Uttara Knitting & Dyeing Ltd. is a knit composite dyeing industry located in Gazipur, Bangladesh. It has 14 dyeing machines from Japan with a total dyeing capacity of over 3,000 kg. The dyeing machines include high temperature jet dyeing machines and atmospheric dyeing machines. The company also has laboratory facilities for dye testing including a light box, balances, iron, sample dyeing machine, washing machine, and pH tester. However, the dyeing laboratory is not very developed.

1. Page no: 1
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
Uttara Knitting & Dyeing Ltd.

2. Page no: 2
CHAPTER – I
PROJECT DESCRIPTION

3. Page no: 3
CHAPTER – I
1. Name of the company: Uttara Knitting & Dyeing Ltd.
2. Status : Private Ltd. company
3. Type : 100% Export oriented composite knit
dyeing industry
4. Year of establishment : 1997
5. Location : South Pansail, Zirani bazaar, Gazipur
Sadar, Gazipur
6. Address :
Factory : South Pansail, Zirani bazaar, Gazipur
Sadar, Gazipur
Head Office : 39, Dilkusha C/A, Dhaka - 1000
7. Sponsor : Late. Md. Moklesur Rahman
8. Product mix : 100% cotton, 100% polyester, Chief
value
cotton, P/C
9. Annual production capacity 1800 tons
10. Project cost 22 crs (Initial), 50 crs (Present)
11. History of the project development
1994 – Establishment of the industry at Tongi with 8 Knitting
m/c.
1997 – Shifted in Zirany, Gazipur Sadar, BKSP with 24 knitting
m/c
(rib – 3, S/J - 21)
1997 – Installment of 7 Dyeing m/c
1997 – Installment of 6 Flat Collar m/c
2000 – Installment of 3 rib m/c
2003 – Installment of 4 Dyeing m/c (Bangla)
2004 – Installment of the 2 Sample Dyeing m/c (5 kg, 25 kg)
2004 – Installment of 3 Pai Lung m/c

4. Page no: 4
12. Different departments :
To run the factory smoothly, there are some department in the
factory . They are given bellow:-
KNITTING SECTION:
 Knitting
 Inspection
DYEING SECTION
 Batch section
 Dye house
 Dyeing lab.
 Quality control
 Finishing
MAINTENANCE
 Electrical
 Mechanical
ACCOUNTS & COMMERCIAL SECTION
ADMIN SECTION
 Time section
 Cleaning
 Security
 Store
13. Total area of the industry : 30 acres
14. Area of the plant : 20 acres
REMARKS:
Uttara Knitting & Dyeing Ltd. is a well established Knit Composite Industry. The
industry stands by the side of BKSP. The area is sufficient for the industry. But
its drainage system is not very good. There is no system for effluent treatment.

5. Page no: 5
Chemical
Store
Q.C.
&
Lab
Office
Store
Delivery
Fabric
Store
Dyeing
manag
er
Mixing
Room
Produc
tion
Officer
Tensionless dryer
Softene
r
Calator
Soft set -
2
Steam
Set m/c 2
Soft set -
1
Steam
Set m/c 1
compacto
r
Hydroextractor
Batch Section
Batch Turner
Tumble Dryer
Finished fabric
store
Dye
Store
Drain
Steam
Water
FINISHING SECTION
DYEING FLOOR
N
S
EW
Dyeing m/c (1 – 15)
LAYOUT OF UKDL

6. Page no: 6
UKDL
BKSP
EPZ - I
EPZ - II
BAIPAIL
ASHULIA
BAZAR
UTTARA
AIRPORT
MOHAKHALI
CTET
FIG: LOCATION OF UKDL

7. Page no: 7
CHAPTER – II
MANPOWER MANAGEMENT

8. Page no: 8
UTTARA KNITTING & DYEING LTD.
JIRANI BAZAR, GAZIPUR SADAR, GAZIPUR
ORGANOGRAM
Sl.
No.
Marketing Commercial A/C &
store
Production
Dyeing
Production
Knit
Quality Utility Administrati
on
01 General Manager
02 DGM DGM DGM DGM
03 AGM AGM AGM AGM (Factory)
04 Manager Manager Manager Manager
(Dyeing)
Manager
(Knit)
Manager Manager Manager
(Admin)
05 Assist
manager
Assist
manager
Cost
Accountant
Assistant
Manager
Assistant
Manager
Assistant
Manager
Electrical
Engineer
Administrati
on Officer
06 Sr.
Executive
Sr.
Executive
Sr.
Executive
Sr. Prod.
Engineer
Sr. Prod.
Officer
QC officer Mechanical
Engineer
Sr.
Executive
Admin
07 Executive Executive Executive Production
Engineer
Asst.
Production
Engineer
Assistant
QC Officer
Sub.
Assistant
Engineer
Executive
Admin
08 Jr.
Executive
Jr.
Executive
Jr.
Executive
Asst. Prod.
Officer
Shift In-
charge
QC In-
charge
Forman Asst. Officer
Admin
09 Assistant Assistant Accounts
Assistant
Lab. Chemist Production
Clark
Sr. QC
Supervisor
Supervisor Security
Officer
10 Cashier Sr. Lab.
Assistant
Sr.
Supervisor
QC
Supervisor
Assistant
Supervisor
Computer
Operator
11 Purchase
officer
Lab. Assistant Supervisor Assistant
QC
Supervisor
Sr. Fitter Office
Assistant/Ti
me Keeper
12 Sr. Store
officer
Report Clerk Assistant
Supervisor
QC Fitter Assistant
Time
Keeper
13 Store
officer
Batch
Incharge
Tr.
Supervisor
Assistant
QC
Assistant
Fitter
Typist
14 Asst. Store
Officer
Finish
Incharge
Fitter Tr. QC Electrician Telephone
Operator
15 St. Store
Keeper
Froman Assistant
Fitter
Tr. Assistant
QC
Assistant
Electrician
Delivery
Supervisor
16 Store
Keeper
Sr. Supervisor Operator QC Man Boiler
Operator
Peon
17 Asst Store
Keeper
Supervisor Assistant
Operator
Boiler
Assistant
Driver
18 Store
Assistant
Assistant
Supervisor
Tr. Operator Generator
Operator
Gardener
19 Helper
Store
Tr. Supervisor Tr. Assistant
Operator
Compressor
Operator
Loader
20 Tr. Asst.
Supervisor
Helper Asst.
Operator
Cleaner
21 Sr. Operator W.T.P.
Attendant
Painter
22 Operator Tr. Operator Sweeper
23 Asst. Operator Helper
24 Tr. Operator
25 Assistant Tr.
Operator
26 Helper

9. Page no: 9
MANAGEMENT SYSTEM:
 Intercom telephone
 Fax
 Written
letters &
 Oral
SHIFT CHANGE:
There are two shifts in this industry. So the shifts are changed at
every 12 hours
RESPONSIBILITIES OF PRODUCTION OFFICER:
I. To give dyeing program slip.
2. To match production sample with target shade.
3. To collect production sample lot sample matching next production,
4. To observe dyed fabric during finishing running & also after
finishing.
5. To identity disputed fabrics & report to P.M/G.M. for necessary
actions.
6. To discuss with P.M about overall production if necessary.
7. To sign the store requisition & delivery challan in the absence
of P.M.
8. Also to execute overall floor works.
9. To maintain loading'/unloading khata.
10. Any other assignment given by higher authority.

10. Page no: 10
JOB DESCRIPTION OF PRODUCTION OFFICER:
REPORT TO: Sr. Production Officer
JOB SUMMARY: To plan, execute & follows up the production activities &. control the
quality production with related activities.
DUTIES & RESPONSIBILITIES:
 Overall supervision of dyeing, finishing production.
 Batch preparation & pH
I chock.
 Dyes & chemical requisition issue & check.
 Write Fabrics loading & unloading time from m/c
 Program making, sample checking, colour measurement
 Control the supervisors, operator, ass. operator and helper
of
dyeing m/c.
 And also any other over work as & when required by the
management.
JOB DESCRIPTION OF Sr. PRODUCTION OFFICER:
REPORT TO: A.G.M. (production)
JOB SUMMARY: To plan. execute & follows up the production activities & control the
quality production with related activities.
DUTIES & RESPONSIBILITIES:
 Overall supervision of dyeing, finishing production.
 Checks the sensitive parameters of different machine for
smooth dyeing
 Checks the different log books of different areas & report
to management
 Checks out the plan to control the best output from
supervisors & workers.
 To trained up& motive the subordinates how to improve
the quality production.
 Control the supervisor, operator, Asstt. Operator & helper
of dyeing.
 Maintenance of machine & equipment Any other works &
when required by the management
REMARKS:
The man power management system of Uttara Knitting & Dyeing Ltd. is well arranged.
Every officer & stuff are responsible for their duty. But there are only five textile engineers
in the industry.

11. Page no: 11
CHAPTER – IIII
MACHINE DESCRIPTION

12. Page no: 12
DYEING FLOOR
DYEING MACHINES:
In Uttara Knit Dyeing Ltd.. There are 14 dyeing machines. Among them 9 machines are
winch dyeing machines, 3 are H.T. dyeing machines and 4 sample dyeing machines. All the
machines are from same company and country. The description and specifications of the
machine are given below-
Name of the machine : Jet Dyeing Machine
Brand Name : Fukuoka
Manufacturing country: Japan
Capacity : 400 Kg
Year of manufacturing: 1995
Specification :
No of nozzle: 2
Pressure/nozzle: 0.5 bar
Motor :
Winch motor – 2
Pump motor – 1
Stirring motor – None
OPERATION PROCESS:
a. Preparation:
1. Turn on power on main panel
2. Open valve for cooling water of main pump
3. Check stream, water & air
+ Steam pressure : 5 – 6 kg/cm2 G
+ Water pressure : 1.2 – 2 kg/cm2 G
+ Air pressure : 5 – 7 kg/cm2 G
4. Adjustment of feeding valve as per production item & capacity
b. Putting fabric into the machine:
1. Select water supply level
2. Supply water automatically by pushing ‘turn on’ button and stop by ‘turn off’ button.
3. Take up edge of fabric to fabric gate through guide of the reel
4. Put edge of fabric to nozzle
5. Start main pump and put whole fabric with adjusting feeding by valve upto remaining
2 -3 meters fabric end
6. Stop main pump and pull up 2 -3 meters of fabric edge by stick
7. Joint both ends of fabric
8. Start main pump & reel to circulate whole fabric and adjust torque of speed
9. Make sure if fabric circulation is normal, then close the door of the gate, (Check again
reel speed)

13. Page no: 13
C. Operation:
1. Close the door
2. In-put the pattern on programme controller
3. Mix dyeing stuff & chemical in dyeing-mixing tank and pour it with using pouring
pump by adjusting feeding valve, after poring, feeding valve shall be closed
4. Switch ‘run’ on programme setting device
5. Automatic operation
1) Select the switch of water supply to ‘automatic’ on main panel
2) Push the button of automatic operation, then automatically operation will go
through heating, holding, cooling, washing as per programming. Put ‘stop’
button when finishing buzzer will ring
3) Open the door and take out fabric
Caution:
1. Before operation:
(1) Check the power (Voltage/hz) wrong Voltage / Hz will cause to brake motor,
meter etc
(2) Check air pressure
(3) Clean inside of tube before dyeing
(4) Set the meter correctly as per dyeing method
(5) Check every valves
2. Starting operation:
(1) Check closing the door perfectly
(2) Set pressure below 1 kg / cm3
by watching pressure meter
(3) When temperature will be over more than 800
C, do not forget item (1) & (2)
(4) Do not start pump when tube is empty
(5) Put definitely cooling water before starting operation because pump & reel is
made for cool water
3. During operation
(1) Check if meter is working correctly during operation
(2) Check if any strange vibration
(3) Check if any strange sound of pumping
(4) Check if pressure in the tube is too high
(5) Check if temperature in the tube meet programming
(6) Start pump when feeding steam & cooling water
(7) Check if reel is working correct under high temperature & high pressure
4. Nozzle installation
Set nozzle base into nozzle-casing and install nozzle by turning it clock wise.
After install nozzle, turn it one round by anti-clock wise to make 2 mm gap. The gap on
nozzle shall be adjusted by kind of fabric
5. After operation:
(1) Before opening the door, check if air pressure of inside the tube is 0 kg/cm2
and temperature of inside the tube is between 800
-900
C if the pressure is still
remained or temperature is more than 800
C, it is very dangerous to open the
door
(2) Temperature inside the tube shall be under 800
C for manual draining

14. Page no: 14
(3) Turn off the power after operation and close the valve
6. Maintenance:
(1) Keep cleaning seal packing of the door and surface to touch the packing to be
prevented from dust and hurting
(2) Keep electric portion, pump and control panel not to be wet by water
(3) Keep tight valve shaft seal ground packing of each valve by tightening
sometime
(4) Check valve seat part of air valve & drain valve sometime
(5) Keep tight each volt
(6) Make often oiling rotating part
(7) Inspect mechanical seal according to manual of pump
(8) Keep adding grease & oil in pump bearing part according to manual of pump
(9) Inspect sometime if safety valve is working correctly
(10) Inspect sometime if steam trap is working correctly
(11) Inspect meters of pressure and temperature

15. Page no: 15
Soft water pipe
Jet mechanism
Winch
Steam pipe
Water pipe Led
filter
motor pump
drain pump motor
Automatic High Pressure Dyeing Machine

16. Page no: 16
TOTAL MACHINE CAPACITY
SL NO M/C TYPE
NO. OF
MACHINE
CATALOGUE
CAPACITY IN
(KG)
ACTUAL
CAPACITY
ORIGIN OF
MACHINE
01
HIGH TEMPERATURE
SAMPLE DYEING M/C
(JET DYEING)
01 20 20
FUKUOKA
IRON
WORKS,
JAPAN
02
HIGH TEMPERATURE (JET)
SAMPLE DYEING M/C
01 20 20 JAPAN
03 H/T (JET) DYEING M/C 01 60 60 JAPAN
04 H/T (JET) DYEING M/C 01 150 150 JAPAN
05 H/T (JET) DYEING M/C 01 150 150 JAPAN
06 H/T (JET) DYEING M/C 01 150 150 JAPAN
07 H/T (JET) DYEING M/C 01 300 260 JAPAN
08 H/T (JET) DYEING M/C 01 300 280 JAPAN
09 H/T (JET) DYEING M/C 01 300 280 JAPAN
10 H/T (JET) DYEING M/C 01 400 320 JAPAN
11 ATMOSPHERIC DYEING M/C 01 400 310 JAPAN
12 ATMOSPHERIC DYEING M/C 01 150 120 JAPAN
13 ATMOSPHERIC DYEING M/C 01 150 120 JAPAN
14 ATMOSPHERIC DYEING M/C 01 300 260 JAPAN
15 ATMOSPHERIC DYEING M/C 01 300 260 JAPAN
16 ATMOSPHERIC DYEING M/C 01 300 260 JAPAN
17 SAMPLE DYEING M/C 01 10 10
BANGLADES
H
18 SAMPLE DYEING M/C 01 15 15
BANGLADES
H

17. Page no: 17
MACHINERIES OF THE DYEING LAB:
The dyeing lap of the UKDL is not so developed. The description of the machineries of the
dyeing lab are given bellow-
Laboratory facilities & equipments:
 Light box
 Electric balance
 Iron
 Sample dyeing m/c
 Lab dip m/c
 GSM tester
 Washing m/c
 PH
tester
 Dryer
Light box:
 Visual assessment of color by reflectance & transmission
 Mainly used for shade matching
 Four types of light source are used
 Sometime it may be more such as TL84, CWD etc
 Metamerism of the fabric is checked
Brand Name Model Manufacturing country
VITIVIDE CAC-60 U.K.
Types of light source which is used in the m/c is given below-
Symbol Full meaning Functions
UV Ultra violet Used for white color
matching
F Fluorescent light Check the metamerism of
the fabric
TL84 Tube light Do
L D65 Artificial day light Used for color matching
Crock meter:
Feature:
 Mainly used for rubbing fastness
 Rub may be wet and dry
Brand name Model Mgf. Country Serial no.
GUVEN SURTME Turkey S-9011

18. Page no: 18
Electric balance:
Features:
 Weight of the fabric and dyes and chemical is measured digitally which give good
result in weighting
 Used for accurate measurement
 Maximum weight that can be perfectly measured is 121 gm and minimum weight
which can be measured perfectly is 1.001 gm
 Accuracy 0.001 gm
Brand Name Company Model Country
Sartorius James H. Heal &
Co. Ltd
BL310 UK
IRON:
Feature:
 Used for drying the sample
 Wet sample is placed between the two white fabric and temperature and pressure is
given
 A dial is provided indication the different temperature marked on tits upper surface
and gives accurate temperature for cootn, silk, wool etc. which is adjusted
manually.
SAMPLE DYEING MACHINE:
There are three sample dyeing m/c in the laboratory, which features are described below in
brief
Solvent – Glycerin
Model – HR
No: 3800
M/c type Brand name Company Country
RAPID LABROTEX.CO TAIPE (TAIWAN)
Sample dyeing m/c:
Feature:
 Sample can be dyed above 1000
C, 1300
C or more
 Glycerin bath is used
 18 holders are providing in this machine
Main parts of the machine:
 Program set panel
 Glycerin bath
 Holder
 Holder carrier
Controlling point:
 Time
 Temperature
 Rotation speed
 Auto stop

19. Page no: 19
Type of fabric processed: COTTON AND POLYESTER
GSM Tester:
Feature:
 Used to measure GSM for gray, dyed and finished fabric
 One GSM tester is in finishing section and another GSM tester is in Knitting
Section
 100 Cm2
cut sample is weighted by electric balance 3 and given value of in gm.
Multiplied by 100 is the GSM of fabric, Say, 100 cm2
sample weight in 1.9 gm
that means its GSM is 180
Washing machine:
 All the washing condition and parameter can be controlled
 Model – RS-12MS
 Temp 1200
C
 Solvent – water + glycerin
m/c no Brand name Company Country
1. INDESIT INDESIT Italy
Wash fastness machine:
It also used as a dyeing machine. Specification is unknown
Hot air rapid drying oven:
Country – Taiwan
Component – Timer, Temperature indication meter
MACHINARIES OF THE FINISHING SECTION:
Dewatering machine:
Feature:
 Used to remove excess water after pretreatment and dyeing
 Delivered fabric is crease free state
 Before squeezing ballon is formed with the help of compressed air passing by a
nozzle
 It can control the diameter of fabric and GSM and shrinkage by over feeding
mechanism
 To impart soft finish to the fabric
m/c no Brand name Country Production Company
1 (modern) ABcalator Sweden Airtex
Main parts of the machine:
- Sqeeze roller (to remove water)
- Stretcher (to control width)
- Over feeding wheels (to control GSM)
- De-twisting device (To delivery the fabric roll in untwisted form)
- Folding device (to delivery the fabric in folded form)

20. Page no: 20
Utilities:
1. Electricity
2. Processed air (to form the tube fabric into ballon with a view to remove crease)
Control system:
1. Overfeed control
2. Pressure
3. Speed control
4. Width control
CALENDER M/C:
Name : Softset
Speed : 100 m /min
20-30 m / min
Origin : Korea
Functions:
1. To calendar fabric
2. To reduce G.S.M.
STREAM SETTING M/C:
Name : KY0D0 DENKI
Origin : U.S.A
Speed : 60 m / min
Functions:
1. To remove crease mark
2. To reduce G.S.M of fabric
HYDROEXTRACTOR M/C:
Name : NGAISHING
Model : NS 2542
Serial : 158
Company : NGAISHING Development
Origin : Hongkong
Function:
1. To extract water from fabric
DRYER:
Tension less dryer
Model : MFG NO-0445
Company : LK & LH CO. LTD
Origin : Taiwan
Speed : 10 – 20 m/min
Functions:
1. To dry the fabric with help of steam

21. Page no: 21
COMPECTOR M/C:
Brand : Parnit – II Delta Plus Compactor
M/c number : BM-9529
Company : Tubular Textile Ltd/
Origin : U.S.A.

22. Page no: 22
Control Point :
- Water pressure 2.5 lb
- Air pressure 4 lb
- Steam pressure 6 lb
Function:
1. To compact the fabric
2. To control the shrinkage
3. To maintain proper width and G.S.M
Main parts of the machine:
1. Heating chamber
2. Blower (8)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
Heating system: Steam
Utility:
1. Steam
2. Electricity (to run the m/c)
3. Compressed air (to spread the fire)
REMARKS:
The average machineries in this factory are more or less same compared to the other
knit dyeing factories but the dyeing machineries are very much different from the other
factories.

23. Page no: 23
CHAPTER – IV
RAW MATERIALS

24. Page no: 24
RAW MATERIALS:
In Uttara Knitting & Dyeing Ltd., the raw materials used for production are –
1. Grey
2. Dyes
3. Chemicals
1. Grey fabrics:
Following types of grey fabrics are dyed-
a. Single jersey
b. Single jersey with lycra
c. Interlock
d. Lacoste
e. Yarn dyed fabrics
f. Rib
g. Lycra rib
h. 1 x 1 rib & others
i. Collar & cuff
j. Polyester fabrics
Sources:
The required grey fabric is produce in the industry
Chemicals Country
01. Hostapol JU Thailand
02. Rocowet RDA Germany
03. NaOH China, India
04. Na2CO3 China
05. Defoamer SF Taiwan
06. Stab SML Thailand
07. H2O2 Belgium
08. Cibafluid-C Singapore
09. A. Acid Taiwan, India
10. Ladiquest – 1097 Thailand
11. Drimazin- E2R Thailand
12. Rlf - 349 Germany
13. Glanber salt India / China
14. NaCl Bangladesh
15. Decol – SN
RFL
Germany
Singapore
16. VNF
ECO
Singapore
Thailand
17. Softerer [NI catalyst] Taiwan
18. Enzyme Germany

25. Page no: 25
Dyes Country
Solazol Taiwan
Remazol Germany
Reactron India
Reactive India
Terasil Switzerland
Materials consumed:
ADD: MANUFACTURING EXPENSES WT. KGS @BDT.
Knitting 610.0 13.49
Dyeing 610.0 33.55
Compacting 610.0 2.12
UTTARA KNITTING DYEING LTD. IMPORTED YARN PRICING THROUGH L/C:
PARTY NAME YARN
CATEGORY
RATE $
(KG)
RATE (Tk. /
KG)
QUANTITY
(KGS)
Shameem Spinning 20s/1 CVC 2.70 158 400.00
Shameem Spinning 30s/1 CVC 2.80 163 500.00
Padma Textile Mills 30s/1 CVC 3.00 175 3628.80
Square Textile Mills 24s/1 Comd 2.95 172 850.00
Square Textile Mills 12s/1 Kard 2.05 120 500.00
Square Textile Mills 10s/1 Kard 1.65 96 1850.00
Prime Composite Mills 32s/1 Comd 2.95 172 2550.00
Arief Knitspin Ltd 20s/1 Kard 2.58 151 2000.00
Arief Knitspin Ltd 26s/1 Kard 2.62 153 2000.00
Arief Knitspin Ltd 30s/1 Kard 2.62 153 3250.00
Prime Composite Mills 32S/1 Comd 2.95 172 22500.00
Arief Knitspin Ltd 24S/1 Comd 3.02 176 10000.00
Arief Knitspin Ltd 34S/1 Comd 3.25 190 20000.00
Shamsuddin Spinning 24S/1 Comd 3.00 175 6700.00
Shamsuddin Spinning 26S/1 Comd 3.00 175 4350.00
Arief Knitspin Ltd 20S/1 Comd 3.00 175 1500.00
Saiham Textile Mills
ltd.
30s/1 Kard 2.55 149 661.84
Shamsuddin Spinning 30s/1 Comd 3.05 178 1150.00
Shamsuddin Spinning 26s/1 Comd 3.00 175 1800.00
Prime Composite mills 20s/1 Kard 2.40 140 1400.00
Prime Composite mills 24s/1 Comd 2.85 166 1900.00
Prime Composite mills 26s/1 Kard 2.82 165 650.00
Prime Composite mills 30s/1 Kard 2.82 165 350.00
Hanif Spinning Mills 28s/1 Comd 3.05 178 3800.00
Square Textile Mills 26s/1 Comd 2.95 172 500.00
Square Textile Mills 24s/1 Kard 2.50 146 500.00
Square Textile Mills 10s/1 Kard 1.65 96 600.00
Shameem Spinning 30s/1 CVC 2.80 163 1600.00
Square Textile Mills 30s/1 Comd 3.00 175 1000.00

26. Page no: 26
CHEMICALS AVERAGE RATE (Tk / KG)
ACETIC ACID 69.33
DEFORMER SF/ALVATEX FFC 161.86
BLUTON BVB 238.00
BLUTON K2 236.00
BLEACHING POWDER 109.00
CAUSTIC SODA 17.00
COMMON SALT 6.45
GLOBER SALT 8.00
H2O2 (50%) 20.35
GEIZYME PR 140.79
SODIUM HYDROSULPHITE 39.06
SODA ASH 11.00
SODIUM SULPHITE 22.00
SODIUM CHLORIDE 60.00
CIVAFLUIDE C 99.00
HOSTAPOL – J – U 96.00
LADIQUEST – 1097 129.03
STABILIZER SF 86.05
SOFTNER CS 118.22
DEKOL SN 132.00
DYES AVERAGE RATE
REACTIVE BLACK-5 129.29
SULPHER BLACK 90.61
REMA BLUE - BB 2245.89
REACTIVE ORANGE – 16 459.50
REMA YELLOW RR-GR 757.83
REMA RED –RR – GR 757.01
REMA RED H-38 780.00
SOLO TURQUISE –BRIE 400% 525.50
REACTIVE YELLOW 160 428.83
TERASIL BLUE 3RL-02 1774.00
TERASIL BLUE BGE -01 1370.00
TERASIL RED F –B 3916.00
REACTIVE BLUE BB 1319.00
REACTIVE BLUE GG 688.50
REMARKS:
UKDL uses best quality raw materials. It produces fabrics from best quality yarn. They
uses the best quality dyes like REMAZOL, REACTRON, REACTIVE , TERACIL etc.
During the time of using dyestuff they give importance upon the quality of dyes than the price
of the dyes and chemicals.

27. Page no: 27
CHAPTER – V
PRODUCTION PLANNING
SEQUENCE
& OPERATIONS

28. Page no: 28
PRODUCTION PLANNING, SEQUENCE AND OPERATIONS:
PRODUCTION PARAMETERS:
a. pH:
- During H2O2 bleaching pH 9.2 – 12
- During reactive dyeing pH 10.5 – 12.5
- During disperse dyeing pH 4.5 – 6.0
b. Temperature:
- For cotton scouring 900
-950
C
- For cotton cold wash 300
– 400
C
- For cotton hot wash 700
-800
C
- For cotton acid wash 600
-700
C
- For cotton dyeing 800
-900
C (For hot brand)
600
C (For cold brand)
- Polyester dyeing: 1000
-1300
C
c. Time:
- For scouring 60-90 mins
- For reactive dyeing 60-90 mins
- For disperse dyeing 60-90 mins
d. M:L ratio:
- For reactive dyeing M:L ration maintained beween 1 : 7.5 to 1 : 10
DESCRIPTION OF PRODUCTION PROCESS:
Washing for colored fabrics:
- The colored fabrics to be washed is loaded in the machine
- Required amount of water is taken
- PCLF (detergents) added & washing continued at 800
C for 20 mins
- Cold washing
Scouring-bleaching:
- Fabric to be scoured is loaded in the machine
- Required amount of water is loaded
- Washing agent/ detergent is added
- Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when the
temperature reaches at 500
C
- When the temperature reaches at 600
C then stabilizer is added
- Then H2O2 is added
- Temperature is then raised to 900
C and the process is then carried out for 60-90 mins
depending on the requirements

29. Page no: 29
- The liquors are then drained
- Then cold wash at 300
-400
C, hot wash at 700
-800
C and acid wash at 600
-700
C is done
Dyeing:
- After acid wash all liquors are drained out
- Required amount of water is taken
- Then leveling agents, anti-creasing agents, de-foaming agents are added according to
the requirement
- Steam pipes are on & after 10-15 mins dyes are added
- Salts are added after another 30 mins
- Then soda ash after another 30 mins
- Then the temperature is raised slowly up to the mark
- The process is carried on and samples are taken after every 30-40 mins to match with
the target shade. It continues until shade matching.
- If the sample is matched, then the liquors drained out
- Then cold wash at 300
-400
C, hot wash at 700
-800
C, acid wash at 600
-700
C is done
- Then softener is added at 400
C for 20-30 mins
- Fixer is applied for deep shade only before adding softener
Re-dyeing:
When shade is not matched then fabric is treated again in dyeing machine for shade matching
is known as re-dyeing.
Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur when
the fabrics absorb one or two colors more or less. One re-dyeing process is described below.
- Drain the let off solution
- Hot wash at 700
-800
C
- Acid wash at 600
-700
C(600
for light shade & 700
for deep shade).
- Soda ash washes at 900
-1000
C for 60mins to reduce the depth of shade.
- Acid wash at 600
C.
- Addition to required dyestuffs.
- Salt addition.
- Soda ash addition.
- Other operations are same as previous described dyeing operations.

30. Page no: 30
PRODUCTION FLOW CHART:
Scouring Scouring H2O2
& bleaching hot killer A. acid
950
C
1 hr 15 m salt dye soda
leveling 700
C
600
C enzyme Hot wash agent
45 – 60 min
40 min
matl
cold wash
400
C
Dyeing curve of 100% cotton fabric with reactive dye
Production flow chart for 100% cotton
↓
Grey fabric loading
↓
Scouring & Bleaching at 95o
C for 1 hour
↓
Scou g HO + (95o
C x 15’)
↓
H2O2 killer [invotex PC or gazyme PC]
↓
A.Acid
↓
Enzyme [pH 4 – 4.5, temp 60o
C for 40’-60’]
↓
Hot wash
↓
Levelling [Ladiquest 1097]
↓
Dyeing
Salt
Color
Soda
↓
A. Acid
↓
Hot wash [Decol SN, RSK, RFL]
↓
Fixing [VNF, ECO]
↓
Softener [LCF, Non ionic]
↓
Unload

31. Page no: 31
CVC DYEING SEQUENCE:
Perergent + Artioreasomg agent at 800
C for 20'
↓
cad wash
↓
A.Acid [pH 4-4.5]
↓
Levelling agent + Antioreasomg agent
↓
Buffering agent [jinlab RFL]
↓
Color at 130o
50'
↓
↓ ↓
If OK If not oK
↓ ↓
Bath Drain temp 1300
↓ ↓
½ scouring If OK
↓ ↓
Cotton dyeing sequence Bath drain
↓
½ scouring
↓
Cotton dyeing sequence
material
400
C
800
C
Detergent +
Anticreasing agent
20’
Cold wash
Leveling &
buffering agent
600
C
dye
1300
C 50’
A. Acid
½ scourig
950
C salt Soda
R. dye
Cold wash &
unload
600
C 50’
DYEING CURVE OF PC / CVC FABRIC WITH REACTIVE / DISPERSE DYES

32. Page no: 32
DYEING SEQUENCE FOR WHITE:
Scouring + bleaching, 950
↓
Blutton´ 50'
↓
15' Sample test
↓
Water drain
↓
Hot (without chem.: at 800
C for 20')
↓
A.cAcid
↓
↓ ↓
If OK If not oK
↓ ↓
Sequester Softener
↓ ↓
Softner Unload
↓
Unload

33. Page no: 33
STANDARD RECIPE OF SCOURING
& BLEACHING OF UKDL
SCOURING & BLEACHING:
DEEP SHADE LIGHT SHADE
01. ALBATEX FFC : 0.15 G/L : 0.15 G/L
02. LADIQUEST 1097 : 0.25 G/L : 0.25 G/L
03. CIBAFUUIDE C : 0.50 G/L : 0.50 G/L
04. HOSTAPOL JU : 2.00 G/L : 2.00 G/L
05. CAUSTIC SODA : 2.50 G/L : 2.00 G/L
06. SODA ASH : 2.50 G/L : 2.00 G/L
07. STABILIZER SF. : 0.35 G/L : 0.30 G/L
08. H2O2 (50%) : 3.50 G/L : 3.00 G/L
09. ACETIC ACID : 1.00 G/L : 1.00 G/L
10. INVATEX PC : 0.30 G/L : 0.25 G/L
LEVELLING:
01. CIVAFLUDIE c : 0.50 G/L : 0.50 G/L
02. LADIQUEST 1097 : 0.80 G/L : 0.60 G/L
(FOR LYCRA S/J CIBAFLUIDE C : 0.70 G/L)
LEVELLING: FOR TURQUISE BLUE, R-BLACK, ROYEL COLOUR
01. CIBAFLUIDE C : 0.70 G/L
02. LADIQUEST 1097 : 1.00 G/L
03. E2R : 0.50 G/L
[ FOR WHITE SHADE ]
H2O2 ( 50% ) : ( 4.00 G/L - 7.00 G/L)

34. Page no: 34
White Dyeing Recipe For (100% Cotton)
Buyer Name : Farnoorr M : L = 1 : 8
Order No : Cross line Mtl wt. = 100 kg
Batch No : 19100 Water = 800 Liter
Fabric Type : (1 * 1) Rib Fab dia. = 42 inch
G. S. M. : 200 – 210 Colour = White
Serial No Name Dosing (g/l) Quantity Remarks
01 Hostapol JU 0.20 160 gm
02 Cibafluide-C 0.20 160 gm
03 Albatex – FFC 0.20 160 gm
04 Cibafluide – C 0.73 584 gm
05 Hostapol JU 1.20 960 gm
06 Sequester – K 1.00 800 gm
07 Caustec Soada 2.25 1.80 Kg
08 Soda Ash 1.00 800 gm
09 Stabilizer SF .30 240 gm
10 H2O2 4.00 3.20 Kg
11 BLUETONE – BVB 0.21 % 210 gm 950
C , 60 min
12 Acetic Acid 0.60 480 gm
13 Sequester – K 0.40 320 gm
14 Softener (Non - Ionic) 1.50 1.20 Kg
Prepared by : ………………… Checked by : …………………………..
Dyeing Incharge : ……………. Production Manager : …………………..

35. Page no: 35
Colour Dyeing Recipe (100% Cotton)
With Reactive Dye
Buyer Name : D. S. L M : L = 1 : 8
Order No : Cross line Mtl wt. = 100 kg
Batch No : 19100 Water = 800 Liter
Fabric Type : S / J Fab dia. = 42 inch
G. S. M. : 160 – 170 Colour = Navy
Serial No Name Dosing (g/l) Quantity Remarks
01 Hostapol JU 2.00 1.60 kg
02 Ladiquest 1097 0.40 320 gm
03 Albatex – FFC 0.15 120 gm
04 Cibafluide – C 0.50 400 gm
05 Stabilizer SF 0.50 400 gm
06 Soda Ash 2.50 3.60 kg
07 Caustec Soada 3.00 2.40 Kg
08 H2O2 4.00 3.20 Kg
09 Acetic Acid 1.00 800 gm
10 Invatex PC 0.15 120 gm
11 Cibafluider – C 0.50 400 gm
12 Ladiquest 1097 0.80 640 gm
13 Reactive S Yellow F3R 0.33 % 330 gm
14 Reactive S Red F3B 0.79 % 790 gm
15 Reactive Black – 5 4.20 % 4.20 kg
16 Salt 62.00 49.60 kg
17 Soda Ash 20.00 16 kg
18 RFL 0.80 640 gm
19 A. Acid 1.00 800 gm
20 Softner (Non Ionic) 1.00 800 gm
Scouring Scouring H2O2
& bleaching hot killer A. acid
950
C
1 hr 15 m salt dye soda
leveling 700
C
600
C enzyme Hot wash agent
45 – 60 min
40 min
matl
cold wash
400
C
Dyeing curve of 100% cotton fabric with reactive dye

36. Page no: 36
REMARKS:
UKDL strictly follow the production parameters like the time, temperature, M:L ratio
pH etc. As they do some difficult shade, it takes more time for the production of the batch.
Because of the trolley shortage and generator failure, the production process is sometime
hampered. Considering these limitations, the production officer and the Sr. Production Officer
try their best to reduce the production time.

37. Page no: 37
CHAPTER – VI
QUALITY ASSURANCE

38. Page no: 38
Q. C. DEPARTMENT
QUALITY POLICY:
It is the policy of UKDL to produce quality dyed knit fabrics that meet or exceed
customers expectations & needs. To implement this policy the top management of UKDL is
committed to provide adequate resources in terms of good raw materials and trained personnel
& continually improve / upgrade its processes and systems.
QUALITY OBJECTIVES:
 Overall material/product loss (Level of rejection) for the company during the
production process (in a year) shall not exceed 1.5 %
 Defects during dyeing & knitting operations to reduced by 10% by the Jan ‘03
 Process capability shall be maximized by maximizing the m/c breakdown time. M/c
breakdown time should be reduced to 20 % form its current status/position by the mid
2003.
 A quality procedure manual in line with the requirement of ISO9001 shall be
developed and implemented by August 2002.
 To ensure better work environment for the personnel working in the organization.
MACHINES:
 Wash Fastness Tester
 Light fastness tester
 Rubbing fastness tester
 Electronic balance
 G.S.M. cutter
 Fabric inspection table
 Light box
 Shrinkage (%) meter
INSPECTION AREA:
 Shade match of fabric
 G.S.M.
 Fabric diameter
 Shrinkage (%)
 Length wise
 Width wise
 Fiber type
 Wash fastness
 Light fastness
 Rubbing fastness
 Faults
 Dyeing faults
 Knitting faults

39. Page no: 39
FAULTS ARE FOUND IN QC DEPERTMENT:
Knitting faults:
 Hole
 Slub
 Thick place
 Thin place
 Neps
 Stripe
 Missing yarn
 Contamination
 Light
 Medium
 Deep
Dyeing faults:
 Uneven shade
 Running shade
 In fastness property
Finishing faults:
 GSM variation
 Spirality
 Shrinkage control
 Length wise

40. Page no: 40
QUALITY ASSURANCE SYSTEM
QUALITY ASSURANCE PROCEDURE:
 Uttara Knitting & Dyeing Ltd. assures the quality of their products in
the following three steps:
 In laboratory
 In Dyeing section &
 In finishing section
 Procedures are described below:
In laboratory:
 Swatch card from buyer according to
their requirement
 Recipe prediction for sample dyeing
 Sample dyeing until matching with swatch card
 If matching is OK, then it is sent to the
buyer for approval.
 If buyer approves the sample then bulk
production.
In dyeing section:
 After approval form the buyer, sample dyeing is done in dyeing
m/c in dyeing shed & again matched with the approved sample
 If result is OK. then balk production,
 During dyeing, samples are taken until accurate shade matching.
The interval may be 30-40 minutes
 After dyeing sample is collected after softening matching is done
 Last of all, sample is collected after fixation & matched
 Then allowed the fabrics to be finished
In finishing section:
 Correctly dyed, after treated & matched fabrics are allowed for
finishing
 By using a series of finishing machines correct width, softness &
appearance are maintained according to requirements
 Then sampling is done for several times to test GSM, Shrinkage &
fastness properties.
 Finally fabric is inspected & prepared for delivery

41. Page no: 41
List of Equipments:
Machineries & equipment used :
 Spectrophotometer with software (Datacolor)
 Colour light box
 Sample dyeing machine (2)
 Lab. Dip
 Iron
 Electric Balance
 Crock meter
 Washing m/c
 GSM Tester
 PH meter
Quality standard:
Uttara Knitting & Dyeing Ltd. follows the quality standard: ISO-9001. 2000,
REMARKS:
Uttara Knitting & Dyeing Ltd. always aware about the quality of the product.
The quality of the product is always approved by the buyer. They follows the
quality standard: ISO 9001: 2000, Uttara Knitting & Dyeing Ltd. is well
equipped for checking the quality of the ptoduct.. They sent the quality
report to the buyer time to time/ batch to batch.

42. Page no: 42
CHAPTER – VII
MAINTENANCE

43. Page no: 43
MAINTENANCE
Maintenanace of Machinery:
Maintenance of machinery is very essential mechanical effort for achieving
smooth running of different machines. Maintenance is a process by which
equipment is looked afterin such a way that trouble free. Services and
increased machine life can be ensured and specific product quality
required by the customers is sustained. On time maintenance increase
m/c lifetime & ensures tuouble free services.
In Uttra Knitting & Dyeing Ltd. 2 types of maintenance
are done:
1. Break down maintenance
2. Routine maintenance
1. Break down Maintenance: Break down maintenance is done
instantly when problem arises in machine. In this case, repairs are
made after the equipment is out of order and it cannot perform its
normal functions.
2. Routine Maintenance: After a particular little the machines are
cleaned & reordered, that is routine or schedule maintenance. PPC
does it once in a month. Schedule maintenance varies, time in time
& also depends on situation according to types of machines, because
maintenance is directly related to production.
Most of the time, all the screws, nuts, bolts & levers are checked,
lubrication is also done. Workers inform about the problem areas of the
machines. Depending on their information. maintenance is done,
Maintainers analyses the machine records & take steps according to
requirements.
Maintenance
Routine Maintenance Break Down Maintenance
Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance

44. Page no: 44
MAINTENANCE PROCEDURE:
During maintenance procedure following points should be checked.
Checklist of different parts:
Maintenance: Mechanical
Machine: Dyeing Machines
Sl.
No.
Item need to be checked & Serviced
1 Crease the winch bearing.
2 Complete cleaning of machine
3 Cleaning of drain valves, replace seals if required
4 Check air supply filter, regulators, and auto drain seals
5 Clean filters element and blow out
6 Greasing of Unloading Roller Bearings.
7 Checking of oil level and bolts of Unloading Roller Gearbox.
8 Checking of unloading roller coupling and packing.
9 Checking and cleaning (if required) of Min Vessel Level Indicator
10 Check the oil level of pump bearing and refill if requird.
11 Check the function of heat and cool modulating valves
12 Check all belts and belt tension
13 Check all door seals
Maintenance: Mechanical
Machine: Lab dyeing m/c.
Sl. No. Item need to be checked & Serviced
1 Check rotating main shaft bearing.
2 Check cooling water inlet and outlet nose and nose clips.
3 Check cooling fans
4 Check driving bells and pulleys.

45. Page no: 45
Maintenance : Mechanical
Machine : Lab dyeing m/c.
Sl. No. Items need to be checked & Serviced
1 Check & clean fluff and dirt at all motor fan covers
2 Check all motors terminals
3 Check min panels (by using compressed air)
4 Check panel cooling fan & clean it filter
5 Clean main pump inverter and its cooling fan
6 Check all circuit breaker, magnetic contractors and relays
7 Check current setting of all circuit breaker & motor over loads.
8 Visual checking of all power & control cables
9 Check DC drive of reel motors
10 Check all pressure switches
11 Check calibration of main vessel & all additional tank
12 Check all pneumatic solenoids
13 Check calibration of heating/cooling. Modulating value
14 Check setting of tangle sensor.
15 Check setting & operation of lid safety switches
16 Check all emergency Switches
17 Check all indicating lamps
18 Check all on/off switches
19 Check all signal isolators
20 Check key pad & display of controller
21 Check proximity switches
The following tasks are generally done during maintenance:
 Inspections & check ups
 Lubrications
 Planning & scheduling
 Record analysis
 Training of the maintenance crew
 Collection or purchase of spares

46. Page no: 46
Maintenance work to the different machines:
BOILER MAINTENANCE SCHEDULE:
Daily:
 Check gas pressure
 Maintain log sheet
 Chemical dosing
Weekly:
 Check all steam line
 Fire quality of boiler
Monthly:
 Check all steam line
 Fire quality of boiler
 Gas consumption report
 Burner clean
Quarterly:
 Burner clean
 Economizer clean
 Feed tank clean
 Chemical tank clean
 Sight glass clean
Half yearly:
 Burner clean
 Feed tank clean
 Chemical tank clean
 Economizer clean
 Replace gasket
 Replace valve
 Check gas line & filter & pressure
Yearly:
 Overhauling of boiler
 Chemical cleaning of boiler
 Safety valve test
 Economizer clean
 Feed tank clean
 Chemical tank clean
 Burner clean
 Check safety valve setting
 Replace valve & gasket
 Boiler inspection by authority

47. Page no: 47
Dyeing m/c maintenance Schedule
Daily:
 Check belt tension
 Check steam or water system & air supply
 Check chemical pump
 Machine clean
Weekly:
 Bearing & belt check
 Check leakage of air, steam &
 Water line
 Greasing bearing points
 Add gland packing at pump
Monthly:
 Greasing bearing points
 Replace bearing points (if required)
 Gaskrt check
 Clean steam trap
 Lubricating all chemical pump
Quarterly:
 Replace belts
 Repairing of pulley, shaft & bearing housing
 Painting m/c & pipe line
 Clean steam trap
 Replace seals (if leakage)
 Change gasket of steam of water lines
Half yearly:
 Replace belts
 Repairing pulley, shaft & bearing housing
 Painting m/c, pipe line
 Replace seals
 Machine body repairing
Half yearly:
 Replace belts
 Repairing pulley, shaft & bearing housing
 Painting m/c, pipe line
 Replace seals
 Machine body repairing
Yearly:
 Machine overhauling

48. Page no: 48
Hydro extractor Maintenance
Daily:
 Machine clean
 Belt checking
Weekly:
 M/c clean
 Belt clean
 Greasing & lubricating of all points
Monthly:
 M/c clean
 Check gear oil quality
Quaterly:
 Change of gear oil
 Belt change
Half yearly:
 Change of gear oil
 Belt change (if required)
Yearly:
 Machine overhauling

49. Page no: 49
TENSIONLESS DRYER MAINTENANCE
Daily:
 Check belt tension
 Check steam supply & air system
 Machine clean
Weekly:
 Check fabric drying quality
 Greasing bearing points
 Clean airfilter & regulator
Monthly:
 Clean radiator & m/c cabinet
 Greasing bearing points
 Clean air filter and regulator
Quarterly:
 Replace belt
 Replace gear oil
 Duct clean
Half yearly:
 Check roller condition
 Greasing & lubricating all points
Yearly:
 Machine overhauling

50. Page no: 50
TUMBLER DRYER MAINTENANCE:
Daily:
 Check belt
 Steam leakage area
 M/c clean
Weekly:
 Heat exchange clean
 Greasing & lubricating of all points
 Belt check
 M/c clean
Monthly:
 Filter clean
 Steam trap clean
Quarterly:
 Replace belt
 Replace gear oil
 Duct clean
 Gasket & valve change
Half yearly:
 Gasket & valve change
 Yearly:
 Machine overhauling

51. Page no: 51
SOFT SET M/C MAINTENANCE:
Daily:
 Check belt tension
 Check Steam supply & air system
 M/c clean
Weekly:
 Check fabric quality
 Greasing bearing points
Monthly:
 Greasing bearing points
 Clean air filter & regulator
 Clean steam trap
Quarterly:
 Replace belts
 Replace gear oil
 Painting m/c & pipeline of the total system
 Replace seals
Half yearly:
 Check roller condition
 Greasing & lubricating of all points
 Check bearing condition
Yearly:
 Machine overhauling

52. Page no: 52
MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS:
Maintenance tools/equipments Functions
1. Adjustable wrench Used for setting nut & bolts
2. Pipe Spanner For pipe fitting
3.Spanner Fixed Spanner for nut & bolts fitting
4.Socket spanner Handle system for nut & bolt fitting
5. hammer To apply load where required
6. Screw driver To release any screw
7. Punch Used to fit any worn out shaft
8. Lock opener To open the clip of bearing
9. Hack saw To cut any metallic thing
10. Outside calipers To measure outside dia
11. Inside calipers To measure inside dia
12. Slide calipers To measure very small dia
13. Vernier scale To measure very small dia
14. Chain ton To lift heavy load
15. Welding machine To join metallic parts
16. Grinding machine To make the smooth fabrics
17. Tester To test electric circuit
18. Pliers To grip anything & cut anything
19. Avometer/Voltmeter To measure voltage
20. Steel tape To measure length, width & height
21. Chisel To cut any metal
22. Gasket cutter For gasket cutting
23. File To smooth the rough surface
REMARKS:
The maintenance department of UKDL is well equipped. It has sufficient
maintenance manpower including mechanical and electrical engineers. They do the
maintenance of the m/cs during the Eid vacation. Otherwise, they do the breakdown
maintenance. To increase the lifetime of the machineries and ensure the proper
running of the machinery.

53. Page no: 53
CHAPTER – VIII
UTILITY

54. Page no: 54
WATER TREATMENT PLANT:
(Water Softening Method – Base Exchange Process)
Technical
Details
Raw water tank Softener tank Soft water
tank
Brine tane
Size Length - 40´
Width - 20´
Height - 15´
Diameter – 6´
Height - 15´
Diameter - 20´
Height - 20´
Salt reqd:
190
kg/day/tank
Regeneration
time 1.30 hr
Capacity 360 Ton 45 Cubic
meter/hour/tank
180 Ton
Source Natural source
Deep tubewell
R.W.T S.T. Salt price
10tk/kg
Project cost Total Project Cost : 113 Lacks
AIR COMPRESSOR:
An air compressor is a m/c to compress the air and to raise its pressure. The air compressor
sucks air from the atmosphere, compresses it and delivers the same under in high pressure to a
storage vessel. From a storage vessel, it may be conveyed by the pipeline to a place where the
supply of compressed air required.
Utility:
1. Air
2. Mobil
3. Electricity
1. U3 – Com - 02
Company : VESPA
Country : Taiwan
Type : Piston type
Component:
- Motor
- Piston
- Compressed a
- Oil drain plug
U3 – Com – O2
Country : England
Type : Screw type
Component:
- Radiator
- Separator
- Air filter
- Oil filter
- Motor
- Screw

55. Page no: 55
BOILER:
Specifications:
1. Type : Fire Tube Boiler
2. Brand Name : Omnical, Germany
3. Type No. : DDH 15.0 – 10
4. Serial No. : 18709
5. Year of manufacturing : 1996
6. Max. Working pressure gauge : 10 bar
7. Max Temperature : 1830
C
8. Max heat capacity : 3.25 MW
9. Water content up to ‘NW’ : 9.62 cubic meter
10. Max steam out put : 5.0 ton/hr
11. Gas pressure in line : 1 bar
12. Gas pressure (in boiler) : 010 bar
13. Gas consumption : 34 cubic meter/day
14. Steam pressure : 7.5 bar
15. Steam header pressure : 120 PSI
16. Blow down line : 4 times/day
17. Soft water supply pipe dia : 1 inch
18. Establishment cost : 60 lacks

56. Page no: 56
Electricity
Electricity is supplied by:
 Generator – 1
- Oil consumption – 25 lit/hr
- Capacity - 250 KVA
 Generator – 2
- Oil consumption – 35 lit/hr
- Capacity - 350 KVA
 REB
Electricity consumption – 50KW/day
(A substation of voltage control – 1100 KV)
Utility cost:
01. Gas bill (Titas) : 7-8 lacs / month
02. Electricity Bill (REB) : 8-9 lacs / month
03. Others : 5-6 lacs / month
Remarks:
In UKDL all utilities that require are available for sufficient production.

57. Page no: 57
CHAPTER – IX
STORE &
INVENTORY CONTROL

58. Page no: 58
CHAPTER-IX
STORE & INVENTORY CONTROL
INVENTORY SYSTEM FOR RAW MATERIAL:
In Uttara Knitting & Dyeing Ltd. there are different inventory systems for different raw
materials.
GREY FABRICS STORE:
All the grey fabrics arc stored in the fabric store, near the batch section. Different types
of fabrics arc listed in the sheet according to the fabric types, quantity &
consumer’s requirements. Fabrics GSM, shrinkage, diameter & other properties are
also taken into consideration. The batches are prepared by taking the required fabrics
from the grey store. At present the grey fabrics store of Uttara Knitting & Dyeing Ltd.
containing the following types of fabrics-
 Single jersey
 1 x 1 Rib
 2 x 2 Rib
 2 x 1 Rib
 Fleece
 Melange..
 Pique
 Single jersey (with lycra attachment)
 1 x 1 Rib (with lycra attachment)
Dyes & Chemicals Store:
There is a different time for dyes & chemicals_ Various types of dyes & chemicals arc
stored here according to the dyes & chemical company.
Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity of dyes &
chemicals are also included. Everyday the sheet is updated & a copy of this sheet is supplied to the
AGM (production), Dye house & lab section.
Spares:
In Uttara Knitting & Dyeing Ltd. required amount of spares of different machines are

59. Page no: 59
stored in the mechanical store room. All the spares are listed in a sheet which is controlled
by the mechanical & maintenance personnel. Spares are arranged in the store room
according to there size, quantity & requirements. There are shelfs in the store room to keep
the small spare parts.
Finished goods:
Uttara Knitting & Dyeing Ltd. supplies its finished dyed fabrics to its garments section So.
dyed finished fabrics are stored for short time in the finishing section. All the delivered
fabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter,
buyers name, color & considering other technical parameters.
Others:
There is a central store at Uttara Knitting & Dyeing Ltd. In that store the various types
of forms, papers, stationary & other necessary goods are kept.
REMARKS:
Uttara Knitting & Dyeing Ltd. has individual stores forrawmaterials, finished goods etc.the sotre
of dyestuff & chemicals arc not so clean. There is no enough space to store the finished
goods. It requirestoincreasethe storearea.

60. Page no: 60
CHAPTER – X
COST ANALYSIS

61. Page no: 61
COSTING OF THE PRODUCT
The following points are considered for costing any dyed product in UKDL
1. Total dyes & chemical cost
2. Total utility cost
3. Salary
4. Payment
5. Transport cost
6. Lunch
7. Entertainment cost
8. Miscellaneous cost
9. Government cash incentive
AVERAGE PRODUCTION COST:
1. White production : 200,000 kg * 5 hr = 1000,000 kg-hr
2. Colour production : 130,000 kg * 11 hr = 1430,000 kg-hr
3. Total wash : 70,000 kg * 3 hr = 210,000 kg-hr
4. PC & CVC : 20,000 kg * 18 hr = 360,000 kg-hr
Total production : 3000,000 kg – hr
Total overhead cost : 30000,000 /=
Average production cost per kg-hr : Total overhead cost / Total kg-hr
= 30000,000 / 3000,000
= 10 /=
REMARKS:
This are not all the costing information. Some other costing information are described in the
previous chapters.

62. Page no: 62
CHAPTER – XI
MARKETING ACTIVITIES

63. Page no: 63
MARKETING ACTIVITIES
CONSUMERS OF PRODUCT:
Uttara Knit Dyeing Ltd. is a 100% export oriented industry. All the goods produced in this
industry are exported into various foreign countries. Name of the main buyers are given
below-
(A) L/C BUYER:
01. PULL & BEAR
02. DSL.
03. COTTON HOME LTD.
04. WLL LORD.
05. PELICAN RESOURCE LTD.
06. FUTURE CLOTHING LTD
07. TOPSTAR SPROTSWEAR LTD.
08. GILL TREADING CORPORATION
09. SOUTHERN LTD.
10. FORNOOR GARMENTS LTD.
11. SHSHALI HOSIERY & FASHION LTD.
12. UTTARA KNITWEARS LTD.
(B) SUB CONTRACT BUYER:
01. FRIENDS WORLD COMPOSITE LTD.
02. PURPLE APPARELS LTD.
03. EXHO TEX LTD.
04. OEKO TEX LTD.
05. MOSTAFA APPARELS LTD.
06. JOINTEX KNITWEARS LTD.
07. WEATERN STORE LTD.
08. HAQUE & SONS LTD.
09. K.R.C. COMPOSITE
10. STANDRED TRADING LTD.
11. NASRIN TEX LTD.
12. FAMILIAR LIMITED.
Local market:
Uttara Knitting and Dyeing Ltd. is not 100% export oriented industry. They have some local
buyer and they also work by sub-contact.
Importing countries:
There are some countries which are importing goods from Uttara Knitting & Dyeing Ltd. The
name of the countries are given below-
 Spain
 Germany
 Denmark
 Europe
 Denmark
 Europe Union
 United State of America

64. Page no: 64
Manpower of marketing:
Marketing plays a vital role in the field of displaying / showing the goods criteria of the
products to the buyer & to communicate with the buyer. There are about 15 people in the
marketing section of the industry.
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 Uttara Knitting & Dyeing 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.
Duties & responsibilities of marketing officer:
Dealing with the buyer & convince the buyer is the main duty of marketing officer. A
marketing officer also has some other duties. The main duties & responsibilities of a
marketing officer are given bellow-
 To prepare cost sheet by dealing with the buyer
 To take different steps by discussing with the high officials & merchandisers
 To maintain a regular & good relationship between commercial officer &
merchandisers
 To maintain a communication with the buyers and buying houses
 Communicate with better criteria of the products
Actually the responsibilities & duties of marketing officer begins from getting order of
buyer & ends after receiving foods by the buyer. So, he should be always smart, energetic
& sincere.
REMARKS:
Uttara Knitting & Dyeing Ltd. has a well learned marketing & merchandising team. They
always communicate with the buyers. Uttara Knitting & Dyeing Ltd. has some fixed buyers.
The marketing section also looks the quality & quantity buyers.

65. Page no: 65
CHAPTER – XII
CONCLUSION

66. Page no: 66
The UKDL is a well-planned versatile project. The administrations,
management, chain of command – all are well organized. They are devoted
to satisfy the customer by their activities. However, some of the point we want
to mention for the good of UKDL .
SOME SUGGESTIONS:
- During the transport of the fabric in the dyeing floor and also during
the loading of the m/c, fabrics are soiled for the contact with floor.
This makes the fabric/part of the fabric dirty. It may require more
scouring/bleaching agent or may create stain making it faulty.
- The dyeing floor is watery most of the time: it should be cleaned all
the time.
- The illumination of the dyeing shade should be enhanced. It may
exert the worker fatigue ness.
- More skilled labour should be used in a project as UKDL. Many time
the dosing pipelines are clogged due to the careless dosing of
chemicals.
- The m/c stoppage time should be analyzed and minimized. The
maintenance should be carried out when the m/c is out of action
(wherever possible)

67. Page no: 67
LIMITATIONS OF THE REPORT:
- Because of secrecy act, the data on costing and marketing
activities has not been supplied & hence this report excludes these
chapters.
- We had a very limited time. In spite of our willing to study more
details it was not possible to do so.
- Some of the points in different chapter are not described as these
were not available.
- The whole process is not possible to bind in such a small frame as this
report, hence our effort spent on summarizing them.
Lastly
What special in this report is that the information, data & description
very much subjective & practical. So, one can easily have an idea about the
whole dyeing unit of UKDL at a single look on it.
The newcomer can use this report for further detailed study or can know
UKDL without much work. But what should be remembered the chemical,
some process steps may be modified within the period this papers goes to the
readers.