1. BANLADESH UNIVERSITY OF TEXTILES
92, SHAHID TAJUDDIN AHMED SARANI
TEJGAON INDUSTRIALAREA, DHAKA-1208
Welcome to our presentation
On Industrial Attachment
At
From 19th May,2015 to 19th July 2015

2. SUPERVISING TEACHER
MD. EMDAD SARKER
Assistant Professor,
Department of Fabric Engineering,
Bangladesh University of Textiles
SUBMITTED BY
SAYEED IBNE REZA (2011-1-081)
MD. FAKHRUL ISLAM (2011-1-086)
YEASIN ARAFAT (2011-1-232)
MONIKA JAHAN (2011-1-250)

3. Square Fashions Ltd. at a glance
Factory Location
Rokeyapur,Jamirdia,Habirbari,Valuka,My
mensingh
Corporate Office
Mascot plaza,(11 𝑡ℎ
−12 𝑡ℎ
Floor ),
Plot# 107/A, Sector# 7,Sonargaon
janapath,Uttara Model Town,Dhaka-
1230,Bangladesh
Year of establishment: 2001
Commencement of production:
June ,2002
Target market : Export oriented
readymade garment Industry
Investment:Us $20 million
Production Capacity : 12 tons of knit
fabrics per day (fabric unit -1)
Total Factory Area: 165000 sq.ft
Production space : 135000 sq.ft

4. Department of Square Fashions Ltd.
Production Pertaining Department:
 Fibre Dyeing department
 Yarn store department
 Yarn dyeing department
 Knitting department
 Physical and chemical lab
 Dyeing
 Finishing department
 Quality control department
 R & D (research & development)
Supporting department:
 Finance & Accounting
 HRM Department
 Utility Department
 Security Department
 Administration
 Marketing & Merchandising

5. Manpower Organogram

6. Section wise Manpower Distribution
Section No of Worker
Fabric Dyeing 75
Yarn Dyeing 30
Knitting 115
Finishing 60
Quality 75
Physical Lab 30
Chemical Lab 15
R&D 20
HR & Admin 25
Others 35
Total Worker & Stuff 750

7. Shift Change
There are three shifts in this industry. So the shifts are changed at every
8 hours.
 General Shift: 8 a.m. to 5 p.m.
 Shift A (Day): 6 a.m. to 2 p.m.
 Shift B (Day): 2 p.m. to 10 p.m.
 Shift C (Night): 10 p.m. to 6 p.m.
General Shift is provided only for General manager/ Assistant General
Manager/ Sr. Manager /Sr. Executive

8. Knitting Section
Number of machines
Needle bed Machine Type No. of machine
Circular
Single jersey 20
Fleece 3
Engineering Stripe 14
S/J jacquard 4
Rib 7
S/J Semi jacquard 3
Interlock 4
Flat 22
Total 77

9. Layout plan of circular knitting section (fabric unit 1)

10. Relanit Technology
Technology of using vertical sinker in circular knitting machine is called Relanit
technology. It is a modern innovation of MAYER & Cie.
Relanit Versions:
 Relanit 1.6R
 Relanit 1.6RE
 Relanit 2. 53SE
 Relanit 3.2 ii
 Relanit 4.0
Diameter of cylinder = Number of feeder / Relanit model

11. Relanit 4.0 (High speed machine)
Higher number of feeder ,Special types needle & cam ,Vertical sinker
Needle Cam Vertical Sinker

12. Feeder stripe
Stripe effect is produced by using different color yarn in different feeder in an
orderly manner according to repeat
10 Course Repeat of a
feeder stripe design:
Red = 5 course
Green = 3 course
Black =2 course
Total = 10 course
While producing this
fabric in a 54 feeder
machine,
active feeder would be =
10×5 =50
The rest 4 feeder will be
all miss cam.
Yarn arrangment would
be :
Feeder (1-4)= miss
Feeder(5-9) =Red
Feeder(10-12)= Green
Feeder(13-14)= Black
Then,
Feeder (15-19) = Red
Feeder (20-22) = Green
Feeder (23-24) = Black
& so on.

13. Engineering stripe
Stripe effect is produced by adding different colored yarn in each feeding position
according to repeat with the help of “ Finger Mechanism”.
45 Course Repeat of a
E-stripe Design
Red =10 course
Green = 5 course
Red = 5 course
White = 5 course
Pink = 10 course
White = 5 course
Red = 5 course
Color of yarn in the Finger
Finger 1 = Red
Finger 2 = Green
Finger 3 = White
Finger 4 = Pink
The Programme will be :
Finger 1 = (1-10)
Finger 2 = (11-15)
Finger 1 = (16-20)
Finger 3 = (21-25)
Finger 4 = (26-35)
Finger 3 = (36-40)
Finger 1 = (41-45)

14. Yarn Selection by Fingering Device Automatic Cam Arrangement System

15. Circular mechanical jacquard knitting machine
Knitting Elements:
1.Peg box
2.Peg
3.Selector
4.Raising Cam
5.Cam box
6.Jack cam
7.Needle cam
8.Pin Cam
9.Sinker Cam
10.Jack
11.Needle
12.Pin
13.Sinker

16. Needle of Different Butt
Position
Needle Selector Knob Cam Box of Semi Jacquard Machine

17. Electrical Circular Jacquard Knitting Machine
Knitting Elements:
 Electromagnetic needle
selector.
 Spring Jack.
 Jack Cam Box and Jack cam.
 Needle
 Pin
 Sinker
 Special cam box for electrical
circular jacquard.

18. Needle and Sinker of Electrical
Jacquard knitting machine
Cam system of Electrical
Jacquard knitting machine
Cylinder of Electrical Jacquard knitting
machine

19. A flow process is given for designing a jacquard design.
 Open Gridm file
 Take a repeat for a design
 Draw the design
 Save the file
 Open the cone file
 Take a new file selecting the
gridm file
 Edit the cone color
arrangement
 Calculate the cone color
arrangement
 Save the file in the same folder
as the gridm file saved
 Open the gridm file
 Open the cone color
arraangement file
 Invert the file
 Give the tuck if necessary
 Save the file as the same of
cone color arrangment
name
 Open the RAP
 Open the cone color
arrangement file through it.
 Convert it For 2 ways or 3
ways technique.
 Edit the file
 Test the file
 Save the file as the same
name as cone file.
 Sent this file to the machine
computer through data
cable.

20. Knitting Cost of Different Fabrics (approx.)
FABRIC NAME COST PER KG (TK)
Single Jersey 10-11
Single Jersey with Lycra 34
Single Lacoste 16-18
Double Lacoste 16
Single Pique 18
Double Pique 18
Rib (1x1) 18
Rib Feeder Stripe(1x1) 30
Design Rib 50
Lycra Rib(1x1) 40
2X2 rib 30-40
2X2 rib Lycra 40
Interlock 30
Feeder stripe 30
Auto stripper 80-100
Auto striper with Lycra 140
Fleece 20
Jacquard Design 250-300

21. List of Buyers:
 Puma
 Mustang
 G-Star
 Mexx
 H & M
 Next
 M & S
 Fire Trap
 S.Oliver
 Engelbert Strauss
 P & C
 Target Australia
 Pierre Cardin
 Malfini
 Gutteridge
 Kitaro
 Espirit
 Tom tailor

22. Types of Yarn Used
 Cotton Yarn(Card and
Combed)
 Polyester Yarn
 CVC
 PC
 Melange
 Spandex (Lycra)

23. Pie chart of Yarn used in Square knit fabric Ltd.
17%
4%
26%
5%
11%
8%
8%
4%
4%
5%
3%
2% 3%
Pie chart of various types of yarn with count
used in knitted fabric at Square fashions Ltd.
20 D lycra
40 D lycra
34's
40 viscose
30's
28's
26's
30 CVC
60/2 mercerised
24's melange
20's slub
60's P/C
others

24. Fibre Dyeing
Fibre dyeing is done to produce
Melange Yarn
Fibre used :
1.Cotton
2.Polyester
3.Viscose
4.Rayon
5.Flax
6.Ramie
Cake Preparation
Scouring+Bleaching+Dyeing at same bath
Hydro extraction (2 hours in 3 steps)
Cake Opener
Dryer (Feeding,wet losing,stream dryer)
Bale pressing and preparation( 50-120 kg/bale)

25. Yarn Dyeing
Yarn are processed in three Forms:
1. Package form (mercerised+non mercerised)
2. Hanks form (only mercerised yarn)
3. Sewing thread preparation(used 100% polyester,50/2
polyester,20/2 polyester,150D filament,120D rayon )

26. Process flow of yarn processing in package form
Grey Yarn from spinning
Making soft winding package
Batching
Dyeing
Hydroextracting
Radio frequency dryer
Hard/Random winding package
Delivery for knitting or weaving

27. Soft Winding Batching Hard/Radom Winding

28. Machine used in yarn dyeing
Types of the machine Quantity
Yarn dyeing machine (package form) 11
Yarn dyeing machine(hank form) 04
Mercerized machine(yarn mercerizing) 01
Soft package winding machine(no.of head-240) 02
Hard /random winding machine(no. of head-312) 03
Hydroextractor machine 01
Radio frequency dryer 01
Gas singeing machine for yarn (No. of head-96) 02
Soft winding package machine for sewing thread 02
Reconning machine 02
Sewing thread dyeing machine 15
Reeling machine 4

29. Batching
Batching is the pre-plan of dyeing process.
Machine used in batch section:
1. Back sewing machine: Laycra/single jersey fabric is turned into tube
form.
2. Turning machine: It makes the face side into back & back side into face.
3. Padder machine: It is used to open out the fabric from roll form.
4. Balance : It is used to weigh the grey fabric.

30. Fabric Dyeing
 Machine used of different Brand:
Sl. No. Brand Type No. Of machine Origin
1 Fongs Sample Dyeing 07 China
2 Fongs Dyeing 02 China
3 Sclavos Dyeing 09 Grece
4 Thies Dyeing 04 Germany

31. Finishing
Types of finishing:
1. Chemical finishing
2. Mechanical finishing
Machines used in finishing:
 Slitting machine
 Dewatering machine
 Stenter machine
 Open Compactor
 Tube compactor
 Dryer
Special Finishing Machine:
 Sueding machine
 Brush Finish machine

32. Finishing Machine used in Square knit fabric Ltd.
Machine Name No. Of Machine
Dewatering machine 01
Slitting machine 02
Dryer 02
Stenter machine 04
Open tube compactor 02
Tube compactor 01
Sueding machine 01
Brush finish machine 01

33. Laboratory tests
 Determination of G.S.M
 Fabric width
 Shrinkage test
 Spirality test
 Brusting Test
 Piling test
 Color fastness to rubbing
 Color fastness to wash
 Color fastness to perspiration
 Color fastness to water
 Color fastness to light

34. Utility section

35. Source of Utilities
 Water- Own supply (Pump)
 Steam- Own supply (Boiler)
 Electricity- Generator and PDB
 Gas- Titas Gas transmission and
Distribution Co. Ltd.
 Compressed air- Own supply (Air
compressor)
Different Machines of
Utility
 Gas generator
 Boiler
 Compressor
 Air conditioning machine
 Chillier

36. Effluent Treatment Plant (ETP)
Treated Water
Storage and Equalization Tank
Mixing Tank

37. In square Fashions Ltd.
Biological process is applied in
ETP plant.
 Capacity of their plant = 4200
m3/day
 (ETP-01+ETP-02)=(50+125)=175
m3/hr
Biological plant
1. Bacteria (Bacilli,Cocei,Spirillum)
2. Yeast
3. Fungy
4. Alge
Micro organism is the main raw material
for Biological plant.

38. Caustic Recovery Plant (CRP)
Square Fashions Ltd. Has a caustic
recovery plant to Recycle fabric and
yarn mercerization machine discharge
wastage weak lye caustic of average 5
Be(32 gm/L).Here collecting of weak lye
seperately from machines and pumped
in CRP storage tank.CRP recover strong
lye at 30 Be( 296.8 gm/L)

39. Thank You