Mill Training.

1. 54
Knitting Parameter
 Machine diameter.
 Machine gauge.
 Number of feeds or feeder in use.
 Machine RPM.
 Count of yarn.
 M/C running time.
 Running efficiency
.
Calculation of the Production
Production/Shift in Kg
( )
( )
Production/Shift in m
Fabric Width in m

2. 55

3. 56
Production calculation for fleece fabric and fleece yarn %
Count S. L
Surface 30 Ne 4.30
Binder 75D 2.80
Loop 20/2 1.60
No of the feeder = 108
Production for the surface:
Production for the binder:
Production for the loop:
Total = (43.84+12.08+48.94) = 104.86 kg/shift
% for the surface yarn = 41.80 %
% for the binder yarn= 11.52 %
for the loop yarn= 46.67

4. 57
Chapter 6
Quality Assurance
Systems

5. 58
Quality Assurance System
All rolls are kept in front of the inspection m/c time to time and are inspected over the grey inspection
m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, bare marks,
fall out, contamination, fly, holes, oil lines, needle lines, slubs etc are recorded in grey inspection
report to classify the fabric based on the four point system.
Collar & cuff are inspected visually under light box, any major & minor faulty collar/cuff like having
wrong ply, hole, needle lines, slubs, wrong design, first line problem etc properly counted and
recorded.
Quality Assurance Procedure
Based on the sequence of grey inspection, the inspector serially numbers each roll ensuring that all
rolls having the knit card with complete details of the roll.
a) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from the cloth or batch
roller and they are carried to inspection section by the helpers.
b) Almost four inspection workers are for every shift to check the fabric rolls. For any kind of
fault they are checked thoroughly. Skilled inspectors find them and indicate them by the
scissors in some cases.
c) Quality is specified on the basis of 4-points system. Here is the point distribution for different
kinds fault in this system:-
List of Quality Assurance Equipments
 Inspection m/c
 Scissors
 Weight balance & Micro balance
 GSM cutter
Four Point Grading System
Size of defects Penalty
3 inches or less 1 point
Over three inch but not 6 inch 2 point
Over 6 inch but not 9 inch 3 point
Over 9 inch 4 point

6. 59
Rejection Criteria for Body & Rib
Rejection Criteria for Collar &Cuff
Faults Response
Wrong ply Reject
Hole Reject
Needle line Reject
Slubs Reject
Wrong design Reject
Wrong tripping Reject
Fly & contamination Acceptable for color but not for white
First round problem Reject
Uneven tension Discuss with manager
Missing yarn Reject
Crease line Reject
Rust line Reject
Oil stripe Reject
Thick-thin Reject
Wrong tube Reject
Faults Response
Needle marks Major needle line is rejected.
Stripe Major needle line is rejected.
Bare marks Rejected
Slubs 1 point
Wrong design Rejected
Pin holes 1 point
Fly & contamination Acceptable for color but not for white
Sinker marks Do
Uneven tension Discuss with manager
Missing yarn Use 4 point
Crease line Do
Uneven tension Discuss with manager
Oil stripe/line Do
Thick-thin place Rejected
Mixed yarn Discuss with manager

7. 60
KNITTED FABRIC FAULT AND REMEDIES
1. HOLE:
Causes:
• Excessive dirt on feeder
• Take up in improper tension
• Improper match of count and stitch length
Remedies:
• Keeping the feeder clean as well as m/c should also be
cleansed
• Adjusting proper take up tension
• Adjusting count and stitch length
2. KNOT:
Causes:
• After thread breakage or bobbin end, Twisting to join thread ends; therefore Hand
dust get incorporated with yarn.
Remedies:
 Knotting should be done in proper way.
 Need skill full worker.
3. DIRTY SPOT
Causes:
• Externally incorporated dirt, lint, grease etc .
• Dead insect.
Remedies:
• By keeping the work place and m/c clean.
 Using cleaning precautions and material like poly
bags to store.
Hole
Knot
Dirty spot

8. 61
4. SINKER MARK:
Vertical line is found at Wales’s direction. (Back side)
Causes:
 Due to sinker decayed.
 Due to faulty adjustment of sinker with sinker cam.
Remedies:
 Change the sinker.
 Make necessary adjustments of sinker with sinker cam
as required.
 Don’t use sinker for long time.
5. LYCRA OUT :
A lycra yarn missing at horizontal direction.
Causes:
 If lycra yarn missed or breakage happened.
Remedies:
 Operator should be more cautious to make
necessary adjustment or replacement or joining
the lycra yarn.
6.OIL SPOT :
Oil spot on fabric surface. It may be created both Wales and coarse wise.
Causes:
 Excessive supply of oil at different friction point.
 If there is any type of problem in needle and
sinker, oil can be bleeded on the fabric.
Remedies:
 Proper lubrication system is must.
 Change the faulty needle and sinker.
 Machine should be cleaned time to time.
Sinker Mark
Lycra out
Oil Spot

9. 62
7. Set Up/Press off:
Found loop gape on knit fabric.
Causes:
 Press off occurred when needle and sinker both
inactive simultaneously in the process of knitting.
Remedies:
 Machine should be stopped as early as possible.
8. FLY YARN CONTAMINATION:
Causes:
 For proper m/c settings and management problem.
 Less care of worker.
Remedies:
 Use separator from one m/c to another.
 By cleaning the floor continuously.
 Worker must be careful.
Set Up
Fly Yarn Contamination.

10. 63
Lab & QC
Introduction
The Quality assurance Department is assigned to maintain consistently uniform quality of the
material in process and various stages of its manufacturing. SKFL is more about concern about
quality. In this factory quality assurance is more preferred than quality control, but both are in
advancement. After collecting fabric rolls from different M/Cs, they are needed to be inspected or
assured required quality by the quality inspectors as if there were no big production hampered and no
complain from the buyers. Here are the details about it.
Objects of Quality Control
1. Research.
2. Selection of raw materials.
3. Process control.
4. Process development.
5. Product testing.
6. Specification test
Scope of Quality Control
1. Testing lab
2. Machine auditing system
3. A good training system
4. Excellent analytical back up
5. Technical expertise

11. 64
Quality Control Flow Chart
Yarn receiving
Sample Knitting
Batching
Dyeing (Check shade & Faults of
dyeing)
Dewatering or slitting
Drying (Check diameter,
Pretreatment, Shrinkage Spirality
and GSM)
Compacting
Final inspection
If sample OK go for bulk
production

12. 65
Quality Control in Grey Fabric Inspection
Some Points Are Needed To Maintain For High Quality Fabric
a) Brought good quality yarn.
b) Machines are oiled and greased accordingly.
c) G.S.M, Stitch length, Tensions are controlled accurately.
d) Machines are cleaned every shift and servicing is done after a month.
e) Grey Fabrics are checked by 4 point grading system.
Quality Control in Dyeing and Finishing
The SKFL assures the quality of the products of dyeing section in the following three steps:
1. In laboratory
2. In Dyeing section &
3. 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
Fastness & other tests of the fabric or yarn are done here.
In dyeing section
According to the buyer’s sample, sample dyeing is done in sample dyeing
machine in dyeing shed & again matched with the approved sample.
If result is OK, then bulk 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
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.

13. 66
Physical Lab
Dimensional stability test:
Working Procedure:
R&D garments
After finishing sample receive
Conditioning
(4hrs,temp-20 degree,flat,R.H-65)
Template (50cm*50cm/35cm*35cm)
Sewing
(3 sides sewing, length side open)
Washing
(60 degree,time-65min,m/c rpm-1105,m/c load- min 2kg)
Drying (Line/flat/tumble)
Measurement

14. 67
Measurement:
Shrinkage
* 100%
Shrinkage calculation (for S/J fabric):
Lengthwise
= 34.33 ; Shrinkage% =
*100 = -1.9
Widthwise
=33.57 ; Shrinkage% =
*100 = -4.095
Spirality calculation:
Distortion
Spirality
* 100%
For 1*1 Rib:
Distortion
= 3.05
After length
= 48.05
Spirality
* 100%
*100%
= 6.34%
For S/J:
Distortion
= 2.25
After length
= 46.75
Spirality
* 100%
*100%
=4.81%

15. 68
GSM TEST
Specification of GSM cutter:
Name: G.S.M CUTTER
Manufacturer: James H.Heal & Company limited.
Origin : England
GSM Test
Procedure of GSM measurement by GSM cutter :
1. Cut the fabric with the G.S.M cutter.
2. Weight the fabric with the electric balance .
3. The cut sample is 100 sq.cm. The weight of the cut sample is multiplied by 100.
4. The result is the G.S.M of that particular fabric .
Suppose ,
The weight of the fabric is 2.51 gm. That means the G.S.M of the fabric is 251 gm.

16. 69
Chapter 7
Maintenance

17. 70
Maintenance:
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. Square knit fabric Ltd. ( SKFL) leads maintenance with a troop of skilled mechanical
fitters.
Maintenance of machinery:
In the knitting floor of SKFL all circular and flat knitting m/cs are maintained regularly and as
necessity requirements. Here, different type of maintenance of machinery, which is taken, different
time on the machineries.
Routine:
Maintenance of circular knitting machine:
Lubrication:
Since the life of the m/c and its correct working depend to a large extend adequate and
proper lubrication. It is recommended that the instructions given in the lubrication charts be
followed conscientiously. The Company can not be need responsible for faults that arise from
wrong or inadequate lubrication.
Routine of maintenance

18. 71
Oiling Needles & Jacks:
Too much oil is preferable to too little. Dark vertical lines in the fabric originate not from
excessive oiling but from too much friction between needle and jacks and the trick walls on account
of lack of oil. Should dark vertical lines makes their appearance is recommended that the
appropriates m/c parts be flooded with oil. This will cause heavy soiling or ht fabrics but the trouble
will disappear quickly correct quantity of oil then can be applied. The supply of oil should be
reduced if light oil striper appears on the fabric.
The Cleaning of Needle & Jacks:
Thin oil is most suitable for this work, about one point heated to a temperature not exceeding
160ºF poured into the oiling position of the cylinder & dial cam races & in the heads of the needles
while the m/c is running. The fabric will found to be cleaned again after few yards have been
knitted. How often cleaning is necessary will depend upon what kind of yarn is being used.
Synthetic yarn cleaning is taken place at lest monthly, yarn with absorbent properties being knitted
at same time.

19. 72
General Cleaning Schedule:
Long m/c life, maximum output & trouble free running depend upon proper care and
maintenance. A general overhaul should take place annually when single shifts are worked &
correspondingly at more frequent interval. When extra shifts are worked. The overhaul involves
removal of all cam section and removal of needles and jacks from their tricks, so tat the tricks
should be thoroughly the cleaned. Before parts are replaced they should be adequately lubricated.
Maintenance Procedure:
1) For there is any mechanical fault of machine which is responsible for
production hamper, operator informs mechanical fitters in duty. Mechanical fitters come
and observe the problem firstly, and then they begin to fix it.
2) If mechanical fitters be unable to fix it, then they inform technical in-charge, he
then comes in spot and fix it.
3) For there is any electrical problem of machine or serious founding
mechanical problem, mechanical and electrical department are informed, they come and
fix the problem. They commence at work after informing of knitting manager. There are
two mechanical engineers in the department.
4) For restorative maintenance, senior production officer orders mechanical
fitters to fit required machine for cam and needle arrangement and other necessary
requirements in case of new design development.

20. 73
Maintenance sequence of circular knitting machine:
Power on/off
↓
MPF/Positive feeder current line off
↓
MPF belt out/loss
↓
Yarn cut
↓
Fabric out by handle
↓
Cleaning and Oiling
↓
Cam box out
↓
Needle & sinker out
↓
Needle & sinker cleaning by oil
↓
Cam box cleaning by air
After opening & cleaning, m/c is leveled by using leveling meter and follows the reverse process to
ready the m/c.

21. 74
Maintenance tools/equipment & their functions:
Maintenance tools/equipments Functions
1. Adjustable wrench Used for setting nut & bolts
2. Air suctioner For cleaning machine
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. Cutting pliers To cut thin wires
13. Pulley key To loosen pulleys
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. Star driver Screw unlocking
20. Steel tape To measure length, width & height
21. Chisel To cut any metal
22. L-key For loosen & tighten the screw
23. File To smooth the rough surface

22. 75
Different types of maintenance tools:
Hammer Double ended wrench
Adjustable wrench One ended wrench
L-key

23. 76
Weekly
 Clean the glass electrode of pH meter.
 Check the filter net of dosing pump.
 Check the current of air pressure.
 Clean air filter of blower (monthly).
Every 4 month
 Calibrate the PH meter with buffer solution, 7 & 4.
 Calibrate the blower meter,
 Grease the oxygen meter.
 Grease the scraping, bridge, bridge wheel of ball bearing.
EVERY 2 YEAR
 Grease the spring ball bearing.
 Change the oil of sludge transfer pump.
 Change the oil of feed pump.
 Change the oil of lifting pump.
 Change the oil of sludge blower.
 Change the sensor of oxygen blower (if necessary).
 Change the electrode of pH meter (if necessary).
 Change the oil of dosing pump.
 Change the oil of scraping grease motor
Remarks:
This mill has a strong maintenance fitter’s troop to fix up all types problem. Two
groups of two shifts obey their duties responsibly and sincerely. With their different tools
or equipments they perform their duties skillfully.

24. 77
CHAPTER 8
UTILITY SERVICE

25. 78
Description of the Utilities
Utility Facilities Available:
The following utility facilities are available at SKFL Water.
- Steam.
- Electricity.
- Gas.
- Compressed air.
Source of Utility:
1. Water- Own supply (Pump)
2. Steam-Own supply (Boiler)
3. Electricity-Generator & PDB
4. Gas- Titas Gas Transmission & Distribution Co. Ltd.
5. Compressed air- Own supply (Air compressor)
Water Conditioner
 Raw water hardness: 18-20 0 (Generally 30 ppm)
 Boiler water hardness: 0 0
 M/c used: Water conditioner
 Submergible pump : 2 (For SKFL) & 1 (For Dormitories)
 Process water: 200m3/hr and 150 m3/hr
 Domestic use: 150 m3/hr
 Company: Cleaver Brooks
 Country of origin: USA.
 Water consumption: 4500-5000m3/day
 Water pressure: 6-6.5 bar
Water conditioner machine

26. 79
Steam:
Fig: Fire tube type gas boiler
 Boiler Steam: 10.2 tons/hr. & 2.3 tons/hr.
 Steam pressure: 7.5-8 bar
 Steam temp: 150-160 0 C
 M/c used: Fire tube type Gas Boiler & Exhaust Gas Boiler
 Piece: 02 (Fire tube type Gas Boiler) & 01 (Exhaust Gas Boiler).
 Capacity: 10.2 tons/hr. & 2.3 tons/hr.

27. 80
Application:
1. The major portion of the steam is supplied to the SKFL. Dyeing section.
To heating the drying Cylinder.
To heating the calendar rollers.
Heating the chemicals liqor.
2. Garments section
For steaming and ironing.
Power Supply:
Fig: Electricity Gas Generator
 Supply: Titas Gas Transmission & Distribution Co. Ltd.
 M/c used: Electricity Gas Generator
 Brand: Cater Pillar
 Origin: USA
 Piece: 05
 Total Capacity: 5.6 MW (1 MW+1 MW+1 MW +1 MW+1.6 M

28. 81
Chiller:
Fig: Chiller
Hot water
chiller
Vapour
absorbent
chiller
Vapour compression
chiller (Centrifugal
Chiller)
Flue gas with steam
absorption Chiller (Dual core
chiller)
Brand:
Prochill
Thermax
Brand: Prochill
Thermax
Brand: Mc Quay Brand: Shuang Liang
Capacity:
400 rt/hr.
Capacity: 400
rt/hr.
Capacity: 400 rt/hr Capacity: 661 rt/hr.
Origin:
India
Origin: India Origin: USA Origin: China
Application:
The maintenance of relative humidity and temp is very important for knitting to
reduce yarn breakage and produce quality fabric. The chiller maintain required amount of
relative humidity (80 – 85%) and temp (22 – 26ºC) in all section of SKFL.

29. 82
Air Compressor:
Piece: 07
Brand: BOGE (No. of machine 6) &
ROLL AIR (No. of machine 1).
Country of origin: Germany
Capacity: 6 m3 /hr
To reservoir
Fig: Working principle of air compression
Application:
1. The major consumption of compressed air is in knitting section.
2. To the air gun for yarn insertion
3. To clean different section and machinery
4. To the sensors where pneumatic pressure required (computerized control machines).
5. For the compensator movement.
6. Pneumatically controlled loading and unloading of yarn dyeing machinery
7. Pneumatically controlled loading and unloading of different machinery.
Air filter
Cooler
Screw compressor
Motor
Oil
filter
Oil tank
Separator
BOGE Air compressor

30. 83
Cooling Tower:
Fig: Cooling Tower
Use in: Generator
Country of origin: Thailand
Piece: 12
Fig: Coiling system of Gas Generator

31. 84
Effluent Treatment Plant (ETP)
Square Knit Fabrics Ltd. is very much concern about its effluent, for this reason they
established two effluent treatment plant and they are ETP-I (capacity1200 m3 per day) &
ETP-II (capacity 3000m3 per day). The ETP in SKFL is a biological one. Here bacterial and
protozoa are the catalyst of biochemical reaction to convert the toxic material into
environmental friendly gases and substances. The initial cost of biological ETP is more but it
has a low running cost if control is greater.
Reaction Time:
8-12 hr for secondary treatment
50 m3/ hr for secondary treatment
3-4 ppm/30-35c(for proper bacterial action)
Quantity of micro-organism 1:4
Total capacity of ETP plant: 1200 m3 /day + 3000 m3/day = 4200 m3/day.
Sludge removes level: 800 MI/ 1/2hr f

32. 85
Effluent Analyzing Report:
Parameter Unit Quantity Std. Value
PH 7.5 6-8
COD mg/lt 39 150-200
BOD5 mg/lt 23 29-50
Color APHA/Pt.Co 335 220-250
Phosphate mg/lt 3.2 5-15
Sulphate mg/lt 560 1000
Ammonia mg/lt 2.50 5-10
Chloride mg/lt 120 500-600
Nitrate mg/lt 6.16 08-10
TSS mg/lt 80 60-80
TDS mg/lt 2075 2100
Chlorine mg/lt 0.1 1
Nitrite mg/lt 0.21 >1
Sludge (wet) ml / ½ hr 800-820 700-800
Ref:
USPEA (United States Environment Protection Agencies)
IWRA (International Water Resources Association)
GOB (Government of Bangladesh)

33. 86
Typical flow diagram of a Physical-Chemical and Biological treatment
Plant in Square Knit fabric Ltd (SKFL):
Influent of
Factory effluent
Activated
Sludge
Sludge disposal
Treated effluent
Equipments for ETP Laboratory:
o HACH method (for measuring BOD & COD)
o BOD Incubator
o Electric Shaker
o Reflex Condensat for COD measuring
o PH meter
o TDS meter
o Inhoff con for measuring sludge quantity
o Desiccators
o Separating funnel
o Electric Balance
o COD Reactor
UHRSCC
Screening Unit Equalization Unit Coagulation Unit
PH control Unit
Aeration Unit
Primary
Sedimentation(Primary
sludge pit)
Flocculation Unit
Sludge dewatering Unit
(Centrifuge)
Sludge thickening
(Centrifuge)
Sedimentation Unit
(Lamella)
Chlorination

34. 87
Parameters of ETP:
 Waste water outlet  3000 m3/day
 Treatment capacity  1500 m3/day
 Running cost  2 – 4 Tk./m3
 Plant capacity  1200 m3/day
 Bacterial: Protozoa  60:1
 Sludge collection at  60 – 70 %
 Screen allowance  1 in2
 PH  6.5 – 8
 Dissolved oxygen (DO)  2 – 3 ppm
 Outlet water temperature  30 - 35ºC
 Dwell time for effluent discharge  48 hrs. (For oxidation tank)
Bacteria in oxidation tank: Protozoa:
Bacilli Paramecium caudatum
Cocehi Euplotes
Beggiatoa Vorticella dutrina
Spirillum Colpidium

35. 88
Biochemical Reaction:
Bacteria decompose the organic matter and other matters are related with oxygen by microbial action i.e.
biochemical reaction and produce gases and free radicals.
Metals are bio-chemically reacting with the enzyme and produces gases.
Mn + O2  Enzyme MnO2
Organic radicals Gases and free radicals
C
+ O2
 MICRO ORGANISM
CO2
H H20
N NO3
S SO4
2-
P PO4
3-
Process Water Test Report
Sl. No. Water quality parameters Unit Dye house standard Test result
1. PH - 6 to 8 6.23
2. Color Pt.Co 5 2.0
3. Turbidity NTU 2 1.0
4. Total Alkalinity as CaCO3 mg/lt 150 46
5. Chloride mg/lt 100 8.7
6. Total Hardness as CaCO3 (TH) mg/lt 2o Gh = (2X17.85) = 35.7 ppm 16.45
7. Manganese (Mn) mg/lt 0.1 Nil
8. Iron (Fe) mg/lt 0.1 0.02
9. Total Dissolved Solid (TDS) mg/lt 100 to 180 145
10. Sulphate mg/lt 100 1
11. Oil & Grease mg/lt Nil -
12. Arsenic (As) ppb 0.005 -
13. Dissolved Silica mg/lt - 42.6
Note: Sample Collection from Hanks Dyeing Area

36. 89
Caustic Recovery Plant (CRP)
Square Knit Fabrics Ltd is very much concern about the environmental issues. Here a large volume of
caustic both liquid and solid used in different wet processes as a basic chemical. In case of Yarn and
Fabric Mercerization most of the liquid caustic produced and effluent containing caustic produced.
The recovery of these caustic of 2º to 5º Be concentration is beneficial for cost minimization and
reduction of effluent which may cause environmental hazard.
Fig: Caustic Recovery plant (CRP)
Few Parameters:
 Inlet steam pressure  7 – 8 bar
 Vacuum condenser pressure  0.3 – 0.4 bar
 Condenser temperature  70ºC - 75ºC, Pressure  2 bar, Flow  60lit/80sec
 Weak lye temperature  35 - 37ºC, Concentration  5-6ºBe
 Strong lye temperature  75 ºC - 85ºC, concentration  28 - 30ºBe
 1st stage:
o Shell side steam pressure  1.2 – 1.6 bar
o Shell side temperature  120 – 130ºC
o Pipe temperature 110 – 115 ºC
 2nd stage:
o Shell side temperature 110 ºC
o Pipe temperature 90 – 100 ºC
 3 rd stage:
 Shell side temperature  85 -100ºC
 Pipe temperature  70 - 85ºC

37. 90
Weak lye
tank
Pre Heater
Pre Heater
Heat Exchanger
Heat Exchanger
Evapurator Evapurator
Heat Exchanger
Evapurator
Condenser
Sedimentation
tank
Strong
lye tank
Heating Steam inlet
Steam inlet
Fig: Shhematic diagram of Caustic Recovery Plant

38. 91
Recovery Process:
Effluent reached to weak lye tank Concentration is 2º - 5º Be

Pre heating done in pre heater Temperature 60ºC - 65ºC

Boiling occurs in 1st Heat exchanger Temperature 120ºC

Evaporation of water in 1st evaporator Concentration 10ºBe

2nd Heat exchanger Temperature 114ºC

2nd Evaporator Concentration 20º Be

3rd Heat exchanger Temperature 84ºC

3rd Evaporator Concentration 30º Be
 Vapor
Condensation at condenser (Condense flow rate)

Strong lye tank / sedimentation tank
Dosing H2O2

Strong lye tank

Mixing tank
Mixing with pre stored caustic (1litre 30o Be Caustic + 25 gm Solid Caustic)
Concentration 40ºBe

39. 92
Rain Water harvesting
Rain water is collected here.
Remarks:
SKFL is using 0-5deg (total) hardness water which is suitable very for dyeing. The underground water is free
from hardness creating metals and eliminates the need for water treatment plant. The electricity supply
system is very good and fluently. It is fully equipped to produce its necessary power. Its capacity of power
generation is increasing with another two generators to be established. The constant pressure of water also
eliminates the need for high rise water tank and maintains flow speed in different machines.

40. 93
Chapter 9
Store & Inventory Control

41. 94
STORE & INVENTORY CONTROL
Inventory is planning and execution involves participation by most of the fundamental segment of business
sales, production, purchase, finance and accounting. Inventory is a wider sense is defined as any idle resource
of an enterprise however it is semi-finished packing spares and other stocked in order to meet an expected
demand or distribution.
Objectives of inventory control:
1) Financial activities:
a) To save amount of investment
b) To know the cash position
2) Property Protection:
a) Preventable waste
b) Insurable damage
c) Unauthorized use
3) Operating:
a) To obtain the best overall balance between production and inventory carrying cost.
b) To minimize losses
c) To avoid stock out and to keep inventory holding costs in costs in balance.

42. 95
Inventory system:
For Raw Materials:
In this factory, Square knit fabric Limited, raw materials are yarn of different type, different count
and of different spinning mills of home and abroad. As according to knitting section demand yarn is
either imported or bought from spinning mills and they are kept in the store for raw materials in
accordance with type and count. As like as polyester, cotton, lycra are kept separately and also to
their count variation. Inventory office
keeps record of this raw materials
amount, their usage and storage.
Central Yarn Store
For Dyes and Chemicals:
There is a different store for dyes and chemicals. Vanes 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 sectio

43. 96
For Spares:
Different spares parts of knitting machines and other equipments are kept in store as
inventory so that there are no time and money losses while it is being used. Here is the list of spare
parts as inventory:
1) Needle detector
2) Fan
3) Air gun
4) MPF belt tensioning device
5) Air nozzle
6) Fabric spreader
7) Fabric light
8) Compressor line + pipe
9) Air blower
10) Memminger
11) Oil Tank
12) Fabric roller
13) Inverter
14) Yarn Guide feeder
15) Oil Nozzle
16) Cam box
17) Magnet
18) VDQ pulley
19) Fan broker
20) Oil Meter cover
21) Oil plutonic
22) Air meter cover
23) Knot catcher
24) Feeder ring bolt

44. 97
For Knitted Fabrics:
After knitting the fabrics are collected according to roll form. There is a big store room beside
knitting section in this factory and fabric rolls are stored here according to fabric types and some
specification is given to fabric rolls such as buyer name, yarn count, lot no, fabric type, m/c no, fabric
weight etc. Collars and cuffs are also stored in this room. A store keeper always does this job
successfully.
For Finished Goods:
SKFL 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, buyer's name, Color & considering other technical parameters.
For Others:
Out of above types there are inventory systems for semi-finished goods like as dyed fabrics,
garments pattern pieces, markers, sewed goods, scrap, surplus, absolute items, garments labels, packages
etc.These goods are maintained by the respective inventory control office different departments this knit-composite
mill.
Remarks:
Proper inventory control of raw materials, semi-finished goods, finished goods and other
miscellaneous goods lead smooth production. As SQUARE KNIT FABRIC LTD. follow the correct way
of inventory control system, it can have a good and huge production as it demands.

45. 98
Chapter10
Cost Analysis

46. 99
COST ANALYSIS
Costing of the Product:
Costing system mainly describe how the cost of the final product is fixed by the company or the
managements. As it is a garments manufacturing factory , so accordind to the buyer or customer
requirements of final garments , merchandiser give the consumption of the fabric with specification . Then it
is calculated how much dyestaffs & chemicals are required for processing. After that, the final cost is fixed
including some profit. Then the unit price is differed to the buyer for their approval.
Costing of the Products is done by the Consideration of the Following Factors:
• Amount raw materials consumed
• Direct Labour
• Indirect Labour
• Factory Cost
• Officer and administrative cost
• Sales and distribution cost
• Profit, etc.
Price of the Product:
Generally price of product is determined by the required profit adding to the total expenses. So,
Price of products^ (Direct expenses + Indirect expenses + Factory verhead) + Required profit
Costing of a Product Includes:
 Yarn cost
 Knitting cost
 Dyes & chemicals cost
 Cost of dyeing
 Cost of finishing
 Cost of cutting, sewing, accessories etc.
 Cost printing
 Labor cost
 Factory cost
 Office & administration cost
 Sales & caring cost
 Others cost
 Profit etc.

47. 100
Price of different operations:
Knitting cost:
Fabric name Charge per kg(Tk)
Single Jersey 9
Single Jersey with Lycra 34
Single locoste PK 16
Double lacoste PK 16
Single PK 18
Double PK 18
1X1 rib 18
1X1 rib feeder stripe 30
Design rib 50
Lyc 1X1 rib 35
2X2 rib 30
2X2 rib Lycra 40
Interlock 35
Fedeer stripe 30
Auto stripper 110
Auto striper with Lycra 140
Fleece 30
J/Q 200

48. 101
Dyeing Cost:
SL no Processing type Price per Kg
01 Light shade 75
02 Medium shade 90
03 Dark 95
04 Extra dark 110
05 Royal /Reactive black 130
06 White 30
07 CVC /TC (white) 130
08 CVC/TC (white) 50
09 Exceptional color (more than 8%) 120
10 Normal wash 25
Finishing charge of different fabrics:
Remarks:
The costing of the product is most secret matter of the industry. They were not interested to share
the cost related data with us. So we could not collect detail the price of the product.
Name of fabric process Charge per kg(Tk)
Slitting only 5
Stenter only 25
Compacting only 15
Stenter + Compacting 35
Stenter + Compacting+ wash 50
Tube Compacting 10

49. 102
CHAPTER11
MARKETING ACTIVITY

50. 103
Marketing Activities
Marketing:
The process of advertising, promoting and making a product popular among the masses is called marketing. It
is the sector of ultimate importance of an industry.
Duties of marketing officer:
1) To collect the order from buyer.
2) To determine the price of product.
3) To inform the buyer when the product in process.
4) To ensure fabric quality, product quality.
5) To concern about the product until the shipment.
Order follow up process:
Buyer sends product package
Costing on product package
Price approval
Sampling
Order confirmation (Order sheet)
Fabric booking
Fabric production
Fabric dyeing and finishing
Garments making
Quality check
Packaging
Shipment

51. 104
Price Quotation:
There are some systems for price quotation as given below -
1. FOB (Free on board)
2. C & F (Cost & Freight)
3. CIF (Cost, Insurance & Freight)
List of Some of Buyers:
I) Puma
II) G-Star
III) Espirite
IV) M & S
V) S. Oliver
VI) Mexx
VII) H&M
VIII) Street one
IX) Matalon
X) Kitaro
XI) Tema
XII) Norwest

52. 105
EXPORT VALUE-2011
EXPORT VALUE-2012
PUMA
28%
G-STAR
11%
S. OLIVER
8%
H & M
7%
MEXX
4%
STRAUSS
4%
OTHERS
9%
ESPRIT
29%
0%
PUMA
32%
G-STAR
7%
S. OLIVER
8%
H & M
11%
MEXX
5%
STRAUSS
3%
OTHERS
7%
ESPRIT
27%
0%

53. 106
Remarks
SQUARE KNIT FABRICS LIMITED 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 points we want to mention for the betterment of SQUARE KNIT FABRICS
LIMITED.
 We asked the concerned persons to cut some sample pieces for us. The samples were cut
very much more than we required. This is noticeable. A huge amount of fabric goes to
wastage. No doubt, this lessens the overall efficiency.
 We found the floor was watery due to overhead sanitary leakage & the problem remains
unsolved due to negligence.
 The dyeing floor is watery most of the time; it should be cleaned all the time.
 Modern material handling tools are to be utilized.
 The machine stoppage time should be analyzed and minimized. Good maintenance practice
is needed.

54. 107
CHAPTER12
Conclusion

55. 108
Conclusion
Two month of industrial attachment at the SQUARE KNIT FABRICS LIMITED (SKFL.) was a part of the
B.Sc. in textile technology course. The eight weeks of the training period were segmented &
scheduled to a systematic routine. We have got the impression that it is one of the most modern
export oriented knit composite factories in Bangladesh. Though it was established only a few years
ago, it has earned very good reputation for its quality products, over many other export oriented
textile mills.
This training gives us actual picture about man, machine, material, methods and market. We have
earned the direct knowledge about the raw materials, actual running condition of the machines,
working technologies, production follow-ups and the administration.
This mill is a well-planned with enough expansion facilities. The working condition & the relation
between employer & worker is wonderful.
We are enough fortunate to get an opportunity of having a training in this factory. During the
training period we received cordial association and co-operation from the authority & found all man,
machines & materials in appreciable working condition. All stuffs & officers were very sincere &
devoted to their duties for achieving the factories goal.
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