Presentation on Beximco Textile industry, Gazipur, Dhaka

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BEXIMCO TEXTILE LIMITED
BEXIMCO Group ("BEXIMCO" or the "Group")is the largest private sector
group in Bangladesh. BEXIMCO was founded in the 1970's by two brothers –
Ahmed Sohail Fasiur Rahman and Salman Fazlur Rahman. Since the early days,
the Group has evolved from being primarily a commodities trading company to a
leading, diversified group with a presence in industry sectors that account for
nearly 75% of Bangladesh's GDP. BEXIMCO's corporatemission is "Taking
Bangladesh to the world".
The BEXIMCO name has now become one of the most recognizable brand names
in Bangladesh. It is synonymous with innovation, trust and quality. The Group
consists of four publicly traded and seventeen privately held companies. the
flagship platform now has operations and investments across a wide range of
industries including textiles, trading, marine food, real estate development,
hospitality, construction, information and communication technologies, media,
ceramics, aviation, pharmaceuticals, financial services and energy. BEXIMCO is
the largest employer in the private sector in Bangladesh and employs over 70,000
people worldwide. BEXIMCO group have a combined market capitalization of
approximately $617.34 million. The Group had total revenues of $834 million in
the year ended December 31, 2018.

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INTRODUCTION TEXTILES: BEXIMCO has developed in-house design
capabilities with teams based in Bangladesh and Spain. Furthermore, it has
partnered with some of the world's renowned design institutes, including Fashion
Institute of Technology, Parsons, London School of Fashions, NIFT and NID, for
access to talented designers. The Group has built strong working relationships with
its core clients through a continuous dialogue. The Group's technology partners
include In vista, Huntsman, CHT, Rudolf and Clariant. Key clients include
American Eagle, Arcadia Group, Calvin Klein, H&M, JC Penney, Macy's, Tommy
Hilfiger, Warnaco and Zara. The Group is planning to expand the textiles business
through capacity additions. Post expansion, the annual capacity of knit fabric is
expected to increase to 80 million lbs. from 11 million lbs. currently and the annual
capacity of apparel knits is expected to reach 145 million pieces from 20 million
pieces currently. The Group is also present in retail apparel through "Yellow", a
youthful brand sold through BEXIMCO owned outlets. Yellow is a design driven
brand that celebrates creative and original thinking to highlight a lighthearted and
optimistic view of life through a superior quality product. Yellow captures a
modern interpretation of fashion and relaxed attitude expresses a comfortable and
confident quality. The adventurous spirit of the line is built from BEXIMCO
Group's heritage in innovation and living a life full of passion that is open to
discovery. Yellow is inspired by its customers; Unconventional yet high-quality.

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Beximco Industrial Park, Sarabo,
Kashimpur, Gazipur
Executive summary:
Bextex Ltd. (the “Company”) was incorporated in Bangladesh as a Public Limited
Company with limited liability on 8 March 1994 and commenced commercial
operation in 1995 and also went into the public issue of shares and debentures in
the same year. The shares of the Company are listed in the Dhaka and Chittagong
StockExchanges of Bangladesh. Bextex Ltd. is the most modem compositemill in
the region. Bextex Ltd. has an installed capacity of 288 high-speed air-jet looms in
its weaving section and a high-tech dyeing and finishing section with a capacity of
100,000 yards of finished fabric per day. This company is located at the Beximco
Industrial Park. Bextex Ltd. has a state of the art composite knit fabric production
mill, which serves the growing needs of high-quality knit garments exporters in
Bangladesh. The project was set up as a state of the art knit fabric knitting. dyeing
and finishing facility. During the year the Company produced and sold high quality
of knit fabrics and bringing forth all the latest in hard and softtechnologies in
knitting, dyeing and finishing of knit fabric. Bextex Ltd. also has cottonand
polyester blended yarn-spinning mill, with 122,000 spindles is one of the largest
spinning mills of the country. The mill was set up to feed the country's export-
oriented industries.

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COMPANY PROFILE
Company name : BEXTEX LIMITED
Corporateheadquarter : Bel TOWER,
17, Dhanmondi RA, Dhaka-1205, Bangladesh
Operational headquarter : Beximco Industrial Park, Sarabo, Kashimpur, Gazipur,
Bangladesh.
Factory : Sarabo, Kashimpur, Gazipur
Date of incorporation : 30 May, 1984
Commercial production : 1990
Business line : Manufacturing & Marketing of Yarn Woven, Knit and
Denim
Listing status : Public listed company
StockExchange listing : Dhaka & Chittagong
Authorized capital in Taka: 3,000 million Taka
Paid up capital in BDT : 1,882.50 million Taka
Number of Shareholders : 37,929
Number of Woven loom Installed : 293
Number of Spindles Installed : 119,520
Number of Denim Looms Installed : 36
Number of Circular knit Machine Installed: 30
Production Capacity : 28 Million Linear Meters
Number of Employers : 3,181

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Factory Equipment : different types of weaving, knitting. Dyeing Cutting,
Sewing, Finishing & Generator machines Supplied by mostly Germany, Italy,
Japan, Taiwan, U.K, USA, Singaporeetc
Production Capacity : 12 to 18 tons‘day
Web site : www.Beximco.org
Mission of the company: BEXTEX Ltd. is a full servicevendor with strong vertically
integrated production facilities as well as creative & analytical capabilities which
clearly sets us apartfrom mostother South Asian vendors.
Vision of the company:
* Gain marketleadership in high value added apparel in USA & Europe.
* Use“Innovation” & “Speed” as prime drivers, rather than cotton & cheap
labour.
* Dominate these markets in high quality: Men's, Women’s, Children Shirts (Dress
& Casual) Blouses (formal& casual), Skirts, Jackets Jeans & Casual non - denim
bottoms Knitted tops & bottoms.

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Sources of raw materials:
1. Main sourceof yarn is Padma Spinning Ltd.
2. Other sources of raw material are as follows:-
3. Jamuna Spn. Mill Ltd,
4. AdvanceGroup
5. Utha Spn. Mill Ltd
6. Amber Spn. Mill Ltd
7. Hanif TEX
8. SquareSpn. Mill Ltd
9. Prim Spn. Mill Ltd
10.Sahin tex
11.Phartali tex(Indian)
12.Munnu tex
13.Youth Spn. Mill Ltd
Material sources also collected fromoverseas like India, Pakistan and Lycra from
South Korea, China, Singapore. Taiwan, India etc.
Consumer of the products:
Beximeco knitting LTD. is 2100%o exportoriented industry. All the goods
produced in this industry are exported into various foreign countries. Name of the
main buyers of the products
of the industry are given below:
1. ZARA
2. OcaLviIn
3. ENYCE
4. COOGI
5. MOTHER CARE
6. ZOO YOCK
7. S-OLIVER
8. TEMA.
9. RIVERISLAND

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10.T.LAND.
11.CHARTER HOUSE
12.BERSHKA
13.MAVIFASHION
14.JC PENNY
15.WEARE APPAREL
16.CALVIN
17.KLEIN
18.USPOLO
19.ROCAWEAR
20.DEREON
Recommendable points of a buyer:
1. Diameter of the fabric
2. Design of the fabric
3. GSM of the fabric
4. Total wt. of the fabric
5. Yarn count
6. Types of yam
7. Color of the fabric
8. Finishing of fabric.
9. Handling & fastness property.
Productionflowchart of knitting section:
1. Knitting program from merchandising department
2. Yam selection according to fabricé& GSM
3. Selection of M:C diameter according to fabric diameter
4. Change the cam setting according to fabric design
5. Set the yaminto T and join to the needle
6. Run the MC with desireRPM of M.C
7. Knitted fabric

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Synthetics: Beximco Synthetics Limited, a member of BEXIMCO Group, has
been a manufacturer of Polyester Filament Yarns, namely, Partially Oriented Yarn
(POY) and Draw Texturized Filament Yarn (DTFY) since July 1, 1994 and has an
annual production capacity of 28 million linear meters.
Jute: The Group is the world's premier jute manufacturer and exporter. The Group
supplies yarn to the world's premier carpet and rug manufacturers in Europe and
the United States. Besides carpet yarn and twine, the Group also produces yarn and
twine for producing Tatami mat and other floor coverings for gardening and
household purposes. The Group specializes in producing high-valued yarn with
special treatments (dyed, sized, polished, rot-proofed and waxed)

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Garment Production Process:
Ready to wear apparel or garment manufacturing involves many processingsteps,
beginning with the idea or design conceptand ending with a finished product.
Apparel manufacturing process involves ProductDesign, Fabric Selection and
Inspection, Patternmaking, Grading, Marking, Spreading, Cutting, Bundling,
Sewing, Pressing or Folding, Finishing and Detailing, Dyeing and Washing, QC
etc.
Manufacturing steps
Receiving Fabrics:
Garment factories receive fabric from overseas textile manufacturers in large bolts
with cardboard orplastic center tubes or in piles or bags. The fabric typically
arrives in steel commercial shipping containers and is unloaded with a forklift.
Garment factories often have a warehouse or dedicated area to store fabric between
arrival and manufacturing.
Fabric Relaxing:
“Relaxing” refers to the process that allows the material to relax and contract prior
to being manufactured. This step is necessary because the material is continually
under tension throughout the various stages of the textile manufacturing process,
including weaving, dyeing, and other finishing processes.

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The relaxing process allows fabrics to shrink so that further shrinkage during
customer use is minimized. Garment manufacturers perform the relaxing process
either manually or mechanically. Manual fabric relaxing typically entails loading
the bolt of fabric on a spinner and manually feeding the material through a piece of
equipment that relieves tension in the fabric as it is pulled through. Mechanical
fabric relaxing performs this same process in an automated manner. Many garment
manufacturers will also integrate quality assurance into this process to ensure that
the quality of the fabric meets customer standards. This step is performed by
manually spot-checking each bolt of fabric using a backlit surface to identify
manufacturing defects such as colour inconsistency or flaws in the material.
Fabrics that fail to meet customer standards are returned to the textile
manufacturer.
Spreading, Form Layout, and Cutting:
fabric spreading and cutting After the fabric has been relaxed, it is transferred to
the spreading and cutting area of the garment manufacturing facility. The fabric is
first to cut into uniform plies and then spread either manually or using a computer-
controlled system in preparation for the cutting process. Thefabric is spread to:
allow operators to identify fabric defects; control the tension and slack of the fabric
during cutting and ensure each ply is accurately aligned on top of the others. The
number of plies in each spread is dependent on the fabric type, spreading method,
cutting equipment, and size of the garment order. Next, garment forms—or
patterns—are laid out on top of the spread, either manually or programmed into an
automated cutting system. Lastly, the fabric is cut to the shape of the garment
forms using either manually operated cutting equipment or a computerized cutting
system.
Laying:
Laying of paper pattern helps one to plan the placement of the pattern pieces in a
tentative manner. Lay large pieces first and then fit in the smaller ones It is very
economical in laying the pattern and cutting. Even a small amount of material
saved in a single layer will help to bring about a large saving of money as hundreds
of layers of fabric will be laid and cut simultaneously. When laying, the length of
the garment should be parallel to the selvedge of the material. Be sure the pattern is

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placed in the correct grain. Fabrics drape and fall better on the lengthwise grain
and also last longer. Parts that have to be placed on the fold should be exactly on
the edge of the fold. All laying should be done on the wrong side of the material.
When laying the paper pattern, consider the design of the fabric. Care should be
taken to see that the design runs in the same direction throughout the garment. All
checks and strips should match the seams both lengthwise and across 60.
Marking:
This can be a manual or a computerized technique. The marker planner uses full-
size patterns and arranges them in an economical manner on marker paper. This is
a specially printed paper having symbols on it which enable the marker planner to
visually controlthe positioning of components according to specified grain lines.
Markers produced onpaper are fixed to fabric with pins, staples or on an adhesive
paper which is heat sealed to the top layer of the fabric. Marker planning provides
details of the spreads. In the cutting room, the fabric is laid manually or a
spreading machine is used to arrange fabric inlays 100 (layers) and markers for the
production, any in orders planned.

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Here planning is done also for fusible, linings, trims, pocketing etc.
The supervisors of marker planner plan and allocates the cut orders to various
operations to be carried out in the cutting room.
Cutting:
This is the major operation of the cutting room when they spread and cut into
garments.

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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 defects. A first
planning consideration is whether the totals arrived at in the cutting room are the
same as those required to maintain full production in the sewing room and
subsequently the planned delivery schedule. Any cloth problems created in the
cutting room can affect the output in the sewing room. Assuming all components
of fabric, design, and trims are acceptable and correctly planned and cut, the next
stage is to extend the cutting room programmed to the sewing room.
All cutting operations are carried out by straight knife cutting machines.
Embroidery and ScreenPrinting:
Embroidery and screen printing are two processesthat occuronly if directly
specified by the customer; therefore, these processes are commonly subcontracted
to off-site facilities.

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Embroidery is performed using automated equipment, often with many machines
concurrently embroidering the same pattern on multiple garments. Each production
line may include between 10 and 20 embroidery stations. Customers may request
embroidery to put logos or other embellishments on garments. Screen printing is
the process ofapplying paint-based graphics to fabric using presses and textile
dryers. Specifically, screen printing involves sweeping a rubber blade across a
porous screen, transferring ink through a stencil and onto the fabric. The screen-
printed pieces of fabric are then dried to set the ink. This process may have varying
levels of automation or may largely be completed at manually operated stations.
Like embroidery, screen printing is wholly determined by the customer and may be
requested to put logos or other graphics on garments or to print brand and size
information in place of affixing tags.
Sewing:
Stitching or sewing is done after the cut pieces are bundled according to size,
colour and quantities determined by the sewing room. Garments are sewn in an
assembly line, with the garment becoming complete as it progresses down the
sewing line.

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Sewing machine operators receive a bundle of cut fabric and repeatedly sew the
same portion of the garment, passing that completed portion to the next operator.
For example, the first operator may sew the collar to the bodyof the garment and
the next operator may sew a sleeve to the body. Quality assurance is performed at
the end of the sewing line to ensure that the garment has been properly assembled
and that no manufacturing defects exist. When needed, the garment will be
reworked or mended at designated sewing stations. This labor-intensive process
progressively transforms pieces of fabric into designer garments.
 The central process in the manufacture of clothing is the joining together of
components.
 Stitching is done as per the specification is given by the buyer.
 High power single needle or computerized sewing machines are used to
complete the sewing operation. Fusing machines for fusing collar
components, button, and buttonhole, sewing machines for sewing button and
buttonholes are specifically employed
Checking:
It is realistic to assume that however well checking or quality control procedures
operate within a factory there will always be a certain percentage of garments
rejected for some reason or other. The best way to carry out quality checks is by
 Establishing a standard as a criterion for measuring quality achievement.
 Production results can be measured and compared to the planned quality
standard.
 Ideally, any systemshould detect possibledeviations beforethey occur
through forecasting. Work produced with minus defects will produce
quality products, enhanceeconomy and productivity.
Spot Cleaning and Laundry:
In addition to identifying manufacturing defects, employees tasked with
performing quality assurance are also looking for cosmetic flaws, stains, or other
spots onthe garment that may have occurred during the cutting and sewing
processes.Spotsare often marked with a sticker and taken to a spot-cleaning area
where the garment is cleaned using steam, hot water, or chemical stain removers.

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Some customers request that a garment be fully laundered after it is sewn and
assembled; therefore, garment factories often have on-site laundry or have
subcontractagreements with off-site laundry operations. Commercial laundry
facilities are equipped with at least three types of machines: washers, spinners, and
dryers. Some facilities also have the capability to perform special treatments, such
as stone- or acid-washing.
Laundering is done by highly sophisticated washing machines if any articles are
soiled during the manufacturing process.However, this step is required only if the
garments are soiled.
Fusing and Pressing:
Fusing and pressing are two processes which have the greatest influence on the
finished look of a garment. Fusing creates the foundation and pressing put the final
seal of quality on the garment. After a garment is fully sewn and assembled, it is
transferred to the ironing section of the facility for final pressing. Each ironing
station consists of an iron and an ironing platform. The irons are similar looking to
residential models but have steam supplied by an on-site boiler. Workers control
the steam with footpedals and the steam is delivered via overhead hoses directly to
the iron. In most facilities, the ironing platforms are equipped with a ventilation

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system that draws steam through the ironing table and exhausts it outside the
factory.
The basic components of pressing are:
 Steam and heat are necessary to relax the fabric and make it pliable enough
to be molded by manipulation.
 Pressure:when the cloth has been relaxed by steam, the pressure is applied
which sets the fibers into their new positions.
 Drying: After the application of steam and pressure, the component or
garment must be dried and cooled so that cloth can revert to its normal
condition. This is done by a vacuum action which removes surplus water
from the fabric and at the same time cools it. Forsome pressure operations
hot air or infrared heating is used instead of vacuum for drying;
Machinery used for pressing and finishing are:
 Hand irons with a vacuum press table
 Scissors press
 Carousel machines
 Steam dolly

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Packaging:
In the last steps of making a productretail-ready, garments are folded,
tagged, sized, and packaged according to customer specifications. Also,
garments may be placed in protective plastic bags, either manually or using
an automated system, to ensure that the material stays clean and pressed
during shipping. Lastly, garments are placed in cardboard boxes and shipped
to client distribution centers to eventually be sold in retail stores.
Most garments are packed in plastic bags, either at the end of production or
when they enter the finished goods store. Products like shirts and
underwear’s are usually bagged and boxed directly after final inspection and
enter the stores in prepacked form. For these and similar types of products,
many automatic machines are used.
Other hanging garments such as Jackets, dresses & skirts are usually bagged
by manual machines, semi-automatic machines, and fully automatic
machines. Some of these automatic machines bag, seal, and transport in
trolley; some 500 garments per hour.
When the boxed or hanging garment has to be transported in bulk the
garment or boxes are packed into cartons which can be sealed by adhesive
paper or plastic Manual and automatic machines are available for both.