1


INDUSTRIAL TRAINING
Course Code: Tex
-4036


INDUSTRIAL ATTACHMENT OF
BISWAS GROUP LTD.

















2

TABLE OF CONTENTS
Serial No. Topic Page No.
01 Introduction 05
02 Company Profile 06
03 Knitting Section 12
04 Quality Control 30
05 Batch Section 33
06 Dyeing Lab 35
07 Dyeing 39
08 Finishing Section 68
09 Fabric Inspection 75
10 Quality Assurance system 77
11 Maintenance 79
12 Utility 85
13 Effluent Treatment Plant 89
14 Conclusion 91





3



INTRODUCTION
By means of practical knowledge its not possible to apply the theoretical knowledge
in thepractical field. For any technical education, practical experience is almost
equal importance in association with the theoretical knowledge.

The industrial attachment is the process, which builds understanding skills and
attitude of the performer, which improves his knowledge in boosting productivity
and services. University education provide us vast theoretical knowledge as well as
more practical attachment, in despite of all these industrial attachment helps us to
be familiar with technical support of modern machinery, skillness about various
processing stages.
It is also provide us sufficient practical knowledge about production management,
work study, efficiency, industrial management, purchasing, utility and maintenance
of machinery and their operation techniques etc.
Textile education cannot be completed without industrial training. Because this
industrial training minimizes the gap between theoretical and practical knowledge
and make us accustomed to industrial environment. We got an opportunity to
complete our industrial training at BISWAS SYNTHETIC LTD. It has well planned &
equipped fabric dyeing-finishing and printing unit in addition to facilitate knitting
and knitwear manufacturing.








4




COMPANY PROFILE


GENERAL INFORMATION ABOUT THE COMPANY:
 Biswas Group was established in 1985
 Biswas Group deals in Apparels, Textile and Accessories.
 Biswas Group have 9 fully automated garments factories in Dhaka.
 7 associate factories in Dhaka.
Product Range- Men's Women's Boys, Girls, Kids and Toddlers, T-Shirts, Polo
Shirts, Woven Women's Blouses, Men's Shirts, Pants/Shorts Casual/Denim Men's,
Women's and kids, Jogging Suits, Swimwear, Nighwear, Winter Wear and All kinds
of Accessories.
Monthly Capacities : 43000 pcs woven bottoms, 300000 pcs woven tops, 380000
pcs pants, 600000 pcs knit tops, 30000 pcs knit bottoms.
 Work force - 9000 employees
 Sewing Lines : 100
 Sewing Machines : 4567
 Knitting Machines : 220
 Weaving Machines : 300
 Dying Machines : 47
Head office:
J.S. Bhaban, 95, BirUttam C.R. Dutta Road (New)299/2A Sonargaon Road (Old),
Dhanmondi, Dhaka-1205, Bangladesh
Tel: 9668835-7,8611796,8610685,9673065
Fax: 88028613367
Email:

5

Web: www.biswasgroup.com


Project location:


6





7


Buyer:
 Aldi - Germany
 C & A - UK
 Calvin Klein- USA
 Carrera - Italy
 Defacto - Turkey
 Ecko– USA
 H & M - Sweden
 Hurley -USA
 Inditex - Spain
 JC Penney - USA
 Kenneth Cole - USA
 Kik - Germany
 LC Waikiki - Turkey/France
 Li & Fung - Internalional
 Lidl - Germany
 Oshkos -USA
 Roca Wear - USA
 Sol's - France
 Sears/K-Mart - USA

 Tema - Turkey
 Wal- Mart - Europe
 Zara – Spain









8


General Manpower Organogram:

Chairman
Director
Executive Director

Production QualityAdminAccounts MarketingMaintenance Utility store security
Production QualityAdmin Accounts Marketing Maintenance Utility store security
ManagerManagerManagerManagerManagerManager Mngr. Mngr.officer
Assistant Senior AdminAccountsMarketingMaintenanceUtilitystore Assist
Manager Officer OfficerOfficerOfficer Engineer Engineer Officer Officer
Senior Assistant Cashier Fore man Assistant Helper security
Production Officer Admin Engineer Guard
Officer Officer Fitter man Worker
Production Lab Helper Worker

officer Assistant
Assistant Lab Worker
Production Boy
officer
Machine
Operator
Helper
Worker





9


Shifting:
In Biswas Synthetic Ltd. the whole day production time is divided into 2shift. Per shift 12 hours.
Shift
Duration
Shift A

8:00 am- 8:00 pm
Shift B

8:00pm – 8:00 am

Responsibility of Production officers:
1. 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.

Title :Production Office
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 & p
H
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

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 Dyeing m/c.
 And also any other over work as & when required by the management.
Title : Sr. Production Office
Report To :Manager

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.

















11

KNITTING SECTION







12

Knitting section layout:



















Office




Store
QC

Wash
room

13

Process flow diagram of knitting:








MERCHANDISER
SAMPLING
TESTING
ORDER PLACEMENT
BY BUYER
YARN PROCURED &
STORE
FABRIC MADE
(YARN TESTING)
PRE-PRODUCTION
SAMPLE

PRODUCTION
QUALITY INSPECTION

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Process control of knitting:
Yarn in cone form
Creels
Pipe
Knot catcher
Tension disk
Inlet stop motion
Yarn guide
PF Wheel
Out let stop motion
Guide
Needle
Fabric
Fabric take up roller
Inspection
Numbering






15

Knitting:

Knitting is the method of creating fabric by transforming continuous strands of yarn into a series
of interlocking loops, each raw of such loops hanging from the one immediately preceding it.
The fundamental structure unit of a knitted fabric is the loop. Any circular knitted fabric is
composed of row after row of intermeshed loops. Different types of fabric are made of different
method of intermeshing the loop. The gross dimension of knitted fabric is simply a relation of
average shape and size of individual loop. There are several key variables in the production
which affect the average shape and size of the loop. After knitting the grease fabric is dyed to
required shade and finished to required weight and width.
 Classification of knitting:









Warp knitting:

A method of making a fabric by normal knitting means is which the loop made from each
warp thread is formed substantially along the length of the fabric. Characterized by the fact that
each warp thread is feed more or less in the line with the direction in which the fabric is
produced.

Weft knitting:

A method of making a fabric by normal knitting means is which the loop made from each
weft thread formed substantially along the length of the fabric. Characterized by the fact that
each warp thread is feed more or less in the line with the direction in which the fabric is

produced.
Knitting
Weft knitting
Warp knitting
Flat knitting
Circular knitting
Double jersey
Single jersey

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Single jersey:

A fabric in which all the loops of the Wales are intermeshed in one direction is called
single jersey. Only cylinder is used to make single jersey fabric.

Double jersey:

A fabric in which all the loops of the alternate wales/wales are intermeshed in one direction and
all the loops of the other wales knitted t the same course are intermeshed in the other direction is
called the double jersey. Dial and cylinder are used to make this type of fabric.
Primary knitting elements:
Needle:
The needles are the most important stitch forming elements. They are displaced vertically up and
down and are mounted into the tricks or cuts of the knitting cylinder.
There are three types of needles namely:
1) Latch Needle.
2) Spring bearded Needle and
3) Compound Needle.
The main function of needle is loop formation.

Cams:
Cam is the second primary knitting element. The cams are the mechanical device which convert
the rotary machine drive into a suitable reciprocating action for the needles or other elements
came are carefully profiled to produce precisely time movement and dwell periods.
Types of knit cam:
1.Knit cam
2.Tuck cam
3.Miss cam




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Sinker:
Sinker is a thin metal plate with action at right angles to and fro between adjoining needles.
Functions of Sinker:
1) Loop formation: The main objects of a sinker are to assist the needles in loop formation by
sinking or knitting the newly laid yarns into a loop.
2) Holding down: It also holds down the loops at a lower level of the needles stems and
prevents the old loops from being lifted as the needles raise to clear them for their hooks.
3) Knocking over: The function is knocking over at which the needle passes through the old
loop by drawing a new loop.
End Products of Single Jersey Circular Knitting Machine:

1.S/J Plain 2.Single Lacoste
3.Double Lacoste 4.Single pique
5.Double pique 6.Terry
7. Fleece


End Products of Rib Machine:

a) 1x1 Rib
b) 2x2 Rib
c) Honeycomb














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Cam arrangement:

▲→ Knit Cam
Π→ Tuck Cam
=→ Miss Cam

Single Jersey: ▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲

▲ ▲ ▲ ▲ ▲ ▲

Rib Stracture:▼ ▼ ▼ ▼ ▼ ▼
▼▼▼▼▼▼
▲ ▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲ ▲

Interlock:▼=▼=▼=
=▼=▼=▼
= ▲ = ▲ = ▲
▲ = ▲ = ▲ =

Single pique: Π▲Π▲Π▲
▲Π ▲ Π▲ Π

Double pique:ΠΠ ▲▲ ΠΠ ▲▲
▲ ▲ ΠΠ ▲ ▲ΠΠ

Single Lacoste:Π▲ ▲ ▲ Π ▲ ▲
▲ ▲Π▲ ▲ ▲Π

Double Lacoste:ΠΠ▲ ▲ ▲ ▲ ΠΠ ▲ ▲ ▲
▲ ▲▲Π Π▲ ▲ ▲▲Π Π

Fleece fabric: = ▲ Π= ▲ Π▲ Π=
= ▲ Π= ▲ Π▲ Π=
= ▲ ΠΠ▲= ▲ΠΠ


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Machine profile of knitting section:
Knitting Machine (Single Jersey)
SL
M/C Dia/Gauge
M/C Quantity
Capacity (Per Day)
Origin
Brand
1
17x24 GG
1 Set
200
Taiwan
Min Hua
2
18x24 GG
1 Set
200
Taiwan
Min Hua
3
20x24 GG
1 Set
200
Taiwan
Min Hua
4
22x24 GG
1 Set

220
Taiwan
Min Hua
5
23x24 GG
1 Set
220
Taiwann
Min Hua
6
24x24 GG
1 Set
220
Taiwan
Min Hua
7
26x24 GG
1 Set
240
Taiwan
Min Hua
8
28x24 GG
1 Set
240
Taiwan
Min Hua
9
30x24 GG
1 Set

250
Taiwan
Min Hua

Total=
9 Set
1990 kg


Knitting Machine (rib Interlock)
SL
M/C Dia/Gauge
M/C Quantity
Capacity (Per Day)
Origin
Brand
1
30x18 GG/24 GG
1 Set
300
Taiwan
Min Hua
2
32x18 GG/24 GG
1 Set
300
Taiwan
Min Hua
3
36x18 GG/24 GG

1 Set
350
Taiwan
Min Hua
4
38x18 GG/24 GG
1 Set
350
Taiwan
Min Hua
5
42x16 GG/24 GG
4 Set
1400
Taiwan
Min Hua

Total=
8 Set
2700 kg


Knitting Machine (Micro-Polar)
SL
M/C Dia/Gauge
M/C Quantity
Capacity (Per Day)
Origin
Brand
1

26x18 GG
7 Set
1750
Taiwan
SandaDask
2
32x19 GG
47 Set
10750
Taiwan
SandaDask
3
28x19 GG/24 GG
19 Set
5320
Taiwan
SandaDask
4
30x18 GG
7 Set
2450
Taiwan
SandaDask
5
30x19 GG
31 Set
10850
Taiwan
SandaDask
6

30x24 GG
10 Set
3500
Taiwan
SandaDask
7
32x24 GG
1 Set
350
Taiwan
SandaDask
8
38x19 GG
1 Set
350
Taiwan
SandaDask

Total=
119 Set
35320 kg



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Knitting Machine
CVC Fleece (Cross/Straight Terry)
SL
M/C Dia/Gauge

M/C Quantity
Capacity (Per Day)
Origin
Brand
1
30x18 GG
6 Set
2100
Taiwan
Min Hua
2
30x20 GG
2 Set
700
Taiwan
Min Hua

Total=
8 Set
2800 kg


Flat Rib
1
60x20 GG
6 Set
2400 Pcs
Chaina
Sen Huang


Total=
6 Set
2400 pcs

































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Knitting variables:

 Yarn count
 Yarn twist
 Spinning system
 No. of ply of the yarn
 Stitch length
 Yarn tension
 Required time (M/C running time);
 Take down tension
 Yarn quality
 Machine gauge
 Machine Diameter
 Machine rpm
 No. of feeds or feeders in use
 Machine running efficiency.

Machine pitch (t) : Is defined as the distance between the centers of two adjacent
Needle of the same needle row indicated in mm.
25.4
Pitch = m.m
Gauge(E)


Machine gauge (E) : Machine gauge denotes the number of needles per inch , arranged
On the needle carrier and based on the nominal machine diameter .
25.4
Gauge (E) = mm.
Pitch

Loops : It is a basic unit consisting of a loop of yarn meshed at its base with
previously Basic unit .

Stitch : The smallest dimensionally stable unit of all knitted fabrics is the stitch . It
consists of a yarn loop which is held together by being intermeshed with another stitch or
other loops

Stitch length:Stitch length is a length of yarn which includes the needle loop & half the sinker
loop on either side of it. Generally the larger the stitch length, the more extensible & lighter the
fabric & the poorer the cover, opacity & bursting strength.



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Raw materials for knitting:







Key accessories used in Circular knitting:

 Yarn feeder guide
 Needle
 Sinker
 Cam
 Cylinder
 VDQ pulley
 Pattern wheel
 Sinker cam cap
 Sinker trick ring
 Dial
 Needle retaining spring
 Cam box
 cam plate
 Inventor
 Belt











Type of yarn

Count
Cotton


20S, 22S,24s,26s,28s,30s,32s, 34S, 40S

Polyester

75D,150D
Lycra yarn

20D,40D
PC (65%Polyester & 35% cotton)

24S, 26S, 28S, 30S
CVC

24S, 26S, 28S, 30S

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Production calculation:
A. Production/shift in kg




B. Efficiency:



















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Relationship between knitting parameter:
1. Stitch length increase with decrease of GSM.
2. If stitch length increase then fabric width increase and Wales per inch
Decrease.
3. If machine gauge increase then fabric width decrease.
4. If yarn count increase (courser) then fabric width increase.

5. If shrinkage increases then fabric width decrease but GSM and Wales
Per inch increase.
6. For finer gauge, finer count yarn should use
7. Grey GSM should be less than finish GSM

Yarn Twist and Yarn Count:
The amount of twist is an important factor in finished consumers’ goods. It determines the
appearance as well as the durability

and serviceability of a fabric. Fine yarns require more twist than coarse yarns. If the yarn twist
increase, the yarn strength increase up to certain level after that yarn strength decrease.
The twist factor for combed cotton yarns for knitted fabrics should not exceed 3.7, whereas in
case of carded yams, a twist factor up to 3.9 is tolerated of yarns for knitted fabrics .

In case of knitting yams a part of the yarn strength has to be sacrificed for a better and softer
handle
Yarns with low twist are used for knitted fabrics, yarns with high twist are used for crepe yarns
Yarnswith average twist are used for regular woven fabrics.





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Effect of stitch length on color depth:

If the depth of color of the fabric is high loop length should be higher because in case of fabric
with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted
then. Similarly in case of light shade loop length should be relatively smaller
Knitting defect & remedies :
Fault name
Causes
Remedies
image





1. Hole Mark
# yarn breakage or yarn
cracks.
# If the yarn count is not
correct on regarding
structure, gauge, course
and density.
# Badly knot or splicing.
# Yarn feeder badly set.
# If yarn tension too
high
#Yarn strength must
be sufficient to
withstand the stretch
as well as uniform.
#Use proper count of
yarn.
#Correctly set of yarn
feeder.
#Knot should be
given properly






2. Needle
Mark




# When a needle breaks
down.
# If a needle or needle
hook is slightly bends .
# If needle does not
catch yarn .


# Needle should be
straight as well as
from broken latch.






3.Star Mark



# Yarn tension variation
during production.
# Buckling of the needle
latch.
# Low G.S.M fabric
production




# Maintain same
Yarn tension during
production.
# Use good
conditioned needles.