1

Industrial Attachment-2014

INDUSTRIAL TRAINING
Course Code: Tex
-4036


INDUSTRIAL ATTACHMENT OF
APS GROUP LTD.

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Industrial Attachment-2014



Introduction
Industrial Attachment is the first step to professional life of a student. Especially of technical side
it’s an indispensable part of study a practically running processing technology of an industrial unit
for a student. In our University, processing machines are not in continuous running condition. So
it would only provide demonstration of mechanical features & processing technology of the
material in accomplishment of the theory there of but not of the situational variables to achieve
practical knowledge. Six weeks industrial attachment program in a dying mill was arranged for us
this type of attachment program enabled us to avoid the gap between theory & its applicability the
mill practice the incumbent was deeded to APS Group (Dyeing Unit).

In the field of ever changing moderns fashion work. APS Group (Dyeing Unit). considers its
prime mission to every new test. Which & demand of customers from around the World & all
strains human culture DGL acts on the basis premise that fashion is an exploration in to the
images people seek to convey about themselves & the way they live.

We have prepared this report as required in competition of my attachment course in regarding
guideline given by the university authority which will lead to a strong guideline and milestone for
our future carrier.


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Industrial Attachment-2014
Table of Content


Chapter
Description
Page no
Chapter-1
Over View of the Factory
5-17
Chapter-2
Raw Materials
18-24
Chapter-3
Knitting section
25-41
Chapter-4
Laboratory section
42-46
Chapter-5
Batch section
47-53
Chapter-6
Dyeing Section
54-76
Chapter-7
Water Treatment Plant “WTP”
77-79
Chapter-8
Finishing Section
80-95
Chapter-9
Quality Control

96-105
Chapter-10
Description of ETP
106-108
Chapter-11
Garments
109-115
Chapter-12
Maintenance
116-118
Chapter-13
Store & Inventory control
119-121
Chapter-14
Social & Environmental information
122-127



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Industrial Attachment-2014







CHAPTER: 1

“Over View of the Factory”









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Industrial Attachment-2014








Address: Pubail, Gazipur, Sadar, Gazipur




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Industrial Attachment-2014
AT A GLANCE


APS Group (Dyeing Unit)
100% Export Oriented Composite Knitwear Factory
Address: Pubail, Gazipur, Sadar, Gazipur
Tel: +88-02-9815028, www.aps-group.org


Head Office - Pubail, Gazipur, Sadar, Gazipur

Tel: +88-02-9815028

Factory - Pubail, Gazipur, Sadar, Gazipur

Nature of project - 100% Export Oriented Composite Knitwear Factory

Bank - Bangladesh Shilpa Bank, Head Office, Dhaka.

Management - 1. Md. Alfaz Managing Director/Chairman


Contact Person - 1. Engr. Md. Rashedul Islam (Babu), General Manager (Fac.)
Mobile: 01713454160

 -2. Md. Rezaul Karim (Babu) Manager (Dyeing & Finishing)
Mobile: 01718218497
 3. Md. Bellal Uddin Manager (Knitting)
 4. Md. Musa Kalim (Manager Finishing)














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Industrial Attachment-2014
Composition of Factory

The Enterprise have been organized in the following manner:

APS Group (Dyeing Unit) Unit : Fabrics Knitting

APS Group (Dyeing Unit) Unit : Fabrics Dyeing

Year of Establishment : January, 2000


Location:

Our Head office is located at a posh area called Uttara while the factory is located in an industrial area
at Pubail, Gazipur which is only 2.2 Km.



Production Capacity and Facilities :










1)
Knitting Division :







Area

:
10,000 sft.




Man Power
:

46




Production
Capacity
:
6000
Kgs/day




List of
machinery
:
As below











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Industrial Attachment-2014








a)
Type of
Machine
Circular Knitting Machineries




















Sl.No.
Dia
Gauge
Qty of
feeder
Brand/Origin
Fabrics
No of
Machine

1
21"
20+24
63
Jiunn
long/Taiwan
Single Jersey
2

2
23"
69

3

3
25"

75

Single
Jersey/Pique
3

4
28"
84

2

5
30"
90

2

6
36"
108

1

7
34"
18+24
68

Rib/Interlock

1

8
40"
18+24
80

1

Equipped With Lycra Attachment
Total
15








b)
Type of
Machine
Flat Knitting Machineries (Specially Collar &
Cuffs)











Sl.No.
Length
Gauge
Colour
Brand/Origin
No of
Machine

1
52"
14
6
Jy-Leh/Taiwan
2

2
68"
1

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Industrial Attachment-2014

2)
Dyeing Division :







Area
:
25,200 sft.



Man Power
:
195



Production Capacity
:
10890
Kgs/day



List of Machinery
:
As below








a)




Type of
Machine
: Dyeing
Machineries





Sl.No.
Origin / Brand
Description of Machine
Capacity in
KG
No. Of
Machine


1
AK / Taiwan

AK brand high
temperature & high
pressure Dyeing
machine ( Model 2007)
500
2

2
250
1

3
100
1








c)
Type of
Machine :
Fabrics Inspection Machineries




















Sl.No.
Model
Origin
Brand
No of Machine

1
HCTIM
Taiwan
Hsing Cheng
1










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Industrial Attachment-2014

4
50
1

5
600
2

6
800
2

7
Atmoispheric Dyeing
Machine
30
1

8
25
1


9
15
1

10

FONGS/China
Atmoispheric Dyeing
Machine
1200
1



Total

5470
13
b)
Type of Machine : Finishing Machineries




Sl.No.
Brand
Origin
Description
of Machine

No. Of
Machine


1
Corino
Italy
Squeezer for
Tubler
Knitted
Fabric
2


2
LK
Taiwan
4- Chamber
Tensionless
Dryer
1


3
FAB-CON
USA
Computerized
Compactor
1


4
Tube-Tex
USA
Computerized
Compactor
1

5
Hsing Cheng
Taiwan
Over Turning
Machine
1






c)
Type of Machine : Laboratory Machineries










The Factory is equipped with a most modern set up of brand new & latest Model Laboratory

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Industrial Attachment-2014
and quality

control machine.




Sl.No.
Description of
Machine
Brand
Origin
No.Of
Machine


1
Infra-Red
Laboratory Dyeing
Machine-12pot
Labtec
Taiwan
1



2
Spectrophotometer
Loepfe
Switzerland
1

3
European Washers
James.H Heal
UK &
Switzerland
1

4
Sartorious Portable
Digital Balances
1


5
Verivide Colour
Assessment
Cabinet
1


6
Crockmeters
1


7
Prespiration
Machine
1



FABRICS BRUSHING UNIT

01
Fabrics brushing Machines:
Per Machine 24 Roller; Made
in Taiwan Ar Tex For S/J Light
Brush, Fleece One side Brush
& polar fleece-bith sides
brushed.
2
Sets
1. We Have 2 set brushing
Machines We are able to
raise/brushing for one side
or both side brush.
Capacity: 6000 Kg per day
with standard quality.



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Industrial Attachment-2014

Factory Information

Factory Type : 100% Export Oriented Knit Composite
Industry.
Year of establishment : 2000
Investor : Mr. Shihab Uddin
Location : Pubail, Gazipur.
Annual turnover : Tk. 10, 00, 00,000 to 12, 00, 00,000
Certification & awards : ISO 9001:2000 & WRAP
Production capacity : Knitting : 15.5 tons/day (Average)
Dyeing : 15.5 ton/day (Average)
Sewing : 100000 pcs/day (Average)
Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt,
Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear&
all kinds of knit garments & Knit fabrics.








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Industrial Attachment-2014
BASIC LAY-OUT OF THE FACTORY

















7




1

2
3
4


9
10
11

12


13



8
1

6

5
Entry

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Industrial Attachment-2014

1. Security office
2. Mosque
3. Store
4. Knitting section
5. Finishing (Gr. Floor)+ Knitting (2
nd
Floor)+ Garment
section (3
rd
-7
th
Floor)
6. Fabric dyeing & finishing section

7. Yarn dyeing section
8. Garments section
9. Garments section
10.Maintenance Building
11.Water Treatment Plant (WPT)
12.Human Resources Department (HRD)
13.Generator House



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Industrial Attachment-2014

Man Power Management in APS Group (Dyeing Unit) Textile Ltd.
Knitting section








Dyeing & Finishing Section













AGM
PM
Store In charge
Knitting Master
Supervisor
Fitter man
Operator
Fitter man
Operator
GM
DGM
PM
SPO
Batch
Incharge
Finishing
Incharge

Lab
Incharge

PO
APO

Supervisor

Sr. Operator
Operator

Astt. Operator
Sewing man
Helper

Turning m/c
Operator
Helper

Sewing man
Squeeze
Operator
Dryer
Operator
Compactor
Operator
Helper

Lab
Technician
Q.C.
Technician

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Industrial Attachment-2014


Section-wise manpower























Department
Manpower
Knitting
300
Dyeing & Finishing, Lab & QC

Yarn
Fabric
309
405
Garments
3325
Power, Boiler, Utility & Maintenance
173
Inventory
15
Administration
54
Security
135
Others
590
Total
5306

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Industrial Attachment-2014







Chapter- 2

“Raw Materials”









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Industrial Attachment-2014
Raw material
Raw material is a unique substance in any production oriented textile industry. It plays a vital role in
continuous production and for high quality fabric.
Types of Raw Materials:
1. Yarn
2. Grey Fabric
3. Dyes
4. Chemical
Raw Materials Sources and Costs:
1. Yarn:

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
Pacific Textile Mills ltd.
20s/1 Kard
2.58
151
2000.00
Luksme Textile Mills ltd.
26s/1 Kard
2.62
153
2000.00
Mosharaf Textile Mills ltd.
30s/1 Kard
2.62
153
3250.00
Prime Composite Mills
32S/1 Comd
2.95
172
22500.00
PHP Textile Mills ltd.
24S/1 Comd
3.02
176
10000.00

Badsha Textile Mills 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

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Industrial Attachment-2014
Tara Textile Mills ltd.
20S/1 Comd
3.00
175
1500.00
Israq 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
2. Grey Fabrics:

Following types of grey fabrics are dyed-

 Single jersey
 Double jersey
 Single jersey with lycra
 Interlock
 Single Lacoste
 Double Lacoste
 Rib
 Lycra rib
 1 x 1 rib & others
 Collar & cuff
 Polyester fabrics
 Single Pique
 Double Pique
 Terry Fillece
 Filleece



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Industrial Attachment-2014
Sources:
The required grey fabric is produce in the industry
3. Chemicals:
Chemicals
Rate per kg
01. Soda ash light
13

02. Caustic Soda
30
03. Common salt
7
04. Glauber Salt
9
05. H
2
O
2

28
06. Acetic Acid
12
07. Oxalic Acid
44
08. Bleaching Powder
22
09. Hydrose
48
10. Leuphore BMB
520
11. Uvtex BHT
309
12. Uvtex BHV
289
13. Uvtex BAM
310
14. Syno White 4BK
340

15. Uvtex BFE
919
16. Albatex FFC
344
17. CHTE nt. K50
249
18. Invadine Lun
136
19. Feloson NOF
174
20. Invadine DA
180
21. Invatex CS
74
22. Cibacel DBC
107

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Industrial Attachment-2014
23. Sarbid LDR
150
24. Mcropan DPE
126
25. Cibapon R
150
26. Ctobalance NSR
189
27. Rucozen RES
118

28. Tinofix FRd
150
29. Lily XXL powder
40
30. Rewan Acp
145
31. Cibatex ECO
150
32. Invatex CRA
200
33. Heptole EMG
114
34. Cibafluide C
89
35. Biovin 109
181
36. Tinozym 44L
569
37. Beizym ULBD
347
38. Invatex PC
97
39. Invatex AC
117
40. Catalar BF
324

4. Dyes:
Dyes
Rate per kg

01. Solazol Black sp GRI
300
02. Reactofix Red ME4BL
262
03. Cottofix Red ME4BL
262
04. Reactofix Orange ME2RL
294
05. Reactofix N.ME2GL
354

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Industrial Attachment-2014
06. Reactive Yellow H4GL
500
07. Reactive Deep Black N
200
08. Cottofix Black B
141
09. Reactive Blue R(SP)
950
10. Remazol Red RR
1080
11. Remazol Yellow RR
746
12. Remazol Blue RR
908
13. Remazol Blue BB NEW
2280

14. Remazol T. Blue G
344
15. Remazol B Yellow 3GL
1167
16. Remazol Red RGD
725
17. Cibacron Red FN2BL
1488
18. Cibacron Red FB
918
19. Cibacron Red FN3G
1018
20. Cibacron Red WB
542
21. Cibacron Blue FNR
1488
22. Cibacron Blue FGFN
1540
23. Cibacron Navy WB
323
24. Drimarin Yellow CL2RL
510
25. Drimarin Red CL5B
494
26. Drimarin Violet K2RL
1600
27. Drimarin Navy CLB
743
28. Drimarin Blue CT2R
1647

29. Bezaktrive Yellow S3R
516
30. Bezaktrive Yellow SLF
975
31. Bezaktrive Yellow V GL
1321

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Industrial Attachment-2014
32. Diss Yellow F5GL
400
33. Diss Red BF
600
34. Diss Blue FRL
1100
35. Diss Navy 2GL
300
36. Diss Black EXNSF
300
37. Terasil Black WNS
300
38. Terasil Red FB
600
39. Terasil Red WFS
600
40. Terasil Red W4BS
600




Remarks:
The APS Group (Dyeing Unit). Ltd 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.










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Industrial Attachment-2014






CHAPTER: 3
“KNITTING SECTION”



















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Industrial Attachment-2014
Machine Description of Knitting Section:

M/C
S/L
M/C
Dia
M/C
Gauge
M/C
Model
No. Of
Feeder
No. Of

Needle
M/C
Spec
Brand
Origin
1
30”
Rib-18
Int-24
XR2B/CE
60
1692
Rib/Inte
rlock
PAI LUNG
TAIWAN
2
28”
24
KS3B-
W/A/CE
84
2112
S/J
PAI LUNG
TAIWAN
3
28”
24
KS3B-

W/A/CE
84
2112
S/J
PAI LUNG
TAIWAN
4
32”
24
KS3B-
W/A/CE
96
2400
S/J
PAI LUNG
TAIWAN


End products of Circular Knitting Machine:
Single Jersey M/C:
S/J Plain
Single Lacoste
Double Lacoste
Single pique
Double pique
Mini jacquard
Terry

Interlock M/C:
Interlock pique

Eyelet fabric
Mash fabric
Honeycomb fabric
Face/Back rib