Final Book 1

AHSANULLAH UNIVERSITY OF SCIENCE AND
TECHNOLOGY
DEPARTMENT OF TEXTILE ENGINEERING

Course No : Tex 500
Course Title : Industrial Training
Session : Fall 2015
Industrial Training Report On

Fariha Knit Tex Ltd.
Submitted by
Name ID No.
S.A. SHADMAN 12.01.06.125
HOSSAIN AL FUAD 12.01.06.133
SHAKIL MAHMUD 12.01.06.143
Supervised by
Mr. A.N.M Masudur Rahman

Assistant Professor
Department of Textile Engineering
October, 2016
ACKNOWLEDGEMENT
First of all, we would like to express our sincerest gratitude to the almighty Allah for enabling
us to complete the industrial training successfully.
We offer heartiest thanks to our honorable supervisor Mr. A.N.M Masudur Rahman,
Assistant Professor, Department of Textile Engineering of Ahsanullah University of Science
and Technology for his proper guidance, supervision, encouragement and valuable
suggestions during the period of our industrial training.
We would like to give our special thanks to Prof. Dr. Ahmed Jalal Uddin, Head of the
Department of Textile Engineering, for his support and official permission for internship at
Fariha Knit Tex Ltd.
Our deepest appreciation goes to Mr. Alamgir Kabir, Assistant Manager, Knitting
Department of Fariha Knit Tex Ltd. for his enormous support and guidance.
We would also like to thank to the authority of Fariha Knit Tex Ltd. for giving us the
opportunity to complete our industrial training. Thanks to all the technicians, employees,
stuffs of knitting department for helping us to get proper information during training.
Intern report on Fariha Knit Tex Ltd. 1

Table of Contents
CHAPTER 1: INTRODUCTION
1.1 Introduction:..................................................................................................................................2
1.2 Objectives:.......................................................................................................................................2
CHAPTER 2: GENERAL INFORMATION ABOUT THE MILL

2.1 About The Company:.......................................................................................................................4
2.2 General Information About The Factory:.........................................................................................5
2.3 Address:...........................................................................................................................................6
2.3.1 Factory Location on Google Map:.................................................................................................7
2.4 Facilities:..........................................................................................................................................8
2.5 Sister Concern of Asrotex Group:.....................................................................................................8
2.6 Asrotex Knit Divisions Business Turnover (USD):..............................................................................8
2.7 Mission:...........................................................................................................................................9
2.8 Vision:..............................................................................................................................................9
2.9 Future plan:.....................................................................................................................................9
2.10 Knitting Organogram:...................................................................................................................11
2.11 Layout Plan:.................................................................................................................................12
2.11.1 Layout Plan of Fariha Knit Tex Ltd.(Knitting floor):....................................................................12
CHAPTER 3: RAW MATERIAL
3.1 Type of raw material:.....................................................................................................................15

3.2 Yarn Sources:.................................................................................................................................16
CHAPTER 4: DESCRIPTION OF THE MACHINE AND MACHINE PARTS
4.1 Knitting Machine of Fariha Knit Tex Ltd:.........................................................................................21

4.1.1 Circular knitting machine:...........................................................................................................21
4.1.2 Flat bed knitting machine:..........................................................................................................22
4.2 Knitting Machine Pictures:.............................................................................................................23
4.3 Different parts of circular knitting machine:..................................................................................28
4.4 Different Parts of Flatbed Knitting Machine:..................................................................................34

4.5 Specification of Needle, Sinker and Needle oil:.............................................................................36
CHAPTER 5: PRODUCT MIX AND THEIR SEQUENCE OF OPERATION
5.1 Production parameters:.................................................................................................................38

5.2 Products of Knitting Floor:.............................................................................................................38
5.3 Yarn count selection:.....................................................................................................................39
5.4 Knitting process flow chart:...........................................................................................................40
5.6 Fabric specification:.......................................................................................................................41
5.7 Methods of Increasing Production:................................................................................................41
5.8 Sequence of Operation:.................................................................................................................42
CHAPTER 6: PRODUCTION AND EFFICIENCY CALCULATION
6.1 Formula for production calculation and efficiency calculation:.....................................................47

6.1.1 Calculation for Single Jersey Fabric:............................................................................................48
6.1.2 Calculation for Lycra Single Jersey Fabric:...................................................................................49
6.1.3 Calculation for rib machine (1×1 rib fabric):...............................................................................50
6.1.4 Calculation for rib machine (2×1 rib fabric):...............................................................................51
6.1.4 Calculation for Interlock:.............................................................................................................52
6.1.4 Production for Fleece (3 Thread):...............................................................................................53
6.1.5 Calculation Efficiency of machine:..............................................................................................54
CHAPTER 7: QUALITY ASSURANCE
7.1 Object of quality control:...............................................................................................................57

7.2 Online Quality Control:..................................................................................................................57
7.3 Off Line Quality Control:................................................................................................................57
7.4 Fabric Inspection system:...............................................................................................................58
7.5 Total defect points per 100 square meter are then calculated:.....................................................59
7.6 Grading system:.............................................................................................................................59
7.7 List of equipments for quality control:...........................................................................................60
7.8 Physical Lab Equipment’s:..............................................................................................................62
7.6 Fabric defects:................................................................................................................................64
CHAPTER 8: MAINTENANCE
8.1 Types of maintenance:...................................................................................................................70

8.1.1 Preventive maintenance:............................................................................................................70
8.1.2 Routine maintenance:.................................................................................................................70
8.2 Routine maintenance task followed in the factory:.......................................................................71
8.3 Servicing Procedures of Circular Knitting Machine:.......................................................................72
8.4 Maintenance tools and equipment:...............................................................................................73
CHAPTER 9:UTILITY
9.1 Utility:............................................................................................................................................77
9.2 Source of utility:.............................................................................................................................77
9.3 Machine for utility services:...........................................................................................................77
9.4 Air compressor:..............................................................................................................................77
9.5 Power generator:...........................................................................................................................79
CHAPTER 10: MARKETING INFORMATION
9.6 Utility costs:...................................................................................................................................80

10.1 Knitting Charge for Various Structure:.........................................................................................82
10.2 Buyer Information:.......................................................................................................................83
CHAPTER 11: CONCLUDING PART
11.1 Limitation of our training and report:..........................................................................................85

11.2 Suggestions:.................................................................................................................................85
11.3 Conclusion:..................................................................................................................................85

CHAPTER 1:
INTRODUCTION

1.1 Introduction:
It is very important for an engineer to have practical knowledge along with theories.
Industrial training is the only way to acquire practical ideas and experiences for a textile
student. Practical knowledge is enriched through the industrial training.
Industrial training is one of the most important parts of engineering and technical education.
The industrial training is the process, which builds understanding, skills and attitude of the
performer, which improves our knowledge in boosting productivity and services. University
education provides us vast theoretical knowledge, in spite of all these theoretical
knowledge, industrial training helps us to be familiar with technical support of modern
machinery, skills about various processing stages in the real field.
Industrial training is essential part of four years B.Sc. program in Textile Engineering to make
an engineer technically sound in this field. In Fariha Knit Tex Ltd. (Asrotex Group) we have
completed 08 (eight) weeks long industrial training. Such training minimized the gap
between theoretical and practical knowledge.
1.2 Objectives:
1. To experience and understand real life situations in industrial organizations and their
related environments.
2. To acquire practical knowledge about the production process of knitting.
3. To gain experience for finding the optimal solution in critical situation.
4. To develop and enhance professional awareness & communication skills.
5. To be familiar with the practical working procedure in production.

CHAPETR 2:
GENERAL INFORMATION ABOUT

THE MILL

2.1 About The Company:
Fariha Knit Tex Ltd (FKTL) is the largest Composite Knit Apparel and Textile manufacturing
business unit of Asrotex Group. It started its journey in 1997. FKTL is comprised of Knitting,
Dyeing, Cutting, Sewing, Finishing, Printing and accessories sections. It has the state of art
vertically integrated garments manufacturing facility which ensures one stop service to the
buyers. The products of FKTL range from mens wear, ladies wear and kids wear. These are
manufactured using technologically efficient machinery imported from USA, Europe and
Asian countries. Its mission is to produce the latest design; quality knit fabrics and apparels
for international markets. It is one of the few elite private sector business group, which
contributed wealth as well as welfare to the struggling economy of Bangladesh.
FKTL has team of skilled and dedicated technocrats backed by adequate number of modern
efficient machinery and equipment’s imported from USA, Europe and Asian countries to
match international standards of all kinds of knitwear products.
Fig : Fariha Knit Tex Ltd.

2.2 General Information About The Factory:
Name of the composite plant Fariha Knit Tex Ltd.

Type 100% Export Oriented Knit Composite Garments
Manufacturing Industry
Year of establishment 1997
Name of the chairman Md. Mamun Bhuiyan
Status Private Limited
Ownership Asrotex Group
Production area(knitting) 7,00,000 sq. f
Market/destination Europe, Asia, U.S.A, Australia
Production capacity(knitting) 7000 ton yearly (open and tubular form)
Total manpower 7,317
Major customer H&M (Sweden) Next (United Kingdom)

NKD (Germany) Matalan (Unite
Kingdom)
Springfield (Spain) Splash (UAE)
Walmart (United States) Siplec (France)
Kmart (Australia) Takko Fashion
(Germany)
Membership and certification Member of BGMEA, BKMEA, BTMEA, EPB & the
Metropolitan Chamber of Commerce. They are an
approved supplier of BSCI, WRAP, OEKO-TEX,
SEDEX, ISO 9001 -2008, GOTS.
2.3 Address:

Factory Address : Baroibogh, Enayet Nagar, Fatullah Narayanganj-1400,
Bangladesh.
Telephone : +88 02 7670381
Fax : +88 02 7670380
Web Address : http://asrotexgroup.com
Corporate Office : House 85, Road 4, Block B Banani, Dhaka 1213 Bangladesh.
Telephone : +88 (02) 883-5670-1
Fax : +88 (02) 989-1921
E-Mail : info@asrotex.com
Web Address : www.asrotexgroup.com
USA Office : 1407 Broadway, Suite 1402 NYC, NY 10018

Telephone : +1 (929) 278-9042
E-mail : info.usa@asrotex.com
Web Address : www.asrotexgroup.com
2.3.1 Factory Location on Google Map:

Figure: Site location of FKTL factory office from AUST
Fig: Earth view of FKTL factory office
2.4 Facilities:
 Knitting
 Dyeing

 Finishing
 Sewing
 Printing (all over print and chest print)
 Embroidery
 Trims & packaging
 Washing
2.5 Sister Concern of Asrotex Group:
 Asrotex Ltd.
 Rimshod tex Ltd.
 Asro fashion Ltd.
 Fariha Knit Tex Ltd.
 Rich apparels Ltd.
 Ruma industries Ltd.
 Logic software Ltd.
 Fariha dyechem Ltd.
 Standard holdings Ltd.
 Fariha trims and accessories Ltd.
 Fibre 2 fashion Bd Ltd.
2.6 Asrotex Knit Divisions Business Turnover (USD):

Table: List of Asrotex Group Business Turnover
facilities 2010-2011 2011-2012 2012-2013 2013-2014 2014-2015
Asrotex $20,050,797 $19,967,639 $21,369,181 $24,371,779 $27,212,286
Asrotex Ltd $20,850,182 $23,664,750 $18,547,389 $19,603,636 $23,311,026
Fariha Knit $31,739,007 $36,236,375 $40,200,917 $62,167,052 $61,289,974
Tex Ltd
Total $72,639,986 $79,868,764 $80,117,486 $106,142,468 $111,813,286

Figure: Yearly Growth of Asrotex Group
2.7 Mission:
The mission of Asrotex Group is to strengthen relationships around the world that will allow
Asrotex Group to offer competitive advantages in the global market. At Asrotex Group their
unmatched pursuit to execute products and services of the highest quality for their valued
customer is their ultimate mission.
2.8 Vision:
The vision of Asrotex Group is to be a leader in the global textile and apparel industry. They
want to lead the way going into the near future by strengthening the business units, by
continuous investments, and through devotion to the development of their most valuable
resource. They feel they are on the fore front of the apparel industry.
2.9 Future plan:
In addition to further strengthening their expertise and competencies in the RMG sector,
ASROTEX Group has plans for diversification in various industries where human benevolence
will be the prime focus. The vision of their management brought them here today, and they
are not coming too far, they’ve just arrived.

They are cordially welcoming companies around the globe to be their development partner in
Agribusiness, Automobile, Ceramic, Distribution, Electronics, Food, Healthcare, Leather & Leather
Goods, Light Engineering, Medical Equipment, Pharmaceuticals, Plastic, Power, Professional
development, Real Estate, Renewable Energy, Ship Building, Telecommunication, Tourism,
Transportation or any other prospective sectors that will cater the demand of a massive population
of 160 million plus people. They are targeting to achieve $500 Million in 2021.

2.10 Knitting Organogram:
AGM
Manager
Assistant Manager
Sr. Executive
Production Marketing
Officer
Sr. fitter Q.C Incharge Production officer
Fitter
Quality Controller Asst. production
Asst. Fitter Officer
Q.C inspector
Shift Incharge
Helper
Supervisor
Cleaner Operator
Asst. operator
Helper

2.11 Layout Plan
2.11.1 Layout Plan of Fariha Knit Tex Ltd.(Knitting floor):
Fig : Layout plan of knitting floor-1

Fig : Layout plan of knitting floor-2

CHAPTER 3:
RAW MATERIAL

Raw material is an important substance in any production oriented textile industry. It plays a
vital role in continuous production and for high quality fabric. Fariha Knit Tex Ltd. takes yarn
as its raw materials for its initial production of knitted fabrics to make garments.
3.1 Type of raw material:

Here mainly cotton, polyester and spandex yarn are used according to the requirements of
buyer. Some of the raw material used in Fariha Knit Tex Ltd are as follows:
1. Carded yarn
2. Combed yarn
3. CVC yarn (60% cotton, 40% polyester) & (80% cotton, 20% polyester)
4. PC yarn (65% polyester, 35% cotton)
5. 100% Polyester yarn
6. Mélange yarn
 Grey mélange
 (95% cotton, 5% viscose)
 Ecru mélange (1-2% viscose, 99-98 % cotton)
7. Slub yarn
8. Spandex yarn
9. 100% viscose yarn

3.2 Yarn Sources:
Spandex yarn used in Fariha Knit Tex Ltd:
S/L no Brand name Origin Count
1 Texlon China 40D
2 Ceora Korea 20D, 30D, 40D
Cotton yarn used in Fariha Knit Tex Ltd:
S/L no Source of yarn Origin Count(Ne)

1 Trident India 30, 34
2 Purbani Bangladesh 10
3 Tafrid Bangladesh 32, 30
4 Rahamat Bangladesh 50, 30, 40,
5 Ayyanar India 40
6 BSB Bangladesh 30
7 R.S.W.M India 24, 30, 32
8 PT Ramgloria Shakti India 34
9 Akij Bangladesh 10, 20
10 S.M Bangladesh 28, 40
11 Mosharraf Bangladesh 30, 34
PC yarn used in Fariha Knit Tex Ltd:

1. N.Z Bangladesh 30
2. Mondol Bangladesh 12, 26, 34
3. Jamuna Bangladesh 24, 26
Mélange yarn used in Fariha Knit Tex Ltd:

1 Huafu China 26
2 Enayetpur Bangladesh 20,28,30
3 Thermax Bangladesh 28
4 Jamuna Bangladesh 24,30,34
5 N.Z Bangladesh 24
CVC yarn used in Fariha Knit Tex Ltd:
1 Akij Bangladesh 30, 34
2 Jamuna Bangladesh 24, 28, 30
3 S.M Bangladesh 20
4 Ha-meem Bangladesh 28, 32
5 Delta Bangladesh 34
6 Al-razee Bangladesh 20, 30
7 N.R.G India 30
Slub yarn used in Fariha Knit Tex Ltd:

1. Keya Bangladesh 28
2. Delta Bangladesh 22

100% polyester yarn used in Fariha Knit Tex Ltd:
S/L no Source of yarn Origin Count
1 Pt. sunsan India 75D
Viscose yarn used in Fariha Knit Tex Ltd:

1 Pt. indo liberty Indonesia 30

CHAPTER 4:
DESCRIPTION OF THE MACHINE AND

MACHINE PARTS

4.1 Knitting Machine of Fariha Knit Tex Ltd:
Fariha Knit Tex Ltd knitting section is divided into two segments. One consisting of 76 circular
knitting machines and other contains 18 Flat Bed (v-bed) knitting machines. Specification of
machines are given below:
4.1.1 Circular knitting machine:
S/L Brand Name Country Machine Type of No of Machine

no of Origin Dia(inch) Machine Feeders Qty
and Gauge
1 Jiun Long Taiwan 38, 20 Single jersey 114 2
2 Ta Yu Taiwan 38, 20 Single jersey 114 7
4 Lisky Taiwan 42, 24 Single jersey 126 1
5 Lisky Taiwan 44, 24 Single jersey 132 1
6 Zentex Singapore 30, 20 Single jersey 90 4
10 Fukahara Japan 22, 20 Single jersey 88 1
14 Ta Yu Taiwan 30, 25 Double jersey 90 4

S/L Country Machine Type of No of Machine
no Brand Name of Origin Dia(inch) Machine Feeders Qty
and Gauge
17 Jiun Long Taiwan 32, 20 Double jersey 96 1
20 Lisky Taiwan 42, 18 Double jersey 88 3
24 Ta China 42, 24 Single jersey 126 7
Yu(Xiamen)
Yu(Xiamen)
Yu(Xiamen)
Yu(Xiamen)
28 Pailung Taiwan 36, 24 Auto stripe 50 2
single jersey
single jersey
30 Ta Yu Taiwan 34, 28 Auto stripe 69 1
single jersey
single jersey
4.1.2 Flat bed knitting machine:
All the flat bed knitting machines are capable for producing collar, cuff and some rib fabric.
S/L Brand Name Country of M/C width No of Machine

No origin and gauge feeder quantity
1 Shima Seiki Japan 60″ × 14G 6 10
2 Jy- Leh Taiwan 80″ × 14G 4 8
4.2 Knitting Machine Pictures:

Figure: Single Jersey Circular Knitting Machine (Ta Yu)

Figure: Single Jersey Circular Knitting Machine (Jiun Long)

Fig: Double Jersey Circulasr Knitting Machine (Ta Yu)

Figure: Auto Stripe Single Jersey Circular Knitting Machine (PAILUNG)

Figure : Flat bed Knitting Machine (Shima Seiki)
Figure : Flat bed Knitting Machine (Shima Seiki)

4.3 Different parts of circular knitting machine:
1. Name: Needle
The needle is the primary knitting element. Needle is a
thin metal bar.
Function:
 It is used to produce loop and thus produce fabric.
Fig: Needle
2. Name: Sinker
The sinker is the second primary knitting element. It is

a thin metal plate. It may perform one or more of the
following functions depending upon machines knitting
action, consequent sinker shape and movement.
Function:
 Holding down Fig: Sinker for Auto striper

 Knocking over
 Loop formation
Fig: Sinker for Single Jersey Fig: Sinker for Fleece
3. Name: Knitting Cam

Cam is the devices which convert rotary machine drive in to a
suitable reciprocation action for the needle.
Knit Cam:
Function:
 To produce knit loop
Fig: Knit Cam
Tuck Cam:
Function:
 To produce tuck loop
Fig: Tuck Cam
Miss Cam:
Function:
 To produce miss loop
Fig: Knit Cam
4. Name: Cam Box

Function:
 It is used to hold the cam according to the

fabric design.
Fig: Cam Box
5. Name: Oiling or lubricating system
Function:
 Lubrication system is used to reduce the heat generation and friction between metal
parts.
Fig: Lubrication system (Uniwave)
Technical data for Uniwave lubrication system:
1. 20 lubrication points.
2. Two, low-flow connections.
3. Compact oil reservoir.
4. Long, reliable service life guaranteed.
6. Name: Air Gun

Function:
 It is used to feed the yarn into the feeding device

through the yarn carrier. Sometimes it used to
clean external dust from the knitting zone and also
for cleaning machine parts.
Fig: Air Gun
7. Name: Variable Diameter of Quality

Pulley
Function:
 It is used to control GSM by varying

the stitch length
Fig: Knit Cam
8. Name: Spandex Feeding Device (lycra

attachment)
Function:
 It is used to apply negative feed of the

spandex
Fig: Lycra attachment
9. Name: Spandex Stop Motion

Function:
 When spandex yarn is worn, it stops the

machines.
Fig: Spandex Stop Motion
10. Name: Memminger Positive Feeder (MPF)
Function:
 It is used to apply positive feed of the yarn
Fig: MPF
11.Name: Cylinder
Function:
 Main part of the machine which hold the

other parts like cam box, trick plate and
rotates when machine run.
Fig: Cylinder
12. Name: Creel

Function:
 Creel is a part of knitting machine. Here

yarn package are store and ready to feed
into the machine
Fig: Creel
13. Name: Feeder
Function:
 Feeder helps yarn to feed into the machine.
Fig: Feeder
15. Name: Needle Trick
Function:
 Where all needle is placed together in a decent

Design.
Fig: Needle Trick
4.4 Different Parts of Flatbed Knitting Machine:

Fig: Flat bed knitting machine (Jy Leh)
Tension Equipment: Provides tension force for yarn to be fed to the yarn feeder.
Cone Stand Plate: Table on which cone is arranged.
Fluorescent Lamp: It is necessary to see the condition of the needle bed gap and so on
during knitting. This lamp is turn on and off in controller screen.
Cone Stand: Holds the cone.
Signal Lamp: There are three indication lamps are as follows:
 Green lamp--------------------Machine is in operation.
 Blinking Green lamp---------Machine is stopped by operation.
 Blinking yellow lamp-------Machine is stopped because of error or completion of

piece.
Carriage: Control the motion of the needle.

Figure: Carriage
Operation Bar: Actuates and stops the carriage. Also used for clearing operation errors.
Figure: operating handle/Operation bar
Stop Switch: The purpose is to stop the machine in an emergency condition.
Side Cover: Installed at the both sides of safety cover.
Safety Cover: Suppresses the noise and dust.
Side Tension Equipment: Pulls the yarn fed to the feeder to create tension as tension
equipment does.

Carrier Rail: Used for the carrier to move on.
Controller: Input the knitting data in the computer screen and command the machine to
execute the data. Modifying and inputting data are available in controller.
Lever: Lever operates a roller which helps the fabric to come outside of the machine.
Main Power Switch: Cuts off power supply. This switch has emergency stop function.
Oil Pump: Supplies oil to the machine parts.

Breaker Switch: This protects the machine from odd power source to the turned off
automatically. The breaker switch is back side of controller.
4.5 Specification of Needle, Sinker and Needle oil:
Item Brand Origin Model no
Groz-Beckert Germany VOL S 78.52. G007

VOL S 78.41. G0025
Needle Vota 78.60. G002
Organ Japan VO 75.50. S005
VO 95.48. S003
Sinker Groz-Beckert Germany
Needle oil TAE-WON Korea

Chapter 5:
PRODUCT MIX AND THEIR SEQUENCE

OF OPERATION

5.1 Production parameters:
 Machine diameter
 Machine rpm (revolution per minute)
 No of feeders in use
 Machine gauge
 Count of yarn
 Required time (machine running time)
5.2 Products of Knitting Floor:
Single Jersey:
 Plain Single Jersey

 Plain Single Jersey with Lycra
 Single Lacoste
 Double Lacoste
 Polo Pique
 Fleece Fabric
Double Jersey:
 1x 1 Rib
 1 x 1 Rib with Lycra
 2 x 1 Rib
 1 x 1 Interlock
 1 x 1 Interlock with Lycra
 Waffle
 Ponte Di Roma
 Mesh
5.3 Yarn count selection:
As we know VDQ pulley on the knitting machine controls GSM of fabric, but its raw material
has direct impact on GSM. Yarn counts and stitch length that are used to achieve required
GSM are given below:

Single jersey:
Yarn count GSM Stitch length (mm)

20s 190 2.85
24s 175 2.94
26 s 160 2.95
28 s 160 2.70
150 2.80
175 2.65
30 s 130 3.20
140 2.75
150 2.70
34 s 180 3.00
40 s 190 3.45
Rib Fabric:
Count GSM Stitch length (mm) Fabric type

26 s 300 2.70 2x1
230 2.65 1x1
28 s 200 2.60 1x1
200 2.75 2x1
30 s 200 2.50 1x1
200 2.60 1x1
34 s 300 2.75 1x1
250 2.60 1x1
Interlock Fabric:
Count GSM Stitch length (mm) Fabric type
40 s 190-200 2.90 1x1

210-220 3.70
34 s 300 3.75 1x1
5.4 Knitting process flow chart:
Order from buyer
Marketing department

Knitting department
Yarn requisition from the mill
Yarn receive by store
Knitting program setting
Yarn requisition from floor to store
Yarn received by floor in charge
Yarn loading on the machine
Knitting
Fabric inspection
Delivery to fabric store
Fabric delivery to dyeing section from store
5.6 Fabric specification:
 Fabric type
 Finished GSM
 Finished diameter
 Color
 Yarn count

5.7 Methods of Increasing Production:
By the following methods the production can be increased:
 By Increasing Machine Speed:

Higher the m/c speed faster the movement of needle and ultimately production will be
increased.
 By Increasing the Number of Feeder:

If the number of feeder is increased in the circumference of cylinder, then the number of
courses will be increased in one revolution at a time.
 By Using Machine of Higher Gauge:

The higher the machine gauge, the more the production. So by using machine of higher
gauge production can be increased.
5.8 Sequence of Operation:

Fig: Yarn Path Diagram of Single Jersey Machine

Fig: Yarn Path Diagram of Single Jersey Machine with Lycra attachment

Fig: Yarn Path Diagram of Double Jersey Machine

Fig: Yarn Path Diagram of Double Jersey Machine with Lycra attachment

Chapter 6:
PRODUCTION AND EFFICIENCY

CALCULATION

6.1 Formula for production calculation and efficiency
calculation:
There are some formulas, commonly used for the calculation purpose in the knitting
industries:
Production/ shif in kg:
No of feeder × RPM ×60 × 12× No of needle × S . L× Efficiency( )

=
10 ×2.54 ×36 ×840 × yarn count × 2.2046
Efficiency (%) of machine:
Actual production
= × 100
Calculated production
In Fariha Knit Tex Ltd. Production is calculated in kg. So we calculated the production of
fabric in kg.

6.1.1 Calculation for Single Jersey Fabric:
No of feeder : 132
R.P.M of machine : 15.2
Machine dia : 44 ″
Machine gauge : 24
Count of yarn :28/1 Ne
Stitch length : 2.73mm
Shift : 12 hr
Efficiency : 85%
Production/ shift in kg:
No of feeder × RPM ×60 × 12× NO of needle× S . L × Efficiency ()

=
10 ×2.54 × 36 ×840 × yarn count ×2.2046
132 ×15.2 ×60 ×12 × ( 3.1416 × 44 × 24 ) ×2.73 ×.85

=
10 × 2.54 ×36 × 840× 28 ×2.2046
= 234.55 kg

6.1.2 Calculation for Lycra Single Jersey Fabric:
No of feeder : 96
R.P.M of machine : 15
Machine gauge : 24
Count of yarn :28/1 Ne
Shift : 12 hr
Efficiency : 65%
Lycra (%) : 4%
No of feeder × RPM ×60 × 12× NO of needle× S . L × Efficiency ()

=
10 ×2.54 × 36 ×840 × yarn count ×2.2046
96 ×15 ×60 ×12 × ( 3.1416 ×32 ×24 ) ×2.90 ×.65

=
10 × 2.54 ×36 × 840× 28 ×2.2046
= 99 kg
99 x 4
Weight of Lycra = kg
100
= 3.96 kg
Total production = ( 99+ 3.96 ) kg = 102.96 kg

6.1.3 Calculation for rib machine (1×1 rib fabric):
No of feeder : 84
Machine gauge : 18
Time : 12 hr
Yarn count : 36s
Stitch length : 3.10 mm
Efficiency : 85%
no of feeder × RPM ×60 ×12 × No of needle ×S . L × Efficiency ()

= ×2
10× 2.54 ×36 × 840× yarn count × 2.2046
84 ×20 ×60 ×12 ×3.1416 × 28× 18 ×3.10 ×.85 x 2

= 10 × 2.54 ×36 ×840 × 36 ×2.2046
= 166 kg

6.1.4 Calculation for rib machine (2×1 rib fabric):
No of feeder : 96
Machine gauge : 18
Time : 12 hr
Yarn count : 36s
Stitch length : 2.48 mm
Efficiency : 70%
no of feeder × RPM ×60 ×12 × No of needle ×S . L × Efficiency ()

= ×2/3
10× 2.54 ×36 × 840× yarn count × 2.2046
96 ×17 ×60 ×12 ×3.1416 × 36× 18 ×2.48 ×.70

= 10 × 2.54 ×36 × 840× 36 ×2.2046
x 2/3
= 186 kg

6.1.4 Calculation for Interlock:
Machine Diameter : 30’’
Machine gauge : 24
No. of feeder : 96
Machine RPM : 25
Time : 12 hr
Count : 36/1 Ne
Production kg/shift
No of feeder × RPM ×Time × No . of needle × Stitch length × Efficiency ()

=
10 X 2.54 X 36 X 840 X 2.2046 X Yarn count
96 ×25 ×60 ×12 ×.9 ×3.1416 × 30× 24 ×1.62

=
10 × 2.54 ×36 ×840 × 2.2046× 36
= 93 kg

6.1.4 Production for Fleece (3 Thread):
Machine gauge : 16
Stitch length : (4.45+3.95+1.75)mm
No. of feeder : 114
Machine RPM : 18
Time : 12 hr
Count : 20/1 Ne+20/1Ne+10/1Ne
Efficiency : 70%
Production in kg/shift
No of feeder × RPM ×Time × No . of needle × Stitch length × Efficiency ()

=
10 X 2.54 X 36 X 840 X Yarncount X 2.2046
38 x 18 x 60 x 12 x 3.1416 x 38 x 16 x 4.45 x .70

= +
10 x 2.54 x 36 x 840 x 20 x 2.2046
38 x 18 x 60 x 12 x 3.1416 x 38 x 16 x 3.95 x .70

+
10 x 2.54 x 36 x 840 x 20 x 2.2046
38 x 18 x 60 x 12 x 3.1416 x 38 x 16 x 1.75 x .70

+
10 x 2.54 x 36 x 840 x 10 x 2.2046
= ( 86+ 76+ 68 ) kg
= 230 kg

6.1.5 Calculation Efficiency of machine:
Actual production
Efficiency = × 100
Calculated production
Production of Single Jersey Plain Machine:
Machine gauge : 24
No. of feeder : 84
Machine RPM : 28
Time : 12 hr
Count : 30/1 Ne
Production at 100% Efficiency in kg/shift
No of feeder × RPM ×Time × No. of needle × Stitch length

=
10 X 2.54 X 36 X 840 X 2.2046 X Yarncount
84 ×28 ×60 ×12 ×3.1416 × 34 ×24 × 2.7

= 10 ×2.54 × 36× 840 ×2.2046 ×30
= 230 kg/shift (Calculated Production)

Actual Production = 185 kg/shift
Actual Production
Efficiency = X 100
Calculated Production
185
= x 100
230
= 80 %

CHAPTER 7:
QUALITY ASSURANCE

Quality assurance is defined as all those possible planed and systematic actions necessary to
provide adequate confidence that a product or service will satisfy given requirements for
quality. The quality assurance department is assigned to maintain consistently uniform
quality of the material in process and various stages of manufacturing.
7.1 Object of quality control:
 Raw material test
 Process control
 Process development
 Product testing
 Research
7.2 Online Quality Control:
First of all, yarn lot and count is checked. Then the VDQ pulley diameter is checked for
specific stitch length. After running the machine, a sample of the fabric is cut. Then the stitch
length and GSM is checked. If the stitch length and GSM is not correct then necessary steps
are taken. Needle mark, sinker mark, hole and various types of faults are checked in the
machine. If any faults are identified, then necessary steps are taken to remove or minimize
the fault.
7.3 Off Line Quality Control:
After knitting,
 The grey fabric was checked by inspection machine.
 Find out the knitting fault & mark by marker pen.

 Make a report sheet in inspection tab (on 4 point system).
7.4 Fabric Inspection system:
All rolls are kept in front of the inspection machine time to time and are inspected over the
grey inspection machine visually in a pre-set speed against light. For any major or minor
faults like thick thin, barre marks, lycra 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 and cuff are inspected visually under light, any major & minor faulty collar/ cuff like
having wrong ply, hole, needle lines, slubs, wrong design, first line problem etc. properly
counted and recorded. The 4-points system is followed to inspect fabric.
The defects found and points given against are recorded in the inspection sheet. Following
table shows the four point grading system followed by Fariha Knit Tex Ltd:
Size of defects Penalty point

3 inches or less 1
Over 3 inch upto 6 inch 2
Over 6 inch upto 9 inch 3
Over 9 inch 4
7.5 Total defect points per 100 square meter are then
calculated:
Penalty per 100 square meter=

total penalty point ×36 ×100
total length∈ yards× total width of the fabric inch
Fabric are then graded according to the penalty points
7.6 Grading system:
Points per 100 square meter Grading

0-20 A
21 to 28 B
Above 28 C (Rejected)
Figure: Inspection Report
7.7 List of equipments for quality control:
The list of equipment to assure quality:
1. Inspection machine
2. Electronic balance

3. GSM cutter
4. Measuring tape
5. Scissors
6. Indication sticker
Fig: Inspection Machine

7.8 Physical Lab Equipment’s:
No Machin Name Brand Name Model Figure
Light Fastness ENOTEST Xenotest

Tester 150S+
UV Perkin Elmer Lambda

Spectrometer 25
pH Tester METTLER TOLEDO

4
Titan Universal
Strength Tester JAMES HEAL
5 Bursting Trueburst
Strength tester
6 Pilling Tester ICI Pilling box
7 Yarn Twist ESSJAY

Tester TECHNOMEASURE

7.6 Fabric defects:
1. Needle mark:
Appearance: Spot line is found at wales direction.
Causes:
 Due to decayed needle
 Due to bend needle
 Due to old needle
 Due to improper needle setting
Remedies:
 Change the defected needle.
 Check the needle settings.
2. Sinker mark:
Appearance: Spot line is found at wales direction.
Causes:
 Due to decayed sinker
 Due to faulty adjustment of sinker with sinker cam.
 Due to dirty track path.
Remedies:
 Change the sinker
 Make necessary adjustments of sinker with sinker cam as required.

3. Hole:
Appearance: Hole on the fabric.
Causes:
 If needle latch is not working properly.
 Due to uneven tension.
 Due to needle head breakage.
 Due to improper cam setting.
 Due to excessive take down tension.
Remedies:
 Change the needle
 Adjust the tension as required
 Adjust cam setting properly
4. Drop stitches:
Appearance: A small hole is appeared on wales direction.
Causes:
 Due to defective needle.
 If yarn is not properly fed during loop formation. i.e. not properly laid on to the
needle hook.
 Due to take down mechanism too loose.
 Due to insufficient yarn tension
Remedies:
 Needle should be straight

 Proper feeding of yarn during loop formation.
 Correct take up of the fabric and correct fabric tension
 Yarn tension should be properly
5. Barre/patta:
Appearance: Stripe effect is found towards the course on knit fabric.
Causes:
 Due to lot mixing of yarn
 If different counts and colors of yarn are missing together.
 Improper cam adjustment
Remedies:
 Operator should be careful about that different lots of yarn cannot be mix up.
 Yarn should be tested before knitting.
6. Slub:
Appearance: A thick place is made in a particular place on fabric surface.
Causes:
 Due to using of low quality yarn
 Lint getting on to yarn face.
Remedies:
 Yarn quality should be good
 Yarn testing should be done properly

7. Fly contamination:
Causes:
 Presence of dead fibers & other foreign materials, such as; dyed fibers, husk &
synthetic fibers etc.
 Dyed & other types of fibers flying from the adjacent Knitting machines cling to
the yarn being used for knitting & get embedded in the Grey Fabric.
Remedies:
 Use rich fiber mixing for the yarns to be used for Knitting in order to have less
dead fibers appearing in the fabric.
 Rigid control measures in the blow room to prevent the mixing of foreign matters
in the cotton mixing.
8. Oil spot:
Appearance: Oil spot on the fabric surface.
Causes:
 Due to excessive lubrication in the machine
 If there is any type of problem in needle and sinker, oil can be bled on the fabric.
 Leakage of knitting oil
Remedies:
 Change the faulty needle and sinker
 Machine should be cleaned after scheduled time

9. Lycra out:
Appearance: Lycra yarn is missing at course direction.
Causes:
 If Lycra yarn is missed or breakage happened.
Remedies:
 Operator should be more cautious to make necessary adjustment or replacement or

joining the yarn.
10. Press off (Set up):
Causes:
 For badly needle break.

 Improper yarn tension.
 In case of Yarn breakage.
Remedies:
 Remove bad needle.

 Maintain proper tension of yarn.
11. Loop:
Causes:
 Due to broken, decayed or bent needle.
 Dirt in the needle latch or groove.
Remedies:
 Change needle
 Proper cleaning

CHAPTER 8:
MAINTENANCE

Maintenance of machineries is very important for any type of industries and it is must for a
knit composite factory.
8.1 Types of maintenance:
1. Preventive maintenance-
a. Mechanical maintenance
b. Electrical maintenance
2. Routine maintenance
3. Corrective maintenance-
a. Mechanical maintenance
b. Electrical maintenance
8.1.1 Preventive maintenance:
Preventive maintenance is a predetermined routine activity to ensure on time inspection/

checking of facilities to uncover conditions that may lead to production break downs or
harmful depreciation.
8.1.2 Routine maintenance:
Routine maintenance usually denotes those activities of maintenance which are bare
minimum to ensure efficient working of machines. These activities have to be performed
according to predetermined frequencies which are based on technical and quality
considerations.

8.2 Routine maintenance task followed in the factory:
Daily work-
 Floor cleaning
 Positive feeder checking
 Oil line checking
 Airline checking
 Take up roller checking
 Motor sound checking
Every 25 days-
 Gear box checking
 All bearing checking
 All bearing greasing
 Panel board cleaning
 Fan filter cleaning
 Checking all control panels
 Lubrication all motor bearing
 All cable terminal tightening

8.3 Servicing Procedures of Circular Knitting Machine :
Power off
MPF belt out
Yarn cut
Removing The fabric
Removing nitting drum (optional)
Running the machine at low rpmwith oil and cleaning
Cam box and sinker box out
Needle and sinker out
Needle and sinker cleaning by oil
Cam box cleaning by air
Sinker,needle,cam and cam boxs joining

8.4 Maintenance tools and equipment:
1. Adjustable wrench:
Use: To set different types of nuts and bolts
 Tightening and loosening of nuts and bolts
2. Spanner:
Use: To set nuts, bolts and pulley
3. T-type L- key:
Use: Use to fitting cam box and other

machine parts
 Tightening and loosening of nuts

and bolts

4. Allen –key:
Use: Use to fitting cam box and other

machine parts
 Tightening and loosening of nuts and

bolts
5. Screw driver:
Use: To fitting to fitting various type screw.
6. Hammer:
Use: To drive nails, fit parts and forge metel.

7. Pliers:
Use:
 To hold machine parts
 Cut metal wire
 Set nuts and bolts
8. Cutting pliers:
Use: To cut metal wire.

CHAPTER 9:
UTILITY

9.1 Utility:
Utility is a major factor in any type of industry. In a textile industry there should be present
four types of utility for the smooth running of the operations. They are:
 Electricity
 Compressed air
 Steam
 Water
9.2 Source of utility:
Electricity: generator
Steam: boiler
Water: pump
Compressed air: compressor
9.3 Machine for utility services:
9.4 Air compressor:
Air compressor used to compress the air and increase the pressure of air. Air compressor
sucks air from the atmosphere, compress it and then deliver it at a high pressure to a storage
vessel. From the storage vessel it may be delivered by the pipeline to a place where the
supply of compressed air is required.

Fig: Air compressor
SL no Brand Product type Max Motor Origin Qty

pressure Power
1 Kaeser Screw type 15 bar 75 kw America 05
compressor
2 Kaeser Screw type 15 bar 55 kw America 02
compressor
9.5 Power generator:
In fariha knit tex, there are eight power generator present and six of them are run by gas and

rest of them run by diesel as fuel. In bellow some information about the generator are given:
Fig: Gas Generator
SL no Brand Model KW Volts R.P.M Fuel Origin Qty
1 Waukesha V.H.P- 900 400 1000 Gas America 05

5900LTDE
2 Waukesha V.H.P- 900 400 1000 Gas America 01
5900GSID
3 B&W AEG Man 1292 400/45 800 Diesel Sweden 02
0
9.6 Utility costs:
As Fariha Knit Tex Ltd. runs with its own electricity plant, it needs to buy gas and diesel to
run the generators. In bellow the bills of previous moths are given:
Month Bill in TK.

June 6252520
July 6597221

Aug 6321557

CHAPTER 10:
MARKETING INFORMATION
10.1 Knitting Charge for Various Structure:
Knitting Charge Per KG in taka

SI. No. Fabric Type
24 Ne -- 32 Ne 34 Ne -- 40 Ne
1. Single Jersey Plain 10 12
2. Single Jersey Slub Yarn 15 18
3. Single Jersey Dyed Yarn Feeder Stripe 20 22
4. Half Feeder Lycra Single Jersey 22 24
5. Full Feeder Lycra S/J Yarn Dyed Stripe 38 40
6. Pique Lacoste 16 18

7. Pique Feeder Stripe 30 33
8. 1×1 Normal RIB 18 20
9. Yarn Dyed (1×1) Stripe RIB 25 28
10. (1×1) Half Feeder Lycra RIB 22 24
11. (1×1) Full Feeder Lycra RIB 26 28
12. (2×1) RIB 25 28
14. (2×2) RIB 28 30
15. (2×2) Half Feeder Lycra RIB 32 34
17. Plain Interlock 30 33
18. Interlock Half Feeder Lycra Attachment 38 40
19. Three thread fleece 20 22
20. Three thread Lycra Fleece 28 32
10.2 Buyer Information:
Buyer name Country

H&M Sweden
Next United Kingdom
Springfield Spain
Splash UAE

Matalan United Kingdom
Walmart United States

Siplec France
Takko Fashion Germany

Kmart Australia

CHAPTER 11:
CONCLUDING PART
11.1 Limitation of our training and report:
Due to lack of qualified technical personal, we did not get enough information about
technical aspects of knitting machines and process.
11.2 Suggestions:
- Marketing activities should be increased.

- Working environment should be developed and modified.
- Technically skilled personal should be employed for improvisation of the unit.
Research center should be integrated in knitting department for developing new
fabric construction.
11.3 Conclusion:
We have completed our industrial training successfully by the grace of Allah. Fariha Knit Tex
Ltd. is a well-known factory in the textile field of Bangladesh. We are very grateful to the mill
authority for providing us the chance to acquire the practical knowledge about their large
and spacious field. It minimizes the gap between theoretical and practical knowledge and
also increase our thought a lot about textile technology. The main objective of industrial
training is to provide us the opportunity to observe, understand and practice the use of
engineering knowledge in textile industry. From this industrial attachment we captured a
detailed idea about the factory environment, factory maintenance system, total
management and many other very important details on the factory. Whatever knowledge
we have gained during our training period, it will help us to build up our carrier as a
successful textile engineer.

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AHSANULLAH UNIVERSITY OF SCIENCE AND

DEPARTMENT OF TEXTILE ENGINEERING

Industrial Training Report On

Mr. A.N.M Masudur Rahman

Intern report on Fariha Knit Tex Ltd. 1

CHAPTER 2: GENERAL INFORMATION ABOUT THE MILL

CHAPTER 3: RAW MATERIAL

3.1 Type of raw material:.....................................................................................................................15

CHAPTER 4: DESCRIPTION OF THE MACHINE AND MACHINE PARTS

4.1 Knitting Machine of Fariha Knit Tex Ltd:.........................................................................................21

Intern report on Fariha Knit Tex Ltd. 2

CHAPTER 5: PRODUCT MIX AND THEIR SEQUENCE OF OPERATION

5.1 Production parameters:.................................................................................................................38

CHAPTER 6: PRODUCTION AND EFFICIENCY CALCULATION

6.1 Formula for production calculation and efficiency calculation:.....................................................47

CHAPTER 7: QUALITY ASSURANCE

7.1 Object of quality control:...............................................................................................................57

8.1 Types of maintenance:...................................................................................................................70

Intern report on Fariha Knit Tex Ltd. 3

CHAPTER 10: MARKETING INFORMATION

9.6 Utility costs:...................................................................................................................................80

CHAPTER 11: CONCLUDING PART

11.1 Limitation of our training and report:..........................................................................................85

Intern report on Fariha Knit Tex Ltd. 4

Intern report on Fariha Knit Tex Ltd. 1

Intern report on Fariha Knit Tex Ltd. 2

GENERAL INFORMATION ABOUT

Intern report on Fariha Knit Tex Ltd. 3

Fig : Fariha Knit Tex Ltd.

Intern report on Fariha Knit Tex Ltd. 4

Name of the composite plant Fariha Knit Tex Ltd.

Major customer H&M (Sweden) Next (United Kingdom)

Intern report on Fariha Knit Tex Ltd. 5

USA Office : 1407 Broadway, Suite 1402 NYC, NY 10018

2.3.1 Factory Location on Google Map:

Intern report on Fariha Knit Tex Ltd. 6

Fig: Earth view of FKTL factory office

Intern report on Fariha Knit Tex Ltd. 7

2.5 Sister Concern of Asrotex Group:

2.6 Asrotex Knit Divisions Business Turnover (USD):

Intern report on Fariha Knit Tex Ltd. 8

2.9 Future plan:

Intern report on Fariha Knit Tex Ltd. 9

Intern report on Fariha Knit Tex Ltd. 10

Sr. fitter Q.C Incharge Production officer

Intern report on Fariha Knit Tex Ltd. 11

2.11.1 Layout Plan of Fariha Knit Tex Ltd.(Knitting floor):

Fig : Layout plan of knitting floor-1

Intern report on Fariha Knit Tex Ltd. 12

Intern report on Fariha Knit Tex Ltd. 13

Intern report on Fariha Knit Tex Ltd. 14

3.1 Type of raw material:

4. PC yarn (65% polyester, 35% cotton)

5. 100% Polyester yarn

 (95% cotton, 5% viscose)

 (90% cotton, 10% viscose)

 (85% cotton, 15% viscose)

 Ecru mélange (1-2% viscose, 99-98 % cotton)

9. 100% viscose yarn

Intern report on Fariha Knit Tex Ltd. 15

S/L no Brand name Origin Count

1 Texlon China 40D

2 Ceora Korea 20D, 30D, 40D