Chapter One

Company Profile

1
1.1 Company Information

Member Details
AL- Hamedi Textiles Ltd.
Primary Information Membership No : A - 04
Year of Membership : 1991

Contact Information Name : Mr Firoze Ali Fakhri

Position : Managing Director
Mobile No : 01730025076
E-mail : firoze@itclinens.com

Office Information Plot: 44 & 45, Sector: 01, South Halishahar, EPZ,
Office Address: :
Chittagong.
Phone No : 031-741009, 741319, 740699
Fax No : 031-800158
E-mail : firoze@itclinens.com
Web Address : www.itclinen.com

Factory Information Factory Category : ---

Plot: 44 & 45, Sector: 01, South Halishar, EPZ,
Factory Address :
Chittagong.
Phone No : 031-741319, 031-741009
Fax No : 031-800158
E-mail : firoze@itclinens.com

Product & Loom Number of Loom (s) : ---

Information Type of Loom (s) : ---
Model Name/Origin : ---
Production Capacity : ---
Export Capacity : ---
Product Specification : ---
Number of Employees : 263 Person
Yearly Turnover (US
: ---
$)

1.2 Top products

 Towels
 Cotton
 Bath
 Bath Towels
 Cotton Terry

2
1.3 Top HS Codes

 HS 63 - Textiles, made up articles; sets; worn clothing and worn textile articles; rags
 HS 48 - Paper and paperboard; articles of paper pulp, of paper or paperboard
 HS 52 – Cotton
1.4 Top countries supplied by Al-Hamedi

3
1.5 Supply chain

4
1.6 Bill of leading

5
 Chapter Two
Terry Towel information

6
2.1 Introduction

Terry or Turkish towels were originated in Constantinople, Turkey, wherein these fabrics were woven in handlooms. In
the middle of 19th century this technique of weaving towels was further refined in the European countries and took a
shape of power driven looms (Hobson 1990). Terry fabrics basically belong to the group of pile fabrics, wherein an
additional yarn is introduced/ inserted in such a manner that forms loop, called as pile, to give a distinct appearance.
These fabrics can be produced either by weaving or by knitting, out of these two methods of terry fabric production,
woven terry fabric, which is the first method invented, still has major share (Kienbaum 1978). This is because the quality
of knitted terry fabric is not comparable to that of woven terry fabric. Besides the methods employed to manufacture
the terry towels, other factors such as use of fibres, parameters of yarn, parameters of weaving, and methods of chemical
processing are also play a significant role in determining the quality of terry towels (Swani et al 1984, Teli et al 2000).

2.2 Historical developments of terry towel weaving

Victor Hobson (1990) described various mechanisms of terry loom being developed at initial stage. He described that
at primitive stage, like other fabrics, handlooms were used to manufacture terry towels, but to produce loops, it was
necessary to insert long rods in the same direction that weft were inserted. Length/size of loops was dependent on the
thickness of rods. Following the invention of power operated looms, mechanical means were used to insert and withdraw
the wires but these were no longer used in production of terry towels due to the complexity of operation. According to
Hobson (1990), all the basic mechanisms for pile formation such as loose reed, shifting of cloth fell, variable fall back
controlled by a pattern chain for sculptured effects, etc., had been developed by the end of 19th century.

2.3 Mechanism of terry weave

In terry fabric manufacturing, two sheets of warp threads run simultaneously, of which, one is kept under normal tension
and other is kept under loose tension (Kienbaum 1978, Ramaswamy 1992). The threads of normal tension warp sheet
are for ground and threads of loose tension warp sheet are for pile. The sequence of operations during weaving for pile
formation in 3-pick terry is given below:

- Insertion of first pick as per the design with loose beating

- Allow a predetermined gap near the feel of cloth

- Insertion of second pick following the first pick with loose beating

- Insertion of third pick with heavy beating and bring all the three picks to the fell of cloth

Ramaswamy (1992) compared the 3 pick terry and 4 pick terry, and observed that 4-pick terry fabrics are heavy in
structure and provide better quality in comparison to 3 pick fabrics.

2.4 Pile formation

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Pile of the towel plays major role for a towel for its water absorbency and other properties. Loop length is decided by
the quality, weight etc. as per requirements. Pile manufacturers use better quality yarn like combed, compact, hydro,
zero twisted yarns.

Piles are made by different high value fibers like superior qualities of cotton suvin, giza, pima, bamboo, modal etc. to
get better absorbency and lint properties. For ground yarn, comparatively coarser counts are used in OE and 2-ply option
to give better strength and compactness in ground fabric. Both piles and ground yarns are prepared in the same manner
of warping, sizing, and drawing-in.

Like other textile products shirting, suiting, sheeting fabrics, towel making has the same process sequences – desizing,
bleaching, mercerizing, dyeing and finishing.

2.5 Parts of a conventional terry

A woven towel consists of five parts. These are the pile area, fringes, beginning and end part, selvedge, border. Every
towel does not have to contain all of these parts. The pile area is considered the toweling part of the towel. Pile warps
which are left unwoven at the beginning and the end edges of the towel.Fringes are tied or an untied tasseled part of
ground warps and. The beginning and end sections are the tightly woven areas of a towel which come before or after
the pile fabric part and prevent this pile area from unraveling. They are woven without pile loops, in a flat weave
construction. The selvedge contains fewer number of warp ends than the pile area, for example 90 comparing to 4000
total warp ends, woven without pile as a flat weave and has the purpose to reinforce the towel sides

The parts mentioned on the above image are known in different names like

 Side Hem is named as Selvedge,

 Cross Hem is named as top and bottom hem,
 Borders are called as Dobby and
 Terry Bar is known as Cuff.

8
A wide variety of towel styles are available in the market. All the above towel parts may not be present in a particular
towel.

2.6 Classification of terry towel

the classification of towels can be made according to weight, production, pile presence on fabric surfaces, weft pick
per pile loop etc.

According to weight: very heavy, heavy, medium, light

According to production: woven, warp knitted, weft knitted

According to pile presence on fabric surfaces: one side or both side pile

According to weft pick per pile loop: 2 pick, 3 pick, 4 pick, 5 pick etc.

2.7 Fibers used in terry towel

According to Acar, the required properties of yarns which are used in terry towels are high absorbency, high wet
strength, and ability to dye well, good colorfastness wash-ability, soft hand, and hypoallergenic, low cost, and easy
availability.

Yarns made of cotton fibres can provide these properties most effectively

More and more towels are being produced from fibres other than cotton such as Modal®, bamboo, seaweed, Lyocel®
and now soybean, corn and other Tri-blend bamboo, silk and cotton blend is also beginning to be used in towels.

Such as Egyptian, Pima and Supima qualities, bamboo can be used in towels because of its softness, luster,
antibacterial properties and greater absorbency.

Flax is also among the natural hydrophilic fibres of cellulose like cotton. Flax has better dry strength than cotton, and
like cotton it gets 25% stronger when wet. It absorbs more moisture, and it wicks. It is longer, smoother, and more
lustrous than cotton.

However it is not used commonly in towels as it has been limited in supply and it is expensive because of the long
processing and intense labor it needs to be turned into a yarn.

2.8 Yarns which are used in terry towel

In a terry towel there are four groups of yarn. These four groups are the pile warp, ground warp, weft (filling), and
border weft.

2.9 Pile warp

One hundred percent cotton yarns, carded or combed, in sizes of 16/1, 20/1 Ne counts, 240-255 turns/meter twist, are
most commonly used.

The use of cotton- rayon blends has diminished, because 100% cotton provides a more pleasing hand and texture then
the blends.

When high quality is required, two or more ply yarns are used. In this case absorbency increases, and the fabric gains
resistance to pile lay.

The use of two-ply yarns is also on the increase as it improves visual appearance. Plied yarns are used to form upright
loops in classic terry, whereas single yarns are used to form spiral loops in fashion terry known as milled or fulled goods.

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2.10 Ground warp

Carded yarns of 20/2, or 24/2 Ne count with 550 turns/meter twist, and of 100% cotton are commonly used for ground
warp ends.

Two ply yarns are preferred because the ground warps ends have the highest tension during weaving.

It is common to use a yarn of cotton/polyester blend for greater strength. Rotor spun yarns are also used in ground
warps.

2.11 Weft

Carded yarns of 16/1, or 20/1 Ne counts with 240 – 255 turns/meter twist, 100% cotton are used usually for weft or
filling picks.

Rotor spun yarns are also used in wefts.

2.12 Border weft

Premium or high end hand towels have complex borders with fancy weaves and use a very wide range of filling yarns.
Decorative, shiny and bulky yarns of rayon, viscose, polyester, chenille, or mercerized cotton are used at different yarn
sizes.

2.13 Physical properties of a towel

Absorbency: High absorbency can be achieved in a towel by increasing the surface area with pile yarns and using
cotton yarns with twists lower than the ground warps.

Heat Insulation: Pile yarns make the fabric thicker and give the fabric a high level of heat insulation. Moreover
cotton fibres which are used in towels are naturally convoluted and bulked. This serves to trap air within the fabric
structure. The air contained between fibres and within them provides thermal insulation. These convolutions plus the
tapered fiber ends also hold the fabric away from the skin, adding to the amount of air trapped and contribution to heat
insulation.

Crease Resistance: Pile yarns give the fabric a third dimension which makes the fabric nearly uncreasable.

Dullness: The pile loops form a very rough textured surface, thus giving the fabric a dull appearance. This situation
is true for only un-sheared toweling. Velour toweling has an appearance even brighter than that of a traditional fabric.
The cut pile forms a very smooth surface and reflects light evenly.

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 Chapter Three
Manufacturing process of terry towel

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 Manufacturing process of terry towel
The following flow chart is used in this mill for terry towel manufacturing:

Manufacturing of Terry Towel:

3.1 Process 01: Warping

Yarn packages are assembled on warping creel as per construction plan, required tensions are set on each yarn package
and are processed on sectional or direct warping machines depending on single/double yarns are used.

All machine settings, machine speed is set as per instruction sheets of weaving plan. All warping sets made from single
yarns are processed on sizing machines where a starch coating is applied on individual threads to make it weave able on
weaving machines. Double yarns sets may or may not be passed through sizing machines. Single sized beams and double
sized or unseized beams are taken to drawing in department and beams are drawn as per drawing in weaving plan to
make them ready to load on weaving machine

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3.2 Process 02: Sizing

Sizing is the most important segment of weaving preparatory process. It is the process of applying protective adhesive
coating on the yarn surface. After winding and warping, sizing of yarn is done during beam preparation. Sizing is done
by applying various types of size materials on the yarn. Better the quality of sizing higher the weaving efficiency & vice
versa. In fact without sizing, in most of the cases it is almost impossible to run the weaving process. During application
of size materials steam is needed. Flowchart of sizing for warp yarn preparation is given bellow.

Sizing for Warp Yarn

3.2.1 Process Flow Chart of Sizing in Weaving

Size Cooking
↓
Creeling
↓
Yarn Feeding
↓
Sizing
↓
Drying
↓
Leasing
↓
Denting
↓
Empty Beam Feeding & M/C Running
↓
Ends Cutting
↓
Doffing

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3.3 Process 03: Terry towel weaving

Terry towel is one type of woven fabrics where during weaving of this fabric 2 beams are used. One beam for ground
fabrication and other beam for loop formation. Top beam is responsible for loop formation by terry loom’s beat-up
mechanism. Commercially 3 pick terry is most popular. 3 picks terry means after each 3 picks insertion full beat-up is
made and one loop pile is formed of the fabric. See the following illustration of beat-up position.

Pile of the towel plays major role for a towel for its water absorbency and other properties. Loop length is decided by
the quality, weight etc. as per requirements. Pile manufacturers use better quality yarn like combed, compact, hydro,
zero twisted yarns.

Piles are made by different high value fibers like superior qualities of cotton suvin, giza, pima, bamboo, modal etc. to
get better absorbency and lint properties. For ground yarn, comparatively coarser counts are used in OE and 2-ply option
to give better strength and compactness in ground fabric. Both piles and ground yarns are prepared in the same manner
of warping, sizing, and drawing-in.

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15
3.4 Process 04: Grey Fabric Inspection:

Grey fabric inspection is the process of identifying weaving faults in the fabric after coming from the weaving
department.

Fig: Grey fabric inspection

3.4.1 Parameters set in the machine:

1. Roller speed set upto100-1500 rev/hour.

2. Lights are used for detecting the fabric faults.

3. Length measuring meter attached with the machine.

3.4.2 Check list before inspection:

1. Machine parameters are set

2. Man power is made available

3. All the tools/accessories are made available

4. Fabric is made ready for inspection.

3.4.3 Investigation
In the inspection table the operator finds out faults in the fabric and analyses their intensity by visual inspection and
give points (rating) to the faults according to the fault size and behavior.

3.4.4 Working procedure:-

 The grey batch roll (500-700mtr) is feed on the inspection machine.

 Then unrolled over the inspection table where it is visually checked (100%) against light and repaired or mended
for any smaller extent of faults like protruding or projecting yarn, yarn naps, slubs, crack, floats, oil stains which
can’t be repaired, the fault area is identified by putting yarn tails or laces in the selvedge area.

 The mended fabric is then inspected over the grey fabric inspection machine visually against light in a pre-set
speed of 100 m/min. Then winded and sent to the batching section.

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3.4.5 Some of the common weaving faults are: -

1. Float (weaving)
2. Pick faults:

 Miss pick (weaving)

 Double pick (weaving)

 Broken pick (weaving)

 Starting mark (weaving)

 Extra pick (weaving)

3. Wrong density /drawing

4. Pattern or design break
5. Selvedge faults:

 Lashing in

 Cut selvedge.

6. Oil stain (weaving)

7. Crack, hole
8. Missing ends
9. Snarls
10. Slubs
11. Stubby weft (spinning)
12. Slough off (weaving)
13. Yarn variation (spinning)
14. Thick place (spinning)
15. Bumping mark (weaving)
16. Double end (weaving)
17. Missing end (weaving)

3.4.6 Key accessories:

 Nipper

 Pointer

 Cutter etc.

3.4.7 Defects Rating (point table):-

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3.4.8 Acceptance of fabric:

 Any piece of fabric with the rating of total 36 points faults per 100 linear meters is allowed to pass as ‘A’ grade
fabric. 36-40 is the point range for ‘B’ grade fabric.

 Any piece having more than 40 points is graded as ‘C’ which is rejected.

3.4.9 Rejection of fabric:

Any area of the fabric that contains:

1. Objectionable (too frequent) presence of weaving faults like stop/starting mark and pick faults.

2. Oil or grease spot.

3. Crack/holes, floats and warp end miss etc. are cut to a separate pieces and recorded as rejected.

4. Any fabric having points more than 40 is graded as “C” and is rejected.

*After grey inspection the fabric is ready for processing, so it goes to batching section.
3.4.10 Fabric Batching:
Batching is the receiving section of grey fabric and sending section of grey fabric to the bleaching section. Batching is
the process to get the fabric ready in its batch form (5000-6000 meter) depends on the fabric GSM. After batching the
package is ready for further processing.
3.4.11 Process flowchart of fabric batching

Fig: Flow path of fabric batching

3.4.12 Working procedure:

 After grey inspection the batch is feed on to the batching machine.

 Through the conveyer belt it is passed to the stitching section.

 After stitching the cloth passes through the cleaning brush fitted with air suction to the guider.

 Guider helps the batch in winding without having any crease. Pressure is maintained at 0-2.5 kg/cm2 or 0-35
lb/in2. For coarser fabric less pressure is used while for fine fabric more pressure is used.

 Frictional force is used for winding the fabric onto the batch.

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*After batching the larger packages are ready for using in the further process

3.5 Process 05: Wet Processing of Terry

In which way grey fabric is dyed is called wet process technology. Normally wet processing depends on buyer's
demand. Suppose your buyer wants the more precised dyed fabric; so in this fact you should mercerize your fabric
during the dyeing pre-treatment process. Basically if the buyer don’t want that so called particular fabric there is no
need to mercerize fabric.

Fig: Dyeing

3.5.1 Flow Chart of Textile Wet Process Technology

Grey Fabric Inspection

↓
Sewing or Stitching
↓
Brushing
↓
Croping
↓
Singeing
↓
Desizing
↓
Scouring
↓
Bleaching
↓
Mercerizing
↓
Dyeing
↓
Printing
↓
Finishing
↓

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 Final Inspection
↓
Delivery

3.5.2 All above process are described briefly:

 Grey Fabric Inspection:
After manufacturing fabric it is inspected in an inspection Table. It is the process to remove neps, warp end
breakage, weft end breakage, and whole spot.
 Stitching:
To increase the length of the fabric for making suitable for processing is called stitching. It is done by plain
sewing m/c.
 Brushing:
To remove the dirt, dust, loose fibre & loose ends of the warp & weft threads is known as brushing.
 Shearing / Cropping:
The process by which the attached ends of the warp & weft thread is removed by cutting by the knives or
blades is called shearing. Shearing is done for cotton & cropping for jute. After Shearing or cropping fabrics
goes under singeing process.
 Singeing:
The process by which the protruding / projecting fibres are removed from the fabrics by burning / heat to
increase the smoothness of the fabric is called singeing. If required both sides of fabric are singed.
 Desizing:
The process by which the sizing mtls (starch) are removed from the fabric is known as desizing. This must be
done before printing.
 Scouring:
The process by which the natural impurities (oil, wax, fat etc) & added/external/adventitious impurities (dirt,
dust etc) are removed from the fabric is called scouring. It is done by strong NaOH.
 Souring:
The process by which the alkali are removed from the scoured fabric with dilute acid solution is known as
souring.
 Bleaching:
The process by which the natural colors (nitrogenous substance) are removed from the fabric to make the
fabric pure & permanent white is known as bleaching. It is done by bleaching agent.
 Mercerizing:
The process by which the cellulosic mills/substance are treated with highly conc. NaOH to impart some
properties such as strength, absorbency capacity, lustier is known as mercerizing. It is optional. If the fabrics
are 100% export oriented then it is done by highly conc. NaOH (48-52° Tw).
 Dyeing:
A process of coloring fibers, yarns, or fabrics with either natural or synthetic dyes.
 Printing:
A process for producing a pattern on yarns, warp, fabric, or carpet by any of a large number of printing
methods. The color or other treating material, usually in the form of a paste, is deposited onto the fabric which
is then usually treated with steam, heat, or chemicals for fixation.
 Finishing:
Then finishing treatment are done according to buyer requirements and then folding, packaging, and at last
delivery.

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3.5.3 Dyeing Terry Towel Fabrics

3.5.3.1 Commonly used dyes:

 Reactive dyes

3.5.3.2 Commonly used machine:

 Winch, Jet/soft flow/overflow: Fabric in rope form

 Pad batch, Pad steam: Fabric in open-width form

3.5.4 Finishing Towel Fabrics

3.5.4.1 Chemical Finishing:

 Hydrophilic softeners

 Enzymatic softening

 Antimicrobial treatment (If no inherently antimicrobial fiber used)

3.5.4.2 Mechanical Finishing:

 Tumble drying: Gives softness, fullness, fluffiness

 Stentering: To straighten up fabric and impart dimensional stability

3.5.4.3 Cutting and Sewing

 Longitudinal cutting

 Longitudinal hemming

 Cross cutting

 Cross hemming

3.6 Process 06: Inspection

The inspections are done to control the quality is means by examining the products without the products any
instruments. To examine the fabric, sewing, button, thread, zipper, garments measurements and so on according to
specification or desired standard is called inspection. There are so many facilities for inspection in every section of
garments industries. The aim of inspection is to reduce the time and cost by identifying the faults or defects in every
step of garments making.

Fig: inspections

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3.6.1 Flow Chart of Garment Inspection

Confirmation of Quantity
↓
Confirmation of accessories
↓
Size spec inspection
↓
Inside Inspection
↓
Outside Inspection
↓
Final Inspection
↓
Packing

3.6.2 Inspection Procedure of Garments are Described Below:

1. Confirmation of Quantity:
First step of garment inspection start with confirmation of Quantity with the vendors packing list by counting
all Pecs. Of each box. If Qty is not matching to the packing list and written in the box then this discrepancy is
informed to the vendor.

2. Confirmation of Accessories:
Next step is the confirmation of accessories, here we confirm brand tags, demerit tags, Price tags, or other tags,
wash care labels, woven labels, or other labels and accessories as required by the buyer.

3. Size Spec inspection:

After confirmation of accessories all pcs are checked as per size spec based on the instruction sheet which is
given by the buyer side. If any measurement problem is noticed then we check the original sample and inform
the buyer same time.

4. inside Inspection:
At this stage garment is checked from reverse side to ensure that there is no fabric defect, poor stitching, and
stains etc in the garment.

5. outside Inspection:
At this stage garment is checked from outside to ensure that there is no color variation, weaving defect, fabric
defect, printing defect, holes, poor stitching, bad smell , dying defect and stains etc in the garment.

6. Final Inspection:
Final Inspection stage is the most important part of inspection process, here garment is rechecked to confirm
that inspection is done properly without missing any checking step if any defect is noticed we put it into rejection
bin or send it for repay.

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 7. Packing:
All “Grade-A” goods are put back into poly bags as per the original packaging and then they are send for needle
inspection.
So, depending on the quality of defect some garments are send for repair and some are rejected.
3.7 Process 07: Stitching

Stitching is the last section of towel manufacturing. In stitching section work is done according to the following
flowchart:

3.7.1 Flow Chart of Stitching Section:

Inventory Receiving
↓
Role Cutting
↓
Ribbon Section
↓
Piece Cutting
↓
Over Lock
↓
Level Sewing
↓
QC Section
↓
Special QC
↓
Quality Audit
↓
Level Confirm
↓
Folding
↓
Packing

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 ↓
QA Audit
↓
Cartooning
↓
Final Inspection
↓
Shipment

3.7.2 The Working Procedure of Stitching Section:

 » At first material is received from wet processing department. Then roll cutting i.e., warp way separation is
done manually by using knife.
 » Then the towels go to ribbon section. Here 2 long sides 9Selvedges) are stitched.
 » Up next; comes the piece cutting section. Here small pitches of towels are separated from a large piece by
cutting with a scissor.
 » Then by using over lock m/c the 4 selvedges of the small towels are sewn.
 » Then level is attached with the towel by sewing this is known as level sewing.
 » Then the towels are sent to the quality Control Section where they are graded as A/B/C/D grade.
 » Next the towels are sent to the special QC for further quality check-up.
 » Then they are sent to the quality audit section. If the towels pass in this section then they are sent to the level
confirm section.
 » In level confirm section the levels are checked in order to assure the correct level has attached.
 » Then the towel are folded in the folding section & then packed in a poly bag.
 » Then they are sent for quality assurance audit.
 » If the towels pass in the audit; then cartooning is done according to the Spec Sheet.
 » Next final inspection is done. If everything is found ok in the final inspection; then the towels are sent for
shipment.

3.8 Process 08: Final Inspection

3.8.1 Process Flow Chart of Final Inspection of Textiles

After completing finishing process here firstly check the shade as-per buyer std with dimensional stability from lab.
↓
2ndly check /with white fabric weight or GSM.
↓
3rdly check fabric surface or appearance as-per buyer STD.
↓
the every roll with every meter check as-per 4-point system.
↓
Make a report.
↓
If ok then ready for delivery.
↓
If not ok then identify the fault.
↓
If it is knitting fault then inform knitting department, by Job card and mail & requested the fabric for replacement.
↓

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If it is Dyeing fault & if we make sure that it is re-process able then we give the job card to Dyeing Dpt. for correction
and if is not re-process able then we reject the fabric & inform the dyeing to replace the reject Qty

3.9 Process 09: Carton Consumption

Garments are delivered to the buyer in cartons. Garments in poly bags are kept in a carton as per instruction of the buyer.
Loading cartons with garments is called packaging. Packaging is one of the important part of garment
manufacturing and exporting. Buyer generally gives written instruction as to the construction of the cartons. So, carton
is the most necessary element for shipment of the goods. Its cost is also important task for merchandisers. Cartoon
consumption and pricing procedure are given below.

Cartooning

3.9.1 Carton cost calculation rule

= [{(Length + width + allowance) X (Width + Height + 4)} X 2] / 10000 X Per square liner rate
= [{(60 + 40 + 6) X (40 + 30 + 4)} X 2] / 10000 X $0.80
= [{(106) X (74)} X 2] / 10000 X $0.80
= {(7844 X 2)} / 10000 X $0.80
= 15688 / 10000 X $0.80
= 1.5688 X $0.80
= $1.25504 / pc (Per carton rate)

For clear concept we can see the following short problems and solutions about cartoon consumption and costing.

Problems-1: A carton with Length 60cm, Width 40cm & Height 30cm, figure out a Cargo Measurement for 208
cartons?

Answer: 60 x 40 x 30 / 1000000 x 208 = 14.976 CBM

Formula: length X width X height / 1000000 X carton quantity

Problems-2: A carton of 7 Ply, Length 80cm, Width 60cm, Height 30cm, total carton 120 pcs, find out carton
measurement in square meter ?

Answer: (80 + 60 + 6) x (60 + 30 + 4) x 2 / 10000 x 120 =329 Square Meters.

Formula: (length + width + wastage) X (width + height + wastage) x 2 / 10000 X carton quantity. (You can avoid
wastage, if you wish)

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3.9.2 Basic Parameters of a Quality Terry Towel

 Weight & GSM: Weight and GSM should be same as required by customer. Every manufacturer has some
template or software (ERPs) where towel manufacturers calculate everything likes pile’s height, density of picks
and ends to meet requirement. This database or any software has been developed through some basic calculation.

 Softness/ Hand feel: It depends on properties of the yarn used in pile, finishing chemicals and too some extent
on pile orientation.

 Pile Orientation: Totally depends on process line.

 Lint: Lint are basically protruding fibers present in a finished towel. It is measured by weight of accumulated
fiber collected from washing machine and tumble drying machine during testing.

 Absorbency: Terry towel should be highly water absorbent.

 Dimensional Stability: How a towel is behaving after washing is fall under dimensional stability properties.
Dimensional stability is measured by the residual shrinkage % in a finished towel.

 Other Parameters are strength, color fastness etc.

3.9.3 Some Useful Calculations

 Production of loom (towel/per day/mc) = Rpm×60×24×efficiency/picks per towel

 Pile Height = Pile ratio x 15 / picks per cm (for 3 pick terry towel-commercially it is running)

 Pile Ratio = (Pile weight in gram × 2.2046 × 840 × pile count × 36) / (pile ends per towel X length of towel X
1000)

 Finished Weight of Towel = (Gsm × Towel length X Width in cm)/10000

 Weight per Dozen (Lbs/doz) = (Finished towel weight × 12)/ 453.6

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Chapter Four
SWOT Analysis

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The SWOT analysis on the Al-Hamedi terry towel industry is given here. Here strength and weakness of the Al-Hamedi
terry towel industry has been depicted and some alternatives and remedies have been suggested so as to make the Al-
Hamedi terry towel industry competitive and efficient against our biggest challengers, India, China, Pakistan and
Vietnam.

4.1. Strength:

The cost of labor is one of the key factors for Bangladesh’s success — the investigation found that the average wage
per hour of garment factory workers in Bangladesh is only 31 US cents. Whereas the per hour wage is $1.66 in China,
56 cents in Pakistan, 51 cents in India, 44 cents in Indonesia, 36 cents Vietnam and higher than this in Europe. The
industry people pointed out that terminal handling and customs dealings have improved here considerably in recent
times. Apparently pointing to the growing number of yarn manufacturing units, the World Bank pointed out that there
has been satisfactory growth in backward linkage textile industries here. Another strength is that the GSP facility upto
2015 to the European Union countries.

4.2 weakness
Shortage of skilled workers and mid-level management people, worker’s unrest were pointed out as another drawback.
Inefficient infrastructure, lack of industrial expertise, outdated social standards and unavailability of raw materials were
also mentioned as the major disadvantages of B Al-Hamedi terry industry.

Lower cost competitiveness has hampered ability to compete with lower cost global players. Labor force in Bangladesh
has a much lower productivity as compared to competing countries like China, India, and Sri Lanka etc. Cost like indirect
taxes and interest are relatively high.

Bangladesh does not produce the basic raw materials (only a negligible quantity of cotton but no manufactured fiber)
and as such has to depend totally on sensitive global market which is sometimes resulting in insufficient investments in
technology. Because of inadequate backward linkage, lead-time happens to be long, nearly 3 months. Bank interest rate
is still high enough, particularly of private sector bank, for investment of export oriented high value project.

4.3. Opportunities:

As global consumption is increasing every day and Al-Hamedi has some core competency which cannot be achievable
by the competing countries, the industry should have been acquiring a lion share of the global market. Al-Hamedi could
have achieved such a price competency which would be impossible for others with the help of further increase of

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productivity, quality and design support. Good signs are floating while we see textile education and research is
spreading. Bangladesh, as a proven experienced terry manufacturer, can expand share in the existing market (USA, EU,
Australia, Canada, etc.) and can also explore opportunity in Japan & CIS countries. In the long run,

4.4. Threats:

Competition is not likely to remain just in the export space; the industry is likely to face competition from cheaper
imports as well. This is likely to affects the domestic industry and may lead to increased consolidation. Ecological and
social awareness is likely to result in increased pressure on the industry to follow the international labor and environment
laws. This has resulted in increased pressure on companies to limit sourcing from countries/companies known to have
such practices. Al-Hamedi industry needs to prepare for the fall out of such issues by improving its working practices.
Regional trade blocs pay a significant role in the global terry towel industry with countries enjoying concessional tariffs
by virtues of being member of such blocs/alliances.

Sudden price hike of cotton and yarn in the domestic market may push Al-Hamedi industry to a very awkward situation
to devastate the business. The type of labor and political anarchies of the recent days if prevails in the future,

At last the largest threat to the textile industry is present gas crisis at every region of our country. As a result no new
terry industry has permitted for erection from the government.

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 Chapter Five
Recommendation and Conclusions :

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5.1 Recommendation

Al-Hamedi is one of the best terry towel supplier in Bangladesh for terry bath towel, terry beach towel, terry hand towel,
terry tea towel, terry towel bathrobe - it has been going to many trade shows around the world. Through sheer
experience, we can tell you that these tips will definitely help the industry.

1. Identify Appropriate Trade show: You need to figure out which terry towel tradeshow you’re going to. In terms of
global reach,

2. Plan! Plan! Plan! Planning is the number one thing you should consider as a terry towel exporter in Bangladesh.
Plan ahead to meet all deadlines.

3. Pre-show marketing: Terry towel manufacturers in Bangladesh are not big on pre-show marketing. However, this
small imitative will feel rewarding when tens and hundreds of buyer come to your booth with that initial information
about you. Make sure to let your existing & prospective buyers know that you’re exhibiting. It might be beneficial to
know the equivalent foreign words for terry bath towel, terry beach towel, terry hand towel, terry tea towel, terry towel
bathrobe and related products.

4. Profile on Show Website: The top terry towel tradeshows let exhibitors open a profile on their website. This is often
free of cost so we highly recommend you take advantage of it!

5. Booth Design: In addition to attractive and premium towels, your booth should also stand out from others. Rather
than sticking to the same design year after year, reach out to booth designers and gear up for a grand looking presence..

6. Materials: Marketing materials play a big part in creating the first impression about a terry towel manufacturer in
Asia. Do not try to create a hundred page brochure without proper planning. Instead, focus on core competencies,
attractive product photos and substance over quantity.

7. Variety: Variety is key to attract different kinds of buyers to your terry towel booth. Stack your booth with
institutional towel, beach towel, bibs, bath mat, bath sheet, bath robe, bath towel, guest towel, hand towel, hooded towel,
wash cloth and any other kind of bath textile you can think of!

8. Specialty towels: If you have specialty towels like bamboo towels, micro-fiber towels, zero twist towels, Egyptian
cotton towel – make sure to display them at the front or a designated corner. Keep in mind that by showing wonderful
products, you could potentially be remembered as that “wonderful terry towel supplier in Bangladesh” in buyer’s mind.

Any terry towel supplier in Bangladesh would know that such trade shows attract not only terry towel manufacturers in
Bangladesh, but also many reliable terry towel manufacturers around the world.

5.2 Conculation

Al-Hamedi industry is a global competitor in towel production with increasing exports. It is important to note that Al-
Hamedi’s exports have increased on both value and volume bases despite its price per SME being substantially lower
than the world average. Al-Hamedi is a value-added leader in towels. Though Bangladesh has not a strong textile and
apparel industry structure which provides a competitive advantage in the global market because of some infrastructure
.Al-Hamedi is well positioned to continue to compete in the global area and be a major supplier of towels. To sustain
its place and to enhance it.

Bangladesh can develop this sector as a wide export earning sector to contribute to our national economy by involving
or producing Textile experts in this sector. Existing manpower should undergo massive and integrated training for skill
and design development.

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