Bangladesh University of Textiles

Presentation on Industrial Attachment

atKNIT CONCERN LTD.

(From 16th May- 15th July)

Submitted By:

Suza Ahmed 2011 – 1 – 003

Noor- E Mostofa 2011 – 1 – 005

Salman Ahmed 2011 – 1 – 019

Pankaj Kumar Das 2011 – 1 – 084

Md. Moniruzzaman 2011 – 1 – 241

SUPERVISING TEACHER:

Prof. Dr. Shah AlimuzzamanHead, Dept. of Fabric Engg.

Dean, Faculty of Textile Engg.

Bangladesh University of Textiles

Knit Concern Ltd. at a Glance

Name of the Project : Knit Concern Ltd.

Type of the Project : 100 % Export Oriented Composite Knitwear Industry

Status : Private Limited Company

Year of establishment : 1990

Address : 62 Water Works Road, Godnail, Narayanganj – 1400, Bangladesh

Phone: 02-7631086, 02-7645641; Fax: 02-7641087

Email: info@knitconcern.com

Web: www.knitconcern.com

Contact Person: : Jahangir Alam

Managing Director, Knit Concern Group

E-mail: jahangir@knitconcern.com

Project Cost: : Initial Cost: 30 core Tk. Present cost: 1000 core Tk. (approx.)

Total Area of the Project : 82,000 sq. ft. (approx.)

Knitting section : 3 floors

Total floor space : 40,000 sq. ft

Physical Infrastructure:

Product Mix:Knitted Grey Fabrics :

Plain Fabric, Lacoste and lacoste derivatives, Double jersey, S/J Cotton Lyc., 1x1 Rib

Cotton Lyc., 2x1 Rib, Interlock, Engineering Stripe, Pointal Rib, Plating fabric, Waffle, and

many more.

Daily Production Capacity: Knitting: 35 Tons/day+ 15,000 pcs (Collar & Cuff)

Dyeing : 35 Tons/day

Knit Apparel : 150,000 pieces/ day

Lingerie: 25,000 pieces/ day

Different Departments:

Knitting:

Yarn storage

R & D

Circular Knitting

Flat Bed Knitting

Fabric Inspection

Grey Fabric Storage

Printing:

Sample Section

Color Kitchen Section

Design Section

Screen Preparation Section

Printing (Floor) Section

Finishing

Knit Dyeing:

Grey Fabric Storage

Inspection

Batch Section

Dye House

Dyeing &Wet Lab

Dyeing Floor

QC

Finishing:

Tubular Finishing

Open Width Finishing

Brush Section

Special Finishing

He works with a troop of operators, helpers, fitters etc. to finish the target production in due time.

Directly related with production, manpower

Follow up knitting production

Decide every machine utilization during production

Regular observation of the knitting floor

Follow up the Program Schedule

Control the incharge, supervisors, operator and helper of knitting m/c.

Explain to the Sr. PO for any type of production hamper

Any other over work as & when required by the management

Responsibilities of Production Officer (Knitting):

Knit Concern Knitting Section

A 6 am 2 pmB 2 pm 10 pmC 10 pm 6 am

Shifting System: Production Officers, Supervisors: 09.00 am to 07.00 pm

Operators, Helpers, Fitter men and other workers:

Knit Concern Knitting SectionThe knitting facility of Knit Concern is equipped with world’s latest and dependable brand machinery like Mayer &

cie., Fukuhara and Lisky. Intensive online inspections at different stages during and after knitting process are carried

out invariably to achieve the desired knitting quality.

Knitting Machine Types:

Circular knitting machine (single jersey)i. Single jersey ii. Engineering stripe single jerseyiii. Fleece m/c

Circular knitting machine (double jersey)i. Double jersey ii. Engineering stripe rib/ interlock

Flat knitting machinei. Computerized flat knittingii. Computerized semi- jacquard

Type Brand Origin m/c Qty.Single Jersey Tube Fukuhara Japan 34 Nos.Single Jersey Lisky Taiwan 04 Nos.Single Jersey Open/Slitting Fukuhara Japan 28 Nos.Single Jersey Open/Slitting Mayer & Cie German 10 Nos.Single Jersey Open/Slitting Lisky Taiwan 08 Nos.Rib / Interlock Fukuhara Japan 21 Nos.Rib 8 Lock Fukuhara Japan 07 Nos.Interlock Fukuhara Japan 08 Nos.Interlock Lisky Taiwan 01 Nos.Rib eyelet Jinhar Taiwan 01 Nos.Auto Striper (Four Color) S/J Fukuhara Japan 04 Nos.Auto Striper (Six Color) S/J Fukuhara Japan 01 Nos.Auto Striper (Four Color) Rib/Interlock Fukuhara Japan 02 Nos.Fleece 3 Thread Fukuhara Japan 04 Nos.Fleece 3 Thread Lisky Taiwan 12 Nos.Flat Knit Semi Jacquard Stoll German 02 Nos.Flat Knit Computerized Shima Seiki Japan 10 Nos.Flat Knit Computerized Matsuya Japan 12 Nos.Flat Knit Computerized Protti, Italy 04 Nos.  Total   173 Nos.

List of Knitting Machines:

Main Parts of Circular Knitting m/c

CreelPositive FeederYarn Guide and FeederNeedleCam and Cam BoxSinkerSinker RingFeeder PlateNeedle Bed VDQ PulleyToothed BeltDust Cleaning FanControl Panel

Lycra Arrangement Device Spreader Take- down Roller Cloth RollerMotorInvertorMachine GateNeedle Detectorm/c Operating DeivceLubrication SystemOil NozzleAir Nozzle

Knitting Elements

Sinker for S/J

Sinker for Fleece

Position of Sinker and Needle

Positive Feeder

Side Creel

Spreader

Take Down Roller

Cylinder and Sinker Ring

Feeders of Fleece m/c Needle Detector

Lycra Arrangement DeviceLycra Guide Lycra Guide

Auto stop motions Gate open Yarn breakage Fabric cut & fell down Needle breakage Oil & air pressure problem Completion of selected target Take-down problem

Lubrication System

Oil Supplying through Oil Nozzles

UNIWAVE Lubricator

Engineering Stripe Knitting M/c:

Finger Actuator Semi- Positive Feeder

Adjustable Cam System for Engg. Stripe

Flat Bed KnittingKCL have the two largest manufacturers of flat knitting machines, Stoll and Shima Seiki, including

Matsuya and Protti. Generally, Flat Bed Knitting Machines are used to produce collar, bottom and cuff.

1 Tensioner2 Cone Stand Plate3 Fluorescent Lamp4 Carriage5 Operation Bar6 Stop Switch7 Safety Cover8 Side Tensioner 9 Carrier Rail10 Control Panel11 Main Power Switch

12 Breaker Switch

Different Parts of Flat Bed Knitting m/c

Raw Material:The main raw material for knitting is yarn. different types of yarn of wide range of count are used. in yarn store, KCL has different yarns of different count to use for knitting.

Cotton Polyester Lycra

- 5 Ne

- 7 Ne

- 8 Ne

- 10 Ne

- 16 Ne

- 18 Ne

- 20 Ne

- 20/3 Ne

- 24 Ne

- 26 Ne

- 28 Ne

- 30 Ne

- 34 Ne

- 34/2 Ne

- 36 Ne

- 38 Ne

- 40 Ne

- 50 Ne

- 100 Den

- 150 Den

 

- 15 Den

- 20 Den

- 30 Den

- 40 Den

- 70 Den

 

Monthly yarn consumption= approx. 450 ton

Yarn Count:

Type of Yarn: 100% Cotton, 100% Organic Cotton, Slub Yarn, BCI Cotton, Lycra/ Elastane, Polyester

CVC (60/40, 80/20), PC (65/35), Polyester Viscose (50/50, 65/35)

Grey Mélange (GM); 90-95% Cotton + 10-5% Viscose

Ecru Mélange (EM); 98% Cotton + 2% Viscose

Knitted Fabric Production Process:Order Collection

Sr. Manager (Knitting) gets production order sheet

Deputy Manager selects the GSM, Yarn count & stitch length

PO analyze the sample; Knitting Master makes the Looping Diagram & Cam Arrangement of the sample

Machine Selection & Sample Making

Approved Rejected (fault occurs) Production Officer fixes up

SL and GSM According to

Deputy Managers Suggestion

Ordering yarn from Storage

Machine Selection

Bulk Production

Fitterman sets the design to the machine and sets cam box

Definite operator operates machine

Supervisors keep daily production report and assure m/c is OK

Fabric roll is checked by a troop of inspectors in inspection unit and weighted

Final product to the required amount is delivered to dyeing unit

General Production Parameters of knitting: • Machine Dia• Machine RPM • No. of Feeders active • Machine Gauge • Machine Running Efficiency • Types of Fabric• Yarn Count• Yarn Type (combed or carded)• Stitch Length • Grey & Finished G.S.M.• Grey Dia & Finished Dia • Pattern Measurement for Stripe Fabric

Type of Knitted Stripe and their Differences

Feeder No. Yarn1-6 Miss

7-15 Blue 16-24 Grey

Mechanism of Feeder Stripe

In a 96 feeder m/c, active feeder would be = 96/18 =5 with remainder 6. 5 patterns produced for one revolution of the machine. The rest 6 feeder will be needle dropped or, all miss cam. For 1 repeat Feeder arrangement,

Feeder Stripe Engineering StripeKnitted on general circular knitting machine Knitted on auto/ engineering stripe machine.We can use a limited stripe or courses. Maximum 5 cm repeat length

Bigger than 5 cm. Theoretically: 16000 Colored StripesPractically: 500 Colored Stripes

The price is comparatively lower. The price is substantially higher.

9 Grey Course9 Blue Course

Mechanism of Engineering Stripe:

Here, total 8 colors: OW, NB, Blue, NB, White, NB, Orange, NB; 5 different colors are used.

Program for 1 repeat

Colors CM CPCM Courses8 NB 1  

  

30

307 Orange 0.4 126 NB 0.4 125 White 0.2 64 NB 0.6 183 Blue 0.3 92 NB 0.8 241 OW 0.6 18  Total= 4.3   Total= 129

Here total individual color is five, NB color used

in four times. The m/c has 48 feeders. As a result,

total no. of courses is 129 which does not exceed

(48x4= 192) courses in 4 finger machine.

Serial No.

Color No. of Course

Finger No.

Sequence

8 NB 30 A 19-487 Orange 12 D 45-48, 1-8

6 NB 12 C, B C33-42, B43-44

5 White 6 C 27-32

4 NB 18 B, C B4-18, C19-26

3 Blue 9 C 43-48, 1-3

2 NB 24 B 19-421 OW 18 A 1-18

M/C Set Up: (4 Finger machine)

Quality Assurance ProcedureYarn Store

Yarn Test

Fail Pass

Send to spinning mill Knitting

Grey fabric inspection

Grade A, B Grade C [up to 32] Rejected Roll

Send to Sr. Manager for Decision;

Approved Rejected

Send to Grey store for Batch Preparation

Sample Send to Dyeing Lab for Testing/ Recipe Making

Bulk Dyeing

Finishing

Finished sample send to Central Lab for Criteria Matching Pass Fail Send Quality Report to QC department Rejected and store as waste material

Quality Standard

4 Point Grading System:

Length of defect in fabric, either length or width Points allottedUp to 3” 1Over 3” up to 6” 2Over 6” up to 9” 3Over 9” 4

 Holes and openings Points allotted1” or less 2 Over 1” 4

Then, Points/ 100 =

= 15.65

Acceptance Criteria:

< 20 Points= A

20-30 Points= B

31-32 Points= C, Sr. Manager’s Approval Needed

> 32 Points, Rejected

Knitted Fabric Faults

Hole Pin Hole Oil Mark Set Up

Loop mark Yarn Out Needle mark Cloth Fall Out

Lycra Out Yarn Contamination

Tests for Quality Assurance

GSM

Shrinkage

Spiralty

Bursting Strength test

Tensile Strength

Abrasion Resistance

Pilling Resistance

Crease Resistance

Shade check

Fastness to Wash

Fastness to Light

Fastness to Rubbing

Fastness to Water

Fastness to Perspiration

Saliva Test

Formaldehyde test

Phenolic Yellowing

PH

Twisting test

Maintenance

Knit Concern uses 3 type of maintenance A. Preventive Maintenance B. Routine Maintenance C. Break down Maintenance

Maintenance sequence of circular knitting machine:Power on/off

  Positive Feeder belt out/ loose and cleaning

  Yarn cut, Fabric taken out

   Cam box out, Cleaning by air gun and Oiling

Needle & sinker out, cleaning by oil

Gears and Belts cleaning 

After opening & cleaning, m/c is leveled by using leveling meter and

follows the reverse process to ready the m/c.

Maintenance Tools

L- Key

T- Key

Screw driver

G Spanner

Tester

Star driver

Pliers

Cutting pliers

Dial gauge meter

Adjustable Wrench

Hammer

Punch

Hack Saw

Outside Calipers

Inside Calipers

Welding machine

File

Steel Tape

Leveler

Transfer Needle

WATER :

KCL dyeing water is lifted from about 600 ft deep by

submersible pumps. There are 3 pump units available here –

1. Knit Dyeing – 3 pumps

2. Yarn Dyeing – 2 pumps

3. Printing- 2 pumps

  Knit dyeing Yarn dyeing Hardness <70 <50 pH 6.5-7 6.5-7 TDS <500 <500 Iron content 0.02 ppm 0.02 ppm

Plant 1 & 2 Knit dyeing Plant 3 Yarn dyeing

Capacity 250000 lit/hr Capacity 150000 lit/hr

Water Treatment Plant:

Utility Services 1. Water Treatment Plant2. Boiler3. Air compressor 4. ETP (Effluent Treatment Plant)5. Electricity (Generator & PDB)

Quality of water Required for Dyeing:

Boiler No of boiler : 03

Type of boiler : Horizontal, Fire tube boiler

Brand : LOOSE INTERNATIONAL

(Germany)

Capacity : 10 ton/hr

Fuel : natural gas, Diesel

Steam Consumption : 2300 kg/hr for 1200-1500 products.

Steam pressure and Temp. : 7-8 bar; 180°-190°C

Water pressure : 3-4 bar

Boiler Temp : 300°C

Chemical Used : For antiscalant,

Tandex SD Tandex BWS Tandex BWT

For Wash,

Sulphuric acid+ Para sulphates+ Caustic+ Nelbross+

Nalco

Feed water Quality : pH – 7-8; TDS – 430-530; Hardness < 2 ppm

Boiler Steam : 10.2 tons/hr. & 2.3 tons/hr

Fig : Chamber of Boiler

Electricity

Technical Details Generator

Type Gas generator Diesel generator

Manufacture Waukesha CATERPILLAR

No. of Generator 06 02

Manufacturing country England U.S.A.

Voltage 415 / 240 400

Rotating speed (RPM) 1500 1500

Battery volts 24  

Source of Power Titas Gas DESA

Capacity 1100 KW (2) & 900 KW 1710 KW

Fig : Generator

Compressed Air

Technical Details Air Compressor

Manufacturer Atlas

Copco

BOGE

KOMPRESSOREN

Origin Belgium Germany

Year of

Construction

2002 2006

Maximum

working pressure

10 bar 8 bar

Free air delivery 78 Liter /

sec

1210 m3/ min

Nominal shaft

power

30 kw 20 kw

Rotational shaft

speed

3000 r /

min

3000 r / min

Natural gas is drawn by pipe through the filter above the compressor & the air is compressed.

Gas:The gas is supplied to gas generator or different

section (Boiler – for heating water) from the main

line of the TITAS.

ETP:

Effluent is the stream of excess chemical liquor

extracted from an industry after using in original

operation.

Chemicals are used in ETP : Sodium Hypochlorite,

Nutrient Salt, Anti-foam, Sulphuric Acid, Decolorant,

Poly Electrolyte etc.

Raw Materials

Yarn

Dyes chemicals store

Grey fabrics

Finished Fabric

General Store

Spare Parts

Stationary & Accessories

Maintenance parts

Inventory Control for Raw Materials: Raw materials partially received from production planning & Head office.

Material Receiving & Inspection Report is prepared and noted down.

Submitted to QC dept.

Some are OK & few are rejected. Goods are arranged according to OK or rejected group.

Store requisition to warehouse. Entry of data of goods in DATATEX.

As per requisition materials supplied & this records are noted down.

Store and Inventory Control

Serial Fabric Type Charge/kg (Tk) 1 Plain Single Jersey 10-142 Plain Single Jersey with Lycra 24- 273 Polo Pique 184 Single Lacoste 185 Double Lacoste 206 Plain Single jersey Y/D Feeder Stripe 527 Plain Single Jersey Engineering Stripe Lyc. 2028 Lyc 1x1 Rib 259 1x1 Rib Feeder Stripe 3010 2x1 Rib 3011 Lycra 1x1 Rib/ Interlock Engineering Stripe 250-30012 Flat Back Rib 3713 Pointal Rib 52-6214 Waffle 3215 Interlock 16-1816 Terry 2017 Fleece 24-2718 Lycra Terry 3019 Plain collar & cuff set(1 collar, 2 cuff) 5.5 20 Y/D plain collar & cuff set(1 collar, 2 cuff) 7 21 Edge 3 tipping collar & cuff 9 22 V-neck 1

Knitting charge of different types of fabric

Knit Fabric Charges

Cost of Circular Knitting Cost of Collar and Cuff makingDepreciation cost 2.5tk/kg Machine depreciation cost 0.98 taka/set

Needle cost 2.23/kg Needle cost 0.27 taka/set

Sinker cost 0.16/kg Lubricant cost 0.02 taka/set

Lubricant cost 0.83/kg Electricity cost 0.095 taka/set

Electricity cost 0.59/kg Salary 0.023 taka/set

Spare parts cost 0.03/kg Knitting floor charge 0.03 taka/set

Knitting floor charge 0.18/kg Brush cost 0.035 taka/set

Salary 1.9/kg Spare parts cost 0.05 taka/set

Others 0.15/kg Knitting cost per set 1.5 taka

Total 8.57/kg    

Costing system mainly describes how the cost of the final product is fixed by the company. Total Knitting Cost is calculated for the specific fabric. After that, the final cost is fixed including some profit. Then the unit price is offered to the buyer for approval.

Cost of Knitting

Marketing

Fig. Logos of Major Buyers

Duties & Responsibilities of Marketing Officer: To prepare cost sheet by dealing with the buyer.

To take different steps by discussing with the high officials and merchandiser.

To maintain a regular & good relationship between commercial officer & merchandiser.

To maintain a regular communication with the buyers & buying houses.

Communicate with the new buyer.

Display the criteria of the products.

Achievements

ISO 9001:2008(Certified)

Oeko-Tex Standard 100 (Certified)

May Day Award 2010

Premium Quality Supplier by JULES

CSR awards

Conclusion

Knit Concern Ltd. is one of the most modern export oriented knit composite complex in

Bangladesh. This training gave us actual information about men, machine, material, methods

and market. We have earned the direct practical knowledge about the raw materials, actual

running condition of the m/c, works of technologist and administration.

We are fortunate enough that we have got an opportunity to have training in this mill. During the

training period we have received enough co-operation and association from the authority and

found all personnel. Above all this training in the Knit Concern Ltd. has given us a new

experience for practical life.

THANK YOU