INDUSTRIAL ATTACHMENT

FAKIR KNITWEARS LTD

Prepared By:

Md. Al Hafij Prodhan.

ID. 12131107008
Intake: 7th
Bangladesh University of Business & Technology
(BUBT)
 FAKIR KNITWEARS LTD
Introduction
Industrial attachment is an essential part of 4 years B. Sc in Textile Engineering course of
Bangladesh University of Business & Technology. As a Textile graduate should have an
experience in the study of Wet Processing Technology, machineries products and over all
situation of the Factory before work in the industries. I have the opportunity to perform the
industrial attachment on Fakir Knitwears Ltd. Fakir Knitwears Ltd, is a renowned and modern
technology integrated industry.

Fakir KnitwearsLtd, started in the year 1988 in knit garment exporter, Fakir Knitwears Ltd.
Crossed over a long way and found us as one of the best knitwear manufacturer-exporter of
Bangladesh.

Fakir Knitwears Ltd. certified with OKEO-TEX, ISO 9001-2000 &SRM and also getting by
WRAP and ISO-14001

Fakir Knitwears Ltd. strive to provide the best quality garment to the buyers. Factory provided
advanced technology in all aspects of operation to attain excellence concerning quality,
dependability and commitment for apparel industry and society. Product quality is ensured with
the practice of advanced technology and our inclination toward meeting with the buyer's
satisfaction with competitive price.
Fig: Location map of the FKL
 Chapter 1:
COMPANY PROFILE

‘’We knit your dreams’’

14 storied newly established building Existing 8 storied Building

Who We Are
Board of Directors

Mrs. Sultana Zaman -------- Chairman

F.A.Zaman---------------------------- Managing Director
F.M.Zaman ( Neaz) ---------- ------Deputy Managing Director
Farzana Zaman ----------------------Director

Our Bankers
1. Dutch Bangla Bank Ltd.
2. One Bank Ltd.
3. United Commercial Bank Ltd.

Company at a Glance
Area of Premises
Area of Production Floor
Number of Employees
Yearly Turnover
Capacity
: 718,740 sqft.
: 1,014,447.66 sqft
: 10,000
: $ 108 million (2012)

Content Fakir Knitwears Ltd

Yearly Turnover $ 108 million (2012)

Manpower 10,000

Garments 2,00,000 pcs/day

Garment Line 100 lines

Knitting 50 tons/day

Dyeing 45 tons/day

Dyeing Finishing 47 Tons/ Day

Garments Washing 30,000 pcs/Day

Printing 1,00,000 pcs/day

Embroidery 200 Head

Our Globally Position
Fakir Knitwears Ltd
 Fakir Akhtaruzzaman (C.I.P)

Message from the Desk of Managing Director

Fakir Knitwears Ltd (FKL) has been leading the knit garment industry of Bangladesh by
being in the forefront since long.
Registering an average growth of about 20 percent every year for over a decade by now,
last year FKL exported knit apparel worth about US$100 million. It foresees the same
growth for years yet to come.
Infusing together the highbred local crafting artistry, cutting edge western technology and
height of professionalism, FKL has specialized itself to emerge as the incarnation of an
ultimate knitwear manufacturer, and has been excelling in the global market since its
inception in 1988.
FKL values its 8,500-member-workforce as one of the major components of its growth
engine. It customarily conforms to the ILO conventions and other labor as well as factory
laws applied in the country, and is very much keen to strengthen relations and develop a
better understanding among the owners and employees. All leads to prevailing of a very high
standard industrial environment – friendly for the workers on one hand and conducive for a
higher level of productivity on the other.
Almost all of the global giants as the apparel brands are the trade partners of FKL. FKL
honors its buyers’ trust on it the most. With their support, FKL is moving forward through
the way where ethical practices, health & hygiene, safety, security, green environment etc are
met with their appropriate meanings.
Apart from business, however, FKL is involved in social welfare activities also. It runs
educational institutions for the students in an underprivileged area in Narayanganj. Now,
about 2,700 students are receiving quality education there.

Vision
The vision of Fakir Knitwears Ltd. (FKL) is to set a benchmark, not only in Bangladesh but
also in the world, by which it would be recognized as one of the leading garment
manufacturers on the global stage. As it envisages, FKL has evolved itself as an ultra modern
and one-stop comprehensive knitwear manufacturing and exporting base, which is
independent in knitting, dyeing, sewing and finishing, and is strengthened with necessary
backward linkage advantages.

FKL’s products are highly lauded across America, Europe and East Asia. Because, the
company strictly sticks to a policy guideline outlined by high quality, innovation and
development, credit standing and gaining through honesty.

It strongly believes in Fair Trade responsibilities and carrying out those for the satisfaction
of all connected to the entire value chain having its esteemed clients at the center. FKL
conforms its management system to the ISO 9001-2008 requirements. The company is fully
committed to providing fair wages and good as well as equal employment opportunities to the
members of the underprivileged section in the society. Providing wages far above the
subsistence level, it always ensures a high level of industrial relations and an exemplary status
in health and security standards for the people working with FKL. Besides, clean
environment and ecological balance, women empowerment as well as equal opportunity and
education to the less-privileged next generation too are some of FKL’s other priorities that
help frame the perspective for its ultimate vision.

Mission

The core mission of FKL is to provide its customers the best value for their money by way of
facilitating them with one-stop knitwear manufacturing as well as sourcing services whereby
satisfaction is always guaranteed leaving virtually no room for any complaint. FKL pursues its
mission complying with all of the requirements on humanitarian ground, ensuring excellent
management practices, and reinforcing working environment in a way that it would be viewed
as a model for others to appreciate and follow as "A BETTER WORKING PLACE." FKL
operates its factory in FULL COMPLIANCE with all of the rules, regulations and conventions
applicable in this industry locally and internationally. As well, FKL is keen to have a
corporate culture wherein quality and innovation are perceived as the top priorities and,
therefore, it has established its own system of applying inspection procedures thoroughly at
each and every stage of production. But yet, though quality is the main feature of FKL’s
successful mission, its top-quality products are competitive in pricing consideration too.

Production Operation

At Fakir Knitwears Limited, cutting-edge technologies merge seamlessly with human

ingenuity and deep seated commitment to ensure excellence in every stage and area of our
activities.

Garments Department
CAD Section
First stage in the production line is the pattern making section. Our CAD division uses so
1) Lectra Software 2) Euro CAD software
Cutting Section
The second stage in line is the cutting section. In this section, materials are cut in the pattern
determined and designed in the previous section.
• We have automated system for cutting the pattern. We have TAKATORY and
• LECTRA auto cutter machine.
• Each machine has 30,000 PCS/ Day cutting capacity.
• Our cutting division has 5 units.
• Cutting Capacity in Cutting division is 1,30000 pcs/day

Sewing Section

The next stage is the sewing section. It has two steps. The 1st step being the sewing part uses
various types of sewing machineries, while in the 2nd step, uses button hole & button
attaching machineries to complete the making operation. Dynamic Industrial Engineering
team is continuously developing the different methods to get the maximum productivity and
efficiency from the sewing lines. Our Sewing machines are equipped with auto trimmers,
Lock stitch Button stitch, Chain stitch machines and Auto Button Hole Machines.

We’ve well equipped training center which continuously producing the multi skill sewing
operators which helps the production lines to face the challenges of any styles. All
sewing lines are under constant and continuous inspection by quality monitoring team to
generate the perfection.

To ensure the in time delivery & capacity planning we’re using world renowned production
planning software named ‘’ FASTREACT’’.

Sewing Machines: 2000 no’s (Pegasus, Juki & Brother from JAPAN)
Sewing lines: 100 lines.

Finishing Section:
At this stage products goes through various stages like removal of loose thread, folding etc &
hanged with hanger & poly bag. Garments finishing section is equipped with steam press with
vacuum table. The other finishing machineries are needle detector, thread blowing, strain
removing, carton box striping etc.
Finished Products Auto Hanger system Sewing Line

Knitting Division
The knitting section is equipped with top-of-the-line machinery. Fukuhara of japan, mayer
and cie of germany, and jung-long of aiwan. The machines are equipped with special
attachments to produce lycra fabrics. A well-integrated system of stringent quality measures
checks all fabrics meticulously to eliminate contamination and other faults.
Our knitting section is well furnished with most modern equipments which is
mentioned below:-
Circular Knitting Machine : Single Jersey, Double Jersey, Auto Striper & Jacquard.

Circular Knitting Machine Brand No’s

Single Jersey / Single Jersey Lycra Masa + Jiunn Long 27pcs
Single
(Open)Jersey (Tube) Mayar & CE, Jiunn Long, Quantex, 41pcs
Masa,
SingleJersey(Tube)+Jacquard Santec , Jiunn Long 2pcs
Rib Jersey / Rib Jersey Lycra Jiunn Long, Terrot, Masa 18pcs
Interlock Jiunn 12pcs
Auto Striper (sj) Fukuhara 2pcs
Pollar Fleece Sanda 5pcs
3th Fleece Jiunn 2pcs
Auto stripe ( rib+interlock) 1pcs
Total no machines 110pcs
No of Lines 10pcs

Pollar fleece Sanda 24pcs

In Total- 134pcs

Other Machine in Knitting Section:

Machines Name Brand Origin Quantity

Flat Bed Knitting m/c Stoll (Jacquard) Germany 7 pcs
Gray Fabric Ins. m/c Uzu cloth insp. m/c Thailand 3 pcs open ,5 pcs tube
Also Have
a) Electric Balance for fabric weight 15 nos b) Electric Balance for GSM check 20 nos
c) Winding machine 5 no’s

Dyeing Division & Process

To cope with present various requirements of world fashion trend we have equipped our
dyeing department with the world’s best dyeing & finishing machineries.

The Process of Dyeing Sections

Batching:
Batching is the process to get ready the fabrics which should be dyed and processed for a
particular lot of a particular order. When the grey fabric roll comes from the knitting section
or other source it is required to prepare the batch of fabric for dyeing according to some
criteria like order sheet, dyeing shade, m/c capacity, m/c availability etc.

Machine In Batch Section

No of Machine : 08
Machine Name : Air Turning Machine
Origin : KOREA

Dyeing Section
The company’s ultramodern process house comprises the latest equipments and machinery in
the world. Latest soft flow dyeing machines from fong’s (hongkong), pmm(turkey),
acme(Taiwan).
Machines can dye polyester under high temperature and pressure conditions.
Producing dyed fabric without any pilling due to low liquid pressure and double nozzle
system, without putting any stress on the fabric. The following Table shows the total dyeing
capacity:

Sample Dyeing Machine:

Sl. No Machine Name Brand Capacity/day No’s
1 Winch Fongs 30 kg 05
2 Winch Fongs 60 kg 08
3 Winch Fongs 120 kg 02
4 Winch Pmm 40 kg 03
5 Winch Pmm 100 kg 03

[Type text]
Production Dyeing Machine:
Sl. No Machine Name Brand Capacity/day No’s
1. Winch Fongs 250 kg 03
2. Winch Fongs 400 kg 02
3. Winch Acme 500 kg 03
4. Winch Fongs 500 kg 02
5. Wings Fongs 600 kg 02
6. Winch Pmm 750 kg 02
7. Winch Fongs 800 kg 03
8. Winch Fongs 1000kg 03
9. Winch Fongs 1200kg 03
10. Winch Fongs 1500kg 04
11 Winch Sclavos (Greece) 1500kg 02
12 Winch Sclavos 1000kg 02
13 Winch Sclavos 750kg 01

Total Dyeing Capacity: 50 Tons/Day

Picture: Dyeing

[Type text]
Dyeing Finishing Section
We have both Open and tubular fabric finishing line. To have perfect finishing on fabric we
are using world class machine with most modern technology.

Sl. No Machine Name Brand Country Total no’s

1. Stenter Bruckner Germany 03
2. Stenter ACC Turkey 01
3. Stenter Chengfu Taiwan 01
4. Open Compactor Lafer Italy 03
5. Open Compactor Ferraro Italy 01
6. Slating Bianco Italy 02
7. Slating EL Italy 02
8. Bag Sewing MTG Italy 03
9. Singcing Osthoff Germany 01
10. Sueded M/C Lafu (Has) Turkey 01
11. Combing I kuang Taiwan 01
12. Shewing I Kuang Taiwan 01
13. Squeezer AB Calator Sweden 02
14. Squeezer AKAB Sweden 01
15. Squeezer Kromson Turkey 01
16. Tube Compactor Fab-Con U.S.A 01
17. Tube Compactor Specttorimar Italy 01
18. Calender Ferraro Italy 01
19. Dryer AMS Turkey 01
20. Dryer Obermaier France 01
21 Tube Compactor Lafer (Has) Turkey 01
22. Dryer Dilmiler Turkey 01

Total Dyeing Finishing Capacity: 50 tons/day

Lab Unit:
Laboratory is an independent department. It plays a critical role in every production
phase especially in dyeing and knitting section to maintain the quality standard.

Fakir Knitwears Ltd have four laboratories as international quality products are always
ensured. Production lab is to ensure adequate production. Quality lab to ensure the best
quality, Dyeing Lab and the other one is Yarn testing lab.

The main objective in knit lab is as follows: To calculate the recipe for sample dyeing.
To compare dyed sample with swatch by light Box or spectra flash. To calculate revise recipe for
sample dyeing. Finally approved Lab Dip.
[Type text]
In Knitting Lab there are 3 Yarn Count Test Machine for Twisting, Measurement
and for counting and it is branded by SLD ATLAS origin Taiwan.

Machineries of Dyeing Chemical Lab:

Sl. No Machine Name Brand Country Total no’s
1. Spectra Photometer Gretag Macbeth U.S.A 02
2. Lab Sample Dyeing IRDYER Taiwan 03
M/C
3. Lab Sample Dyeing RAPID Taiwan 02
M/C
4. Lab Sample Dyeing ATAC Turkey 02
M/C
5 Auto Lab Dispensing Lawer Italy 01
system M/C
6. Squeezer ATAC Turkey 01
7. Hydro Extractor ATAC Turkey 02
8. Dryer ATAC Turkey 02
9. Mixer M/C ATAC Turkey 02
10. Heater ATAC Turkey 02
11. Electronic balance SHIMADZU Japan 02
12. Light Box VERIVID U.K 03

Pic:-Dyeing Lab

[Type text]
Boilers:
Five Boilers have been using by Fakir Knitwears Ltd.

Model Serial no Brand Country Total no’s

DDHI 5.0-10 188/9 Omnica Germany 2
UL-S-1000 103730 Loos Germany 2

Fig: Boilars

Washing Plant:
We believe the word SUCCESS” is the other name of “START”. This belief haunts us, as
well as takes us towards new horizons of knitwear and knitwear finishing sector. We have
included best efficient garment washing plant that has a capacity of 40000 pcs garment
(Normal Wash) & Pigment washing 25,000 pcs garments per day.

Fig: Washing Machines.

[Type text]
Embroidery Section
Fakir Knitwears Ltd. Has sophisticated computerized embroidery unit with sequins, beading
& roof embroidery. The embroidery unit is capable of 80 million stitches per day.

Sl no. Machine Name Country of Origin Brand No of Head Total no’s

1 Electric multi head Japan Tajima 20 20
automatic Machine
2. Applic Laser Cutter China Golden n/a 4
3. Fusing Machine Japan Hashima n/a 2

Total Production Capacity In Embroidery: 20,000 pcs/day

Printing Section
Printing unit is well equipped with necessary equipments including Auto Print Machine. We
are capable to print various types including flock, discharge, emboss, and sugar print, all types
of stone and studs heat transfer and many special types of printing. We can print 100000
pcs/day.

[Type text]
Power Plant:
Our Country’s most important issue is power sector. The government faces lots of problem
for supplying the power for industrial sector. Considering all these, at the very beginning of
establishment of Fakir knitwears Ltd; we are using our own power generator. We have
vast setup for the own power source and generating 24 hour power system to successfully
running our whole project.

Model Brand Country of Origin Total no’s

ASD-47 Kaeser Germany 5
CSD-102 Kaeser Germany 5
TEL-141 Kaeser Germany 5
VHP5904GSID WAUKESHA U.S.A 6

ETP Plant:
Fakir Knitwear’s Ltd commitment to the environment can be gauged from the fact the we
seek to meet all the legal norms. Taking for instance the establishment of ETP & WTP
because for us, nothing is more important than the maintenance of pollution-free environment.
Fakir Knitwears Ltd. Establish a ETP plant which is the biggest and no.1 ETP plant in
Bangladesh.
. 3
Capacity of our ETP is 5000 m

Picture: ETP Plant

[Type text]
Our Global Partners
Fakir Knitwears Ltd. (FKL) often visits the new arenas with niche market opportunities and new
products to meet the buyers’ requirements ensuring their superior quality standards and
honoring their desire for creativity as well. Some of the valued clients of FKL are:

 H&M
 TEMA
 PRIMARK
 PEACOCKS
 PENNYES
 ZARA
 ALDI

Quality Control
Fakir Knitwears Ltd. (FKL) believes that, in the world apparel market, quality counts. So, it has
established a highly qualified and efficient Quality Control (QC) Department. As
its quality policy, FKL focuses on providing products at price and service advantages of its
clients ensuring height of quality through direct response mechanism.

In order to sustain the command in the key technological areas concerning the garments industry,
FKL has made significant investments in acquiring world-best testing and quality assurance
equipment and technologies. It applies company-wide standardized discipline through
implementation of OEKO-TEX and ISO 9001:2008. These are reinforced regularly.

[Type text]
The QC team of FKL follows some international standards such as 4-point Fabric Inspection
System; Traffic Light System; AQL 2.5; Needle Detection Report; 9-point Quality Check
System and many more. As well, it always takes the advantages of GSM Check Reports and
Light Box System Reports etc.

The processes that the QC system here customarily undergoes are:

• Pattern Test
• Trial Inspection
• In-line Process
• Pre-final Process, and
• Final Process

FKL takes pride in mentioning that, in Bangladesh, it is the only factory, till date, that has
been successfully nominated for “Skip Process” operation from the world renowned
buyer like H&M. FKL is the PLATINUM MEMBER of H&M also. Its quality team carries out
all the quality inspections for H&M in-house.

Merchandising
Merchandising department is the star of the department among all the working departments in
the Export concern, because Merchandising is the only department having maximum
control over the departments and total responsible for Profit and loss of the company. Fakir
Knitwears have strong merchandising dept ; the merchandising team who are always concern
about the main objectives of their job description that is 4R

 Right Quantity: To dispatch right quantity of product what buyer ordered.

 Right Quality: It should be with right quality as accepted both parties.
 Right Cost: Everybody wants more from what they are paid.
 Right Time: No one wants to wait idle even in a Restaurant. Keeping delivery
schedule is mandatory.
Contact US
Factory and Head Office
Fakir Knitwears Ltd
Kayempur, Fatullah,
Narayanganj-1400
Phone:-
+88-02-7641379-80
+88-02-7643242, +88-02-7643271
IP Phone: +880-961-34-44555
Fax:- 88-02-7634611
Email: fklinfo@fakirgroup.com
Web: www.fakirknit.com
Commercial
89, Lucky Chamber,
1st floor, Motijheel ,
Dhaka-1000, Bangladesh
Phone:-
88-02-9553075
88-02-9560742
IP Phone: +880-961-34-44556-57
Email: fklinfo@fakirgroup.com
Web: www.fakirknit.com
Organogram
 Chapter 2:
Raw Materials

Yarn
The raw material for knitting is the yarn. Different types of yarn of wide range of different
count areused. Both carded and combed yarn is used for knitting.

Generally used yarn and their count:

Yarn Type Count

Cotton 24S, 26S, 28S, 30S, 32S, 34S, 40S

Polyester 75D, 100D

Spandex yarn 20D,40D, 70D

Grey Mélange 24S, 26S

PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S

CVC 24S, 26S, 28S, 30S

Fabric:

Fakir Knitwears Ltd.is a knit composite textile industry. In the industry fabric is used as raw
material in dyeing-

Grey Fabrics:

Following types of gray fabrics are dyed:

• Single jersey
• Single jersey with lycra
• Polo pique
 • Fleece
• Interlock
• Interlock with lycra
• Rib
• Rib with lycra
• 1Χ1 rib
• 2Χ2 rib
• 6X2 rib
• Sugar rib
• Regular drop needle
• Irregular drop needle
• Different types of collar & cuff

Chemicals:

List of Chemicals used in Fakir knitwears Ltd. is as follows-

Basic Chemicals:

• Acetic Acid

• Hydrochloric Acid

• Sulphuric Acid

• Caustic soda

• Formic acid

• Bleaching powder

Detergent & Scouring agent:

1. SUNMORL CK-2
2. AssistB26f/SL2F(CK)
Levelling Agent

1. Neocrystal-200BF
2. LevagalDLP
Sequestering Agent

1. Neocristal 150
2. Neocristal-DMBF
3. NOBLEACH N(Multi-function)
Salt

1. Glauber Salt
2. Common Salt
Whitening Agent

1. Syno White BYB

2. Syno White 4BK
Softener

1. Sapamine FPG
2. Aleamine-CWS
3. Necipole PR 99
4. Gramazin-E2R
Fixing Agent

1. NeofixRP70
2. Neofix-R-250
3. Albafix ECO
Reducing Agent

1. Hydrose
2. Caustic
3. Visco Color
4. ViscoBleah
Bleaching Agent

1. (50%)H2O2
Enzyme
1. Retrocell PLX
2. BIO-C35
Stabilizer
1. Nobleach N(Multi-function)
2. Neorate PH 55 NF
3. Neorate PH 150
Anticreasing Agent

1. Texport GL 500
2. Texport D-600
3. AC-200
 PH Controller
1. Acetic Acid

2. Formic Acid

3. Soda Ash

4. Caustic

5. Invatex AC

Per-oxide Killer

1.Croaks NF

Antifoaming agent

1. Albatex FFC
Dyes

Fakir Knitwars ltd uses the followingdyes-

1.Sumifix 2.Boductive 3.Ciba 4.Livafix 5.Terafix

Remarks
As quality is the prime concern of the factory, qualitative raw materials are always bought by
the management of the factory. Besides, there is enough space to keep those raw materials in
the factory.
 Chapter 3:
Knitting section
Process Flow chart of Knitting:
Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device.

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

Parts of knitting Machines:

Creel: Creel is used to place the cone of yarn.

Feeder: Feeder is used to feed the yarn to make a fabric.

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

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

Guide: Guide is used to guide the yarn.

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

Spreader: Spreader is used to spread the knitted fabric before take up roller.

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

Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine
to feed the yarn at specific finger.
End products of circular knitting machine:

Single Jersey M/C:

a) S/J Plain
b) Single lacoste
c) Double lacoste
d) Single pique
e) Double pique
f) Terry
Rib M/C:
a) 1x1 Rib fabric

b) 2x2 Rib fabric

c) Honeycomb

End product of Flat bed knitting machine:

a) Collar

b) Cuff

Production Calculation:
A. Production/shift in kg at 100% efficiency

RPM  No.of Feeder  No.of Needle  SL(mm)


3527.80 Yarn count

B. Production/shift in meter

Course / min.
 Course / cm

RPM  No.of Feeder  60 12  Efficiency


Course / cm 100

C. Fabric width in meter:

Total no.of wales

 Wales / cm 100

Total no.of Needles used in knitting


Wales / cm 100
Fault of Knitting:

 Hole Mark
 Needle Mark
 Sinker Mark
 Star
 Drop Stitche
 Oil stain
 Rust stain
 Pin hole
 Grease stain
 Cloth fall- out
 Barre
 Fly dust
 Yarn contamination

Yarn Faults:
 Neps.
 Slubs.
 Yarn count variations.
 Thick/Thin place in yarn.
 Hairiness

Flat Knitting Machines Fault:

• Holes
• Missing Needle
• Oil mark
• Loop Miss
 Chapter 4:
Batching section

Batch process flow chart :

Flow process chart of Batching Section of Fakir KnitwearsLtd.

Fabric Received
↓
Inspection
↓
Fabric Divided according to Diameter
↓
Supervisor batches the fabric according to quantity by Calculation
↓
Sent for Dyeing

Function of batch section :

1. To receive the grey fabrics roll from knitting section or other source.
2. To turn out the tubular fabric to safe the face side of the fabric from any type of friction
during dyeing.
3. To prepare the batch of fabric for dyeing according to the following criteria-

 Order sheet (Receive from buyer)

 Dyeing shade
 M/c available
 Type of fabrics (100% cotton, PC, CVC etc.)
 Emergency

4. To send the grey fabric to the dyeing floor with batch card.
5. To keep records for every previous dyeing.

Batch Calculation:
= Batch Quantity (M/C Quantity) / Total Quantity X Diameter quantity

Equation for Rope Length

=Diameter Quantity (Weight of Fabric in a roll) X 39.37 X1000 / Finished GSM / Finished
open Diameter

Batch management:
Primarily batching is done by dyeing manager taking the above criteria under consideration.
Batch section incharge receives this primary batch plan from dyeing manager. According to
machine condition or emergency purpose this batching schedule can be changed some
times.

In batching section grey fabrics are weighted for ensuring the actual weight. We know that
during knit dyeing process fabrics loss some weight due to scouring and bleaching process.
So, during delivery a certain amount of weight loss is adjusted with the delivery quantity.

Machines in batch section :

No of Machine : 06
Machine Name : Air Turning
Machine Origin : KOREA

Air Turning Machine: It is also called Turn over machine. It is used for Single jaurcy knit
fabric for Change the Face side of the fabric.

Remarks:
The batch section of the factory is well equipped but it lacks in a quality controller.
 Chapter 5:
Lab section

Lab dip:

Lab dip is a process by which buyers supplied swatch is matched with the varying dyes
percentage in the laboratory with or without help of “DATA COLOR”

Lab dip plays an important role in shade matching & and detaching the characteristics of the
dyes and chemicals are to be used in the large scale of production so this is an important task
before bulk production.

Objective of Lab dip

The main objectives in lab are as follows:

 To calculate the recipe for sample dyeing.

 To compare dyed sample with swatch by light Box or spectroflash.
 To calculate revise recipe for sample dyeing.
 Finally approved lab dip (Grade: ABC)

The responsibilities of the laboratory are:

 Sample preparation according to buyer requirement

 Different properties test (Wash fastness, Color fastness, rubbing fastness,
Perspiration Test, Pilling Test etc.)
 Strength test of Dyestuff
 Chlorine test, Peroxide test
 Product Development etc.
Laboratory work sequence :
Sample received (Fabrics)
↓
Check & note the Lot no, Style no, Item no& Collar
↓
Sample Preparation
↓
Run the test
↓

Physical test Wet lab

Color Fastness to wash

Pilling Color Fastness to washing

Crocking

Evaluate the sample Pre-production Sample Final sample

Report Making Test Test

Prepared the report prepared the report

Pass Fail

Deliver Refinish Pass Fail Pass Fail

Need to test again Refinish

Lab Dyeing process follow up :
The laboratory dyeing process of Fakir Knitwears Ltd. is as follow:

Sample Received
↓
Standard is checked with the Reference from the inventory
↓
If matched then sample prepared from that recipe
↓
If not matched than the color percentage is calculated by using Data Color
↓
Recipe Prepared
↓
Sample prepared according to recipe
↓
Standard (From Buyer) and Sample prepared is Compared
↓
If Okay then the sample is sent to Buyer
↓
Buyer approves the sample and order for the bulk production.

 Sample Received:
Buyer sends a sample which is considered as standard in whole process. Buyer also
gives some requirements about the properties of the standard fabric. For example, Buyer
wants good wash fastness, light fastness, rubbing fastness, pilling formation etc. The lab
receives this standard to make this fabric according to buyer requirements.
 Standard is checked with the Reference from the inventory:
The factory dyed a lot of fabric in its running years. It also stores a lot of sample in its
inventory. The standard is first checked with the samples kept in the inventory.
 If matched then sample prepared from that recipe:
If the standard is matched with the sample of inventory then the next process becomes
easier. Because after matching the sample with standard previously maintained recipe is
followed. If the sample does not match with the standard then the process goes to data color.
  If not matched than the color percentage is calculated by using Data
Color:
If the standard does not match with the samples of inventory, then the standard
percentage of color is found out from the data color machine.

 Recipe Prepared:
According to the results of data color machine the recipe is prepared to get the
desired sample of that standard.
 Sample prepared according to recipe:
Following the procedure the sample is prepared.

 Standard (From Buyer) and Sample prepared is Compared:

After getting the sample is compared with the standard. And several tests are done
to meet the buyer requirement.
 If Okay then the sample is sent to Buyer:
Sample is then sent to the buyer for the final approval.

 Buyer approves the sample and order for the bulk production:
When buyer gives the final approval the fabric is sent to production floor for the
bulk production.

Machines used in lab :

Robolab :
It’s a automatic color matching wherewe can match any colour to within 0.01% accuracy,
with no discrepancies between product sample and bulk production.

Specification:
Name: Robolab
Type: Robolab 240
Brand :Sclavos
 Fig :Robolab

Sample dyeing machine :

Sample Dyeing Machines are ideally suitable for sample dyeing of fabric and yarn at high
temperature and high pressure. The process of dyeing gives color to the fabric, yarn or
garments. Far East Knitting & Dyeing Industries Limited has 5 sample dyeing machine.

Specification :
Type Nr: BFA12 98998
P/N: 220
V: 50 Hz
P:2.3 Kw
 Fig : Sample Dyeing machine

Spectrophotometer:
Spectrophotometry is the quantitative measurement of the reflection or transmission
properties of a material as a function of wavelength.It is more specific than the general term
electromagnetic spectroscopy in that spectrophotometry deals with visible light, near-
ultraviolet, and near-infrared, but does not cover time-resolved spectroscopic techniques.
Spectrophotometry uses photometers that can measure a light beam's intensity as a function of
its color (wavelength) known as spectrophotometers.Important features of spectrophotometers
are spectral bandwidth, (the range of colors it can transmit through the test sample), and the
percentage of sample-transmission, and the logarithmic range of sample-absorption and
sometimes a percentage of reflectance measurement.

Specification :

Model : UV-5500
Wavelength range :190-1100
Bandwidth :2nm
Wavelength accuracy :±0.5nm
Wavelength repeatability :0.3nm
Wavelength setting : Auto
Stability :±0.002A/h @ 500nm
Weight :12 kg
 Fig : Spectophotometer

Shaker :
This machine is useformixing of solvents/solutions and chemicals and as well as for rinsing.
Specification :
Model :DL-2002M
Capacity: 24
Temp,range:25°C to 99°C
Temp,accuracy:±0.5°C at 50°C
Heat capacity:6000w
Drive motor : 750w
Power source : 220VAC 50/60 Hz single phase

Fig : Shaker

Washing machine:
It used to wash the fabric for various purpose .
Specification :
Model :BK-3600
Voltage : AC 220V
Frequency : 28KHz
Power :3.6 Kw
Capacity:308L

Fig : Washing machine

Light box :
Color light box / Color matching cabinet, used for color matching or assessment of
all industries and Applications where there is a need to maintain color consistency and
quality.
Specification:
Brand :Spectralight-111
Origin : USA
Light source: Day light (D-65)
Cool white
Horizon
UV
TL-84
A (F11-10 dergee)

Fig : Light Box

Pilling tester:
Pilling is a fabric surface fault characterized by little pills of entangled fibres clinging to the
surface. Pills are formed during wearing or washing by the entanglement of the loose fibres,
which protrude from fabric surface.
Specification :
AMPS:3

Phase :1

Volts :220

Cycle:50

Serial no:2059202

Weight : 35 kg

Fig :Pilliing Tester

Crock meter:
It is used to determine the rubbing fastness of a fabric in wet and dry condition.
Specification :
Brand: James H.Heal& Company
Dia of rubbing finger : 16 mm
Size of crocking cloth : (5*50 cms
Force on the rubbing finger:9N

Fig : Crock Meter

Dryer :
It is used to determine the colorfastness to water and perspiration in textiles. A
stainless steel frame with a capacity of 20 samples of 10cm x 4 cm held between acrylic
separator plates, loading weights not included.

Specification :
Hard plastic board: 15 x 63 x 3 mm, 21 pcs
Specimen load: 10 lbs
Supporting rack

Fig : Dryer

GSM cutter :
It is Used to measure GSM for gray, dyed and finished fabric.This GSM Cutter is
circular fabric sample cutter with which uniform circular fabric is cut without measuring. The
specimen which is cut with the help of fabric GSM cutter is 100 cm2 areas. The instrument is
equipped with a set of four replaceable blades and normal cutting pads.

Fig :GSM cutter

 Chapter 6:
Dyeing section
Dyeing:
Dyeing is a method which imparts beauty to the textile by applying various colors and their
shades on to a fabric. Dyeing can be done at any stage of the manufacturing of textile- fiber,
yarn, fabric or a finished textile product including garments and apparels. The property of
color fastness depends upon two factors- selection of proper dye according to the textile
material to be dyed and selection of the method for dyeing the fiber, yarn or fabric.After
dyeing, dye molecules have uncut chemical bond with fiber molecules. The temperature and
time controlling are two key factors in dyeing. Fakir Knitwears Ltd., they used to do knit
fabric dyeing and knit garments dyeing.

Fig: Dyeing Machine.

 Classes of dyes on the basis of suitability of dyeing different fibers:

Sl. no Name of dyes Suitable for Fibers

01 Acid dyes Wool, silk and Nylon

02 Basic dyes Nylon, Acrylic, Acetate Rayon, Silk, Wool and Jute

03 Direct dyes Cotton, Viscose Rayon, Linen, Nylon, Wool and Silk

04 Azoic dyes Cotton, Viscose and Linen.

05 Vat dyes Cotton, Viscose and Linen.

06 Sulpher dyers Cotton, Viscose and Linen.

07 Reactive dyes Cotton, Viscose, Linen, Wool & Silk

08 Disperse dyes Polyester, Nylon, Acrylic, Acetate Rayon and Triacetate

Rayon.

Knit Dyeing Flow-chart

Fabric receiving

Fabric inspection

Batching

Scouring & Bleaching

Dyeing

After treatment & Softening

Fixing

Dewatering/ Squeezing

Drying

Compacting

Final Inspection

Some Process:

Pretreatment:
Pretreatment is the preparation period of fabric fro dyeing. For getting proper fastness of fabric
and proper dyeing pretreatment is a mandatory process.
Demineralization:
It is a process of removing mineral materials from the water. It is done in water treatment plant.
Water from natural sources contains many mineral materials which may hamper the dyeing
process. If the mineral materials are present in water then it may lead to uneven shade in
dyeing. Besides it may also damage the fabric and the machine.

Scorning:
The process to remove fats, oil, waxy substances and added the impurities by certain percentage
of alkali treatment and which increase the absorbing power of the textile units, is called
scouring.

Bleaching:
The process by which the natural color of a fiber can be removed and make the textile this pure
white and bright is called Bleaching.

Components: Upon which dyeing Process Depends:

(1) Sulostrate

(2) PH
(3) Dyeing Assistant

(4) Temperature

Factors to be considered for dye & dyeing process selection:

(1) Hue
(2) Shade

(3) Brightness

(4) Cost

Dyeing Process:

1. Process flow chart for 100% Cotton ( White Color):

Fabric loading

Demineralization
(Wetting /Detergent +Antricreasing+Deminaralizing agent)
[Dosing time  5min temp 400 C ]

Run Time at 550 C 20 min

Draining & Fill

Detergent + Caustic [Dosing time  10 min temp-500 C
Linear] (Run time 10min)

Temp raised 700 C

H2 O2 (50%) added [700 Cmin]

linear Dosing
(Run time 5 min)

Brightening agent added
[Dosing time  30 min 700 C ]

Temp raised 980 C
Run Time 40 min

Sample check

Drain wash

Normal hot wash

PH control at 4.5 (acetic acid leveling agent)

Unload

Note:
 1. Enzyme wash happened after brightener for minimizing time.
2. The required temp for enzyme wash in 55 0- 600C. At high temp (800-820C) the
enzyme destroyed or can ................ during the enzyme wash PH must be 4.5 cause in
alkaline condition enzyme wash can not get well.
3. At high temperature caustic must be not use, otherwise create hates on fabric surface.
4. Demineralization have done for remove water hardness and also remove grey fabric
hardness.
5. Draining have not done directly at 80 0C to protect crease mark.

2. Process flow chart for100% Cotton (Black Color):

Fabric loading

BSL Process

PH control (6.0-6.5)
Leveling+ Auxilieries
Dosing At 30 min
(Run time 10min)

Drain wash/ Rising 5min

Color dosing, Dosing time 30 min 60 0C Linear

Run Time 20min

Salt Dosing, Dosing time 30 min 30 0C Linear (Run time 20min )

2% soda Dosing at 30*c X 20min (linear)

Steam raise up at 50* C & Run Time 10min


Again, 98% soda Dosing At same temperature x30min

Color steam (60 0C60 min)

Sample check

Drain wash

Acetic acid, PH -4.5 30 0 C 15min

PH check & Drain Wash

R/C at 80 0C-20min
 
Normal Wash

Unload the fabric

Note:-

(1) This dyeing process for any deep color such as Navy, Red etc.
(2) Black or any deep color dyeing there is no need scouring & bleaching.

(3) No bleach N or leveling agent mixed with dyes for better dye figure or get best
solution of dye figure and happened dye mixing tem not in dye bath.
Process flow chart S/J Lycra For Blue Color:
Fabric load

Demineralization ( dosing Detergent, Anti
Creasing Agent & Demineralization agent)
Run time 55 0C X 20min

Scouring as it is
Run time 90 0C X 20min

Neutralization (Acid)

H2O2 Killer ok (with Cat)

Dyeing Process

Leveling+ Enzyme at PH, 5.5-7.0
Run Time 10min

Color dosing At 40 0C X 30min
Tun time 10min

Salt Dosing at 40 0C X 20min
Run Time 20min

2% Soda Dosing at 40 0C X 20min

Temp. Increase 50 0C & Run time 10min

98% Soda Dosing at 50 0C X 40min

0
Temp. increase 60 C run time 40min for color streaming

Drain & wash 30-40min at 60 0C

0
Acid Dosing 40-50 C X 5min & Run time 10min

Sopping

Normal Wash & Check Ph

Unload the Fabric
Process Flow chart for Torques combination :

Fabric loading

Demineralization {Dosing time= 15 min 40 0C5min}

Temp raised at 50 C 20 then Draining
0


Detergent {Dosing time= 5 min 50 0 C5}
+multifunction agent (Nobleach N) SDT=5 50 0C5

Caustic { Dosing time= 15min 50 0C5 min

Temp raised at 70 0C

Added H2O2 (50%) { Dosing time= 10 min 70 0C5}

Temp raised at 98 0Cmin

Draining & wash (cold wash)

cat (80 C 20 min)
0

(H2O2 Killer)
Draining wash

Acetic acid {Dosing time 40 0C 5 min}

enzyme wash {550C 60min}


Run 60 0×20min

after PH Check added leveling agent (anticilConz
+Sarabid MIP) {Dosing time=10} 60 0 C10}

Color dosing {Dosing time = 30min 60 0 C10 min

Temp raised at 75 0C 20 grade

Salt added {Dosing time 20 min 75 0C10 min}

Temp dropped at 60 0C

Sample check

 Soda ash added {Dosing time= 30 min 60 0 C10

Color steam {60 0 C40min}
(Shade check)

Temp raised at 80 0C 20 min

Drain wash

Hot wash (Ultraw 350/RBR)

Unload fabric

Dyeing faults Causes and Remedies:

Uneven dyeing:
Causes:

 Uneven Pretreatment
 Improper addition of color
 Improper addition of chemical
 Using dyes of high fixation properties
 Less control of dyeing machine
 Less circulation time

Remedies:

 By ensuring even pretreatment

 By proper addition of color and chemicals
 Correct circulation time
 By controlling the dyeing machine properly

Batch to batch Shade variation

Causes:

 Using improper dyes and chemicals

 Incorrect pretreatment procedure
 Batch to batch weight variation of fabric
 Batch to batch chemicals and dyes variation (lot variation)
 Improper dosing of dyes and chemicals
Remedies:

 By using standard dyes and chemicals

 By correcting the pretreatment procedure
 By maintaining batch to batch weight variation
 By avoiding lot mixing of dyes and chemicals
 By correcting the dosing time of dyes and chemicals
 By following different dyeing parameter.

Dark colored spots:

Causes:

 Dyestuff precipitation during dyeing

 Incompatibility of dyestuff used for producing combined shade
 Too high dyestuff concentration in the dye bath
 Precipitation of unabsorbed dyestuff during after treatment

Remedies:

 By ensuring proper dyeing condition

 By selecting proper dyestuff
 By checking the solubility limit of the dyestuff before dyeing
 By ensuring proper after treatment

Patchy dyeing:
Causes:

 Due to hardness of water

 Due to faulty color addition
 Due to faulty injection of alkali
 Due to improper salt addition
 Due to improper PH of solution

Remedies:

 By using proper sequestering agent

 By correcting the color addition
 By correcting the salt addition
 By proper injection of alkali
 By maintaining the PH level of the solution
 Crease mark:

Causes:

 Poor opening of the fabric rope

 Due to high speed of machine running
 Unequal pump pressure and reel speed

Remedies:

 By maintaining proper pump pressure and reel speed.

 By controlling the speed of the machine.
 Correct opening of the fabric rope.

Roll to roll variation:

Causes:

 Poor migration property of dye.

 Hardness of water.
 Improper dyes solubility.
 Faulty machine speed.

Remedies:

 Use standard dyes and chemicals

 Proper machine speed.
 Using soft waste.

Remarks
The dyeing process of Fakir knitwears ltd. is very much satisfactory. Fakir knitwears only
cares for quality. It is heard from the management of the company, after establishing the
factory till now, a single order is not cancelled. That’s why it is sure that the company is
well enough to produce quality fabric.
 Chapter 7:
Finishing section

Introduction of Finishing:

Textile finishing involves treating a textile material in such a way that the product has the
desired properties required for its intended useand therefore has great market value. The desired
properties may include the fabric dimensions and their stability, its weight, drape, appearance,
softness and handle, as well as any required functional properties such as resistance to
creasing, flame, water, oil, dirt or bacteria. Textile finishing is therefore an extremely diverse
field involving an extensive range of chemicals.

Objective of Finishing :

1. To control GSM.

2. To control Shrinkage.

3. To control Fabric Dia.

4. To Applying Finishing Chemical.

5. To Control Moisture.

6. To Control Sparility.

7. To heat set the fabric.

8. To Dried the fabric.

9. To control loop of the knit fabric.

Flow Chart of finishing for tube fabric:

Dyed Fabric

Hydro extractor Tube Squeezer

Tube Dryer

Tube Compactor

Final Inspection

Delivery to Garments
Flow Chart of finishing for Open Width fabric:

Dyed Fabric

Open Squeezer

Stenter

Tumble dryer Ultra-soft

Compactor

Final Inspection

Delivery to Garments

Types of finishing:
1. Chemical finishing.

2. Mechanical finishing.

Finishing effects:

1. Easy - care
2. Crease recovery.
3. Dimensional stability.
4. Good abrasion resistance.
5. Improved tear strength.
6. Good sew ability
7. Soft or stiff handle.
8. Shine or luster
Functions of Different Finishing Machine:

Dryer Machine
Functions:
1. To dry the fabric with help of steam
2. To control the shrinkage
3. To prepare for next subsequent process
4. To dry tubular and open width fabric without tension
5.
Heating system:
1. Gas fired
2. Steam

Utility:
1. Gas (to make fire)
2. Steam
3. Electricity (to rum the machine)
4. Compressed air (to spread the fire)

Slitting Machine
Function of the Machine:
1. To slit the tube fabric by the knife for opening of the fabric and ready for
stentering
2. Delivered fabric increase free state
3. Before squeezing balloon is formed with the help of compressed air passing by a
nozzle or air sprayer
4. It can control the diameter of fabric and GSM and shrinkage by over feeding
mechanism
5. To open the fabric from tubular form to open width form
6. Fabric is cut according to the needle drop

Fig: Slitting m/c

Utilities used:
1. Electricity(to drive the m/c only)
2. Compressed air(to keep the tubular fabric to be cut in proper tension)

Operational parameter:-
-Set the padder pressure as required (3-7bar)
-Set the speed as much as possible (30-80m/min)

Stenter Machine
Function of the m/c:
1. Heat setting
2. Drying
3. Width control
4. Finishing chemical application
5. Loop control
6. Moisture control
7. GSM increase & decrease.
8. Dia increase & decrease.
9. Shrinkage increase & decrease.
10. Spirality increase & decrease.
11. Color shade light & deep.

Fig: Stenter m/c

Heating system: Gas Burner
Gripping system of fabric edges: pinning

Utilities used:
 Electricity
 Gas
 Steam

Controlling points:
 Fabric speed
 Fabric width
 Temperature
 Overfeed %
 Compactor machine

Function of the machine:

o Shrinkage control
o GSM control
o Width control
o To compact the fabric

Fig: Compactor m/c

Special feature of Compactor:
1. Operating system is computerized.
2. Steam bar present which soften the fabric for compacting.
3. In compacting zone, edge & retard roller, compacting shoe and steel plates are present.
4. A pair of pulley present for fabric dia control.
5. Fabric G.S.M, shrinkage and dia control.

Utilities used:
 Electricity
 Steam
 Compressed air

Control Point
- Water pressure
- Air pressure
- Steam pressure
-
Faults in Finishing and Their Remedies:

1. Wet squeezer marks

Causes
 These marks are caused due to excessive pressure of the squeezer rolls on the wet fabric.
Remedies
 Use the padding mangle only for the application of the softener.
 Use a hydro extractor (centrifuge) for the extraction to avoid the squeezer roll marks.
 After extraction open the fabric manually to prevent crease marks in the damp fabric
 2. GSM Variation
Causes
 Roll to roll variation in the process parameters of the fabric like overfeed and widthwise
stretching of the dyed fabric on the stenter, calender and compactor machines.
Remedies
 Make sure that all the fabric rolls in a lot are processed under the same process
parameters.

3. Bowing
Causes
 Uneven distribution of tension across the fabric width while dyeing or finishing the
fabric.
Remedies
 Bowing can be corrected by reprocessing the fabric by feeding it from the opposite end.

4. Skewing
Causes
 Improper feeding of the fabric while compacting.
Remedies
 Use a drop needle line as a reference line to keep the grain lines straight while feeding
the fabric slowly on the compactor machines.

5. Shrinkage
Causes
 Shrinkage is primarily due to high tension during the knitting, dyeing and the finishing
processes.
Remedies
 Allow the fabric to relax properly before it is cut out.
 Give maximum overfeed to the fabric during the processing on the stenter and
compactor machines.

6. Over Compaction
Causes
 Excess shoe pressure.
 Excess overfeed (compaction) given to fabric with respect to potential shrinkage.
Remedies
 Potential shrinkage test.
 Correct setting of machine.
 Re-compaction with lesser over-feed.
 7. Fabric width variation
Causes
 If the stretched width is vary from roll to roll while feeding the fabric in the stenter and
compactor.
Remedies
 The stretched width of the fabric should remain constant for each roll during finishing in
the stenter and in the compactor

Fabric Inspection:
The finished fabric may have different kinds of faults. This may occur during Knitting,
dyeing or finishing. If the fabric delivered then the quality of the fabric may not be good and
the buyer will reject the finished garments. For this reason careful inspection of this finished
fabric is so important. In finished fabric the following faults are generally found:

Fabric inspection report:

Here, 4- point system is used for inspecting goods. Spining knitting and processing faults are
inspected and enlisted here, commons fauls that are found here are yarn, cont............... slub,
neps hole, needle mark, niuker mark lyera miss/out, oil stain , crease mark, softener mark,
color spot mark, Bowing mark etc.

() 4 Point system:

Fault size –––––––––––– Points

0-3––––––––––––––––– 1

>3 -6––––––––––––––– 2

>6 -9––––––––––––––– 3

>9––––––––––––––––––– 4

Hole ––––––––––––––––– 4

Acceptance:

Up to 20 Points =A, 21-28 Points =B

above = Rejected
Calculation:

Roll length (YD) = Kg/Roll155036/dia/GSM= length

PTS/100 lenier yds = Total Point / {roll length*(Actual width/36)} * 100

Here, PTS= Total fault (%).

 Chapter 8:
Quality Assurance System

Quality Assurance System

The quality assurance department is assigned to maintain consistently uniform quality of the
material; in process and various stages of its manufacturing.
The focus of the quality policy of Fakir Knitwear Ltd has been to provide products at a
price and service advantage through direct response mechanism. In order to sustain the
investments in the key technology area concerning our business, Fakir Knitwear have made
significant investment testing and quality assurance equipment from the best in the world in
each of our production bases and also ensured a Company-wide standardization discipline
through implementation of OEKO-TEX & ISO 9001:2000. These are reinforced periodically
through personal interactions between their filed representatives and consumer of their
products. Fakir Knitwear Ltd advance management team along with well-trained Quality
Assurance team ensures the best quality of products to meet the international standard.
Quality Control:
Quality control is concerned with the evaluation of test data and its application to control of
the textile process, raw materials, intermediate products and final products. It is concerned
not only with quality level and cost of maintaining this quality level but also concerned with
the presentation of tangible values to measure quality and changes in quality. In order to
control quality one must know about the consumers expectations.

Quality assurance:
Quality assurance is defined as all those possible planned and systematic actions necessary to
provide adequate confidence than a product or service will satisfy given requirements for
quality. The Quality Assurance Department is assigned to maintain consistently uniform
quality of the material in process and various stages of its manufacturing

Quality Control Flow Chart:

Yarn receiving

Sample Knitting

Batching

Dyeing (Check shade & Faults of dyeing)

Dewatering & Untwisting

Drying (Check diameter, Pretreatment, Shrinkage Spirality and

GSM)

Compacting

Final inspection

If sample OK go for bulk production

Quality Management system:
Quality assurance procedure may be provided by the following two major parts-
Quality
Control

On-Line

Off-Line

Online quality control:

Online quality control comprises with the raw material control, process control & finish
fabric inspection.

Raw material control:

As the quality product depends upon the raw material quality, quality assurance department
must ensure that the best qualities of raw material (with economical consideration) are used
in
production.
 The Yarn should be with a known concentration and high degree of purity.
 The yarn & Lycra should be compatible with each other.
 The fabric must be with out faults, with proper absorbency, whiteness as
per requirement of the subsequent process.

Process control:
 The method chosen for process must be provided with necessary
parameters.
 During knitting, samples are taken and G.S.M checks with the reference
samples.
 If not properly reset the machine parameter.
 Sample is collected after fixation & matched.
 During finishing, temperature, speed, padder pressure, overfeed should be
controlled as per requirement.
 GSM, width, spirality, shrinkage (both length & width) should be
maintaining as per buyer requirement.
 Finish fabric inspection:

Purpose:
To ensure that only an acceptable quality fabric is used for producing garments and
proper quantity of shipment is received from the supplier.

Scope:
All produced and incoming fabrics of Fakir Knitwears Ltd.

Procedure:
 Store in charge will check the received fabric with the reported length,
color and type of fabric with the stated shipment document quantity and
the actual order quantity.
 The finding will be recorded in inventory report and discrepancy regarding
fabric type, color and length will be notified to the Factory
Manager/Manager (Dyeing & Finishing).
 For in-house products quality control officer will guide all over inspection.

1. Body & rib inspection:

All rolls are kept in front of the inspection m/c time to time as require. The fabric are
spread over the milky white acrylic inspection board ensures high transparency and even
reflection of light. Then by the inspection machine fabrics are inspected visually at a
standard speed against light. For any major or minor faults like thick-thin, barre mark, fall
out, contamination, fly, holes, oil lines, needle line, slubsetc are recorded in inspection
report to classify the fabric based on the four points system.

2. Collar & cuff inspection:

Collar & cuff are inspected visually under the light box. For any major or minor fault in
collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round
problem etc are properly counted and recorded.
Quality inspector (fabric) shall check 100% of receive fabric for quality. He will identify
any defect, hole or stain in the fabric and make calculation given bellow-
Scope of Quality control and testing:
The scope of quality control testing in FKL is little good. It has the following ability for
quality control & testing,

- Fabric inspection by 4-point system.

- GSM & Shrinkage test.

- Wash fastness test.

- Rubbing fastness test.

- Color difference check by data base.
- PH test.

- Pilling and snagging test.

Defects found in the final inspection:

Oil mark/Spot Crease mark Shade dull/bright Color spot
Shrinkage Stripe Bowing/Skewing Uneven shade
Running shadeSticky mark Blake tripe problem Softener spot
Shade not OK (Occurred by buyer’s representative) Roll to rllo shade
variation

On-Line Tests:

For Pretreatment For dyeing

 PH test Shade matching check
 Absorbency test PH check
 Fabric width measure Wash fastness Check
 Whiteness test Machine checking
 Water quality test
Off- line Quality Control:

FKL have all the facility for off-line quality control of the materials used and processed
materials. There are two types of materials are tested in GKL laboratory for the purpose of
quality control. This are –

A. Fabric testing.
B. Raw materials testing.
A. Fabric testing:
All the Off-line tests for finished fabrics can be grouped as follows:
1. Physical Tests.
2. Chemical Tests.

Physical tests:
 Fabric inspection by 4-point system.
 G.S.M test.
 Width of the fabric measure.
 Rubbing test.
 Pilling and Snagging test.
 Shrinkage test
 Twisting test
Chemical tests:
 Color fastness to water.
 Color fastness to wash.
 Color fastness to perspiration.
 Oxidative test damage.
 Saliva test.
B. Raw material testing:
 Yarn count test.
 Yarn strength test.
 Yarn TPI test.
 Lycra count test.
 Color Fastness:-
The resistance of a material to change in any of its color characteristics, to transfer its
colorant to adjacent material or both as a result of exposure of the material to any
environment that might be encountered during the processing, testing , storage or use of the
material.

Color fastness types:

 Wash fastness to hot water as per ISO method
 Wash fastness to cool water as per ISO method
 Rubbing fastness (dry & wet)
 Light fastness
 Perspiration fastness
 Dry cleaning fastness
 Chlorinated or sea water fastness

Factors affecting color fastness:

 Dye size or molecular structure of a dye
 Types of bonding (i.e., ionic , co-valent, H-bond etc.)
 Amount of dye present in fibre
 Chemical nature of fibre or compatibility of dye with fibre
 Presence of other chemicals like binder
 The actual condition prevailing during exposure and after treatment

Reasons of color loss:

 Due to decomposition of dye molecules
 Due to removal of external media
 Due to reaction of dye molecules with acid, alkali, or perspiration
 Due to friction with other surface
 Chapter-9
Garment Section

Sample Section
Responsibilities:

 Overall management of developing appropriate sample garments as per buyer's

requirement.
 Conduct Fit & Pattern evaluation.
 Make basic block pattern.
 Ensure production as per planning and also ensure target of production with standard
of quality.
 Coordinate merchandising team, procurement team, garments manufacturing team for
smooth production.
 Ensure effective workforce management of the sample division for smooth operation
of the factory.
 Coordinating all fabric + trims which are required for sampling purpose
 Coordinating print, embroidery, wash for sampling.
 Checking all the technical aspects of samples before releasing to customer.
 Checking all the aesthetic aspects of samples before releasing to customer
 Checking the quantity requirement of each sample.
 Checking the necessary paper work of reach sample.
 Follow up the buyer reg. each sample comments.


They make three types of sample. Such as

Quotation sample:
At first they make a sample of medium size as per buyer requirements is called quotation
sample. If the sample is not ok they make another sample called revised quotation sample.

Size set sample:

If the quotation sample is ok then they make the samples of all size which are call size set
sample. If it is not ok the make revised size set sample.

Production sample:
Finally they make the sample for production called production sample
Working procedure:

The working procedure of sample making department is as follows

At first they collect the measurement chart from merchandizing dept.


Make basic block pattern by hand or by CAD (middle size only)

Cut the fabric according to the pattern (for 2-3 sample)

Then the dept. Head or coordinator provide the cutting sample to the sewing operator and
provide the measurement sheet by buyer.

Sew a sample according to buyer requirements


Inspect the sample after finishing.

The sample is then provided to merchandizing dept.

If it is ok they are called to make size set sample or if it is not ok they have to make
revised quotation sample

They make grading pattern by the CAD department

Make sample of all size as the same procedure and provide to merchandizing department.
If it is ok they make production samples or not they have to make revised size set samples.

CAD (Computer Aided Design) Section

Responsibilities:
 Make basic pallern and production pattern.
 Make more efficient marker identifying each part of the Garments,
 Coordinate merchandising team, procurement team, sample section, garments
manufacturing team for smooth production.
 Make fabric consumption with allowance %, shrinkage% and total process loss %.
 Identify fabric diameter for each si/e of Garments.
 Make easy the fabric cutting.
Usage equipments:
1. Misfires software for pattern making.
2. Dimarien software for marker making.
3. Lectra printer for marker print.

MARCHANDISING

Art work Spread sheet from Merchandiser


Making Pattern sewing. Allowance as per Spread Sheet+ Art Work for a large size sample

Make an efficient marker As per Color Art Work

Calculate required fabric consumption with shrinkage% and process loss%

Marker Delivery to Concern Merchandiser for approval with consumption and fabric
diameter

Received buyer approval Master Pattern '%


Completion of Grading as per spread sheet sample

Grading pattern with marker send to cutting section for Trial cat / Size set


Pattern update after getting Report as per color wise


Delivery to cutting production

 Chaptar10:
Printing

Textile Printing involves the production of a predetermined colored pattern on a fabric,

usually with a definite repeat. It can be described as a localized form of dyeing, applying
colorant to selected areas of the fabric to build up the design. Textile Printing, like Textile
dyeing, is a process for applying color to a substrate. However, instead of coloring the whole
substrate (cloth, carpet or yarn) as in dyeing, print color is applied only to defined areas to
obtain the desired pattern. This involves different techniques and different machinery with
respect to dyeing, but the physical and chemical processes that take place between the dye and
the fiber are analogous to dyeing.

A Typical Printing Process Involves the Following Steps:

Color paste preparation
when printing textiles, the dye or pigment is not in an aqueous liquor, instead, it is usually
finely dispersed in a printing paste, in high concentration

Textile printing
the dye or pigment paste is applied to the substrate using different techniques, which are
discussed below

Fixation
Immediately after printing, the fabric is dried and then the prints are fixed mainly with steam
or hot air (for pigments). Note that intermediate drying is not carried out when printing
carpets (too much energy would be needed for removing the highly viscous liquor)

After-Treatment
This final operation consists in washing and drying the fabric (it is not necessary when
printing with pigments or with other particular techniques such as transfer printing).
Flow chart of printing:
Computer design

Engraving section

Develop sector (styck off)

Printing (dyed fabric/ white fabric)

Drying (1800 c)

Finishing

Packing

Delivery

Printing Paste Preparation

Dye Printing process traditionally starts with the preparation of the paste. Compared to
pigment printing, the composition of the pastes is more complex and variable, being
determined not by the dye used, but by the printing technique, the substrate, the application
and the fixation methods applied.

Apart from the dye, printing pastes contain a thickening agent and various other auxiliaries,
which can be classified according to their function as follows:

 Oxidizing agents (e.g. m-nitrobenzenesulphonate, sodium chlorate, hydrogen

peroxide)
 Reducing agents (e.g. sodium dithionite, formaldehyde sulphoxylates, thiourea
dioxide, tin(II) chloride)
 Discharging agents for discharge printing (e.g. anthraquinone)
 Substances with a hydrotropic effect, like urea
 Dye solubilisers, which are polar organic solvents like glycerine, ethylen glycol, butyl
glycol, thiodiglycol, etc.
 Resists for reactive Resist printing (e.g. sulphonated alkanes)
 Defoamers, (e.g. silicon compounds, organic and inorganic esters, aliphatic esters,
etc.).All the necessary ingredients are metered (dosed) and mixed together in a mixing
station. Since between 5 and 10 different printing pastes are usually necessary to print
a single pattern (in some cases up to 20 different pastes are applied), in order to reduce
losses, due to incorrect measurement, the preparation of the pastes is done in
automatic stations. In modern plants, with the help of special devices, the exact
amount of printing paste required is determined and prepared in continuous mode for
each printing position, thus reducing leftovers at the end of the run.
Screen Making Procedure:
Put chemical on screen

Put film on the fabric

Light pass on the fabric (light pass through the white portion & block the black portion
of the film)

Chemical is permanent in white portion

And chemical is gone from black portion by washin

Black portion become hole so that print paste pass through black portion

Fig: Printing Machine.

 Chapter: 11
Inventory
And
Chemical Store

There are different inventory systems for different raw materials In Fakir Knitwears Ltd.
The flow chart is given below:—

Raw material receiveing

Material Receiveing Report (MRR) Sent to head office.

Store in main go-down by bin card.

Running go-down.

Production floor.
Grieg Fabric:
All the grey fabrics are stored in the fabric store, near the batch section. Different types of
fabrics are listed in the sheet according to the fabric types, quantity & consumer’s
requirements. Fabrics, shrinkage, diameter & other properties are also taken into
consideration. The bathes are prepared by taking the required fabrics from the grey store. At
present the grey fabrics store of FKL containing the following types of fabrics-
 Single jersey.
 1x1 Rib.
 2x2 Rib.
 2x1 Rib.
 Melange.
 Pique.
 Single jersey (with Lycra attachment)

Spare Parts Store: In FKL required amount of spare parts of different machines are stored in the
mechanical storeroom. All the spare parts are listed in a sheet, which is controlled by the mechanical
&maintenance personnel. Spare parts are arranged in the storeroom according to their size, quantity &
requirements. There are shelves in the store room to keep the small spare parts.
 Dyes & Chemicals store : According to Chemical Stock Report
Name of Chemicals Type Balance (kg) Company

Green Acid Neutralization 1300 Tubingen Chemical

Enzyme N2000 Acid Enzyme 150 ArescoTex

JQ- RSL Neutral Enzyme 180 Transfer Chemical

H2 O 2 Bleaching Agent 6800 ASM Chemical

SID IB 135 Stabilizer 2000 Transfer Chemical

CIC Stabilizer 80 Color Chem

Invazyme CAI Peroxide killer 120 Huntsman

K. PSK Peroxide Killer 70 Huntsman

SeatFast CRD Soaping Agent 250 Dystar

Rucogen NZA Soaping Agent 260 Huntsman

TR 2 405 Wash off 350 Transfer Chemical

Kappawet Boss Detergent 460 Kappa Chemi

Invatex CRA Detergent 100 Huntsman

Inopon OLS Disperse soaping 30 Huntsman

agent

Kappabon FCB Ant creasing agent 220 Kappa- chemi

TUSOFT- HQS Ant creasing agent 150 Huntsman

Apuric 2 Ant creasing agent 300 Transfer Chemical

Albatex DBC Levelling agent 200 Huntsman

Kappacom F20 Levelling Agent 620 Kappa chemi

TOP Polyester levelling 500 Huntsman

Kappacom HS Sequestering agent 600 Kappa chemi

DF- 2000 Anti-foaming agent 250 Huntsman

 Sera Gal Multifunctional 700 Dystar

Sera DLSBS Multifunctional 540 Dystar

Albatex NBO Multifunctional 290 Huntsman

Uvitex BBT HQ Cotton Brightener 18 Huntsman

Syno White 4bk Cotton brightener 280 Kisco

Uvitex QB PET Brightener 10 Huntsman

Albafix ECO Fixing agent 55 Huntsman

Kappafix GG100 Fixing agent 55 Kappa chemi

Kappatex R98 Cotton Stripping 250 Kappa chemi

agent

Eganol DP liquid PET striping agent 250 SK. Traders

LM-7

Kappasoft Softener 200 Kappa chemi

Softer Hack Softener 3000 Transfer chemi

Kappasoft SM Silicon softener 9120 Kappa chemi

Softnar Hack White softener 2100 Transfer chemical

Sapamine FPG White softener 100 Transfer Chemical

Glubar Salt Salt 40000 Regent Chemical

Soda Ash Light Soda 18000 Regent Chemical

Caustic Soda Soda 650 Wintexint

Hydrose Hydrose 500 Transfer Chemical

Metacid BD Dispersing Agent 25 Metatex

UltraTrash NM v2 Antibacterial 11 SK traders

 Dyes Balance
NOVACRON YELLOW S3R 500

NOVACRON YELLOW FN2R 180

NOVACRON RED S3B 160

NOVACRON PINK S2B 50

NOVACRON DEEP CHERRY SD 200

NOVACRON BR. BLUE FN 3GL 25

NOVACRON BLUE TS3G 37

NOVACRON BLUE TSGC 100

NOVACRON DARK BLUE SGL 350

NOVACRON DEEP NIGHT SR 1145

NOVACRON OCEAN SR 110

NOVACRON SUPER BALCK G 8010

NOVACRON RUBY S3B 560

AVLTERA YELLOW SR 50

AVLTERA RED SR 120

AVLTERA BLUE SR 18

SYNOZOL YELLOW HF4GL 58

SYNOZOL YELLOW KHL 135

SYNOZOL YELLOW K3RS 170

SYNOZOL YELLOW HF2GR 310

SYNOZOL RED KHI 110

SYNOZOL RED K3BS 168

SYNOZOL RED HF3B 70

Trims & Accessories Store:
 Main, size & care label.
 Back neck tape.
 Button.
 PSP paper.
 Tag pin.
 Master carton.
 Poly sticker.
 Carton sticker.
 Poly bag.
 Logo gum tape.
 Heat transfer.
 Interlining.
 Woven twill fabric.
 Country flag sticker.
 Hang tag.
 Mobil on tape.
 Security label
 Chapter 12:
Maintenance

Maintenance

Maintenance:
Maintenance is the 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 customer is sustained. Maintenance can increased machine life and ensured trouble
free service.
Objective of Maintenance :
1. To reduce Machine Problem.
2. To Increase production.
3. To Improve product quality.
4. To Improve production Efficiency.
5. To reduce Production Time & cost

Maintenance of Machinery:

Maintenance

Preventive Routine Corrective

Maintenance Maintenance Maintenance

Mechanical Electrical Mechanical Electrical Mechanical Electrical

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance

Preventive Maintenance:
Preventive Maintenance is a predetermined routine actively to ensure on time inspection or
checking of facilities to uncover conditions that may lead to production break downs or harmful
description.
Routine Maintenance:
Maintenance of different machines is prepared by expert engineers of the maintenance department. Normally
in case of dyeing machine maintenance after 30 days complete checking if different important parts are done.

Corrective Maintenance:
Corrective Maintenance is done after a failure has occurred. Fakir KnitwearsLTD. has an expert team for
maintenance. When problem occurs they actively solve the problems.

Maintenance Procedure :
As a part of maintenance normally Fakir KnitwearsLTD. follows preventive maintenance. During
maintenance procedure following points has to be checked.
Maintenance: Mechanical
Machine : Dyeing

S/l No. Items need to be checked and serviced

1 Complete cleaning of machine

2 Check air supply of the machine

3 Cleaning of inside of the m/c

4 Greasing of unloading roller bearings

5 Check water supply of the machine

6 Checking of cooling valve

7 Checking of steaming valve

8 Checking exhauster

9 Checking of heat exchanger

 Maintenance: Electrical

Machine : Dyeing

S/l No. Items need to be checked and serviced

1 Check all motor terminals.

2 Check main panels.

3 Clean main inverter.

4 Check all circuit breaker.

5 Check all pressure switches.

6 Visual checking of all power and control cables.

7 Check all pneumatic solenoids.

8 Check all emergency switches.

9 Check all on/off switches.

10 Check all signal isolator.

 Chapter 13:

Utility Services

Utility Services

Available Utility Facilities:

 Electricity
 Gas
 Water
 Compressed air
 Boiler etc.

Gas:
Mainly gas is delivered from TITAS. It is mainly used for steam production. Generally 36 m3
gas is required to produce 1 ton of steam.

Boiler:
Boiler is mainly used to produce and deliver steam to different section as required .

Fig: Boiler of boiler Fig: Steam Delivery Chamber

Four Boilers have been use by Fakir Knitwears Ltd.

Serial Brand Name Origin Capacity Type

1 Boss USA 10 Ton Automatic
2 Loss USA 10 ton Automatic
3 Omonical Germany 8 ton Automatic
4 Omonical Germany 5 ton Automatic

Power plant:

Our Country’s most important issue is power sector. The government faces lots of
problem for supplying the power for industrial sector. Considering all these, at the
very beginning of establishment of Fakir Knit wears Ltd; Fakir Knitwears Ltd. using
their own power generator. They have vast setup for the own power source and
generating 24 hour power system to successfully running our whole project. They
have:

Electricity:
The main utility electricity is supplied by generator.
Gas Generator:
Total Generator contain 6 at Fakir knitwears Ltd.

Total Manufact Volts RPM Hz A KVA KW Generate Used Duty Origin

No’s urer /Day) /Day

06 Waukesh 415/ 1000 50 1565 1125 900 3.6 Mw 2.8 Conti USA
a Power 24 MW nuous
Systems hr

Total power is then distributed as per requirements of different section like

knitting, Dyeing (yarn/ fabric), Finishing, Garments, Maintenance, WTP, ETP etc.

Compressor:
Compressor is mainly used to deliver compressed air to different section as required.
In FakirKnitwears Ltd. they usedcompressors to produce and deliver compressed air to
different section.

Name Model Brand Country Total Total No.

of Origin No’s of
Reserve
Tank
Dryer ASD-147 Kaeser Germany 5
Compressor CSD-102 Kaeser Germany 5
(Big) 02
Compressor TEL-141 Kaeser Germany 5
(Small)
Generator VHP5904GSID WAUKESHA U.S.A. 6
 Chapter 14:
Effluent Treatment Plant (ETP)

ETP:
Effluent is the stream of excess chemical liquor extracted from an industry after using in original
operation. In the case of dyeing industry, the excess dye liquor extracted from textile industry
after dyeing is an effluent of that industry.

Fakir Knitwear’s Ltd commitment to the environment can be gauged from the fact they seek to
meet all the legal norms. Taking for instance the establishment of ETP & WTP because they
have, nothing is more important than the maintenance of pollution-free environment. Fakir
Knitwears Ltd. Establish a ETP plant which is the biggest and no.1 ETP plant in Bangladesh.

Capacity 5000

Fig: ETP Plant

Process sequence:
Screen brush

Lifting pump unit

Storage tank

Neutralization tank

Distributor tank

Biological oxygen tank

Sedimentation feeding tank

Sedimentation curve

Sludge return pump slump

Sludge thickener

Filter press
Used chemicals:
 Sodium hypochlorite
 Nutrient salt
 Anti foam
 Sulphuric acid
 Poly electrolyte
 decolorant
Testing lab instrument:
 microscope
 BOD sensor system
 Thermo reactor
 Spectrophotometer
 Digital muffle furnace
 Portable DO meter
 Portable DO meter
 Micro-processor PH meter
 Electrical balance
 Chapter 15:
Conclusion

Conclusion

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

We have completed my industrial attachment fromFakir Knitwears Ltd.During my two

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

My Achievements:
 We have got a lot of knowledge about the laboratory work and the steps that should be
maintained before bulk production.
 We have identified the process sequence dyeing and gathered adequate knowledge
about each process sequence.
 We have earned some mechanical knowledge about dyeing machine.
 We have found some special points that should be considered during dyeing production.
 We have understood about industrial environment and administration.

Limitations of the report:

 Because of secrecy act, the data on costing and marketing activities have not been
supplied.
 We had a very limited time. In spite of our willing to study more it was not possible to
do so.
 Some information in different sections are not included as these were 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 our hard to summarize all the information that we are provided.