Industrial attachment

BANGABANDHU TEXTILE ENGINEERING COLLEGE
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GOVERNMENT OF THE PEOPLE’S REPUBLIC OF BANGLADESH
(BTEC)
Kalihati, Tangail.
[Affiliated: University of Dhaka]
Report on
Industrial Attachment
@
Fakhruddin Textile Mills Ltd.
Gargaria masterbari, Kewa, Sreepur, Gazipur.
Duration: 21 October 2017 to 21 December 2017
Supervising Teacher Industrial Supervisor
Engr. Md. Abdul Mozid Md. Aman
Principal of Assistant General Manager
BTEC, Kalihati, Tangail. HR Department
Submitted by:
Name Roll Reg. Session
Sajib Chakma 72 1870 2013-14

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ACKNOWLEDGEMENT
First of all, I am grateful to almighty without whose help, it would not have been
possible for me to prepare this report. I wish to express my sincere appreciation to all who
have directly or indirectly contributed towards completing my industrial attachment.
Although a full list of names would be too long for publication, I would particularly like to
express my gratitude to the following.
Engr. Md. Abdul Mozid sir principal, of Bangabandhu Textile Engineering
College for whom I achieve my intended goal to complete the B.Sc. in Textile Engineering
course. I am grateful to him for his sincere supervising and constant guide lines during the
period of my industrial attachment. I also express my sincerest gratitude to Md. Ruhul
Amin sir, GM, Dyeing and Finishing department of Urmi group for his cooperation
during the period of my training.
Finally I would like to acknowledge that I remain responsible for the inadequacies
and error, which doubtless remain in the following report.

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FAKHRUDDIN TEXTILE MILL LTD.
Gargaria masterbari, Kewa, Sreepur, Gazipur.

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INTRODUCTION
The textile and clothing (T&C) industries provide the single source of economic
growth in Bangladesh's rapidly developing economy. Exports of textiles and garments are
the principal source of foreign exchange earnings. By 2002 exports of textiles, clothing,
and ready-made garments (RMG) accounted for 77% of Bangladesh’s total merchandise
exports. By 2013, about 4 million people, mostly women, worked in Bangladesh's $19
billion-a-year industry, export oriented ready-made garment (RMG) industry. Bangladesh
is second only to China, the world's second-largest apparel exporter of western brands.
Sixty percent of the export contracts of western brands are with European buyers and about
forty percent with American buyers. Only 5% of textile factories are owned by foreign
investors, with most of the production being controlled by local investors. It can be
emphasized that among the entire textile sector knit composite is the most fast growing
sector in Bangladesh because of smaller investment requirement, greater backward linkage
facility and higher profit. We are very fortunate at such type of present situation we have
completed our industrial training at a reputed 100% export.
Oriented knit composite factory“FAKHRUDDIN TEXTILE MILLS LIMITED.”

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“FAKHRUDDIN TEXTILE MILLS LIMITED” is fully concerned about knitting, knit
dyeing and knit garments which vertically setup well planned textile unit in 2005. From
the beginning of production it has earned lot of reputation due to its quality product and
approval of several multinational inspection firm i.e. Oeko Tex, SGS, WRAP as well as
renowned buyer i.e. MARKS & SPENCER, S.OLIVER. At “FAKHRUDDIN TEXTILE
MILLS LIMITED” we have completed eight weeks long industrial training on knitting,
knit dyeing and finishing. During entire training period we had tried as much as possible
to keep ourselves at actual working condition by implementation our knowledge, thoughts
and ideas and this report is mainly a little effort to express such experiences gathered in
training.
1.1. Profile of Fakhruddin Textile Mills Ltd.:
Primary Profile
Company Name : FAKHRUDDIN TEXTILE MILLS LTD.
BKMEA Membership Number : 678
Membership Type : Ordinary Member
Year Of Registration : 09.03.2003
General Profile
Status : Private Limited Company
Type : Fakhruddin Textile Mills Ltd is a 100%
export oriented knit composite mill
Year Of Establishment : 2005
Year Of Starting Production : 2005
Location : Sreepur, Gazipur
Factory Address : 1036/1 Gargaria Master bari, Kewa,
Sreepur, Gazipur

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Head Office : 235 /A, Tejgaon Industrial area, Dhaka
Sponsors : Urmi Group
Owner : Asif Ashraf
Raw materials :  100 % Cotton
 100 % Polyester
 100 % Viscose
 95 % Cotton 5% Lycra
 95 % Polyester 5% Lycra
 95 % Viscose 5% Lycra
 60% Cotton 40 % Polyester
 48 % Cotton 48% Modal 4% Lycra
 Nylon
Different Departments
a) Knitting section :
b) Dyeing section :
c) Garments section :
- 2 Knitting section - Inspection
- Batch section
- Dyeing lab
- Dyeing section
- Quality control
- Finishing
- Cutting - Sewing
- R.N.D. / Sample
- Finishing & Packing
d ) Merchandising & Marketing :
e) Maintenance section :
f) Store section :
- Quality control
- I.E.N. & Planning
- Store
- Electrical
- Mechanical

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Supporting Departments : - Security department
- HRD
- Procurement
- Finance & accounting
- Personnel administration
Total Manpower :
Major customers :  Marks & Spencer (M&S)
 S. Oliver
 Auchan
 Vert
 Toray Japan
 Triton
 Bengal Tex
1.2. Site layout
Security, Medical,Mosque, Administration, Knitting section,
Car park
Garments 1&2 Packaging Canteen Dyeing sec. ETP Power house

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1.3. Location of Fakhruddin T extile Mills Ltd. :

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MAN POWER MANAGEMENT
2.1. Organogram:

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2.2. Management System:
 Buyer sample is sent to G.M.
 Matching is done by lab in charge.
 Sample is prepared by asst. dyeing master.
 Sample is resent to the buyer for approval.
 Approved sample is returned and taken as standard sample for bulk production.
 Asst. dyeing master gives responsibilities to production officer
 Then production officer, with the supervisors start bulk production
 On-line and off-line quality check is done by lab in charge and asst. dyeing master.
 After dyeing finishing in charge controls the finishing process with the supervision
of production officer
 After finishing, the material is checked by asst. dyeing master
 Finally G.M. checks the result with asst. dyeing master and decision is taken for
delivery
2.3. Shift Change: Three shifts (A, B, C): each of 8 hrs. A Shift: 7 A.M to 2 P.M.
 B Shift: 2 P.M. to 10 P.M
 C Shift: 10 P.M. to 7 A.M
 General Shift: 9 A.M to 5 P.M.

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2.4. Overall Man Power of FTML:
Departments No. Of Employees
Knitting 240
Garments-1 566
Garments-2 349
Sample 35
Project Implement 12
Printing 118
Fabric dyeing 135
Human resources 10
Planning 10
Security 32
Maintenance 22
Cutting 110
Store 21
Accounts & Finance 11
Lab & QC 10
Quality Assurance 21
Finishing 43
Total 1750

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KNITTING SECTION

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3.1. Raw Materials Used In Knitting:
Cotton 18s,20s,24s,26s,28s,30s,32s,34s,40s
Viscose 18 s,20s,24s,26s,28s,30s,3s,34s,40s
Polyamide 20 D, 40D,75D, 100D
Polyester 75 D, 100D
Spandex 20 D, 40D
Grey mélange (C-90%, V-10%) 24 s,26s
Ecru mélange (C-85 %, V-15%) 24 s,26s,28s
Anthra mélange (C-60%, V-40%) 24 s,26s,28s
PC(65% Polyester 35% Cotton) 24 s,26s,2s,30s
CVC(40%Polyester & 60% Cotton) 24 s,26s,28s,30s
3.2. Sources of Yarn for Knitting:
Yarn Count Yarn Type Brand Name
28/1 Combed Cotton NRG
30/1 Carded slub Thermax
40/1 Polyester-Viscose SQR
40/1 Carded slub Bangol
40/1 CVC NRG
36/1 Combed Cotton AA
32/1 Grey Mélange Thermax
32/1 Combed Cotton Thermax
34/1 Organic Cotton Nahar
24/1 Combed Cotton AA

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24/1 Carded slub UniTex
24/1 Carded slub Bangol
20/1 Carded slub Anwara
16/1 Polyester-Cotton SQR
75/72 Polyester Thermax
28/1 Carded slub Kamal
32/1 Viscose Liberty
30/1 Carded slub Techno
3.3 Product Mix:
# Single Jersey # Double Jersey
1. Single Jersey (plain) 1. 1×1 Rib
2. Polo pique 2. 2×1 Rib
3. Single Lacoste 3. Interlock
4. Double Lacoste
5. Fleece
3.4 Knitting Machine:
Fakhruddin Textile Mills Ltd. is well equipped modern export oriented industry. It has
high quality machinery with large production. There are 2 types of machines in this
industry. These are:-
 Circular knitting machine

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• Single jersey machine
• Double jersey machine
 Flatbed machine (cuff & collar)
Machine at a Glance:
Machine type Machine name Total no.
Circular knitting machine
Flat knitting machine
Single jersey 53
Double jersey 11
Collar, Cuff 10
Circular Knitting Machines:
M/c No. M/c
Type
M/c Dia
(inch)
M/c
Gauge
No. of
Feeder
No. of
Needle
Brand Origin
1,2,3 S/J 28 24 84 2112 JIUNN LONG Taiwan
13 S/J 36 24 108 2412 JIUNN LONG Taiwan
18 S/J 38 24 90 2856 KEUMYONG Korea
19 Rib 40 18 80 2256 PAILUNG Taiwan
20* . . . . . . .
22 Rib 42 18 84 2376 KEUMYONG Korea
23,24 S/J 24 24 72 1800 PAILUNG Taiwan

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25,26 S/J 26 24 78 1944 PAILUNG Taiwan
27,28 S/J 28 24 84 2112 JIUNN LONG Taiwan
31 Interlock 32 18 64 1800 PAILUNG Taiwan
32 Fleece 32 24 64 2400 PAILUNG Taiwan
33 Honey
comb
30 24 60 2256 PAILUNG Taiwan
35 Interlock 38 24 114 2856 KEUMYONG Korea
39 S/J 30 24 90 2256 JIUNNLONG Taiwan
40 S/J 30 24 90 2220 PAOLO ORIZIO Italy
43,44 Philip 30 20 46 1872 PAILUNG Taiwan
45,47 Fleece 32 24 96 2400 PAILUNG Taiwan
46 Philip 32 24 96 2400 PAILUNG Taiwan
51,52,53,
54 , 55
S/J 30 24 90 2256 JIUNN LONG Taiwan
63,64** Stripe

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Flat Bed Knitting Machines:
M/C No. Brand Name Origin Model M/C Type Gauge No. of
Feeder
1, 2 MATSUYA Japan 100 Fully automatic flat
knitting m/c
6 14
3, 4, 5, 6 JY-LEH
INDVSRIAL
Taiwan JY-303 Computerized Flat
knitting m/c
6 14
7, 8, 9,
10
MATSUYA Japan M-17283 Fully automatic flat
knitting m/c
6 14
Important Parts of Knitting Machine and Their Functions:
1. Needle: The needle is the primary knitting element .Needle is a thin metal bar.
Function: It is used to produce a loop.
2. Sinker: The sinker is the second primary knitting element .It is a thin metal plate.
Function:
 Holding down
 knocking over
3. Knitting Cam: Cam is the devices which convert rotary machine drive in to a suitable
reciprocation action for the needle.
i. Knit Cam
Function: To produce knit loop.
ii.Tuck Cam

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Function: To produce tuck loop.
iii. Miss Cam
Function: To produce miss loop.
4. Cam Box
5. Function: To set cam on the slider.
6. Quality Adjustments Pulleys
Function: It is used to control GSM.
7. Memminger Positive Feeder
Function: It is use to apply positive feed of the yarn.
8. Lycra Feeder Device
Function: It is used to apply positive feed of the spandex.
3.5 Knitting Process:
Knitting is the process to develop a fabric by intermeshing of loops when commercially
a knit fabric is produced it contain it some specification i.e. structure/design, GSM,
dia/width that determine the characteristics of a finished fabric. As Fakhruddin Textile
Mills. Is an export oriented industry its knitting section has to follow some knitting
parameters strongly to meet those specifications .In this segment we have tried to give a
basic concept on the implementation of knitting process.

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Process Flow of Knitting:
Yarn in cone Form
Feeding the yarn Cone on the Creel
Feeding the yarn in the feeder via positive feeding
Arrangement
Tension Device
Knitting
Withdraw the Rolled Fabric and Weighting
Inspection
Numbering
3.6 Production Parameter:
1. Diameter of the machine
2. RPM of the machine
3. No. of feeders
4. Machine gauge
5. Efficiency of production
3.7 Quality Assurance System:
After collecting fabric rolls from different machine it becomes necessary to ensure require
quality. Fakhruddin Textile Mills Ltd. maintains ISO: 9001 standard in case of quality.
Therefore it ensures quality through four point system, where fabric are inspected and give
against respective defect.

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4-Point System
 Maximum point for any fault is 4.
 One meter fabric should not mark over-4 point system whatever the faults are.
 Rejected if faults point/100 yards is 40 or over.
 4- Point Grading System
Fault Length Penalty point
3 inches or less 1
3-6 inches 2
6-9 inches 3
Over 9 inches 4
 Body and Rib Inspection
Faults Response
Loop/Drop stitch Give 4 point
Wrong design Reject
Slub Give 1 point
Hole Give 4 point
Thick/thin place Give 1 point
Star mark Give 4 point/1 point(for small point)
Pin holes Give 4 point
Barre Reject
Needle mark Major needle line is rejected
Sinker mark Major sinker mark is rejected
Birds eye Give 1 point
Oil drop Give 4 point
Contamination &fly Give 1 point
 Collar & Cuff Inspection

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Faults Response
Wrong ply Reject
Hole Reject
Missing Yarn Reject
Wrong tipping Reject
Wrong tube Reject
3.8 Fabric Faults and Their Causes:
There are various type of faults is occurred in the section of knitting .But during our
training we found the following types of faults.
1. Thick Yarn Course
Causes:
• Lot mixing
• Negligence of worker etc.
2. Hole
Causes:
• Bad needle
• Knots in yarn
• Take down mechanism too tight High tension on the yarn Bad yarn
etc. 3. Missing Yarn
Causes:
• Yarn breakage
• Faulty stop motion etc. 4. Lycra Out
Causes:
• Incorrect position of yarn guide

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• Improper sinker ring setting etc.
5. Barre/Patta
Causes:
• Uneven dial &cylinder relationship
• Lot missing Yarn count mix etc.
6. Sinker Mark
Causes:
• Old sinker
• Sinker mixing
• Dust in sinker ring etc.
7. Needle Line
Causes:
• Bad needle
• Needle mixing
• Dust in needle track etc.
8. Drop Stitch
Causes:
• Bad needle latch.
3.9 Ways of Increasing Production:
Production of knitting can be increased by the following ways:
 By increasing machine speed
 By increasing the number of feeder
 By using higher machine gauge

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 By introducing auto motion
3.10 Production Calculation:
Production/shift in kg at 100% efficiency:
No. of feeder x No of needle x Gauge x S.L. (mm) x 60 x 8
=
1000 x 840 x 2.2046 x Yarn count (Ne)
3.11 Maintenance in the Knitting Section:
To get maximum efficiency is it necessary to ensure smooth running of a machine and at
Fakhruddin textile mills ltd it is carried out by m/c servicing. At this case main objectives
are:
• To ensure required quality of the fabric
• To minimize the fabric fault
• Removal of dust from the machine
• Cleaning of different parts of the machine
Turning is a process to turn the fabric roll and it is done those fabric which are not similar
in both face and back side .The main objectives of turning is:
- To protect the side of the fabric from any dust, spot, staining and friction of machine

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CHAPTER-4
DYEING SECTION

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4.1 Machine Description of Dyeing Section:
M/c
No.
Brand Type Origin Capacity
(Kg)
M:L Max.
Temp
(0C)
Max.
Pressure
( bar )
1, 2 DILMENLER DMS
15HTsample
dyeing m/c
Turkey 15 1:6 135 3
3 DILMENLER DMS
50HTsample
dyeing m/c
Turkey 50 1:6 135 3
4 DILMENLER DMS 11HT
Jumbo Jet
Flow
Turkey 175 1:6 135 3
Jumbo Jet
Flow
Turkey 225 1:6 135 3
Jumbo Jet
Flow
Turkey 450 1:6 135 3
Jumbo Jet
Flow
Turkey 675 1:6 135 3
Jumbo Jet
Flow
Turkey 350 1:6 135 3
9 DILMENLER DMS 11HT Turkey 1050 1:6 135 2.5

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Jumbo Jet
Flow
10 TONGGENG TGURV-
NUV-6-900
China 900 1:!0 98 Low
11 TONGGENG TGURV-
NUV-6-600
China 600 1:10 98 Low
12 TONGGENG TGURV-
NUV-6-300
China 300 1:10 98 Low
Jumbo Jet
Flow
Turkey 1400 1:6 135 2.5
16 THEN DMS 11HT
Jumbo Jet
Germany 1500 1:4 140 3
Flow
17 J & X China 100 1:8 98 Low
18 EA (BD) Bangladesh 25 100 Low
19 THEN DMS 11HT
Jumbo Jet
Flow
Germany 1600 1:4 140 3
20 THEN DMS 11HT
Jumbo Jet
Flow
Germany 1600 1:4 140 3
21 Guangdong
Hessian Hongfa
China 10 1:10 140 High
Jumbo Jet
Flow
Turkey 175 1:6 135 2.5
Jumbo Jet
Flow
Turkey 350 1:6 135 2.5

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4.2 Chemical & Auxiliaries Used in Fakhruddin Textile Mills:
S/L No. Name of Chemical Common Name
1 Grad prep Hooley Detergent
2 Neuron BWLF Detergent
3 Gees QSE Sequestering agent
4 Optavon 4UD-QSE Sequestering agent
5 Lubrifil TFV- P Anti-creasing agent
6 Geistabe RS Stabilizer
7 Danilube P Anti-creasing agent
8 Gyszyme PR Peroxide Killer
9 Caustic Soda (NaOH) Alkali
10 Hydrogen Peroxide Oxidizing agent
11 A. Acid Acid
12 Glauber Salt Salt
13 GSS Multifunctional agent
14 Gradtech RDLB Leveling agent
15 Corscolor ADM Leveling agent
16 Setavin RCO Leveling agent
17 SkiantanNW Soaping agent
18 Hydroprotec COMP B Softener (for stenter)
19 NearcandPC 15 Viscose Scouring agent
20 Bio polish B 600N Enzyme
21 Retro cell PLEX Enzyme

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22 Jinsoft ECO ECA Anti-creasing agent
23 Softener SA 1000 Softener (color)
24 Jintexalate SQ 117CA Sequestering agent
25 Benlon 5020 Color softener
26 Benlon 3525 Silicon softener
27 Benlon 3526 Silicon softener
28 Aristan PSR Polyester Softener
29 Nova TTC Stenter softener
30 Grosoft SCA Silicon softener
31 Zetesal 2000 Fixing agent
32 Croscolor OZ Polyester leveling
33 Croscolor PLD Polyester leveling
34 Croscolor PCD Polyester buffer
35 Fin scour OSP Detergent
36 Setavin PA/SANZ Leveling
37 Antimussol UDF Antifoaming
38 Setasel PNT/LSP Leveling
39 Zetesall NR/NRF Fixing Agent
40 Oleophobol CO Stenter softening
41 Bilsoft 200 White softener
4.3 Dyes:
The following dyes are used:
1. Reactive 2.Disperse

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S/L
No.
Name of Dyes Manufacturer
1 Remazol RedRR Dystar
2 Remazol Yellow RR Dystar
3 Remazol Blue RR Dystar
4 Remazol Orange RR Dystar
5 Remazol Yellow 3GL Dystar
6 Remazol T/Blue G Dystar
7 Remazol BR Blue RSP Dystar
8 Bemacron Rubine SERDL Bezema
9 Bemacron orange SERDL Bezema
10 Bemacron Red SERDL Bezema
11 Bemacron Yellow SERDL Bezema
12 Bemacron Blue SERDL Bezema
13 Bemacron Turqse SERDL Bezema
14 Bemacron Black SERDL Bezema
15 Bemacron Navy SERDL Bezema
16 Bemacron Carmine HP3R Bezema
17 Bemacron Blue HP3R Bezema
18 Solazol T/Blue SPVG SOLAR FINE CHEMICAL CO.
19 Solacion Red SOLAR FINE CHEMICAL CO.
20 Solacion Orange SOLAR FINE CHEMICAL CO.
21 Solazol Orange SP3R SOLAR FINE CHEMICAL CO.
4.4 Process Flow Chart:
Production Flow Chart For 100% Cotton Fabric:
Fabric Load
Water Level - As Required
Raise temp to 60°C

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Add detergent, stabilizer, sequestering agent, H2O2
Add Caustic at 70°C - Dosing time 10 min
Raise temp to 105°C and run 40 min (pH - 10.5-1 1)
Cooling 80°C
Rinse
Drain
Fill with water
Peroxide killer inject & temperature rise 80°C & run l5 min
Rinse
Drain
Water Level - As required
Add Acetic Acid for neutralization
Add enzyme at 55°C and run 45 min (pH - 4.5 to 5.5)
Temp rise 80°C
Run l0 min
Drain
Rinse for l0 min
Add Leveling agent and run l0 min at 55°C (pH 5.5 to 6)

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Add salt run l0 min
Add color and dosing time 10 min
Machine Run time - 20 min
Add Soda at 55°C - Dosing time 45 min
Machine Run & after 20 min Sample Cutting & Shade Matching
Run the machine as required to match the shade
If shade match
Drain (Bath Drop)
Rinse until unfixed dyes are removed
Drain
Add Soaping chemical & run 30 min at 80°C
Add Fixing agent at 40°C and run for 10 min
Drain
Add Water
Cold Wash
Unload Fabric
Production Flow Chart For 100% Polyester Fabric:
Fabric Load

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Hot treatment at 80°C 20 min
Wash at 30°C 10 min
Drain
Add Acid to adjust pH
Leveling at 60°C 10 min (pH 4 - 4.5)
Color dosing at 60°C 20 min (Run time 20 min)
Raise the temperature 1.5°C /min =100°C Raise the temperature 1°C /min
=130°C
Color steaming at 130°for 60 min
Dropped the temperature 1°C/min =100 °C
Dropped the temperature 1.5°C /min =80°C
Sample cutting for shade matching
If the shade is OK
Reduction clearing
For dark shade at 90°C 30min
Cooling
Wash
Drain

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Softener dozing at 50°C
Unloading
Production Flow Chart For 100 % Viscose Fabric:
Fabric Load
Raise temp to 70°C
Add detergent, stabilizer, sequestering agent, H2O2
Add Caustic at 98°C - Dosing time 40 min
Raise temp, to 105°C and run 40 min (pH - 10.5-11)
Cooling 80°C
Rinse
Drain
Fill with water
Peroxide killer inject & temperature rise 80°C & run l5 min
Rinse
Drain
Add enzyme at 55°C and run 45 min (pH - 4.5 to 5.5)

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Temp rise 80°C
Run l0 min
Drain
Rinse for l0 min
Add Leveling agent and run l0 min at 55°C (pH 5.5 to 6)
Add salt run l0 min
Add color and dosing time 10 min
Machine Run time - 20 min
Add Soda at 55°C - Dosing time 45 min
Machine Run & after 20 min Sample Cutting & Shade Matching
Run the machine as required to match the shade
If shade match
Drain (Bath Drop)
Rinse until unfixed dyes are removed
Drain
Add Soaping chemical & run 30 min at 80 °C
Add Fixing agent at 40°C and run for 10 min

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Drain
Add Water
Cold Wash
Unload Fabric
4.5 Different Problem and Remedies in Wet Processing of Knit Fabric:
Problem Possible Cause Possible remedies
Uneven dyeing in
rope
- It can be due to fast
addition dyes/ chemicals
- Check dyestuff dissolution is
proper and uniform dosing in
machine. - Control rope speed - Use
suitable leveling agent to improve
dye migration
Dye spots - Improper dissolution of
dyestuff - Inadequate salt
solubility of the dyestuff
Metal ion sensitivity causing
precipitation of dye metal
complex.
-Ensure proper dissolution of
dyestuff and filter through fine
cloth. -Linear/progressive dosing of
alkali as per dyestuff class used
Tailing effect on
critical shades like
khaki/olive/grey
- Due to poor migration of
dyestuff
- Use of suitable leveling agent
Proper selection of tri-chromatic
combination of dyestuff
Poor washing off
fastness
-Improper fixation of
dyestuff - Improper washing
off of hydrolyzed dyestuff
Use of poor quality salt and
hard water in washing off
- Use suitable soaping agent to
wash out unfixed hydrolyzed
dyestuff Use of soft water during
washing off

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CHAPTER-5
FINISHING SECTION
5.1 Process Flow of Finishing Section:
The finishing section is divided into two lines and each line have own process flow:

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5.2 Machine Description of Finishing Section:
Fabric Slitting Machine:
Machine Name: Slitting Machine for open Fabric.
Brand name: BIANCO
Country of Origin: Italy
Year of Manufacturing: 2004
Speed of Machine: Maximum 90m/min Machine, Capacity: 10 Ton
Machine Name Brand Origin Qty
Slitting Machine Bianco Italy 02
Dewatering Machine Bianco Italy 01
Stenter Sun-Super Korea 02
BRUCNER Germany 01
Open Compactor m/c Ferraro Italy 02
Tube Compactor m/c Fab-con USA 01
Brushing m/c Kuang Taiwan 03
Dryer M/C Dilmelner Turkey 01
Air Turning m/c Dong num Korea 03
Bag Sewing m/c Hsing Chebg Taiwan 01
Total 17
Fabric unload
Finishing section
Open line Tube line
Slitting Dewatering
Stentering Drying
Compacting by open compactor Compacting by tube compactor
Inspection Inspection
Delivery Delivery

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Tubular Fabric Slitting Machine / Dewatering Machine:
Machine Name: Dewatering Machine for Tube Fabric.
Brand name: BIANCO
Speed of Machine: Maximum 80 m/min
Machine Capacity: 8 Ton
Stenter Machine 1: Machine
Name: Stentering machine
Machine Type: SST-6 GP (V1.1)
Brand Name: SUN SUPERS
Speed: 100 m/min
Country of Origin: SOUTH KOREA
Width Range: 2700 cm
Chamber of Flame: 06
Stenter Machine 2: Machine
Name: Stentering machine
Type: VN-SFP-26/8-999
Brand Name: BRUCNER
Country of Origin: GERMANY
Width Range: 2800 cm
Chamber of Flame: 08
Tube Compacting Machine:
Machine Name: Compacting machine
Machine Type: SST-6 GP (V1.1)

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Brand Name: FABCON
Speed: 75 m/min
Country of Origin:
U.S.A.
Capacity of Machine: 10 Ton
Open width Compacting Machine:
Machine Name: Compacting machine
Brand Name: FERRARO
Speed: 80 m/min
Capacity of Machine: 8
Ton
Dryer Machine:
Machine Name: Dryer machine
Brand Name: DILMENLER
Country of Origin: Turkey
Speed: 50 m/min
Capacity: 12 Ton
Power Consumption: 139.25 KW
Working Width: 2400 mm
5.3 Process Description on Tube Line Finishing:
1. Dewatering
The removal process of excess water through squeezing by means of pressure (applied by
two cylinders).

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Function of the Machine:
 Use to remove excess water after pretreatment and dyeing
 Delivered fabric is crease free state
 It can control the diameter of fabric and GSM and shrinkage by over feeding
mechanism To impart soft finish to the fabric by using required softener.
Important Parts:
 Stretches (to control width)
 Over feeding wheels (to control GSM)
 De –watering device (to deliver the fabric roll in untwisted form)
 Folding device (to deliver the fabric in folded form)
 Squeezing roller
 Air injector to form balloon
Controlling Parameter:
 Overfeed
 Speed
 Padder pressure
 Stretch
2. Drying
Drying is defined as a process where the liquid portion of the solution is evaporated from
the fabric.
Function of the machine in
drying: To control
GSM
 To control the shrinkage
 To prepare for next subsequent process
 To dry tubular fabric without tension

41
Important parts:
- Over feed roller
- Conveyor belt
- Heating chamber(3)
- Blower
- Burner
- Exhaust fan
- Filter net
- Folding device - Vibrator
Controlling Parameter:
Temperature: It depends on GSM and shade % of a fabric. Normally following
temperature is maintained depending on the shade%
- Dark shade: 140-170°C
- Medium shade: 130-150°C
- Light/ white shade: 110-130°C
2. Speed: Normally 6-18 m/min speed is maintained.
3. Overfeed (%): It depends on construction of fabric.
- Plain/single Jersey:
18-20 % - Rib: 14-16
%
Checking Parameter:
1. Shade checking: After running the machine the shade is checked with approved swatch
at delivery side.

42
2. Width checking: Required width is measured at delivery side.
3. GSM Checking
3. Compacting
Compacting is a method whereby the course loops are compressed upon themselves.
The fabric is steamed to add moisture and then introduced to the compacting zone. The
compaction mechanism, along with heat and moisture, forces the length stitches(courses)
to be compacted.
Function of compactor
 Shrinkage control
 GSM control
 Width control
Important parts
 Over feed control
 Steam sprayer
 Stretcher Cylinder Blanket
 Teflon covers
Controlling parameter
1. Temperature
2. Speed
3. Blanket pressure
4. Overfeed

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5.4 Process Description on Open Line Finishing:
Slitting
Slitting is a process that is applied for cutting the tubular fabric through the intended
break wales line on length wise direction.
Function of slitting machine:
1. De-twisting
2. Extraction
3. Slitting
4. Opening
5. Plaiting
Important parts:
 Squeezing roller (to remove water)
 Stretcher (to control width)
 Over feeding wheels(to control GSM)
 De-twisting device (to deliver the fabric roll in untwisted form)
 Plaiting device (to deliver the fabric in folded form)
Controlling parameter:
 Pressure
 Speed
Checking parameter
 Cutting line check
 Faults check

44
Stentering Function:
 Drying
 Heat setting
 Width control
 Chemical finishing
 GSM control
Different parts/ zone at stenter frame:
1. Feed zone: fabric feeding.
2. Chemical padding zone: Here fabric is washed or padded with required chemical and
excess materials are removed by squeezing.
3. Over feed roller: Depending on GSM over feeding or under feeding is given by over
feed roller.
4. Selvedge detector: It detects the selvedge, prevent the curling and adjust the rail for
proper gripping of the fabric in the pin arrangement.
5. Brush roller: For attaching the fabric with the pin of the chain.
6. Drying zone: Each chamber of stenter contains two burners, two blowers, two ducting
line, nozzle, and suction fan attached with suction line. The burner produces hot flue
gases which through the ducting line by the help of blower. There are nozzles placed
above and below the rail. When the fabric is passed through the rail then hot air is
sprayed to the above and bellows the fabric with the help of nozzle. The hot air is
circulating in the chamber and moisture of fabric which is evaporated; leave the chamber
with the help of suction fan through the ducting line. Temperature of each chamber can
control automatically by controlling the intensity of burner.
7. Cooling zone

45
8. Delivery zone
Controlling
points: a)
Temperature
b) Over feed
c) Fabric width setting
d) Speed
Compacting Function:
1. Shrinkage control
2. Width control
3. GSM control
Important parts:
 Overfeed roller Blanket
 Steam sprayers
 Cylinder
 Teflon covers
Controlling
parameter:
Overfeedi
ng
 Blanket pressure
 Steam pressure
 Temperature
 Speed

46
CHAPTER-6
QUALITY ASSURANCE
In textile industry; quality is assured in different stage of production. From the raw
materials to the finished goods, quality is assured by the quality control department. Quality
is assured in fiber selection, yarn production, fabric manufacturing, wet processing and
apparel manufacturing. Also, quality is checked for dyestuff and chemicals which is used
in dyeing, printing and finishing. Most of the times, quality control department gives a
quality pass certificate before export. In this section we have tried to provide activities of
quality assurance at Fakhruddin textile mill Ltd.
6.1 Quality Control
Quality control is a process to ensure quality product by following standard inspection
and testing system. At this case Fakhruddin Textile mill Ltd. maintain following
standard to ensure quality product:
 ISO standard
 AATCC standard
 M&S standard
The quality assurance system at Fakhruddin Textile mill Ltd. is maintained by two
ways:
1. Online Quality control
2. Offline Quality control
Online Quality control:
The functions of Online Quality control are:
a) Raw material control
- Selection of materials and supplies
-

47
-
- Maintaining proper specification of
materials - Checking /Inspection of
incoming materials
b) Process control
- Proper controlling of process parameter I .e .time,temperature ,speed, pressure, addition,
or discharge of dyes, chemicals liquors. - Checking /monitoring of process parameter. -
Ensuring require quality at every process
c) Finished goods Inspection
The finished goods inspection is carried out through four point grading system.
Offline quality control:
Offline quality control generally comprises different tests of final product so that it is
possible to identify whether it pass against the norms given by buyer.
The following test are generally done-
- GSM test
- Shrinkage test
- Spirality test - Shade check
- Wash fastness test
- Fastness to water
- Perspiration test
- Rubbing fastness test
- Durability test
- Dimensional stability

48
CHAPTER-7
LAB- DIP UNIT
7.1. Function/Activities:
 Color measurement, recipe formulation &correction by computer color matching
system To carry out lab dyeing
 Maximization of “right-first- time” dyeing and minimization of re-dyeing, color
addition/ topping.

49
7.2. Computerized Color Matching System:
In case of color measurement, recipe formulation & correction Fakhruddin Textile
mill Ltd. use following instrument and program:
Spectrophotometer
Specification:
Brand Name: Spectrophotometer SF600 CT PLUS
Made by: Data color Institution
Wavelength range: 400-700 nm
Wavelength interval: 10 nm
Dual beam Light source: Pulsed xenon lamps
Functions:
Measure the reflectance of colored sample in at least 16 wavelength in the visible
spectral region 400-700 nm.
The wavelengths are measured at 10 nm interval.
Uses: The reflectance value of a sample can be used to calculate the tri-stimulus
values of that sample under the given illuminant.
Program
 Data color software
 M & S standard software
Function:
 Colorant recipe formulation and correction
 Color difference assessment in various light source

50
 Predict mesmerism ,cost , and fastness of each recipe
 Give the decision of pass/fail of a dyed sample by assessing color difference at
tolerance limit.
Personal computer
All the CCM system is controlled & observed by this computer
Printer
It give hard copy of formulated recipe, color difference, reflectance value /curve
Lab dyeing process
In case of lab dyeing Fakhruddin Textile mills Ltd. have developed following programs
depending on the shade % and type of substrate which is always perform on 10 gm. of
sample.
Dyeing program for light shade
Dyeing program for medium
shade. Dyeing program for
dark shade. Dyeing program
for turquoise color Dyeing
program for polyester.
7.1 Material Testing:
Fakhruddin Textile Mills Ltd. has well equipped quality control lab. There lab is
recognize by Marks & Spencer. They follow Marks & Spencer testing procedure for
testing fabric and raw materials. There are two types of materials are tested in Fakhruddin
Textile Mills Ltd. laboratory for the purpose of quality control.
This are- A. Fabric testing
B. Raw materials testing

51
A. Fabric testing:
To control the quality of the fabric two types of tests are mainly done-
1. Physical test
2. Chemical test or color fastness test.
1. Physical test:
- G.S.M
- Spirality test
- Shrinkage test
- Durability test
- Level wash test
- Garments durability test - Print durability test
2. Chemical test / color fastness test:
- Color fastness to water
- Color fastness to wash
- Color fastness to rubbing
- Color fastness to perspiration
B. Raw material testing:
a. Water : pH & Hardness test
b. Glauber’s salt : Purity test
c. Acetic Acid : Strength test
d. Caustic soda : Strength test
e. Soda ash : Strength test
f. Hydrogen per oxide : Strength test

52
7.4 List of the Test Performed in the Dyeing Laboratory:
Name of The Test Purpose Method
Color Fastness test to
Wash
To check color fastness after
washing.
ISO 105 C03
Perspiration
To check color fastness
against perspiration
ISO E04:1994
Water
against hot and cold water
ISO E01:1991 ISO
E08
Crocking
against rubbing
AATCC-08
ISO-105 X 12
Light
against light
AATCC-16
Dimensional Stability To check the Dimensional
Stability after finishing.
AATCC-135/150
Torque To determine the Spirality AATCC-179
Bursting To determine the bursting
strength of a finished fabric
ASTM-D3786
Pilling To determine the pilling
property of a finished fabric
ASTM-D3512
AATCC-18000
ISO-3000
Color Fastness Test to Wash (ISO 105 C 03):
Test Specimen:
1) Colored
Sample: Type:
Fabric Size:

53
10cmx40cm 2)
Multi-fiber
Fabric: Type: DW
Size: 10cmx4cm
Recipe:
Soap: 5g/L
Soda ash: 2g/L
Temperature: 600
C
Time: 30 Minute
M: L: 1:50
Color Fastness Test to Perspiration (ISO E 04:1994):
Test Specimen:
1) Colored Sample:
Type: Fabric, Size: 10cm
x 4cm 2) Multi-fiber Fabric:
Type: DW, Size: 10cm x 4cm
Recipe:
Chemicals
Condi
Tions
Acidic Alkaline
l-histadine monohydrochloride
monohydrate
0.5 gm. 0.5 gm.
NaCl 5 gm. 5 gm.
Di-sodium hydrogen
orthophosphate dehydrate
2.2 gm. 2.5 gm.

54
Color Fastness Test to Water (ISO 105-E01:1991) Cold:
Test Specimen:
1) Colored
Sample: Type:
Fabric Size:
10cm x 40 cm
2) Multi-fiber
Fabric: Type:
DW
Size: 10cm x 4 cm
Recipe:
Immersion:
Distilled Water: 250ml
Temperature: Room Temperature
Time: 15Minute
Pressure: Pressure: 12.5 Kpa
Temperature: 370
C
Time: 4 hours
Distilled water 1000 ml 1000 ml
pH 5.5 8.0

55
Color Fastness Test to Water (ISO 105-E08) Hot:
Test Specimen:
1) Colored
Sample: Type:
Fabric Size:
10cm x 4cm 2)
Multi-fiber
Fabric: Type:
DW
Size: 10 cmx4cm
Recipe:
1) M:L : 1:50
2) pH: 6
3) Temperature: 68-720
C
4) Time: 30 Minutes
Color Fastness Test O Crocking (ISO 105 X 12):
Test Specimen:
1. Colored Sample:
Type: Fabric
Size: 14cm x 5cm
2. Rubbing Cloth:
Size: 5cm X 5cm

56
Properties: Desized, scoured, bleached, mercerized but not finished.
Apparatus:
I. Crock Meter
Manufacturer: James H.
Heal Origin: England
II. Grey Scale for staining
Grey Scale for Shade Change
Spirality Test / Skewness Change In Fabric & Garments Twist
Resulting From Automatic Home Laundering (AATCC-179):
PRINCIPLE: Change in skewness in fabric or twist in garment specimens resulting
from procedures typical of home laundering practices is measured using benchmarks
applied to the specimens before laundering.
Apparatus & Materials Used:
1. Indelible ink marking pen
2. Right triangle, L-square or marking template
3. Tape or rule marked in mili-meters, tenths of an inch or similar increments.
4. Conditioning or drying racks with pull-out screens or perforated shelves.
5. Automatic washing machine.
6. AATCC standard reference Detergent.
7. Automatic tumble dryer.
8. Facilities for drip drying & line drying.
9. Digital imaging system.

57
CHAPTER-8
MAINTENANCE MANAGEMENT
Maintenance is a process by which equipment is looked after in such a way that
trouble free. Services and increased machine life can be ensured and specific product
quality required by the customers is sustained. Machine, building & facilities are subjected
to deterioration due to their use & exposure to environmental condition. Process of
deterioration, if unchecked, culminates in rendering these service facilities unserviceable
& brings them to a standstill. In industry, therefore has no choice but to attend them from
time to time to repair & recondition them so as to elongate their life to extent it is
economically & physically possible to do so. It is in this in the context that maintenance
assumes important as an engineering function. It is made responsible for provision of a
condition of these machines, buildings & service that permit uninterrupted implementation
of plans requiring their use. Maintenance of machineries is very important for any type of
industries and it is a must for a knit composite mill. All machines and machines parts of
knitting, dyeing and garments are maintained with extreme care. Because production
quality and quantity, both depends on the maintenance with regularity.
8.1 Objectives of Maintenance:
1. To keep the factory plants, equipment’s, machine tools in an optimum working
condition.
2. To ensure specified accuracy to product and time schedule of delivery to customer.
3. To keep the downtime of machines to the minimum thus to have control over the
production program.
4. To keep the production cycle within the stipulated range.
5. To modify the machine tools to meet the need for production.

58
Flowchart of maintenance:
Problem
Inform to maintenance department
Detect problem
Problem can be repairing or replacing
Repair can be solved immediately, replacing requires time (parts needed to buy & then
solved the problem)
8.2 Maintenance System:
8.3 Maintenance Procedure of Different Machineries:
1. Dyeing machine
Maintenance:
Mechanical Items need
to be checked & Service
 Grease the winch bearing.
Maintenance
Preventive Breakdown
Electrical Mechanical Electrical Mechanical

59
 Complete cleaning of machine.
 Cleaning of drain valves, replace scale if required.
 Checking air supply filters, regulators and auto drain scales Cleaning filter
element and blow out.
 Greasing the unloading roller bearings.
 Checking oil level and bolts of unloading roller gear box.
 Checking of unloading roller couple and packing.
 Checking and cleaning of main vessel level indicator.
 Check the oil level of pump bearing and refill if required.
 Check the function of heat and cool modeling values.
 Check all belts and belt tension

1. Dewatering machine
2. Maintenance: Mechanical
Items need to be checked & Service
 Grease padder bearing & expender device unit by Staburg NBU Complete
cleaning of m/c.
 Checking oil level and bolts of unloading roller gear box.
 Check oil level of hydraulic system.
 Check all belts, all chain and belt tension.
 Check gear box plotting and its oil.
 Check main line air pressure and air pressure gauge.
 Check pneumatic belts, brushes, if required tight them properly.
 Check in feed motor.

60
 Check squeeze roller hydraulic cylinder.
 Check turn table, belt tension, and gearing.
3. Dryer machine
Maintenance: Mechanical
 Clean filter net of the machine. clean hot air ducting of the machine Burner
blower impeller cleaning.
 Complete cleaning of the m/c
 Greasing of all the bearing
 Conveyor net checking & repairing if required
 Inside chamber all fiber rail checking
 Exit conveyor checking properly & repair if required
 Plaiter checking

4 .Tube compactor
 Check & clean fluff & dirt at all motors fan covers.
 Clean panel’s vs cards & inverter by using compressed airs.
 Check photocell & adjust if required.
 Check all safety limit switches.
 Check all on/ off& emergency switches.
 Check all indicating lamp.

61
 Check steam solenoids.
 Check all circuit breakers, magnetic contractors & relays.
 Visual inspection of all control & power cables.
 Check all motor terminals.
 Check the potentiometer of main speed.
 Check temperature controllers of cylinder.
 Check compensator for speed synchronization of 1st and 2nd cylinder.
 Check carbon brash for 1st & 2nd cylinder heating system.
5. Bianco Slitting m/c
 Grease padder bearing (staburg NBU-12 energrease 1002)
 Complete cleaning of m/c
 Check turns table and grease with BP energrease LS-2
 Check turn V –belt & adjust its tension if required
 Check all belts and chain tension
 Check oil level of turn table gear box
 Check basket roller drive ,gearbox ,and grease as required
 Check all roller rubber gripping tape
 Check alignment of all chains ,check tensions, and give oil if required
 Checking turn table
 Checking knife
 Checking all scroll rollers and its bearing

62
6. Stenter machine
 Grease all bearing with stuburg NBU-12 energrease 1002
 Complete cleaning of the machine
 Check all belt and belt tension
 Check all door silts
 Check gear box of platting and its oil
 Check all pin bars and clean
 Check chain and give oil if required
 Clean exhaust blower and duct
 All chamber blowers check and clean
 Chamber nozzle cleaning
 Check gas pressure , adjust if required
7. Open Compactor
 Check steam pressure and adjust it if required
 Complete cleaning of m/c
 Check steam and pneumatic pipeline for any leakage and service/repair if required
 Check the function of all pneumatic cylinders and service/repair if required
Check all pneumatic solenoids
 Check all talons for visible damage , foreign particles and check its position

63
 Check all motors ,gearbox, roller and its bearing for any defect and grease the
bearing
 Check all the belts for tension , visible damage and position on roller
 Check impellers of suction & exhaust blower for clogging with foreign particles
and clean
 Check all chain and sprockets for alignment ,tension and lubrication
 Check the exit conveyor for smooth running and visible damage
 Check all belts and belt tension
 Check plaiter for smooth operation
 Check loading device
 Check steam trap
8. Boiler
 Check and clean fluff & dart at all machine
 Feed pump servicing
 Main boiler servicing
 Check all temperature & pressure gauge meter
 Check gas strainer
 Clean gauge glass & change if required
 Clean feed tank
 Clean fire tube
 Clean all safety values
 Check all steam values (ball value, glove value, pneumatic value etc.)
 Check all gas regulator
 Auto blow down operation check

64
CHAPTER-9
UTILITY SERVICES

65
As Fakhruddin Textile Mills Ltd. is large manufacturing unit obviously it
has some utility service. The available utilities are:
a. Water
b. Steam
c. Electricity
d. Compressed air
e. Gas
Water:
Source of water is land water which is pumped by deep tube well.
Water treatment plant: Small, medium, & big size industries use treated water
to different machine like boiler, dyeing, washing machine. They collect this water from
land by deep tube well. But raw water content different types of foreign materials like oil
or gummy substances. Iron, Copper, Manganese & their salt, etc. The hardness of raw
water is 100 ppm or more. To use it in dyeing and in boiler this water needs to be
softened & foreign materials needs to be removed. Otherwise this may create problem in
processing like precipitation of soap, redeposit on fabric & scale formation on pipe line
etc. There is no WTP at Fakhruddin Textile Mills Ltd.
Supply water is used there for every process as the hardness of water is very low.
Steam:
Steam is produced by boiler .From the Water Treatment Plant, water is stored in
a reserve tank and from there water goes to boiler & steam is produce.

66
Speciation of Boiler:
Boiler No: 01
Serial 23/3599
Brand Name Cochran
Type Fire tube boiler
Country of Origin UK
Year of Manufacturing 2006
Maximum Allowable Pressure 11 bar
Maximum Allowable Temperature 188 0
c
Hydraulic test date 28-04-04
Maximum Heat output 2820 KW
Safety Value set Pressure 10.9 bar
Hydraulic test pressure 16.50 bar
Boiler No.: 02
Serial 23/4171
Brand Name Cochran
Type Fire tube boiler
Country of Origin UK
Year of Manufacturing 2006
Maximum Allowable Pressure 11 bar
Maximum Allowable Temp. 188 0
c
Hydraulic test date 26-06-06
Maximum Heat output 2820 KW
Safety Value set Pressure 10.9 bar
Hydraulic test pressure 16.50 bar

67
Source of electricity:
1. Gas generator
2. Diesel generator
Generator specification:
M/c No: 01
Model MTG 846
Serial BZ5L 4895
Brand Name LS2000
Origin USA
Type Gas generator
Manufacturing date 2004
KVA prime 200KW
KVA prime 250 KVA
Power factor 0.8
Volts 415
AMPS 1304
Frequency 50 Hz
RPM 1000
Phase 3
Temp Rise 105o
c
Maximum Ambient Temp 40o
c
M/c No: 02
Model G3516B
Serial SWNO 2962
Brand Name CAT
Origin U.K
Type Gas generator

68
KVA prime 1145 KW
KVA prime 1431 KVA
Power factor 0.8
Volts 400
AMPS 2066
Frequency 50 Hz
RPM 1500
Phase 3
Temp Rise 105o
c
c
M/c No: 03
Model GEH 275-2
Serial OLY PMPN O2584
Brand Name OLYMPIAN
Origin U.K
Type Diesel generator
KVA prime 250 KW
KVA prime 200 KVA
Power factor 0.8
Volts 415
AMPS 2066
Frequency 50 Hz
RPM 1500
Phase 3
Temp Rise 105o
c
c

69
CHAPTER-10
INVENTORY MANAGEMENT
Inventory is stock or store of good. Inventory management is a vital part for any factory
because smooth production as well as cost of storage depends on it.

70
10.1 Scope of Inventory Control:
- Raw materials inventories
- In process inventories Finish good inventories
- Maintenance, repair and operational inventories
- Miscellaneous inventories
10.2 Function of Inventory:
- To smooth production requirement
- To meet anticipate demand
- To protect against stock outs
- To take advantages of order cycles
- To take advantages of quality discounts
10.3 Inventory Store System for Raw Material:
In Fakhruddin Textile Mills Ltd. there is different inventory systems for different raw
materials.
Grey Fabric Store:
All the grey fabrics are stored in the fabric store near the batch section. Different types of
fabric are listed in the sheet according to fabric types, quantity and consumer's
requirement.

71
Dyes and Chemicals store:
There is a different store for dyes and chemicals. Varies types of dyes and
chemicals are stored here according to dyes and chemicals companies. Different types of
dyes and chemicals are listed in a sheet. In the sheet the stored quantity of dyes and
chemicals are also included. Every day the sheet is updated and a copy of this sheet is
supplied to the dyeing manager, dye house and lab section.
Finished goods store:
In Fakhruddin Textile Mills Ltd. supplies its finished dyed fabrics to its
garments section. So, dyed finished fabrics are stored for short time in the finished fabric
store section. All the delivered fabrics are noted on the tally khata according to the lot no,
quantity, fabrics diameter, buyer's name, Color & considering other technical parameters.
Spares part store:
In Fakhruddin Textile Mills Ltd. required amount of spears of different
machines are stored in the mechanical store room. All the spears are listed in a sheet
which is controlled by the mechanical & maintenance personnel. Spares are arranged in
the store room according to their size, quantity & requirements. There are shelves in the
store room to keep the small spare parts.
Store capacity:
Items Amount
Dyes 10- 15 tons
Chemicals 40-50 tons
Yarn storage 60 tons
Grey fabric 140 tons

72
Frequency of Inventory control:
Daily inventory control Monthly inventory control - Yearly inventory control
Re-order point:
The re order point is stated in terms of level of inventory at which an order should be
placed for replenishing the current stock of inventory. Re order quantity depends on the
lead time of the product with some additional safety period. It also depends on the store
capacity of factory. For example if the lead time of a product is two month then normally
re ordering quantity may be for two and half months.

73
CHAPTER-11
MARKETING
In an uncertain world market Fakhruddin Textile Mills Ltd. doubled their
efforts with our design team leading the way; they increased their calls as the customers &
looked for ways to add new ones also. Having established a strong relationship with Buyer
and becoming one of their core suppliers, Fakhruddin Textile Mills Ltd. targeted Europe
& USA also and made inroads there. Fakhruddin Textile Mills Ltd. added new and
dynamic designers to the existing team & can proudly say that their spring and autumn

74
collections were hailed as some of the best to be presented. These meetings
boosted the confidence of existing buyers and attracted new customers. Fakhruddin
Textile Mills Ltd. continued with their strategy to market value added products like dyed
fabrics with special finishes. This is reflected in the increase in average price per linear
meter.
11.1 Product & Customer:
As it is an apparels manufacturing industry, its main product are fashion T-shirts,
Polo shirts, knitted shorts, Leggings, Nightwear and school wear, Trousers, Fleece Jacket,
Vest. Ladies dresses etc. The factory ensures safe/metal free garments as per customer
requirements, through practice of metal detection & needle/metal control procedures. All
kinds of S/J, Rib, Interlock, Pique ,French Terry, Brushed Fleece, Dobby Pique, Drop
Needle etc. of:
 100 % Cotton & Different blend of Cotton and Polyester.
 95 % Cotton, 5% Lycra.
 100 % Organic Cotton.
 Blend of Organic and normal Cotton. 100 % Modal. T/C & CVC
Special Fabrics: Category
Mix:
• Coolmax. > Men's -25 %
• Soil / Stain Release. > Ladies -45 %
• Water Repellent.
> Children -20
%
• Silver Finish (Anti-Bacterial) > Infant -10 %
• UV Finish.
• Viscose- Elastane

75
• Polyamide- Elastane
BUYER NAME:
Triton
Auchan
S.oliver
Tesco
V-tex
Holy prom
La redoute
Vert
H & M
Ellos
Sonnet
Lidl Germany
Brylante USA
Kiabi
Regatta UK
Avenue USA
M & S
11.2 Exporting Countries:
The major countries where Fakhruddin Textile Mills Ltd Export their goods are given
below:
 Germany Spain
 Denmark
 Europe
 USA

76
11.3 Buyers Compliance:
The factory is full compliance with ILO and Bangladesh Labor Law.
Their company policy is as follows:
 No child labor.
 No forced labor.
 Transport facilities for worker.
 Hours of work.
 Voluntary over time.
 Intervals for rest.
 Weekly holidays.
 Annual leave.
 Festival holidays & leaves with bonus.
 Maternity protection.
 Worker's welfare committee.
 Mineral drinking water.
 Sanitary facilities.
 First aid box.
 Canteen services.
 Day care center.
 Health care activities for the worker & employ company doctor.
 Fire extinguisher each & every floor & conduct fire drill at least 12 times a year.
We are giving a top priority on prevention of fire and eventual evacuation.
 Other safety department (no discrimination).
 Compensation cases department.
 The development of compliance programmer.
 Environmental developer. Smoking free zone.

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11.4. Marketing Strategy:
Marketing strategy is a very important factors to sale the products to the buyer. If
the marketing strategy is not so developed, it will be very hard to reach the goal. In case of
garments marketing the dealings with the buyer is a very important factor.
In Fakhruddin Textile Mills Ltd. mainly senior marketing officers, merchandiser &
higher officials deal with the buyer. There are some fixed buyers of the industry. The
buyers give their orders continuously all over the year. The marketing officers & the
merchandisers communicate with the buying houses to collect the orders. By both side
understanding the rate & the order quantity are fixed.
11.5. Duties & Responsibilities of Marketing Officer:
Dealing with the buyer & convince the buyer is the main duty of the marketing
officer. A marketing officer also has some other duties. The main duties & responsibilities
of a marketing officer are given below:
 To prepare cost sheet by dealing with the buyer.
 To take different steps by discussing with the higher officials & merchandisers
To maintain a regular & good relationship between commercial officer &
merchandisers To maintain a regular communication with the buyers & buying
houses .
 Communicate with the new buyers.
 Display the better criteria of the products.
Actually the responsibilities & duties of marketing officer begins from getting order of
buyer & ends after receiving goods by the buyer . So he should be always smart, energetic
& sincere to his duties.

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11.6 Marketing Information:
The declining retail sales and the losses shows by big retailers worldwide and
consequent drop in order in the world wide garment industry proved to be a major challenge
to our marketing efforts and strategy. In an uncertain world market, Fakhruddin Textile
Mills Ltd. doubled their efforts with our design team leading the way; they increased their
calls as the customers & looked for ways to add new ones also. Having established a strong
relationship with Buyer and becoming one of their core suppliers, Fakhruddin Textile Mills
Ltd. targeted Europe & USA also and made inroads there. It. added new and dynamic
designers to the existing team & can proudly say that their spring and autumn collections
were hailed as some of the best to be presented. These meetings boosted the confidence of
existing buyers and attracted new customers. Fakhruddin Textile Mills Ltd. continued with
their strategy to market value added products like dyed fabrics with special finishes. This
is reflected in the increase in average price per linear meter.
Remarks:
Fakhruddin Textile Mills Ltd. has a well learned marketing & merchandising team.
They always communicate with the buyers. This has some fixed buyers. The marketing
section also looks for the quality and quantity buyers.

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CHAPTER-12
ENVIRONMENT INFORMATION
12.1 Environment Management System of Fakhruddin Textile Mills
Ltd:
Fakhruddin Textile Mills Ltd. recognizes that its activities impact upon the
environment through its routine internal operations, its infrastructural development and
through its influence and effects on the wider community. It acknowledges a
responsibility for and commitment to, protection to the environment at all levels and try
to minimize the potentially harmful effects of such activity wherever and whenever
possible. They comply fully with environmental legislation application in garments
industry. As part of their continuing drive for quality in all things they therefore develop
a comprehensive policy system which will enable them to set a target which will enable
them to measure and monitor their efforts on sustainable environmental improvement on
regular basis. Sources of environmental hazard in the factory complex:
 Wastages of fabric and accessories and other storage.
 Electrical wastage and other storage.
 Empty chemical container.
 Effluent (Factory waste water).
12.2 Fabric and Accessories Wastage Management System:
Wastage baskets are placed in the production floor. During the working hour
cleaners and loaders keep the floor wastage in the basket. Once the basket is about to be
full loader carry all the wastage to waste designed area which is 100 yards out side of the

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main factory building. When 80% of waste stores filled up, then the waste is sold to the
customer.
12.3 Electrical and Mechanical Wastage Management System:
Electrical wastage will be stored in the designed area of the factory complex and
maintenance department disposed of the wastage by burning or selling.
12.4 Empty Chemical / Dye Container Management System:
Empty chemical containers are stored in designed chemical wastage area and sold
to outside people or disposed of by burning in the desire area on weekly basis.

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CHAPTER-13
EFFLUENT TREATMENT PLANT

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Effluent means liquid waste from the wet processing industry. Dyeing, printing
and finishing- industries produce a large amount of liquid waste. The characteristics of
effluent are summarized as follows-
1. PH and alkalinity.
2. Suspended solids (SS).
3. Dissolved solids (DS).
4. Total solids (TS).
5. AOX (Absorbable organic halogen).
6. BOD (Biological oxygen demand).
7. COD (Chemical oxygen demand).
8. Color
9. Metal ion.
Effluent Parameters (Bangladesh Standard):
Flow Rate 30 m3/hr.
pH 7-8
BOD < 50 PPM
COD <250 PPM
TSS <100 PPM
TDS <2000 PPM
Oil & Grease <10 PPM
Color Clean
Temperature <300
C

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Types of effluent treatment plant:
1. Physico-chemical treatment plant.
2. Biological treatment plant.
3. Physico- chemical- biological treatment plant.
In ETP of FTML biological treatment plant is used.
Machine Used In ETP Plant:
1. Equalization tank (where air supplied through a blower )
2. ECR (Electro contaminant removal )
3. Flash mixer tank
4. Flocculation tank
5. Tube settler 1
6. FAP 1
7. pH control tank
Capacity of ECR:
There are two ECR in this plant. Capacity of each ECR is 60 m3
/hr.
Flowchart for ETP:
Drainage water (after dyeing)
Equalization tank (where air is inserted through a blower which makes oxygen)
(Pumping )

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ECR (Electro contaminant removal)
Flash mixer tank
Flocculation tank (where polymer is added which worked to thicker the sludge which is
produced due to waste)
Tube settler 1(Here several tube is present for keep the sludge below the liquor)
FAP 1(Where air is added to produce O2)
PH control tank (where HCl is used & kept pH 7) →Discharge Water
Aeration Tank
Clarifier Tank→ Treated Effluent
Excess sludge recycle tank
Dispose/Brick fire
Chemical Used:
1. Polymer (Electrolyte )
HCl (to keep pH at 6-8)

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CONCLUSION
Industrial training is an essential part for textile education because it minimizes the
gap between theoretical and practical knowledge. Undoubtedly, this industrial training
helped us a lot about textile technology, production process, machineries, and industrial
management and made us comfortable with industrial life. Besides it give us the first
opportunity to work in industry. During our two month industrial training at Fakhruddin
Textile Mills Ltd. we have got the impression that this factory is a modern export oriented
knit composite industry. Though it was established 5 years ago, it has achieved a very good
reputation in foreign market for its best quality product over many other export oriented
textile mills by establishing on-line and off-line quality control system of each product.
They have well equipped and modern textile testing laboratory. They do all the chemical
& physical tests of dyed good and the results are very good and within the buyer’s
acceptance limit. During our training period we have rarely saw many faulty dyeing. If
there was any problem it was quickly removed with the help of experienced and skilled
manpower. During this period we have never seen any stripping of color from fabric.
Moreover they use good quality yarn, dyes, and chemicals in production. The
administration & management are well organized. In our training period, talking with the
clients of this mill we knew that the mill is fulfilling the country’s best export oriented
white finished fabric as well as very good colored fabric due to its modern machinery &
good management system. Mill is settled with utility to give all convenient supports to the
productions for twenty-four hours. We are enough fortunate that we have got an
opportunity of having a training in this mill. During the training period we are received co-
operation and association from the authority & found all man, machines & materials on
appreciable working condition. All stuffs & officers were very sincere & devoted their
duties to achieve their goal.

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