The document is a presentation on a study of operations and maintenance at Esquire Knit Composite Ltd, a leading garment manufacturer in Bangladesh. It covers the company overview, utilities, dyeing, finishing, sewing, and effluent treatment processes. It also discusses problems found, solutions, and recommendations. The presentation contains diagrams of the facilities and processes to explain the utility systems, dyeing machines, finishing equipment, sewing lines, and ETP plant.

1. WELCOME TO MY
PRESENTATION

2. 2
Prepared by:
Md. Jaber Ahmed Patwary
ID: 16207054
Supervisor:
Dr. KMN Sarwar Iqbal
Professor,
Department of Mechanical Enigneering

3. 3
A STUDY ON OPERATION AND
MAINTENANCE OF UTILITY,
FABRIC DYEING, FINISHING AND
SEWING SECTION OF ESQUIRE
KNIT COMPOSITE LTD.

4. Table of
Content
 Introduction
 Objective
 Limitations
 Company Overview
 Utility
 Dyeing
 Finishing
 Sewing
 Problem finding, solutions, and analysis
 Recommendations
 Conclusion
4

5. Introduction
 Based on Esquire Knit Composite Ltd.
 Covering Section: Utility, Dyeing, Finishing,
Sewing.
 Operations and maintains of the industrial
machines
 Data and information is collected from the
field operators, field engineers, and manual of
the machines
5

6. Objective
◦ To study how a knit composite industry
works.
◦ To explore the main operational activities
of Utility section.
◦ To study operation of fabric dyeing and
fabric finishing section.
◦ To understand and isolate the probable
problems and find it’s solutions in
industry.

7. Limitations
 As per company policy it is prohibited to take
photograph in certain section.
 They are not allowed to given data anyone
from outside due to their business policies.
 As knit Composite is a big industrial area, it is
not possible cover all the sections of the
industry within this short time.
7

8. 8
Company Overview
 Company Name: Esquire Knit Composite Ltd
 EKCL one of the leading garments institute, exporting RMG to the EUROPE &
AMERICA
 Situated at Kanchpur,Narayanganj
 Head office at Esquire Tower, 21 Shaheed Tajuddin Ahmed Sarani, Tejgaon I/A,
Dhaka-1208, Bangladesh.
 Date of Incorporation: February 16, 2000
 Converted to publicly listed company : January 22, 2015

9. Esquire
Group
◦ ESQUIRE KNIT COMPOSITE LTD-
Manufacturer of circular knitted
garments
◦ ESQUIRE DYEING INDUSTRIES LIMITED
Yarn dyeing and finishing
◦ ESQUIRE ACCESSORIES LTD
Manufacturer of garment accessories
(Labels, Hangers, Cartons etc.)
◦ ESQUIRE ELECTRONICS LTD Bangladesh
agent for Japanese electronic/electrical
brands like General, Sharp etc.
9

10. Company
mission
& Vision
Vision:
Esquire’s vision is
to work for
continuous self-
improvement to
serve our
customers with the
best possible
products and
services and
emerge as one of
the most admired
companies in the
textile arena.
Mission
Esquire’s mission is to
ensure quality
products and services
to the customers
within the shortest
possible lead-time
based on optimum
utilization of the
resources to achieve
sustainable growth.
EKCL want to make
sure that the overall
purpose and scope of
the business is
meeting stakeholders.
10

11. PRODUCTS
FABRIC RANGE
Jersey, Pique, Interlock, Ribs, Thermal, Fleece, Terry etc in SOLID and YARN DYED
Auto stripe Yarn Dyed – Jersey, Pique
Feeder stripe Yarn Dyed - Jersey, Pique, Interlock and Rib
PRODUCT RANGE
Polo shirts, Tee shirts, Tops , Sweat shirts, Jogging sets, Nightwear,
Intimate wear –MENSWEAR, WOMENSWEAR, KIDSWEAR

12. CLIENTS
12
Name Country Logo
Esprit Germany
Marks & Spencer UK
C&A Germany
Zara Spain
Celio France
Jordache USA
Mascot Denmark

13. INFRASTRUCTURE
TOTAL COVERED SPACE 550,000sq ft
 Sewing floors with 54 sewing lines 78,000sq ft
 Knitting 45,000sq ft
 Dye house (solid) 56,000sq ft
 Dye house (yarn) 20,000sq ft
 Auxiliary services (Warehouses, Laboratory etc) 23,000sqf
 The new 12 storied building has an area of 35,000sq ft and
will provide more space for production and worker amenities.
13

14. Organogram
14

15. Utility
Section
◦ Utility is not a product, to maintain a
factory it is essential. It is an essential
unit for maintaining the best production
for the factory. We can call it as a
stomach of the factory. Utility section is
consist of
 Electrical Power
 Water
 Steam
 Air
15

16. Electricity
◦ Electrical power is used to run the
machine in industry. It is the power
source of the machinery. As a source
of this power there are different
types of power generators, public
utility (DESCO, BREB and DPDC).
◦ Power required for entire plant is
approximately 11 MW which comes
from 6 generators & public utility.
16

17. Electricity
Electricity Generated by gas
generator
◦ 4 gas generator
◦ 2 diesel generator
◦ Around 4MW power
generated
17

18. Block
Diagram of
Generator
18

19. Generators
19

20. WATER
TREATMENT
PLANT
 WTP at EKCL is used to produce
soft water for boiler feed which
produces steam for entire plant.
 Underground water is the primary
source of water which is collected by
7 submersible pump.
20

21. 21
BLOCK DIAGRAM OF WTP

22. 22

23. SOFTNESS
TEST
 Measured in
PPM- Parts per
million.
 10–50 ppm is
considered soft
water
 1 tablet in 25 ml
of water.
 Colour change
to violet is soft
water. If blue its
still hard water.
23

24. BOILER
 Water tube boiler is
used.
 There are 6 boiler at
EKCL facility.
 Capacity of each
boiler is 1.5
ton/hour.
 Total capacity 9
ton/hour.
24

25. BLOCK DIAGRAM OF BOILER AT EKCL
25

26. DYEING
SECTION
Dyeing is the application
of dyes or pigments on
textile materials such
as fibers, yarns,
and fabrics with the
goal of achieving
desired color.
Raw materials :
 Grey Fabric
 Dyes
 Chemicals
26

27. Dyeing
process
• Use to make the fabric
colorful
• Uses pigment or dye to
color the fabric
• Whole process
controlled through a
automation system
• All the machines
monitored by online
system.
27
Figure : dyeing materials

28. Proces
s flow
of
Dyeing
28
Grey fabric Batching
Turning and
Sewing
Bleaching or
pre-treatment
Enzyme Wash Dyeing
Finishing Softener

29. Chemical
used in
Dyeing
For Bleaching:
 Sodium sulphate.
 Anti-Creasing Agent: Its main
function is to avoid the crease
mark to the fabric during the
washing.
 Different chemical solution for
different color through
Chemical Dosing System.
29

30. MACHINES AT FABRIC
DYEING SECTION
Central Chemical Dosing,(Dosatex, Italy) Compactor (Tubetex, USA)
Sclavos, Greece Icomatex, Spain

31. Dyeing Diagram
31

32. PRODUCTION
CAPACITY
OF DYEING
SECTION
Solid dyed fabric
390tons/month
Yarn dyed fabric
185tons/month
32

33. Fabric
Finishing
The word “finish’’ means all the different
treatments applied to a fabric to
change its:
 Appearance
 Feel.
 Wear ability or care requirement.
33

34. Process flow chart of finishing
34
De-
Watering
Dryer Stenter Compactor
There are two types of finishing process:
Tubuler form
Open form.
At EKCL finishing process of fabric is open form.

35. Purpose of
fabric
finishing
 To dry the wet fabric.
 To control GSM
 To compact the fabric
 To increase the
diameter as well as
control the diameter.
 to make smooth surface
of fabric
35

36. GSM
Calculation
GSM stands for
grams per square
meter. Fabric GSM
means the weight
of one square
meter fabric
in grams.
◦ Cut the fabric with the
GSM cutter (gram per
square inch).
◦ Weight the fabric with
the electric balance.
◦ The cut sample is 100
sq.cm. The weight of
the cut sample is
multiplied by 100.
◦ The result is the GSM
of that particular
fabric.
36

37. Maintenance
of Dyeing &
Finishing
section
Monthly Maintenance of dying
Machine
( Athena2-500H1)
 Changing of bearing for motor.
 Applying glue for water/oil
sealing
 Applying lubricant(Grease) in
existing moving parts( bearing,
shaft)
 Changing gasket
 Changing coolant in pump
 Applying coolant in gear box
37

38. Maintenance
of Dyeing &
Finishing
section
Corino Machine(De-Watering m/c)
 Shaft change
 Teflon change in roller
38

39. Cutting
Section
Cutting means to cut out
the garments pieces from
lays of the fabric with the
help of cutting template
or marker.
39

40. Cutting
section
machinery
40
Name of Machines No. of M/C
Straight Knife Cutting M/C 10
Auto Cutter M/C 02
Auto spreading M/C 05
Marker printer 03
Cutting target/ day = 65000 kg of fabric

41. Straight knife
Bend knife Cutting M/C
Auto Cutter M/C

42. Sewing
Section:
42
Sewing section is the most
important department of a
garment manufacturing
industry. Sewing machines of
different types are arranged as
a vertical line to assemble the
garments. Sequence of types
of sewing machine
arrangement depends on
sequence of assembling
operations.
Elements of
sewing section:
•Sewing thread
•Needle
•Sewing Machine

43. Process
flow of
Sewing
Section
43
Product sends to finishing section
End line Quality check
Online Quality check
Sewing Different parts
Bundle input to line
Line Balancing
Set up Machine layout on the basis of target
Production analysis & set up target for line

44. Production
capacity of
Sewing
Section
44
T-shirts 85,000doz/month
Polo shirts 35,000doz/month
Sweat shirts 35,000doz/month

45. Effluent
Treatment
Plant
Effluent is the stream of excess chemical liquor which is
extracted from an industry after using in original
operation.
The excess dye liquor which is extracted from textile
industry after dyeing from different processes are treated
with various chemicals to remove or neutralize the toxic
materials before discharging to environment (e,g- ground
water) . This is called effluent treatment.
45

46. ETP
Process
46
ETP EFFLUENT
INFLUENT
SLUDGE

47. ABOUT
THE
ETP OF
EKCL
TOTAL CAPACITY: 100m3/hr by
using BIO-Chemical based ETP plant
from ION-Exchange INDIA
47

48. FLOW
CHART OF
ETP
48

49. ETP
Process
Screening:
Screening is the first unit
operation used at
wastewater treatment
plants. Screening
removes objects such as
rags, paper, plastics,
and metals to prevent
damage and clogging of
downstream equipment,
piping, and
appurtenances.
49

50. ETP
Process
Equalization Tank:
Equalization tanks for
wastewater treatment
plants refer to a holding
tank that allows for flow
to be equalized over a
specific period of time.
larger equalization tanks
provide greater absorption
and more effectively
reduce the impact of batch
dumps and unwanted
discharges.
50

51. ETP
Process
◦ Ultra high rated solid
content clarifier
(UHRSCC):
◦ Due to use of lime
powder, ferrous
sulphate and polymer in
the UHRSCC there
would be some sludge
formation in the bottom
of the clarifier.
51

52. ETP
Process
Aeration unit:
Aeration is required in
biological treatment
processes to provide
oxygen to
microorganisms that
breakdown the organic
waste.
52

53. ETP
Process
Chlorination tank:
The purpose of chlorination is to
destroy disease- causing
microorganism. If the factory
waste would have many
significant number of
pathogens and would release of
unchlorinated effluent is
unlikely to represent a
significant additional health
risk
53

54. ETP
Process
Sludge treatment:
After treatment the raw
effluent, sludge come from
the primary clarifier and
secondary clarifier then the
sludge goes to treatment in
centrifuge for making solid
cake.
54

55. Problem
finding,
solutions,
and
analysis
Fabric Width Variation:
Different rolls of the same fabric
lot having difference in the
finished width of the fabric
Causes: Roll to roll difference in
the dyed fabric stretched
width while feeding the fabric
on the stenter and compactor
machine.
Remedies: The whole lot of the
grey fabric should be knitted
on the same type of knitting
machines.
55

56. Problem
finding,
solutions,
and analysis
(Cont’d)
GSM Variation :
The fabric will appear to have a visible variation in the
density from roll to roll or within the same roll of the
same dye lot.
Causes:
The stretched width of the grey fabric should remain
constant during finishing on the stenter.
56

57. Problem
finding,
solutions,
and analysis
(Cont’d)
Over Compacting: It is excess compaction given to
a fabric over its potential shrinkage. It leads to
marbling effect in fabric which is clearly seen while
inspection.
Causes: Excess overfeed (compaction) given to fabric
with respect to potential shrinkage in fabric before
compaction.
Remedies:
◦ Potential shrinkage test
◦ Re-compaction with lesser over-feed
57

58. ◦ Recommendations
◦ All the worker and officers should be concerned about
safety.
◦ The company should employ new and modern
technology to raise its productivity.
◦ Wastage should be minimum to increase the productivity
and decrease the cost of production.
◦ The drainage and sewerage should scientifically&
environmentally acceptable.
◦ New dyeing technology should be implemented as the
existing machines there are inferior compared to today’s
technology.
58

59. 59
Conclusions:
Being an intern at Esquire Knit Composite Ltd was a fruitful
opportunity. The skill and knowledge that I have achieved during
my internship period is very beneficial to me because now I’m able
to say that I can maintain many mechanical equipments, machines,
devices etc. I have learnt many things during our intern session in
Esquire Knit Composite Ltd; I have learnt the way of production of
fabric, supervision & maintenance of the production line. There are
many things to learn like; maintenance system, different inspection
methods, working principle of numerous mechanical equipments
and so on.
Thus I would like to conclude by saying that I’m really grateful to
be a part of such a worthy company.

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