, poor stitching, and stains etc. in the garment.

Out Side Inspection:

At this stage garment is checked from outside to ensure that there is no color
variation, weaving defect, fabric defect, printing defect, holes, poor
stitching, bad smell , dying defect and stains etc in the garment.

Final Inspection:

Final Inspection stage is the most important part of inspection process, here
garment is rechecked to confirm that inspection is done properly without
missing any checking step if any defect is noticed we put it into rejection bin
or send it for repay.

Packing:

All ―Grade-A‖ goods are put back into poly bags as per the original packaging
and then they are send for needle inspection

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12.7 PRESSING OR FOLDING:

Although pressing remains largely a manual task, new automated process exists
that apply force and steam to garments placed over a body form.

Different type of folding:

 Standard folding

 Semi standard folding

 Flat folding:
- Roll folding
- Hang folding
- Half folding
- Eco folding

12.8 Assortment :

 Solid color solid size

 Solid color assort size

 Assort color assort size

 Assort color solid size

Buyers generally place order of garments in certain assortment of color

and sizes. The production of such colors and sizes is called assortment.
Another order with an assortment of 1:2:2:1 is shown below:

Color/size S M L XL Quantity

Red 1000 2000 2000 1000 6000

Yellow 1000 2000 2000 1000 6000

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Olive 1000 2000 2000 1000 6000

Violet 1000 2000 2000 1000 6000

Total= 24000

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Chapter 13: Quality Control Department

13.1 Introduction:

Quality is of prime importance in any aspect of the business. Customers demand and
expect value for money. As producers of apparel, there must be a constant endeavor to
produce good quality work. ―The systems required for programming and coordinating
the efforts of the various groups in an organization to maintain the required quality.‖
As such, Quality Control is seen as the agent of Quality Assurance or Total Quality
Control.
For quality control, FAL finally used AQL for garments checking at AQL level 1.5
and sometimes level 0.

13.2 Objectives of Quality Control

• Research/ analysis.
• Selection of raw material.
• Product testing.
• Specification test.
• Should be given financial requirements.
• Quality assurance & so on.
13.3 Finish Fabric Inspection:
 To ensure that only acceptable quality fabric is used for producing garments &
proper quantity of shipment is received from the supplier.
 Point calculation system

Table-Point calculation system

Defect Area Point

1‖-3‖ 1
3‖-6‖ 2
6‖-9‖ 3
9‖- Above 4
For Hole in Fabric 4

Calculation of point is done by–

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If the point grade is below 40, then the fabric is ok. If the grade point is more than 40
points, inform the officer.
The fabric is also checking for the shading defect side by side & length. Any non-
Conformities/shading will notify the manager using inspected reports. Roll-wise color
uniformity card is maintained for the identification of shade variations.
The result of the fabric inspection shall be recorded in the fabric inspection report.

13.4 QUALITY MANAGEMENT SYSTEM:

13.5 ACCEPTABLE QUALITY LABEL (AQL) -2.5:

 Before start finishing work - BGL & BDL follow AQL system
through a format;

 Buyer, item, style, purchase order, order quantity, audit time, lot quantity,
sample quantity,
 measurement, total d fects percent of defects. Pass/fail
 Pass >> for start the finishing work
 Fail >> full lot - 100% re-inspection

13.6 ONLINE QUALITY ASSURANCE TEST:

The entire online QA test for finished fabric of BGL & BDL can be grouped as-

 Pattern measurement
 Marker making
 Fabric spreading

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 Cutting check
- Fabric fault
- Shade variatio
- Size measurement
- Cutting pieces matching

 Sewing inspection
 Packing & finishing

13.7 OFFLINE QUALITY ASSURANCE TEST:

The entire offline QA test for finished fabric of BGL & BDL can be grouped as-
 Physical test
 Chemical test
The detail of all application QA test for finished fabric are discussed in bellow-
 Physical test:
The applicable QA physical test for finished fabric is as follows-
- Tensile strength test
- Tear strength test
- Abrasion resistance test
- Pilling resistance test
- Crease resistance test

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Chapter 14: Merchandising

14.1 Introduction:

The term „Merchandising‟ has been derived from the „Merchandise.‟ Merchandise
means buying and selling vast amounts of goods.
Merchandiser is the bridge between the industry and the buyer. He has to look after
every job, like buying the raw material required to finish the product, make the
garment, finish the garment, document, and finally shipping. He is the person
responsible for making the product. Generally, a garment export unit has many
departments like stores, cutting, production, packing, checking, etc. The
Merchandising department is a linking device of all. The job of a merchandiser is to
co-ordinate with the entire department in the office and the customers.
The merchandiser is the one who creates a good relationship between exporter & buyer.

14.2 Why Merchandising:

―Advertising moves people toward goods; merchandising moves goods toward

people.‖
-
Morris Hite As in the above sayings by Mr. Morris, who is an Author & by
Mr.M.Hite, Morris Hite was a classic American advertising man, self-educated and
self-made. Nowadays, a merchandiser‟s role is significant. Without a merchandising
strategy, products on the store shelf are left to fend for themselves among a sea of
competing products. With the help of a carefully formulated merchandising strategy,
retail marketers can highlight the unique value and benefits of a featured brand to
attain the status of a category leader.
Merchandising is an integral part of the marketing plan and should allocate a
reasonable budget, even for a retailer operating on a shoestring. In today's competitive
retail environment, a retailer cannot afford to consider merchandising as a 'frill.'
Everyone is competing for the customers' dollar. There are more choices out there for
consumers than ever before. So, the competition in the market is more than years
before. Therefore, Merchandising plays a good role in the role of marketing.

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14.3 Responsibilities:
 Responsible for monitoring and sourcing for individual orders from
beginning to shipment.
 Expert in collecting orders, shipment follow-up, and communication with buyers.
 Ensure the timely submission of samples, pricing details, and any other
specifics requested by the buyer.

Communicate with suppliers for raw materials, booking, and delivery

14.4 Elements of Merchandising:

Retail merchandising includes different elements that are layered to create a complete merchandising
picture in your storefront. These elements include:

 Store layout: The layout of your store acts as a tour guide directing shoppers through all the
products you have to offer.

 Product displays: Create temporary or permanent displays so that you can showcase key
products to your customers.

 Product selection: To motivate shoppers to buy, retailers need to have attractive products
that complement each other and create a cohesive brand image.

 Pricing strategy: Product pricing needs to be high enough to make a good profit, but
competitive enough to appeal to shoppers. Retailers also offer promotions to strategically
encourage spending.

 Ecommerce merchandising: Your business‘s online store should also utilize merchandising
strategies to create a compelling online presence.

 Loss prevention: Use smart product placement and theft prevention merchandising to avoid
lost inventory.

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 Store upkeep and cleanliness: Merchandising will require constant upkeep and rotation to
keep your visuals fresh and your best products at the forefront.

13.5 Benefits of Merchandising:

 Higher profits
 More satisfied shoppers
 More engaged buyers (longer on-site time)
 Faster inventory turnover
 Increased brand loyalty
 Increased brand recognition

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Chapter15 : Store & Inventory
INVENTORY: – Inventory in a wider sense defined as any idle resources or assets
of an organization;

15.1 CAUSES OF MAINTAIN INVENTORY:–

1. To run manufacturing operations economically.
2. To take care of uncertainties demand.
3. To reduce the clerical cost & to take advantage of discounts,
transportation etc.
4. It takes time to complete one operation & more products from
one stage to another.
5. To take care of order cycles.

15.2 SCOPE OF INVENTORY CONTROL:–

1. Raw materials inventories.
2. In process inventories.
3. Finished goods inventories.
4. Miscellaneous inventories.

15.3 Frequency of inventory control:–

1. Daily inventory control.

2. Monthly inventory control.
3. Yearly inventory control.

15.4 Store Capacity:

dyes 10-12 tons
chemical 20-25 tons
yarn storage 10-15 tons
grey fabrics 20-25 tons
finished fabrics 30-35 tons

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Chapter 16: ETP(Effluent Treatment Plant)

Objective: To treat effluent and dispatched it in pure condition as possible

Strength:
• Digital screen to see the pH level. Generally 7.5
• Application of the law of fluid mechanics to control temperature
• Continuous circulation of Oxygen.
• Reuse of sludge

Weakness:

pH level is little bit in the higher region.

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Chapter 17: Industrial Engineering Department

17.1 introduction:

Industrial Engineering (IE) is a graphical and symbolic representation of

the processing activities performed on the work piece. It is also known as
systems engineering, production engineering, and operations management.
Industrial engineering plays a pivotal role in increasing productivity.
The IE department basically do work on production. They fixes some
terms for gaining better result. They are:
 Lean
 5S
 Motion study
 SMV
 Efficiency
 Time Study
 Capacity Study
 Consumption
 Machine layout
 Breakdown
 Line layout
 Target Set

17.2 calculation:

Efficiency % = (Production*SMV)/ (Working hour*Worker*60) *100

EXAMPLE:
If,
Manpower = 28
SMV = 8.01
Working hour
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= 8 hours
Production =
1400 piece
Efficiency %
=?
Calculation:
Efficiency % =( Production*SMV)/ (Working hour*Worker*60) ×100
= (1400× 8.01)/ (8×28×60) × 100
= 0.834375× 10
= 83.44%
SMV Calculation:
The full form of SMV is Standard Minute Value. It indicates the period of
time an individual worker needs to complete a particular process in
standard conditions.
Example:
If, Manpower-28 SMV-8.01
Working hour- 480 mints Expected Efficiency-70%

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Chapter18: Supply Chain Management
18.1: Method of Purchasing Raw Materials:

Here fabric and some related accessories are the main raw materials. They are:

 Lab-Dip
 Approval the Lab-Dip
 Collect price Quotation
 Negotiation
 P.I. Received
 Back to Back L/C transfer
 Delivery Chelan received

18.2: Procedure of import Goods:

 Procure of IRC
 Price Inquiry (Quotation)
 P.I. Received and Placing Order
 L/C Opening
 Received Shipping Advice
 Facing Customs
 Closing Transaction

18.3: List of Trims and Accessories

 List of Trims
 Elastic
 Label
 Zipper
 Motif
 Shoulder pad
 Hook & Loop
 Twill tape
 Velcro tape
 Pon pom
 Wadding
 Ribbon Rivet
 Lining
 Interlining

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 Stopper
 Lace
 Applique
 Braid
 Snap Button
 Hasps and Slider
 Drawstring
 Bows

 : List of Accessories:
 Scotch tape
 P.P Band
 Inner Carton
 Outer carton
 Iron seal
 Tarpaulin paper
 Carton Sticker
 Safety sticker
 Arrow sticker
 Butterfly
 Both side tape
 Plastic staple
 Hanger
 Hangtag
 Tissue paper
 Backboard
 Neck board
 Paper Band
 Pin/Clip
 Tag pin
 Polybag
 Elastic bag
 Mini polybag
 Collar stand
 Gum tape
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Chapter19 : Impact of Internship

IMPACT OF DIFFERENT SECTION:

IMPACT OF SAMPLE SECTION:

 Understood why sample section is called a mini-

industry

 Observed how skilled workers work in sample

section
 Learned the process of preparing a pattern for an individual size &
design
 Cleared the conception about different types of sample required to
produce agarment

 Learned about the digitizing board in CAD room

 Learned the process of determining breakdown ratio for a particular order

 Understood how to make marker from a pattern by software in CAD room

 Observed the process of printing a marker on a paper with plotter machine in
CAD room

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 Industrial attachment
IMPACT OF CUTTING SECTION:
 Learned about different type of cutting machines (i.e. Straight knife
cutting machine, Round knife cutting machine, Band knife cutting
machine etc.)
 Learned the process of fabric spreading
 Observed the process of fabric cutting according to
the marker

 Understood different process of fabric lay

 Realized the use and importance of metal gloves for fabric cutting
process through different cutting machines
 Observed the panel check process for different type of fabric of
different style and design
 Understood how numbering and
bundling is done
 Understood the role of input man in the
industry

IMPACT OF SEWING SECTION:

 Observed different sewing or joining process of different body
parts of a shirt
 Learned about different type of machines used in a sewing floor
(i.e. Single or double needle lock stitch machine , Multi needle
chain stitch machine, Over lock machine, Feed of the arm machine
etc.)
 Observed the ironing and fusing process for different body parts (i.e.
Collar, Placket, Facing Interlining etc.)
 Learned about Standard Minute Value (SMV) of different sewing
process
 Learned the process of determining operator‘s efficiency in an
individual process for a shirt

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IMPACT OF FINISHING SECTION:

 Observed various type of finishing process after sewing and washing

 Observed different type of machines used in finishing section (i.e.
Neck press machine, Metal detector machine etc.)
 Learned about different type of iron machines
 Learned about various type of accessories used to attach to the garment (i.e.
 Security alarm, Hang tag, Price tag, Barcode label etc.)
 Observed the application of different chemicals for the removal of
various type of stain

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Chapter 20: CONCLUSION

We have completed our Industrial Training successfully by the grace of Allah.
Industrial Attachment sends us to the expected destiny of practical life. Fakir
Apparels Ltd is one of the best factories in the textile field of Bangladesh. The
completion of the six weeks industrial attachment at Fakir Apparels Ltd. gave
us the inspiration that factory is one of the appropriate destiny to implement the
theoretical knowledge. From this industrial attachment we got the details idea
about the factory environment, production process, total management, store &
inventory process, maintenance, utility etc.

Fakir Apparels Ltd. is well equipped and the working environment is

excellent. The relation between top management to bottom level is so nice. We
are lucky to get the opportunity of having training in this mill. The factory runs
by a number of efficient Textile Engineers, Skilled technical & Non-technical
persons.

All the Textile Engineers, technical & Non-technical persons are very sincere, co-
operative and helpful. We wish good luck of them and also for this factory

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Chapter 21: References

 http://fakirapparels.com/

 http://fakirapparels.com/mission-vision/

 https://www.google.com/search?q=bangladesh+rmg+
sector&ie=utf-8&oe=utf- 8&client=firefox-b

 http://rmgbd.net/

 https://www.google.com/search?q=govt+facilities+in+gurments+industries&ie=utf-
8&oe=utf-8&client=firefox-

 https://www.google.com/search?q=labour+law&ie=
utf-8&oe=utf-8&client=firefox-b

© Sheikh Kamal Textile Engineering College