Final Intern Reports

BGMEA University of Fashion and Technology
BEXIMCO INDUSTRIAL PARK

Sarabo, Kashimpur, Gazipur.
Submitted by:
ID: 171-052-0-135 Name:
NayeemHossenShimul
Supervisor
ZahidHasan
Lecturer,Department of KMT, BUFT
This Internship Report Submitted in Partial Fulfillment of the

requirements for the Degree of B.Sc. in Knitwear Manufacturing &
Technologyof BGMEA University of Fashion &Technology (BUFT)
Department of Knitwear Manufacturing & Technology
Jun, 2021
BEXIMCOINDUSTRIAL PARK
Sarabo, kashimpur, Gazipur.
From 1 –April -2021, to 1-Jun -2021.
Submitted by:
ID:171-052-0-135 Name:
NayeemHossenShimul
Project Supervisor:
ZahidHasan
Lecturer,
Department Of KnitwerManufacturing &
Technology
Exam Committee:
Examiner 1(Supervisor): ZahidHasanSignature:
Examiner 2(External Member): Signature:
Examiner 3(External Member): Signature:

Summary of the Industrial Training
I have completed my Industrial Attachment successfully by the grace of Allah.Industrial Attachment sends
me to the expected density of practical life.The completion of Two month Industrial Attachment of Beximco
Industrial Park.That factory is one of the most export oriented company in Bangladesh.
Woven factory are playing vital role in Bangladesh RMG sector .I work in Beximco Industrial Park in woven
division .Beximco is 100% export oriented company .Company has well planned and setup with various
international certification fulfilling all demands of foreign buyers.During my training period,I have learn from
top to bottom of the working process.Ibelive this Industrial Trainning will be massive help in my job life.
DECLARATION
Herewith I assure that I have done industrial internship in BIXCIMCO INDUSTRIAL PARK.
under the supervision Of Mr. YogeshwaranRamanathan, Manager , Mechandisingof
Beximco Textile & Apparel Division From 1April 2021 to 1 jun,2021.
I also declare that neither this internship report nor any part of this internship report has
been submitted any award or degree.
NayeemHossenShimul
ID- 171-052-0-135
BGMEA University of Fashion and Technology(BUFT).

ACKNOLEDGEMENTS
I would like to extend thanks to Honorable chairman, Board of Trustees Mr. Muzaffar U.
Siddique, BUFT, for not only for his tremendous academic support, but also for giving me
many wonderful opportunities and logistics supports to do this project.
Special thanks goes to our enthusiasticProf.Dr.Nazamuddin, Vice Chancellor BUFT &

prof.Dr. Eng. AyubNabi Khan, Pro-Vice Chancellor, BUFT, who so generouslyinspired &
contributed to do this type of project work.
Special thanks to my enthusiastic supervisorZahidHasan, Lecturer, DepartmentKMT ,BUFT

has been an amazing experience and I thank her wholeheartedly,not for her tremendous
academic support, but also for giving me so many wonderfulopportunities.
I would like to extend thanks to all of persons, who contributed to the work presented in
thisproject.
TABLE OF CONTENTS
Page
Industrial Summary Report ....................................................................................................... ………...ii
Acknowledgment................................................................................................................................. iii
List of Figures ....................................................................................................................................... vi
List of Tables........................................................................................................................................ vii
Abbreviations ......................................................................................................................................viii
TABLE OF CONTENTS
CHAPTER ONE……………………………………………………………………………...………1
1.1 Introduction.............................................................................................................................17
1.2 History of BEXIMCO Groups.................................................................................................18
1.3 Objectives................................................................................................................................18
1.4 Company Profile.....................................................................................................................19
1.5 Project Description..................................................................................................................20
1.6 BEXIMCO Textile Division...................................................................................................21
1.7 BEXIMCO group contact information..................................................................................23
1.8 Mission & Vision....................................................................................................................24
1.9 Products...................................................................................................................................25
1.10 Buyers...................................................................................................................................28
CHAPTERTWO……………………………………………………………………………………29
2.1 Factory organogram…... ………………………. ……………………………….………. .29
2.2 Organogram of cutting.............................................................................................................30
2.3 Organogram of production......................................................................................................30
2.4 Total Employees summary ....................................................................................................31
2.5 Commitment to the Environment............................................................................................31
2.6 Others Facilities......................................................................................................................32
2.7 Management Body..................................................................................................................33
2.8 Board of Directors…………………………………………………………………………...34
CHAPTER THREE…………………………………………………………………………………35
MACHINE DESCRIPTION…………………………………………………………………….35
3.1 Section 1: Padma Textile Mills Ltd. (Plant 2).........................................................................37
List Of Machine………………………………………………………………………………….37
Machine Specification………………………………………………………………….………..38
3.2 Section 2 : BEXIMCO Textile Ltd.(weaving & Dyeing)…………………………..…………………………………………..39
3.2.1 Winding………………………………………………………………………..…………..39
List Of Machine……………………………………………………………………..…………..39
Machine specifications………………………………………………………….……………….39
3.2.2 Sizing………………………………………………………………………………………40
List of machine..............................................................................................................................40
Machine specifications..................................................................................................................41
3.2.3 Warping……………………………………………………………………………………42
Types of warping………………………………………………………….……………………..42
3.2.4 Weaving................................................................................................................................43
List of machine..............................................................................................................................43
3.2.5 Wet processing.....................................................................................................................44
3.2.5.1 Pre-treatment.....................................................................................................................44
3.2.5.2 Dyeing...............................................................................................................................44
3.2.5.3 Finishing............................................................................................................................55
3.3 Section 3: BEXIMCO Denim Ltd...........................................................................................56
3.3.1 Winding................................................................................................................................56
List of machine..............................................................................................................................56
3.3.2 Dyeing (Yarn dye)................................................................................................................57
List of machine..............................................................................................................................57
3.3.3 Sizing....................................................................................................................................58
List of machine..............................................................................................................................58
3.3.4 Weaving:...............................................................................................................................58
List of machine..............................................................................................................................59
3.3.5 Finishing:..............................................................................................................................59
List of machine..............................................................................................................................59
3.4 Section 4: Printing & Embroidery...........................................................................................59
3.4.1 Printing.................................................................................................................................60
List of machine..............................................................................................................................60
3.4.2 Embroidery...........................................................................................................................60
List of machine..............................................................................................................................60
3.5 Section 5: Crescent Fashion & Design Ltd. (Apparel Manufacturing)...................................60
3.5.1 Cutting..................................................................................................................................60
List of machine..............................................................................................................................60
3.5.2 Sewing..................................................................................................................................52
List of machine..............................................................................................................................60
3.5.3 Finishing...............................................................................................................................61
List of machine..............................................................................................................................61
3.6 Section 6: RR Washing Limited..............................................................................................61
List of machine..............................................................................................................................61
CHAPTER FOUR...............................................................................................................................61
MATERIAL MANAGEMENT........................................................................................................62
4.2 Section 2: BEXIMCO Textile Ltd...........................................................................................63
4.3 Section 3: BEXIMCO Denim Ltd...........................................................................................64
4.4.1 Printing.................................................................................................................................65
4.4.2 Embroidery...........................................................................................................................66
CHAPTER FIVE................................................................................................................................70
PRODUCTION PLANNING SEQUENCE & OPERATION..........................................................71
5.1.1 Production parameters..........................................................................................................71
5.1.2 Production flow chart of carded yarn...................................................................................71
5.1.2 Production flow chart of combed yarn.................................................................................72
5.2 Section 2: BEXIMCO Textile Ltd...........................................................................................73
5.2.1 Weaving................................................................................................................................73
5.2.1.1 Production parameters.......................................................................................................73
5.2.1.2 Winding flow chart............................................................................................................73
5.2.1.3 Flow chart of warping process...........................................................................................74
5.2.1.4 Flow chart of weaving (warp yarn):..................................................................................74
5.2.1.5 Flow chart of weaving (weft yarn)....................................................................................74
5.2.2 Wet processing.....................................................................................................................75
5.2.2.2 Production process of wet processing...............................................................................75
5.2.2.3 Flow chart of pretreatment................................................................................................76
5.2.2.4 Flow chart of dyeing..........................................................................................................76
5.2.2.5 Finishing............................................................................................................................77
5.2.2.6 Flow chart of finishing......................................................................................................77
5.3 Section 3: BEXIMCO Demin Ltd...........................................................................................79

5.3.2 Winding……… …………………………………………………………………………………………………..…………………………..78
5.3.2.1 Winding flow chart............................................................................................................79
5.3.2.2 Flow chart of warping process...........................................................................................80
5.3.3 Yarn dyeing..........................................................................................................................81
5.3.3.1 Process flow chart..............................................................................................................81
5.3.3.2 Recipe................................................................................................................................81
5.3.4 Weaving................................................................................................................................81
5.3.4.1 Flow chart of weaving (warp yarn)...................................................................................81
5.3.4.2 Flow chart of weaving (weft yarn)....................................................................................82
5.3.4.3 Process flow chart of finishing..........................................................................................83
5.4.1 Printing.................................................................................................................................84
5.4.1.2 Flow chat of printing process............................................................................................84
5.4.2 Embroidery...........................................................................................................................85
5.4.2.2 Flow chat of embroidery process.......................................................................................85
5.5.1 Cutting..................................................................................................................................86
5.5.1.2 Production flow chart of cutting........................................................................................87
3.5.1.3 Description of the production process.........................................................................88
5.5.2 Sewing..................................................................................................................................91
5.5.2.2 Production flow chart of sewing........................................................................................92

5.5.2.3 Description of the production process...............................................................................92
5.5.3 Finishing...............................................................................................................................94
5.5.3.2 Production flow chart of finishing.....................................................................................94
5.5.3.3 Description of the production process of finishing...........................................................96
5.6.2 Process flow chart of garments washing..............................................................................97
5.6.3 Description of the production process of garments washing................................................98
5.6.4 Recipe.................................................................................................................................103
CHAPTER SIX.................................................................................................................................106
6.1 Quality assurance procedure..................................................................................................106
6.2 Cutting...................................................................................................................................107
6.3 Sewing & finishing................................................................................................................108
6.4 Remarks.................................................................................................................................109
CHAPTER SEVEN...........................................................................................................................110
MAINTENANCE............................................................................................................................110
7.1 Maintenance of machinery....................................................................................................111
7.2 Maintenance in utility department.........................................................................................111
7.3 Remarks.................................................................................................................................112
CHAPTER EIGHT...........................................................................................................................113
8.1 Utility facility available.........................................................................................................114
8.2 Capacity & other technical details.........................................................................................115
8.3 Source of utility.....................................................................................................................115

8.4 Cost of different utilities........................................................................................................115
8.5 Remarks.................................................................................................................................116
CHAPTER NINE..............................................................................................................................116
STORE & INVENTORY CONTROL............................................................................................116
9.1 Fabrics Store..........................................................................................................................117
9.2 Dyes & chemicals store.........................................................................................................118
9.3 Others:...................................................................................................................................117
9.4 Spares.....................................................................................................................................119
9.5 Finished goods:......................................................................................................................119
9.6 Inventory system for raw materials.......................................................................................118
9.7 Remarks.................................................................................................................................119
CHAPTER TEN................................................................................................................................119
COST ANALYSIS..........................................................................................................................119
10.1 Cost of the product..............................................................................................................120
10.2 Remarks...............................................................................................................................120
CHAPTER ELEVEN........................................................................................................................120
MARKETING ACTIVITIES..........................................................................................................120
11.1 Consumer of the product.....................................................................................................121
11.2 Duties & responsibilities of marketing officer……………………………………………118
11.3 Remarks………………………………………………………….………………………..119
CHAPTER TWELVE……………………………………………………………………………..119
EFFLUENT TREATMENT PLANT…………………….…………………………………….119
12.1 Characteristics of raw effluents.................................................................................................
12.2 Chemicals used & their colors…………………………………………………………….120
12.3 Product quality check..........................................................................................................123
12.4 Flow chart of effluent treatment…………………………………………………………..120
12.5 Sludge separation………………………………………………………………………….121
12.6 Typical output of the plant……………………………………………………...…………122
IMPACT OF THE INTERNSHIP………………………..…………………………………….122
CONCLULATION………………………………………………………………………………………..………………………………………….125
LIST OF FIGURE
Figure 1.1: Industrial Building……………………………………………..………............………14
Figure 1.2: Factory Locatio……………………………………………………………….…..……15
Figure 1.3: FactoryLayout………………………………………………………...……….….……16
Figure1.4:Corporate Logo …………………………………….………..…………………………21
Figure 1.5: Main Buyer Logo…………………………….……….………………..…………….. 28
Figure3.1: cutting Machine……………………………..……………………...………………... 50
Figure 3.2:single Needle Lock Stich Machine…………………………………….……………….51
Figure 3.3: Double Needle Lock Stich Machine………………………………...............................52
Figure 3.4: Button Hole Machi..ne…………………….……………..………………..…………...54
Figure 3.5: Steam Iro………………………………………………………….………..…………..56
Figure 3.6: Rivet attaching Machine………………………………………………..………...……57
Figure 3.7:RR wash Layout……………………………………………………..………………….58
Figure 3.8: Inside View Of RR Wash………………………………………………………...…….59
Figure 5.1:Front view of BDL……………………………………….………………………….......78
Figure 5.2: Sorting & Bundling……………………………………….………………………….....89
Figure 9.2:Fabric Warehouse……………..……………………………………………………….115
LIST OF TABLES:
Table 4.1: Basic Chemical Used In RR Wash………………………….…………………………...67

Table 4.2: Enzym used in RR Wash……………………………………………………..…….……68
Table4.3: Dyeing Auxiliaries…………………………………………,,,,,,,,,,,,………..…………...68
Table 4.4: Some Special Chemical…………………………………………………….……….…..69
Table 5.1: Flow Chart Of Carded Yarn……………………………………………………….…….70
Table 5.2:…Flow Chart Of Combed yarn…………………………………………………….…….71
Table 7.3: Chemical used in Washing…………………………………………………...…..……...83
Table 5.3:Description of product process………………………………….……..…….....………..81
Table 5.4: Garments Washing Process………………………………..…..………………………98
Table 5.5: Basic Chemical For Garments Wash…………………………………………………100
Table 5.6: Pretreatment for garments wash ……………………………………………………..101
Table 5.7:special dyeing auxiliaries……………………………………………………………...102
Table 5.8: Finishing of garments wash…………………………………….………..…………...103
Table 12.1:Chemical used & Their Color…………………………………………….………….120
EQUATION
Equation( 0.1):………………………………………….…………………………………………87
Equation(0.2):……………………………………………………………………………………..88
Equation(0.3):……………………………………………………………………………………..89
Abbreviations:
AQL: Acceptable Quality Level
GPT: Garments Performance Test
EPB: Export Promotion Bureau
C&F:Cost &Freight
CIF:Cost,Insurance and Freight
BL:Bill Of Loading
LC: Letter of Credit
UD : Utilization Declaration
LCA: Letter Of Credit Authorization
PSI : Pre-Shipment Inspection
Mand W : Men and Women
PTS : Primary Textile Sector
ETP: Effluent Treatment Plant

CHAPTER ONE
Figure 1.1: Industrial Building

Figure1.2: Factory Location
Figure:1.3: Factory inside Layout
INTRODUCTION
1.1Introduction:
Industrial attachment is the most important part of academic syllabus. This allows students to go
through on the job type experience in where he/she can learn the full process and helps him/her to
build understanding. It is also improves knowledge in boosting productivity in service. University
education provides us vast theoretical knowledge as well as a more practical attachment, in despite
of all these industrial attachment helps us to be familiar with the technical support of modern
machinery, skill about various process stages.
By means of practical knowledge, it's not possible to apply the theoretical knowledge in the
practical field. For any technical education, practical experience is almost equally important in
association with the theoretical knowledge.
It also provides us sufficient practical knowledge about production management, work study,
efficiency, industrial management, purchasing, unity and maintenance of machinery and their
operational techniques, etc..the above mentioned cannot be achieved successfully by means
theoretical knowledge only.This is why it should be accomplished with practical knowledge in which
the industrial atmosphere and improve courage and inspiration to take self-responsibility.
RMG (Ready Made Garment) is very important and helpful for our Bangladesh. Bangladesh has
emerged as a key player in RMG (Ready Made Garment) sector since 1978. Textiles and clothing
account for about 85% of total export earnings of Bangladesh. Out of which, 75% comes from the
apparel sector which covers the major products of knit and woven shirts, blouses, trousers, skirts,
shorts, jackets, sweaters, sports wears and many more casual and fashion items. The sector
currently employs approximately 1.5+ million workers, mostly females from underprivileged social
classes. I have completed this report on the basis of weaving department of RMG sector such as
Winding Department, Warping Department, Sizing Department, Loom Department Design
Department, Fabric Inspection Department, Human Resource Department, Compliance Department,
and relevant organization like BGMEA, BKMEA, Export Promotion Buru, Yarn suppliers, Chittagong
Port, Insurance Company, Shipping Company. So by completing this report I get overall idea about
RMG sector, so its carry more value than any books. I preferred this attachment in BEXIMCO Group,
which is a 100% export oriented composite Woven & Knit industry. For continuing the study of
internship in the BEXIMCO Group we almost worked all the sections of this company and tried to
find out the activities, planning and many other things as well. In context, we have discussed about
these things deliberately to let you know about.
Apparel education can't be completed without industrial training. Because this industrial training
minimizes the gap between theoretical and practical knowledge and make us accustomed to
industrial environment. I got an opportunity to complete industrial training at BEXMICO TEXTILE &
APPAREL DIVISION, which is a 100% export-oriented industry. It has well planned & equipped fabric
dyeing-finishing and garments units in addition to facilities knitting and knitwear manufacturing.
1.2History of BEXIMCO Groups:
Since independence Bangladesh has come a long way, and the BEXIMCO Group of Companies is
honored to have had a role in the development of its parent nation. The Group has worked with a
simple philosophy; identify an important need and then do everything possible to successfully
satiate that need, in a manner which best facilitates the well-being of the nation. As a result
BEXIMCO has focused on those industries which give Bangladesh a competitive advantage in the
global market place in many cases creating the industries for the first time in the region. Throughout
its four and a half decade journey the Group has been one of the leading innovators in the country.
Presently BEXIMCO Group comprises twenty one companies of which five are listed with the Dhaka
Stock Exchange employing over 35,000 personnel and is the largest private sector industrial
conglomerate in the nation. . In the course of its growth, it has created industrial and management
capabilities that will serve the country for generations to come. It was the first local conglomerate
to embrace an international corporate structure which is the foundation of its success. BEXIMCO's
industrial businesses include jute, textiles, basic chemicals, pharmaceuticals, and ceramics.
BEXIMCO's non-industrial undertakings are focused on real estate and construction, engineering,
media, information technology, trading and financial services. It is the creation and expansion of
businesses critical to Bangladesh development, businesses, which are developed and run by
Bangladeshis, businesses that develop technologies and practices specific to the needs of the
country, which is the defining characteristic of the BEXIMCO story. Today the BEXIMCO Group
(“BEXIMCO” or the “Group”) is the largest private sector group in Bangladesh. BEXIMCO was
founded in the 1970‟s by two brothers – Ahmed SohailFasiurRahman and Ahmed
SalmanFazlurRahman. Since the early days, the Group has evolved from being primarily a
commodities trading company to a leading, diversified group with a presence in industry sectors
that account for nearly 75% of Bangladesh‟s GDP. BEXIMCO‟s corporate mission is “Taking
Bangladesh to the world”.
To describe the history of BEXIMCO Ltd., I would like to clarify the establishment of BEXIMCO
Groups.
1965-1975 BEXIMCO was born
1965 New Dacca Industries Ltd.-Jute Yarn Manufacturer
1972 Bangladesh Export Import Co. Ltd.
1973 BEXIMCO U.K. Branch.
1976-1989 BEXIMCO Diversifies
1978 BEXIMCO Foods Ltd.- Marine Food Processing & Export
1978 BEXIMCO Pharmaceuticals Ltd.- Pharmaceuticals Drug Formulations.
1980 BEXIMCO Fisheries Ltd.- Shrimp Farming & Export
1982 Expansion of Jute Yarn Manufacturing- Shinepukur Jute Spinners ltd.
1984 BEXIMCO Computers Ltd
1985 Beximco Apparel Ltd.- Garments Manufacturer & Exporter
1990-1995 BEXIMCO Expands
1990 Padma Textile Mills Ltd. (Phase i)
1991 BEXIMCO Infusion Ltd.
1992 BEXIMCO Synthetics Ltd., Padma Textile Mills Ltd. (Phase ii)
1995 Padma Textile Mills Ltd. (Phase iii)
1996-1999 BEXIMCO Preparing for the New Millennium
1996 BEXIMCO Textiles Ltd., BEXIMCO Knitting Ltd., BEXIMCO Denim Ltd.
1998 BEXIMCO Fashions Ltd.
1999 Shinepukur Ceramic Ltd.

1.3 Objectives:
Objective means the purpose of this report. The objectives of this report are as follows:
 Its documents for future.
 To know detail about RMG sector.
 Information gathers about Winding procedure.
 Getting idea about Warping procedure.
 Concept develops about Design and loom production.
 Comparison between class room learning and practical learning.
 Knowledge gather about RMG sector related other organization.
 To mark out the important part of Internship Report.
 To have skill labor for quality product.
 Regularly behavioral theory practice in garments industry.
 To find the current scenario of backward supply chain status of BEXIMCO Group.
1.4 Company Profile:

BEXIMCO Group is one of the largest private sector industrial conglomerates in Bangladesh engaged
in diverse business areas. BEXIMCO comprises of five publicly listed companies and sixteen private
companies. Where, pharmaceuticals and textile section are the biggest one. BEXIMCO covers one of
South Asia’s largest vertically integrated textile and garment companies. The Textile division is a
fully integrated manufacturer of cotton and polyester blended garments for men, women and
children, both for domestic and export markets. BEXIMCO is also the largest exporter of
pharmaceuticals in Bangladesh with a presence in 45 countries. The Pharmaceuticals division
manufactures and sells generic pharmaceutical formulation products, active pharmaceutical
ingredients (API) and intravenous (IV) fluids. The Group is also the largest ceramics exporter and has
an investment in GMG Airlines, the largest private commercial airline in Bangladesh and in Unique
Hotels & Resorts, which owns the Westin Hotel in Bangladesh.
Figure:1.4: Corporate Logo
Bangladesh Export Import Company (BEXIMCO) maintains this logo from the initial stage of its
business. They have a mission of taking Bangladesh to the world. So, with this logo BEXIMCO has
taken its identity towards the people of the world.
1.5 Project Description
Name : Beximco Apparel Ltd.
Business line : Manufacturing & Marketing of high Quality Garments.
Listing status : Public listed company
Stock Exchange listing : Dhaka & Chittagong
Year of establishment : March, 1985
Owners of the Projec : A S F Rahman, Chairman
Salman F Rahman, Vice Chairman
M A Qasem, Director
A B SiddiqurRahman, Director
Factory and Head Office: BEXIMCO Industrial Park, Chakraborty

BEXIMCO Industrial Park
Sarabo, Kashimpur, Gazipur.
E-mail: [email protected]
Web Site: www.bextex.net
Sponsors, Associate organizations:
World Bank, M Arubeni, CDC, DEG.
Sonali Bank, Local Office- Motejheel C/A, Dhaka-1000.
City Bank N.A., Chamber Building, 122 - 124, Motijheel C/A, Dhaka-1000.
State Bank of India, 24 - 25, Dilkusha C/A, Dhaka.
Standard Chatard Bank, 18 - 20, Motijheel C/A, Dhaka-1000.
Number of Shareholders: 37,929
Product mix : Manufacturing & Marketing of High Quality Garments.
1.6 BEXIMCO Textile Division:
The BEXIMCO Textile Division is a truly integrated undertaking. The Textile Division has the
capability to offer a complete product range for the export and domestic textile markets. The goal
of the Textile Division is to become the preferred partner for sourcing high quality fabrics and
clothing from Bangladesh. With highly advanced technology and an emphasis on developing local
human resources, the Textile Division has the potential to make an important contribution to the
nation‟s growing readymade garments export sector. The rationale behind the existing structure
and future expansion of the Textile Division is to capture value-added at each stage of the textile
manufacturing process. Despite Bangladesh’s lack of indigenous cotton production capability,
BEXIMCO has leveragedBangladesh‟s labor cost advantage and export competitiveness to the
maximum. BEXIMCO Textile Division consisting of 7 industries having the capability to offer a
complete product range for the export and domestic textile markets.
The Textile Section of BEXIMCO Group is given below:
 BEXIMCO Textile Ltd.
 BEXIMCO Fashions Ltd.
 BEXIMCO Apparels Ltd.
 International Knitwear & Apparels Ltd.
 Crescent Fashion & Design Ltd.
 Essess Fashions Ltd.
 RR Washing Ltd.
Here, BEXIMCO Textiles Ltd (BTL) is the most modern composite million the region. BTL has an
installed capacity of 288 high-speed air-jet looms in its weaving section and a high-tech dyeing and
finishing section with a capacity of 100,000 yards of finished fabric per day. BEXIMCO Knitting Ltd is
a state of the art composite knit fabric production mill, which serves the growing needs of high-
quality knit garments exporters in Bangladesh. BEXIMCO Denims Ltd was set up to capitalize on
Bangladesh's growing volume of high-value-added niche garments. BEXIMCO Apparels Ltd is
another 100%export oriented garments factory of the Beximco Textiles Division. It specializes in
women's tops and men's shirts. BEXIMCO Fashions Ltd is a100% export oriented garments factory is
located in the Dhaka Export Processing Zone at Savar. Padma Textile Mills Ltd cotton and polyester
blended yarn-spinning mill, with 122,000 spindles is one of the largest spinning mills of the country.
BEXIMCO Group Jute
New Dacca Industries Ltd.
SonaliAnsh Ltd.
BEXIMCO Group Synthetics

BEXIMCO Synthetics Ltd.
BEXIMCO Synthetics Ltd is a polyester filament yarn and drawn textured yarn (DTY) production unit
located near the BEXIMCO Industrial Park.
Location: State-of-the-art manufacturing plants located in the vicinity of Dhaka provide the Group
with a highly cost effective manufacturing base. A majority of its plants are in the BEXIMCO
Industrial Park, a vertically integrated self-contained facility. This facility provides ready access to
captive power generation, water purification, liquid nitrogen, waste water treatment and other key
infrastructure. This place has an ample space for every work stations with all independent facilities.
1.7 BEXIMCO Group Contact Information:For Investment Information
Corporate Secretarial Department

BEXIMCO
17 Dhanmondi R/A, Road No. 2
Dhaka 1205, BANGLADESH
Fax: +880-2-8613888 Fax: +880-2-8613470
For Business Opportunities Corporate Business Department

BEXIMCO
Fax: +880-2-8613888 Fax: +880-2-8613470
Corporate Human Resource Department

BEXIMCO
Fax: +880-2-8613888 Fax: +880-2-8613470
Website http://www.beximco.com/
1.8Mission & Vision:
BEXIMCO Textile and Apparels Ltd. (the "Company") was incorporated in Bangladesh as a Public
Limited Company with limited liability on 8 March 1994 and commenced commercial operation in
1995 and also went into the public issue of shares and debentures in the same year. The shares of
the Company are listed in the Dhaka and Chittagong Stock Exchanges of Bangladesh. This is the
largest textile mill in South Asian region. Here, in industrial park, Bextex Ltd. is the most modern
composite mill in the region. Bextex Ltd. has an installed capacity of 288 high-speed air-jet looms in
its weaving section and a high-tech dyeing and finishing section with a capacity of 100,000 yards of
finished fabric per day. BEXIMCO Knitting Ltd. has a state of the art composite knit fabric production
mill, which serves the growing needs of high-quality knit garments exporters in Bangladesh. The
project was set up as a state of the art knit fabric knitting, dyeing and finishing facility. During the
year the Company produced and sold high quality of knit fabrics and bringing forth all the latest in
hard and soft technologies in knitting, dyeing and finishing of knit fabric. The mill section also
consisted with cotton and polyester blended yarn-spinning mill, with 122,000 spindles is one of the
largest spinning mills of the country. The mill was set up to feed the country's export oriented
industries.
Mission: BEXTEX Ltd. is a full service vendor with strong vertically integrated production facilities as
well as creative & analytical capabilities which clearly set us apart from most other South Asian
vendors.
Our purpose is to generate customer’s value by delivering quality products at the right time in the
most cost effective ways. We will realize this mission by setting the highest standards in individual
and organization performances in the industry and continuously rewarding achievements. Vision:
Gain market leadership in high value added apparel in USA & Europe. • Use “Innovation” &“Speed”
as prime drivers, rather than cotton & cheap labor • Dominate these markets in high quality.
• To establish ourselves as a one-stop source for the global apparel market
• To satisfy and meet customers expectation by developing and providing products and services on
time, which offer value in terms of quality, price, safety & social responsibility
• To assure complete compliance with the international quality standards
• To provide the employees internationally acceptable working condition/standards
• To promote the developments and best use of human talent & equal opportunity employment
• To procure the most advanced & sophisticated technology suitable for producing desired product
• To attain the highest level of competence through continuous development of the professional
management system
• To ensure complete transparency in all aspects of business
• Our sense of social responsibility reflects through our effort towards employee welfare
• To ensure a healthy environment of our employees as well as for the greater society
• To participate in social upliftment project.
1.9 Products:
Yarn products which are different in counts, types, fibers. These products are ranged from the knit
counts of 60-120. Products are included with Lyocell, Tencel, Modal, Rayon, Viscose etc.
Fabric products which are consisted with different types of dyed fabric and finishing. According to
buyer‟s requirements various designs are produced here. Twills are mostly used fabric here.
Knit products which are based on cotton and lycra basically. These products are stretchable and
used to produce very basic styles. Jersey, Polo pique, Back pique, Herringbone, Crepe, Auto Stripe,
Rib, Jacquard are mainly ordered products here.
Denim products which are heavy fabric with different enzyme wash. So, these products are hugely
ordered by the customers throughout the year. Here, black, blue, colored, over dyed, bull, stretched
denim products are produced.
Special yarn products are produced according to the buyer‟s requirements. These products are
produced in case of fancy styles with multi counts and other special attributes.
Unique wrinkle free products are generally special products. These products can be produced but it
depends on the order quantity and feasibility.
Fabric – Jersey, Elastane jersey, Auto stripe and feeder stripe jersey, 3 thread fleece ( with or
without elastane ) Pique, Back pique, Elastane pique, Auto stripe and feeder stripe pique, Rib, Rib
with elastane, Interlock, Terry, Terry with Elastane, Flat knit collar and cuff and other CAM design
fabrics.
Garment – T-shirt, Polo shirt, Tank top, Cut and sewn T-shirts and polo shirts, Sweat shirt, Jackets,
Hoody, Turtle neck, Strap Tee, Shorts, Trouser and other fancy dresses.
1.10 Our Buyers:

Major Customer:
USA & CANADA:

American Eagle. Richlu Canada.
Wal-Mart. YM Canada.
Target Corp. J.C. Penny.Sears/K-mart.Dickies.
Kohl‟s.Charming Shop.
Oxford USA. Macy.
Berne Apparel.Regatta.
EUROPE:
H & M. Bershka.
C & A.Zara.
River Island.Pull & Bear.
OTHERS:
Marks & Spencer.s.Oliver.

Next.Tesco.
Tom Tailors. Hanes.
Stanley & Stella.Decathlon, etc.
Figure:1.5:Factory Buyer Logo
CHAPTER TWO
MAN POWER MANAGEMENT / ORGANOGRAM
2.1 Factory Orgagram: Chairman
Vice Chairman
CEO
SGM
DGM
Senior Manager
Deputy Manager
Assistant Manager
Senior Executive
↓
Executive
Junior Executive
2.2 Organogram of cutting:
Cutting manager
Cutting executive
Cutting management trainee
Cutting supervisor
Cutting assistant supervisor
Trainee supervisor
Senior cutting man
Cutting man
2.3
Organogram of production:
2.4
BEXIMCO Textile in total a huge part of organization with a large number of employees. This is a combination
of Blue collar and White collar employees with different responsibilities. This total division contains several
sections like Design studio, Textile Head office, Lab units, Factories, Plants etc. so, overall there is
45,00employees for whole textile section where more than 1200 work as Management stuffs.
2.5 Commitment to the Environment:
BEXIMCO is very committed to preserve a healthy and pollution-free environment. It has a very efficient
waste collection and disposal system. In order to reduce air pollution by exhaust of gas from
enginegenerators, it maintains a costly plant that uses the exhaust gas to generate steam for chilling unit.
Above measures not only help keep the water & air free from pollution but also help save cost of water
treatment & air conditioning. Your company uses only AZO-free dyes and is dedicated to ensure a healthy
and ecofriendly environment.
2.6 Other Facilities:
BEXIMCO Textile is situated in the industrial park so, it is facilitated with employees‟ transport, lunch
facilities and also for workers of factories it has day care center and also prayer rooms for both men and
women. Managerial staffs have their different canteen of lunch and other facilities. Numbers of foreign
managers work here so, they have residence facilities also.
2.7 Management body
BEXIMCO Group is the largest private sector industrial conglomerate in Bangladesh engaged in diverse
business areas. BEXIMCO‟s shares constitute 4.84% of the market capitalization of DSE. So, BEXIMCO is well
positioned to capitalize on strong growth across industries in both the domestic and global markets. Each
Group company is managed by an independent, professional team with significant depth of experience.
Management teams have established a clear strategic plan that will further strengthen the overall platform.
BEXIMCO intends to leverage its market position and global scale, further diversify operations into highly
profitable sectors, capitalize on the domestic growth opportunity and selectively pursue international
opportunities going forward.
2.8 Board of Directors:
A S F Rahman
Chairman, BEXIMCO Group A S F Rahman is Chairman of the BEXIMCO Group, the largest private sector
industrial group in Bangladesh. During the past 45 years A S F Rahman has played the leading role with his
brother, Salman F Rahman, in building up the Group's industrial and service activities. He has presided over
an expansion and deepening of the Group's interests, leading the flagship investments in textiles.
Salman F Rahman
Deputy Chairman, BEXIMCO Group Mr. Salman F Rahman, the Deputy Chairman of the BEXIMCO Group, has
been one of the driving forces in the emergence of the Group as the largest industrial entity operating in the
private sector in Bangladesh today. He is one of the advisors of Honorable Prime Minister of Bangladesh also.
Board of Directors:
 Mr. A S F Rahman, Chairman & Managing Director
 Mr. Salman F Rahman, Vice Chairman
 Mr. Iqbal Ahmed, Director
 Mr. M A Qasem, Director
 Mr. O K Chowdhury , Director
 Mr. A B S Rahman, Director
 Dr. Abdul Alim Khan, Director
 Mr. Md. AsadUllah, Company Secretary
Key Officers:
Mr. O K Chowdhury, Director
Mr. Md. LuthforRahman, Chief Financial Officer
Mr. AzaharUddin Ahmed, FCA, Head of Internal Audit
Auditors:
M/s. M. J. Abedin&Co. M/s. Wellers, Registered Auditors, Accountants
Legal Advisers: M/s. Huq& Co.
Bankers: IFIC Bank LTd.Dhanmondi Branch,
Dhaka-1205
SonaliBank, Local Office, Motijheel C/A,
Dhaka-1000
Registered Office: Bell Tower House No.17, Road No.2,
Dhanmondi R/A, Dhaka-1205.
CHAPTER THREE
MACHINE DESCRIPTION
3.1 Section 1: Padma Textile Mills Ltd. (Plant 2)

List of machine:
1. Blowroom
2. Carding
3. Draw frame
4. Lap former
5. Comber
6. Simplex / Speed frame / Roving frame
7. Ring frame
8. Auto cone
Machine specifications:
Machine name : Carding

Brand name : Trutzschler
Model : DK 760
Processing capacity : 140 m/min
No of machine : 28
Machine name : Draw frame

No of machine : 24
Machine name : Lap former

Machine name : Comber

Machine name : Roving frame

Machine name : Ring frame

No of Spindle : 573
No of machine : 88
Machine name : Auto cone

Speed : 1300 meter/min
No of machine :4
3.2 Section 2: BEXIMIMCO TEXTILE Ltd.(weaving & Dyeing)
3.2.1 Winding:
Types of winding:
1. Soft winding
2. Hard winding
Soft winding:
List of machine:
1. Fadis winder
2. RJK Winder
3. Harish Winder
4. Mettler winder
Machine name :Mettler
Origin : Switzerland.
Type : Soft Winding.
No. of head : 48X2, 1.5 turns per drum.
RPM : 600 (Depends on yarn count)
No of machine : 02
Volt : 440V
Hard Winding:
List of machine:
1. Textool Winder
2. Kamitsu winder
3. Mettler Winder
Machine name : TEXTOOL Winder
Origin : India
Type : Hard Winding.
No. of head : 60X2, 2.5
RPM : 650m/min
No of machine : 12
Machine name : Kamitsu Winder.

Origin : Japan.
Type : Hard Winding.
No. of head : 40, 2.5 turns per drum.
RPM : 650m/min
No of machine : 02
Machine name : S. S. Mettler

Origin : Switzerland.
Type : Hard
No. of head : 84 drum, 84 motor
RPM : 600 (D)
No of machine : 01
3.2.2 Sizing:
List of machine:
1. Benningerzell sizing machine
2. Keawamoto sizing machine
Machine name : Benninger Zell Sizing M/C.
No. of machine : 2, 2box 10 cylinder, 1 box 12 cylinder.
Manufacture : Germany
R.P.M : 160 m/min.
Size box : 2 (single dip).
Beam creel : 20.
Voltage/frequency : 400v/50hz
Controlled voltage : 20v/dc.
Main fuse : 20 a.
Working width : 2200 mm (between the flanges).
Sizing bath : working place width 2200mm, roller width 2400mm
Dryer : Steam Pressure 3.5-5 bar, temp. 147ᵒC
Machine name : kawamoto sizing machine
No. of machin : 1, 1 box 16 cylinder
Manufacturing : Japan
Speed : 160mt/min
Width of fabric : 74’’
Roll : 5000 meter
Total ends : 6626
Creel : 20
Size box temperature : 85 degree
Creel tension : 2500N
Cylinder temperatur : 4 chamber (140,140,135,130 degree)
Squeezing temperature: 7.0 KN
Refractometer : cheek chemical present in solid fabric and cone tension is 9%
Viscosity : check how much time it will take
Production : 3000-35000 meter per day.
Chemical used : PVA – 8% acrylic – 90%,wax,starch- 85%,water.
Temperature : 92 degree
Time : 35-35 min
Water quantity : 665 liter
3.2.3 Warping:
Types of warping:
1. Sectional Warping
2. Direct/Solid Warping
Sectional Warping:
Machine name : Beninger
Model : Supertronic-2200
Origin : Switzerland
Creel Capacity : 720
Creel Type : V shape
Warping Spee : 600m/min
Reed Type : Plain reed.
Machine type : Sectional
No. of machine : 03
Direct/Solid Warping:
Machine name : Kawamoto
Origin : Japan
Creel Type : V shape
Warping Speed: 550m/min
Reed Type : Zigzag reed.
Machine type : Direct
3.2.4 Weaving:
List of machine:
Air jet loom
Types of weaving machine:

1. Conventional
2. Modern
Conventional loom:
Hand loom
Modern loom:
1. According to peaking mechanism
2. According to shading mechanism
In BEXIMCO Textile Ltd. Air jet loom used as Picking mechanism, Dobby and Crank also.
List of machine:
1. Air jet loom
2. Dobby loom – 16 shaft
3. Crank loom – 8 shaft
4. Knotting machine
Total no of looms - 293
1. Dobby machine: 36
2. Crank machine :257
3. Knotting machine: 4
Machine Name : Air Jet Loom
Motor R.P.M : 1410
Machine Speed:625 PPM
Motor pulley diameter : 100 mm
Machine pulley diamet : 225 mm
Reed : Profiled Reed
Shedding Cam : Electric Dobby
Take up motion : 7 wheel ( Mechanical )
Let off motion : Electronic
Warp Stop : Electrical
Weft Stop : Electronic
3.2.5 Wet processing:

1. Pre-treatment:
a. Singing
b. De-sizing
c. Scouring + Bleaching
d. Mercerizing
2. Dyeing
3. Finishing
3.2.5.1 Pre-treatment:
Singeing
Machine name : Gas singeing machine
Brand :Kuster
Origin : Germany
No of machine : 1
Scouring + Bleaching
Machine name : Sinze Cool Bleaching
Brand name : Wuppertal
Origin : Germany
Brand : Goller
Origin : Germany
Temperature : 103 degree
No of machine :1
Mercerizing:
Machine name : Mercerizing machine
Brand : Oshtoff
Origin : Germany
No. of machine : 1
3.2.5.2 Dyeing:
Machine name : Ziggerdyeing machine
Brand : Goller
Origin : Germany
No. of machin : 1
Machine name : Thermosoldyeing machine

Brand : Goller
Origin : Germany
No. of machine : 2
3.2.5.3 Finishing:
Machine name :Stenter machine
Brand : Brückner
Origin : Germany
No. of machine : 1
Finishing type : Mechanical finish
Machine name :Sunforizing machine (Shrinkage Control)
Brand :Mofortex
Origin : Germany
No. of machine : 2
Finishing type : Mechanical finish
3.3 Section 3: BEXIMCO Denim Ltd
3.3.1 Winding:
List of machine:
1. West Winding
2. Benimger
Machine name : Benimger
Origin : German
Max : 1000kg/beam
Max Thread : 90000
Daily Production: 45k meter
RPH : 1000rpm
3.3.2 Dyeing (Yarn dye):

List of machine:
1. Weist Point
2.Bensizetex or Benninger
Machine name : Weist Point
Origin :
No. Of Beam : 14
Dye : Indigo
Dyeing Section : 6 section
Washing chamber: 3(Cold + Hot)
Drying chamber : 10 drum
Machine name : Bensizetex or Benninger

No. Of Beam : 14
Dye : Indigo
Dyeing Section : 6 section
Washing chamber : 3(Cold + Hot)
Drying chamber : 10 drum
3.3.3 Sizing
List of machine:
1. West Winding
2. Benimger
3.3.4 Weaving:
List of machine:
Air jet loom. (dobby)
Total no of looms: 110
Machine name : Air jet loom
Brand name : Tsudakoma(56)
Motor R.P.M : 350
Machine Speed : 625 PPM
Motor pulley diameter : 100 mm
Machine pulley diameter: 225 mm
Reed : Profiled Reed
Shedding Cam : Electric Dobby
Take up motion : 7 wheel ( Mechanical )
Let off motion : Electronic
Warp Stop : Electrical
Weft Stop : Electronic
Daily Production : 120 meter
3.3.5 Finishing:
List of machine:
Finishing machine.
3.4 Section 4: Printing & Embroidery

3.4.1 Printing:
List of machine:
1. M& R Octopus machine
2. Rotary screen printing machine
3. Flatbed screen printing machine
4. Belt curing machine
5. Heat press machine
6. Gas curing machine
7. Flash dryer
8. Auto dryer
9. Hand dryer
10. Manual print table
11. Mixture machine
Machine name: M& R Octopus printing machine
Brand Name : YOUCHENG
Model No : YC-P1616
Origin : China
Plates : 16
No of machine: 5
Machine name: Rotary screen printing machine

No of machine: 1
Machine name: Flatbed screen printing machine

No of machine: 1
Machine name: Belt curing machine

No of machine: 2
Machine name: Heat press machine

No of machine: 6
Machine name: Gas curing machine

No of machine: 1
Machine name: Flash dryer

No of machine: 10
Machine name: Auto dryer

No of machine: 13
Machine name: Hand dryer

No of machine: 10
Machine name: Manual print table
No of machine: 2
Machine name: Mixture machine

No of machine: 1
3.4.2 Embroidery:
List of machine:
1. Electronic multi head automatic embroidery machine
2. Bobbin winding machine
Machine name : Electronic multi head automatic embroidery machine.
Brand : JINTEL
Origin : China
Number of head : 20
Number of needle per head: 9
Number of machine : 9 machine of 20 heads and 1 machine of 6 heads.
Number of color used :9
Production capacity : if 1000 stitch required, 300 pieces per hour
3.5 Section 5: Crescent Fashion & Design Ltd. (Apparel Manufacturing)

3.5.1 Cutting:
Figure:3.1: Cutting Machine
List Of Machine:
1. Straight knife cutting machine.

Machine name: Straight knife cutting machine
Brand name : KM
Model no : KM-10"
Origin : Japan
No of machine: 6
Function : To cut the fabric lay according to marker direction.
3.5.2 Sewing:
List of machine:
1. Single needle lock stitch
2. Double needle lock stitch
3. Single needle chain stitch
4. Double needle chain stitch
5. Overlock
6. Feed of the arm
7. Kansai special
Figure:3.2 : single needle lock stich Machine
Machine name : Single Needle Lock Stitch

Brand name : Brother
Model no : S-7100A
Origin : Japan
No of machine : 14
No of Needle : 1
Figure: 3.3: Double Needle Lock Stich
Machine Name: Double Needle Lock Stich Machine

Model no : SL-777B
Origin : Japan
No of machine: 10
No of Needle : 2
Machine name : Single Needle Chain Stitch

Brand name : Chiness
Model no : 481
Origin : China
No of machine: 10
No of Needle : 1
Machine name : Double Needle Chain Stitch

Brand name : Chiness
Model no : 380
Origin : China
No of machine: 10
No of Needle : 2
Machine name : Overlock

Brand name : Pegasus
Model no : Mx3213-03
Origin : Japan
No of machine : 15
No of Needle : 1 (2 for 4 & 5
thread)
Machine name : Feed Of The Arm

Model no : DA-9270
Origin : Japan
No of machine : 10
No of Needle : 2 (1 needle can be
used)
Machine name : Kansai Special
Brand name : Kansai Special
Model no : PMD-1404 PSF
Origin : Japan
No of machine: 5
No of Needle : up to 32 needle can
be used
Figure:3.4:Button Hole Stitch Machine
Machine name : Button Hole

Model no : HE-800B-2
Origin : Japan
No of machine: 10
Machine name : Button Stitch

Model no : BE-438FX2
Origin : Japan
No of machine: 10
No of Needle : 1
Machine name :Bartack

Model no : KE-430FS
Origin : Japan
No of machine: 15
No of Needle : 1
Machine name : Flat Lock

Brand name : Kansai
Model no : B2000C
Origin : Japan
No of machine: 5
No of Needle : up to 2
Machine name :Fusing Machine

Brand name : HASHIMA
Model no : HP-1000LS
Origin : Japan
No of machine: 1
3.5.3 Finishing:
List of machine:
1. Steam iron
2. Bottle steam iron
3. Thread sucking machine
4. Metal detector machine
5. Single needle lock stitch
6. Rivet attaching machine
7. Button hole
8. Button stitch
Machine specifications: Figure:3.5:Steam Iron

Machine name : Steam Iron
Brand name : NISSHO
Model no : NH 6361
Origin : Japan
No of machine : 5
Machine name : Bottle steam iron

Brand name : SILVER STAR
Origin : US
No of machine : 30
Machine name : Thread Sucking Machine

Brand name : NgaiShing
Model no : NS-55
Origin : US
No of machine: 1
Machine name : Metal detector machine

Brand name : HASHIMA
Origin : Hong Kong
No of machine: 1
Machine name : Single Needle Lock Stitch

Model no : S-7100A
Origin : Japan
No of machine : 20
No of Needle : 1
Machine name : Rivet attaching machine
Brand name : SERA
Origin : Germany
No of machine : 15
Machine name : Button Hole

Model no : HE-800B-2
Origin : Japan
No of machine: 10
No of Needle : 1
3.6 Section 6: RR Washing Limited
Figure:3.6 : Rivet attaching machine

Figure : 3.7: RR Wash Layout
List of machine:
1. Washing machine
2. Reactive / Over dye machine
3. Hydro-extractor
4. Dryer:
a.steam dryer
Figure:3.7:Inside Of RR Washing
Machine name : Washing machine
Brand Name : Tonello machine
Origin : Italy
Model : G1 420 MW2
Installed power : 46 kw
Machine height: 2600 mm
Machine Width : 2940 mm
Machine Depth : 3100 mm
Machine Name : Belly Wash Over Dye Machine

Origin : China
Capacity : 10-150 kg
Machine Name : Hydro-extractor

No. of Machine : 07
Capacity : 250 pcs
R.P.M :220
Machine name : Gas dryer

Capacity : 200-250 pcs
No of machine : 2
Machine Name : Steam dryer

Capacity : 300-350 pcs
No of machine : 23
CHAPTER FOUR
MATERIAL MANAGEMENT
Raw material, also known as a feedstock or most correctly unprocessed material, is a basic
material that is used to produce goods, finished products, energy, or intermediate materials
which are feedstock for future finished products.

Raw Material Use in Padma Textile Mills Ltd.:
1. Coal Max Polyester
2. Tencel
3. Indian Type(MCU-5)
4. Sanlcer-6
5. USA Pima Cotton(Type-Star)
6. Cis
7. Syria
8. Burkina Faso Cotton
9. China Cotton (Type SHODU)
10. USA MEMPHIS Cotton etc.
Yarn produced:
1. Mélange yarn.
2. PC
4.2 Section 2: BEXIMCO Textile Ltd.

Raw materials used in BEXIMCO Textile Ltd.:
1. Yarn
2. Gray
3. Dyestuffs
Yarn: Yarn is collected mainly from Padma Textiles Ltd (plant 2).
Fabric: Fabric is collected from weaving section of BEXIMCO Textile Ltd.
Types of fabric:
1. 100% cotton fabric
2. Canvas
3. Lycra poplin
4. Fine Canvas
5. Down proof
6. Rasatello
7. Dallas
8. Air Pop
9. Heavy Twill Elastic
10. Lycra twill fabric
11. Air Twill GB
12. Lotus
Dyestuff:
In this factory they used only reactive dye in BEXIMCO Textile Ltd. The name of the reactive
dyes used in BEXIMCO Textile Ltd. are:
1. CibacronTurq P GR 150%
2. Cibacron Brown P-6R Gran 150
3. Cibacron Red C-2BL
4. Cibacron Red C-2G
5. Cibacron Navy CR
6. Cibacron Navy CB
7. Cibacron Super Black B
8. Cibacron Black C-2R
9. Cibacron Black P-SG
10. Cibacron Black CNN HE
11. Cibacron Super Black G
12. Cibacron Blue 4R
13. Cibacron Yellow NP
14. Cibacron Yellow C-R-01
15. Cibacron Blue P-3R
16. Everzol Navy C-GG
17. Everzol Turk Blue G
18. Everzol Yellow 3RS
19. Everzol BR Blue R S/p
20. Everzol Black CB
Chemicals & Auxiliaries used in BEXIMCO Textile Ltd.:
1. Sodium Hydrosulphite (Reducing Agent)
2. Sirrix AK (Sequestering Agent)
3. Hostapol (Detergent)
4. Stabilizer SIFA (Stabilizer)
5. Cibaflow pad (Multi-purpose)
6. Soda ash (Medium alkali)
7. Wellin (Wetting agent)
8. Lyoprint RG (Sequestering Agent)
9. Common salt (Fixing Agent)
10. Sodium silicate (Dye fixation)
11. Caustic (To maintain pH)
12. Peraprit (Stiffening agent)
13. Alfalina (Softener)
14. Acetic acid (To maintain pH)
15. Polyflex (Softener)
16. Avivan (Softener)
17. Raomina (Foam Producer)
18. Enzyme (Desizing Agent)
Chemical Source:
1. Huntsmen
2. Clarient
3. Shasha
4. China
5. BASF
6. Italy
7. India
8. Lamberti
4.3 Section 3: BEXIMCO Denim Ltd.

Raw materials used in BEXIMCO Denim Ltd.
1. Fabric
2. Dyestuffs
3. Chemicals & Auxiliaries
Fabric: Fabric is collected from weaving section of BEXIMCO Denim Ltd (26-27k meter) &
purchased from outside (33k meter). & Yarn is collected mainly from Padma Textiles Ltd (1 &
2).
Types of fabric:
1. Raw Denim
2. Vintage Denim
3. Selvage Denim
4. Poly Denim
Dyestuffs: There used Vat dye in BEXIMCO Denim Ltd. The name of the vat dye used in
BEXIMCO Denim Ltd. are as below:
Chemicals & Auxiliaries:

1. Synthetic Indigo Dye (C16H10N2O2)
2. dark blue crystalline powder
3. chloroform
4. nitrobenzene
5. concentrated sulfuric acid
6. sodium phenylglycinate
7. sodium hydroxide
8. sodamide.
9. aniline
10. picric acid
11. sulfuric acid

4.4.1 Printing: (Flatbed screen printing)
The basic raw materials are:
1. Fabric
2. Dyestuffs
Dyestuffs:
1. Pigment
4.4.2 Embroidery:
1. Fabric
2. Dyed yarn

1. Fabric roll
2. Trims
3. Accessories
Trims: Item that enhances appeal or function of a garment.
List of trims:
1. Sewing thread
2. Zipper
3. Interlining
4. Button
5. Label
6. Motif
7. Pocketing fabric
8. Elastic
9. Rivet
10. Hook and Loop
11. Collar bone etc.
Accessories: Accessories are not directly attached with garment by sewing. These are used
to make a garment attractive for sale and packing. In a word, accessories are used for
decorative purposes.
List of accessories:
1. Plastic collar insert
2. Hang tag
3. Ball head pin
4. Tissue paper
5. Poly bag
6. Carton
7. Carton sticker
8. Safety sticker
9. Hanger
Raw materials used in RR Washing Limited
1. Basic Chemical
2. Detergent / Pretreatment
3. Enzyme
4. Dyeing auxiliaries
5. Finishing
6. Special chemical
Basic Chemicals:
Table:4.1:Basic Chemical Used IN RR Wash

SL No Description Function
1 Acetic acid (GLACIAL) Acid
2 Sodium sulphate (Glauber salt) Salt
3 Sodium carbonate (Soda ash) Alkali
4 Sodium Hydroxide (Caustic soda) Alkali
5 Caustic Soda (Liquid 45%) Alkali
6 Sodium sulphide (Flakes) Alkali
7 Sodium meta bi-sulphate Neutralizer
8 Lava cone mex-02 Neutralizer
9 Hydroxyl ammonium sulphate Neutralizer
13 Bleach K.C.I Bleach chlorine
14 Hydrogen peroxide-50% Oxidizer
15 Pumic stone Stone
16 Potassium permanganate (potash) Oxidizing agent
Enzyme:
Table :4.2: Enzyme Used In RR Wash:

1 Ecozyme 15L Bio polishing agent
2 Hidros ted Bio polishing agent
3 Ecozyme ultra Neutral enzyme
4 Lerzyme 330 Neutral enzyme
5 Lava cell NHC cold Neutral enzyme
6 Denilite 11S Laccas enzyme
7 GZyme ultra Amylase
Dyeing Auxiliaries:
Table:4.3: Some Dyeing Auxiliaries

1 Acramin prefix K Cationizer
2 Asufix EP-F Nuevo Fixing agent
3 Albafix ECO Fixing agent
4 Jinfix ECO RFC-536 Fixing agent
5 Linex HW Cationizer
6 Mordiente Mac Cationizer
7 Mordiente M new Cationizer
8 Rucowet VL Wetting agent
9 Jintexalate SQ-114FE Sequester
10 Jintexalate SQ-117CA Sequester
11 Rewash RNP Stabilizer
12 Geltab RS Stabilizer
13 Helizerin binder ET ECO Binder
14 Faip TIU Levelling agent
15 Solopol LDE Levelling agent
16 Pretreatment zip Anti-creasing
17 Imacol C2G Anti-creasing
18 Asugal TDB new Levelling agent
chemical:
Table:4.4: Some Chemical

1 ASU salt Oxidizer
2 GT chlor plus Bleach activator
3 GT-crockichi T-K9N Fixing agent
8 Sodium hexameta phosphate Chilleting agent
9 Lava con PAP PP activator
CHAPTER FIVE
PRODUCTION PLANNING SEQUENCE & OPERATION
Production planning means planning of production. Planning demands a careful and

exhaustive study which of co-ordinate and related activities which are necessarily performed
by a host of different departmental Groups.
5.1.1 Production parameters:
1. Yarn count
2. Spindle speed
3. Drafting
4. Twist etc.
5.1.2 Production flow chart of carded yarn:
Table:5.1:Flow Chart of Carded Yarn

Stage Machine Input material Output material Package
form
Opening & Blow Room Raw cotton Lap or chute -
cleaning machines feed
Carding Card Lap or chute Card sliver Slivers
feed
1st drawing Breaker Draw Card sliver Drawn sliver Sliver can
frame
2nd Finisher Draw Drawn sliver Drawn sliver Sliver in
drawing frame can.
Roving Speed Frame Drawn sliver Roving Roving
Spinning Ring frame Roving Ring-spun yarn Cops
Post- Winding & Yarn in spinning Yarn Cone,
Spinning Reeling cops Cheese &
processes Hank
5.1.2 Production flow chart of combed yarn:
Table:5.2: Flow Chart of Combed Yarn

Stage Machine Input Output Package
material material form
Opening & Blow Room Raw cotton Lap or chute -
cleaning machines feed
Carding Carding machine Lap or chute Card sliver Carded
feed Slivers in
Cans
Pre Breaker Draw Carded Sliver Drawn Sliver Drawn
comber Frame slivers in
Drawing cans
Lap Super Lap or Lap Drawn Lap Laps in
Formation Former Slivers spools
Combing Comber Lap Combed Sliver Combed
sliver in Cans
Post Finisher Draw Combed Drawn sliver Post comber
comber Frame sliver Draw frame
Drawing slivers
Roving Speed Frame Post comber Roving Roving
Draw frame bobbin
sliver
Spinning Ring spinning Roving Ring-spun yarn Spinning
frame Cops
Post- Winding&Reeling Yarn in Yarn Cone,
Spinning spinning Cheese &
processes cops Hank
5.2 Section 2: BEXIMCO Textile Ltd.

5.2.1 Weaving:
5.2.1.1 Production parameters:
1. EPI
2. PPI
3. GSM
4. Fabric width
5. Reed count
5.2.1.2 Winding flow chart:
Cone tray
↓
Ceramic guide
↓
Weight disc
↓
Stop wire
↓
Connecting rod
↓
Drum
↓
Adapter
5.2.1.3 Flow chart of warping process:Creel

↓
Guide
↓
Disc tensioned
↓
Ceramic guide
↓
Sensor
↓
Lease rod
↓
Second lease rod
↓
Reed
↓
Tapered drum
↓
Warp beam
Sizing Process flow chart:
Warp beam
↓
Sizing
↓
Drying
↓
Leasing
↓
Weavers beam
5.2.1.4Flow chart of weaving (warp yarn):

Yarn from Spinning Section
↓
Warp Preparation
↓
Winding (Cone, Cheese, Spool, Flange, Bobbin)
↓
Creeling
↓
Warping
↓
Drafting/ Drawing
↓
Denting
↓
Weaving
↓
Inspection
↓
Measuring
↓
Packing
↓
Delivery
5.2.1.5 Flow chart of weaving (weft yarn):

↓
Yarn Preparation
↓
Weft Preparation
↓
Winding (Pirn, Cop, Cone, Cheese)
↓
Weaving
5.2.2 Wet processing:

Production planning for dyeing is called 'Batch Plan'. According to the batch no. And color,
width, style and construction the batch plan is made. For easy understand this section gives
some 'T.' cards. 'T' cards are serialized according to the priority of delivery. The batches and
'T' cards also serialized as to dye light shade at first and lastly the dark shades, since faulty
shades can be converted to dark color later.

1. Shade matching
2. Shrinkage
3. Dimensional stability
4. Bleaching
5.2.2.2 Production process of wet processing:

Gray fabric inspection
↓
Dyeing
↓
Finishing
↓
Inspection
↓
Delivery
5.2.2.3 Flow chart of pretreatment:
Gray inspection
↓
Laying
↓
Sewing
↓
Scouring & Bleaching
↓
Mercerizing
5.2.2.4 Flow chart of dyeing:
Receiving fabric from Pretreatment
↓
Chemical preparation
↓
Dyeing with reactive dye
↓
Washing (5 chamber,100 degree)
↓
Neutralization (acetic acid)
↓
Dryer (17 rollers, 100 degree)
↓
Quality checking (pH., absorbency)
5.2.2.5 Finishing:
Finishing schedule is same us the dyeing. After dyeing the material goes to the finishing
section with the batch plan. Finished data is written to the batch card and is informed to the
planning section.
5.2.2.6 Flow chart of finishing:

Receive Fabric from Dyeing
↓
Chemical Preparation
↓
Finishing according to buyer requirement
↓
Quality check
5.3 Section 3: BEXIMCO Demin Ltd.
Figure:5.1: Front view Of BDL

1. EPI
2. PPI
3. GSM
4. Fabric width
5. Reed count
5.3.2 Winding
5.3.2.1 Winding flow chart:

Cone tray
↓
Weight disc
↓
Stop wire
↓
Connecting rod
↓
Adapter
5.3.2.2 Flow chart of warping process:
Creel
↓
Guide
↓
Disc tensioned
↓
Ceramic guide
↓
Sensor
↓
Lease rod
↓
Second lease rod
↓
Reed
↓
Pressing roller
↓
Tapered drum
↓
Warp beam
5.3.3 Yarn dyeing:

5.3.3.1 Process flow chart:
Beam Come from warp section
↓
14 Beam yarn wind in one beam
↓
Scouring, Bleaching, Mercerizing
↓
Wash (Normal cold Wash+ Hot wash)
↓
Drying (Steam Dryer)
↓
Sizing
5.3.3.2 Recipe:
Sizing
Water-600 liter
starch- 50kg
pva-10kg
wax-3 kg
Winding (average 3000 meter; RPM: 20)
5.3.4 Weaving
5.3.4.1 Flow chart of weaving (warp yarn):
Yarn from Sizing Section
↓
Yarn Preparation
↓
Warp Preparation
↓
Winding (Cone, Cheese, Spool, Flange, Bobbin)
↓
Creeling
↓
Warping
↓
Sizing/ Dressing (Jute)
↓
Looming
↓
Weaving
↓
Inspection
↓
Measuring
↓
Folding
↓
Packing
↓
Delivery
5.3.4.2 Flow chart of weaving (weft yarn):
↓
Yarn Preparation
↓
Weft Preparation
↓
Winding (Pirn, Cop, Cone, Cheese)
↓
Weaving
5.3.4.3 Process flow chart of finishing:

SperottoRimermachine(Italy)
↓
Winding
↓
Brushing-Dust removal
↓
Sinzing by gas
↓
Mercerizing (NaOH Box)
↓
DE sizing
↓
Washing (Normal+ Steam at 70c)
↓
Softening (Acetic Acid+ Wetting agent+ silicon)
↓
Skewing
↓
Steam drying
↓
Moisture controlling by Mahalu Machine
↓
Fixed width by stenter Machine
↓
J-Box (fabric Reserve for check)
↓
Batching
↓
Inspection

5.4.1 Printing:
1. Size of screen
2. Required design
3. Dryer temperature & speed etc.
5.4.1.2 Flow chat of printing process:

Mesh fabric tight with frame
↓
Applied chemical autosol and potassium dichromate on the mesh & dried 8 min in air.
↓
Placed design paper under the mesh.
↓
Light passes through the design paper & mesh fabric for 3-4 min.
↓
Remove the colored TXR from the design area by water spraying.
↓
Cleaning
↓
Drying
↓
Curing to fix the dye
↓
wash
↓
Dry
↓
Inspection
↓
Ready to stitching
5.4.2 Embroidery:
1. Sketch of design
2. Needle selection
3. Stitch width
4. Setting of the tension
5.4.2.2 Flow chat of embroidery process:

Art work from buyer
↓
Input to ES-65(Software)
↓
Design analysis
↓
Send to buyer
↓
Send to buyer
↓
If approved, then for bulk production
↓
Designed the buyer design by CAD software (WilcomeTrueSizer)
↓
Design installed into the machine
↓
Fabric clamped by the clamp board
↓
Machine run until finished the design
↓
Fabric collected for delivery

5.5.1 Cutting:

1. Sketch
2. Pattern design
3. Sample making
4. Fabric relaxation
5. Shrinkage (after wash)
6. Production pattern
5.5.1.2 Production flow chart of cutting:
Received the fabric from dyeing finishing
↓
Shrinkage test (after wash)
↓
Grading pattern pieces & adding shrinkage
↓
Received the cutting ratio from apparel merchandiser
↓
Make the cutting quantity plan
↓
Decide the quantity of fabric spreading
↓
Fix the number of lay per cutting
↓
Take the fabric roll from store
↓
Unwind the roll for fabric relaxation
↓
Fabric spreading
↓
Marker setting on lay
↓
Every pattern piece of marker is added to fabric lay by gum tape
↓
Fabric cutting
↓
Sorting & Bundling
↓
Bundles are sending to sewing section for bulk production
3.5.1.3 Description of the production process:
Received the fabric from dyeing finishing:

When merchandiser confirm about the work order sheet, then cutting section received the
required fabric from the dyeing section.
Fabric relaxation:
Fabric relaxation is performed for a certain period. But the minimum time of relaxation is
twelve (12) hours. This time also may vary on buyer’s recommendation.
Shrinkage test:
Before wash: For the single style, from every fabric roll a sample in square length wise 35cm
& 35cm in the square width wise (at least 2" away from salvage) is cut. We take the
measurement with the help of Marks & Spencer scale. Marks in the fabric salvage shows the
direction of length & width. Over lock is done in the cutting edge. Then it sent for the
washing
After wash: Fabric sample is washed with the help of standard washing method which will
be done after sewing to find the shrinkage percentage to washing. Then we measure the
sample after wash with Marks & Spencer scale again.
35cm x 35cm square sample, after shrinking results was

Length wise measurement =34.5cm
Width wise measurement = 28cm
[Width of square block before shrinking] - [width of square block after shrinking] / width of
square block before shrinking x 100
Length wise total shrinkage percent Formula: [(35- 34.5) / 35] x 100 = 1.429%
Width wise total shrinkage percent Formula: [(35 - 28) / 35] x 100 = 20%
Received the cutting ratio from merchandiser:
Merchandiser sends a cutting ratio for every style of garment to do this job smoothly.
Make the cutting quantity plan:
Cutting manager should make the perfect cutting quantity plan.
Lay planning:
Before fabric spreading, cutting manager and in-charge make a plan about fabric lay.
Make marker ratio:
In this stage marker maker prepare a marker ratio to complete this cutting process.
Marker making:
To finish the accurate cutting process, marker making must be needed for each style of
garment.
Decide the quantity of fabric spreading:
Before spreading, cutting in charge take the decision, how many fabrics spreading are
required
Fix the number of lay per cutting:
They also fixed the number of lies which are appropriate for each cutting.
Take the fabric from store:
For cut every style of garment, cutting in charge receive the fabric from store.
fabric spreading:
In this stage, fabrics are spread on cutting table according to correct lay height and ply
tension.
Figure:5.2: Sorting & Bundling
Marker setting on lay:

When fabric spreading completely done, then the different size and styles of marker set on
the top layer of the fabric lay
Numbering:
When the cutting process is finish then numbered every style of fabric parts to avoid the mix
Cutting quality check:

In this stage check the all cutting fabrics quality.
Figure:5.2: Sorting & Bundling
Storing & Bundling:

Fabric cutting parts are sorting and bundling here according to color, size and style.
Bundles are sending to sewing section for bulk production:
Finally, all bundles are sending to the sewing section for completing bulk production.
5.5.2 Sewing:
1. S.P.I
2. Stitch class
3. Stitch type
5.5.2.2 Production flow chart of sewing:

Product analysis
↓
Set up target for production
↓
Set up machine layout on the basis of target
↓
Set up operator layout on the basis of target
↓
QC check of product
↓
Distribution all the processes
↓
Cutting parts received section
↓
Cutting parts distribution to the operator and helper
↓
Complete parts making individually
↓
Online QC check
↓
Counting output and checking with the target
↓
Final quality check (for each Garment)
5.5.2.3 Description of the production process:
Table :5.3: Description Of Product Process:

S/L Process Job
In which way, a product have to sew, it’s
01 Product analysis decided here.
Set up target for Have to set a target for production on the basis
02 production of shipping schedule.
Set up machine layout Have to prepare machine setup layout on the
03 on the basis of target basis of daily target quantity.
Set up operator layout Prepare operator layout setup on the basis of
04 on the basis of target machine quantity.
Each garment must have to fulfill its right
quality. So, product checking must be needed by
05 QC check of product QC.
All the processes of sewing must be distributed
Distribution all the to the right person to avoid the damage of
08 processes garments.
Cutting parts received A section, which received the cutting parts from
09 section the cutting department.
All the cutting parts should be distributed to the
Cutting parts operator and helper after receiving those from
10 distribution cutting department.
Complete parts making By joining all the parts, a complete garment has
11 individually to make here individually.
During running of garments sewing, online QC
check must be needed to make fault free
12 Online QC check garments.
An online quality audit must be needed here to
show the buyer actual fault free product making
13 Online quality audit process.
14 Counting output and Comparing with target quantity, all the output
checking with the garments should be counted here to make sure
target achieving the target quantity.
In this section, all the output garments are
checked finally by maintaining one by one
Final quality check method to provide fault free garments into the
15 (for each Garment) finishing department.
5.5.3 Finishing:
1. Garments length measurement
2. Shade matching
5.5.3.2 Production flow chart of finishing:

Receive garment from wash
↓
Thread Sucking by Machine
↓
Barcode label put in garments
↓
Barcode label attach
↓
Loop rows cut
↓
Top side trimming and turning
↓
Primary inside check
↓
Turning/top side check/ button marking
↓
Button attach
↓
Top side ironing
↓
Button/ rivet
↓
Cut measurement check
↓
Lot pass
↓
Size/color sorting/ ratio/ solid/ multipack
↓
Waist tag attach
↓
Hang tag attach
↓
Alarm device attach
↓
Folding
↓
Poly
Garments put in cartoon

↓
Cartoon make
↓
Cartoon close
↓
Cartoon sticker attach
↓
Cartoon carrying for lot to warehouse inspection
5.5.3.3 Description of the production process of finishing:

Receive garment from wash:
At first, finished garments are received from sewing section as per order quantity. Good
received from sewing section is the first step to finishing section.
Thread Sucking by Machine:

In this step extra lose sewing thread are sucking by Figure:5.3 sucking
machine in garments. Threads are suckered by two cartooning
systems. One by done by hand which is manual system
and the other is done by sucking machine.
Ironing:
Figure:5.5: Fabric Finising process
Measurement Check by QC:

When ironing process running that time also
check measurement of garments. During the
ironing process measurement is also
check out by the QC.
Attach Price Tags and Accessories:
After above process, different types of tags and accessories are attached with the garments
as per buyer comment. For an export order, must attach price tags with the garments.
Metal Detection: (rarely used)
Garments are passed through into the metal detectio m/c for metal check. Now most of the
buyer recommended to use metal detector for garments more safety. To use mdetector for
kid’s item is must.
Folding:
Garments are folded according to buyer directions in a standard area. There are fore types
of folding in garments. They are as follows-
1. Stand up
2. Semi stand up
3. Flat back
4. Hanger pack.
Packing:
After folding garments are ready for packing. The size of polythene is varying according to
the size, garments ratio. Before packing it is needed to ensure the placement of sticker in
proper place.
Assortment:
After completing the packing, it must be placed the garments in a predetermined packed by
sorting according to the size and color is called assortment.
Cartooning:
At last cartooning is done according to buyer comment into the inner boxes and is properly
warped by the scotch tape. Some information like carton box no, size, shipping mark,
destination is printed on the cartoon.
Final Inspection:
Final inspection is an important part and last step of garments finishing. Normally final
inspection is made by buyer. Buyer checks the garments according some rules like Accepted
Quality Level (AQL).

The technology is used to modify the outlook, appearance, fashion and comfort ability of
garments is calling garments washing.

1. Shade matching
2. Required effect
5.6.2 Process flow chart of garments washing:
Garments receive from the sewing department
↓
Garments send to dry process (if needed)
↓
Hand scraping
↓
Whiskering
↓
Tacking
↓
Garments send to the wet process
↓
Washing
↓
Drying
↓
Garments send to the dry process (if more needed))
↓
pp. sprayed garments send to the wet process
↓
Loading into washing m/c
↓
Washing
↓
Extracting
↓
Drying
↓
3D (if needed)
↓
Quality check
↓
Send to the finishing department
5.6.3 Description of the production process of garments washing:
Table:5.4:Garments Washing Process:

SL no. Process Procedure
Garments receive
from sewing At first, garments should be received from the
01 department sewing department.
All the garments are sent to the dry process
Garments sent to the department if the buyer approved wash
02 dry process reference garment containing dry process.
Here hand scrapping is done by following buyer
03 Hand scrapping approved wash reference garment.
Whisker process is completed here by following
04 Whiskering buyer approved wash reference garment.
After completing all the required dry processes,
Garments sent to the garments are sent to the wet process
06 wet process department.
Garments loading
into the washing Here the garments are loaded into washing
07 machine machine for required wash.
08 Washing By following buyer approved wash reference,
garments are washed here using required
chemicals.
When the garments wash will complete, then
these are unloaded from the washing machine
09 Extracting and extracted by using hydro extractor.
All the garments are dried here by using gas or
10 Drying steam dryer which is depended on the shade.
After drying, all the garments are sent to the dry
process for completing p.p process if the buyer
Garments sent approved wash reference garment contains this
11 to the dry process process.
Here p.p spray should be done using required
chemical by following buyer approved wash
12 PP spray reference.
After completing p.p spray, garments are sent to
PP sprayed garments the wet process for completing rest of the wet
sent to the wet processes such as p.p neutral, tinting and
13 process softening.
PP sprayed garments
loading into the Here p.p sprayed garments are loaded into the
14 washing machine washing machine.
P.p neutral, tinting and softening is done here
by following buyer approved wash reference
15 Washing garment.
When all the machine wash is completed then
garments are unloaded from the machine and
16 Extracting extracted by using hydro extractor.
Here, the garments are dried by using gas or
steam dryer which is totally depends on the
17 Drying required shade.
18 Garments sent to the If the buyer approved wash reference garment
dry process contains 3d process then these garments should
be sent again to the dry process for completing
3d.
Here 3d process is completed by following
19 3D buyer approved wash reference garment.
After completing all above the processes,
washed garments are checked here by following
21 Quality check (QC) buyer approved wash reference garment.
Send to the finishing Finally all the garments are sent to the finishing
22 department department for the next required processes.
5.6.4 Recipe:
Basic Chemicals:
Table:5.5: Basic Chemical For Garments Wash

1 Acetic acid (GLACIAL) Acid
2 Sodium sulphate (Glauber salt) Salt
3 Sodium carbonate (Soda ash) Alkali
4 Sodium Hydroxide (Caustic soda) Alkali
12 Bleach singclone-65% Bleach chlorine
13 Bleach K.C.I Bleach chlorine
14 Hydrogen peroxide-50% Oxidizer
15 Pumic stone Stone
16 Potassium permanganate (potash) Oxidizing agent
Detergent / Pretreatment:
Table:5.6: Detergents For Garments Wash

1 Sultafon-D1 Detergent
2 Rewash APT Detergent
3 SeykoSperse SPW 801 CONC Anti backstain
Dyeing Auxiliaries:
Table:5.7: Dyeing Auxiliaries

1 Acramin prefix K Cationizer
2 Asufix EP-F Nuevo Fixing agent
3 Albafix ECO Fixing agent
4 Jinfix ECO RFC-536 Fixing agent
5 Linex HW Cationizer
6 Mordiente Mac Cationizer
7 Mordiente M new Cationizer
8 Rucowet VL Wetting agent
9 Jintexalate SQ-114FE Sequester
10 Jintexalate SQ-117CA Sequester
11 Rewash RNP Stabilizer
12 Geltab RS Stabilizer
13 Helizerin binder ET ECO Binder
14 Faip TIU Levelling agent
15 Solopol LDE Levelling agent
16 Pretreatment zip Anti-creasing
17 Imacol C2G Anti-creasing
18 Asugal TDB new Levelling agent
Finishing:
Table:5.8: Finishing Of Garments Wash

1 Ressoft A090 Antiozon softener
2 Elam 109 Antiozon softener
3 Geisoft WCS Nonionic softener
4 Elam GRM CONC Cationic softener
5 Elam RP-CONC Silicon softener
6 Ressilk MES Silicon softener
7 Jingen sis 60 (IT0003) Silicon softener
8 Rucofin GWE Silicon softener
9 Feran-ice Silicon softener
10 Skay white 2B Optical
brightening agent
11 Skay white BBU Optical
brightening agent
12 Skay white 4BK OBA
13 Legaflex zero Resin
14 Product PPUB new Finishing agent
Special chemical:
1 ASU salt Oxidizer
2 GT chlor plus Bleach activator
3 GT-crockichi T-K9N Fixing agent
4 Jinsofter PRH Polyethilene
5 Denim Col spec EPD Polyethilene
6 Sodium hydrosulfide CON (hydros) Solubility
7 Oxalic acid Acid
8 Sodium hexameta phosphate Chilleting agent
9 Lava con PAP PP activator
CHAPTER SIX
QUALITY ASSURANCE
Quality assurance means with need of customer demand, that means a sample or substance
will be bulk products as like a sample or equivalent of the sample. A quality assurance
system is said to increase customer confidence and a company’s credibility, to improve work
processes and efficiency, and to enable a company to better compete with others. In
developing products and services, quality assurance is any systematic process of checking to
see whether a product or service being developed is meeting specified requirements.
6.1 Quality assurance procedure:

In Beximco Apparel Ltd. assures the quality of their products in the following steps:
1. Online inspection
2. Offline inspection
6.2 Cutting:
After cutting every pattern pieces are inspected and fault piece is replaced by a new one.
Types of fault: (cutting)

Dirty mark
Foreign fiber
Knot
Line mark / Loom stop mark
Missing yarn
Slub
Spot
Thin yarn
Weaving
6.3 Sewing & finishing:
In sewing 2 or 3 or more QC table is placed for inspection. It varied according to buyer
requirement.
Types of fault:
1. Measurement 19. Part of GMT caught in 37. Missing
defect seam
2. Material flow 20. Unmatched stripe

3. Open seam 21. Poor shape
4. Broken stitch 22. Uneven
5. Skip stitch 23. Left and right uneven
6. Raw edge 24. High & Low
7. Irregular/uneven 25. Twisted
stitch
8. Misaligned 26. Improper stitch
9. Run off stitch 27. Poor join stitch
10. Seam puckering 28. Shading
11. Excessive tight 29. Misplaced
12. Wrong position 30. Dirt/oil spot
13. Wrong color of 31. Hole
thread
14. Crooked
15. Gathers inequality
16. Damage
17. Needle cut
18. Seams breaking
For sewing fault defected garments is sent for alter and non-alterable garments is rejected.
Offline inspection:
Offline inspected is done in finished garments. In BEXIMCO offline inspection is done by 1.5
system where buyer done it by 2.5 system. (AQL)
Lot which passed AQL is prepared for shipment.
6.4 Remarks:
Figure:6.1: CFDL Sample
CFDL is always aware about the quality of the product. The quality of the product is always
approved by the buyer. They follow the quality standard: ISO 9001: 2000, this mill is well
equipped for checking the quality of the product. They sent the quality report to the buyer
time to time/ batch to batch.
CHAPTER SEVEN
MAINTENANCE
7.1 Maintenance of machinery:

Every machine is thoroughly tested & inspected by manufacturers before selling it & the
purchaser before it is put to use. When it is used, it will be subjected to wear & tear, hence
proper attention should be given to protect the machine & its components from undue wear
& thus protect them from failures. A proper attention means lubrication, cleaning, timely
inspection & systematic maintenance. Maintenance of a machine means efforts directed
towards the up-keep & repair of that machine.
There are two types of maintenance:

1. Breakdown Maintenance
2. Preventive Maintenance
Breakdown Maintenance:
Breakdown of a machine occurs due to the followings two reasons:
1. Due to unpredictable failure of components
2. due to gradual wear & tear of the parts
In breakdown maintenance, defects are rectified only when the machine cannot perform its
function any longer and the production department is compiled to call or maintenance
engineers for repair. After repairing the defect, the maintenance engineer does not attend
the machine any longer until another failure occurs.
Preventive Maintenance:
Preventive maintenance is sometimes termed as “Planned maintenance” or “Scheduled
maintenance” or “Systematic maintenance” etc. It is an extremely important function for the
reduction of maintenance cost and to keep the good operational condition of equipment
and hence increase the reliability. Preventive maintenance aims to locate the sources of
trouble and to remove them before breakdown occurs.
Routine maintenance:
1.Daily Maintenance:
Every machine is taken maintenance daily by the operators during production. When a
production is started by the operator after handing over from previous shift operator, he
takes a routine maintenance on the machine. He cleans the machine, assures fabric is fed to
the machine properly, cleans the roller & motor etc. All around of the machine are kept neat
and clean as if there is no dirt/spot in the fabric.
2.Schedule/Routine Maintenance:
Every machine has a schedule of maintenance of 10 or 15 days. According to date, schedule
maintenance is taken on the machines. Operators are informed about the time of
maintenance. After pre-estimated production, they hand over the machine to the fitters.
Thus, fitters assure all machines are ok for any time. For an even flow of production Routine
Maintenance is done once in 6 months in CFDL.
3.Break down maintenance:

When product quality hampered and to complete production in due time break down
maintenance is taken. There are many faults seen in the garments during production. Then
operators inform the mechanical fitters and they fix it.
7.2 Maintenance in utility department

Utility department contains the following machines:
1. Fire tube Boiler
2. Generator
3. Compressor
4. Air Conditioner
Following maintenance check should be done in these machines:
1. Boiler gas burner
2. Boiler filter
3. Water filter
4. Boiler blow down
5. Heating arrangement
6. Compressor moisture management system
7. Air duct & conditioning of air
7.3 Remarks:
Maintenance department of BEXIMCO is very skilled. But the scheduled maintenance is done
once in 6month for not disturbing the production process thus their breakdown
maintenance is more.
CHAPTER EIGHT
UTILITY SERVICES
8.1 Utility facility available:

1. Electricity
2. Gas
3. Steam
8.2 Capacity & other technical details:

Electricity:
The main utility electricity is supplied from REB and also by Generator.
General Parameter of Generator:
1. Oil System : 1500rpm
2. Ignition : Time setting for each cylinder
3. Gas system : Amount of gas per cylinder
4. Exhaust system : 7000 Cubic meter/min
5. Water Temperature : 93-95c
6. Load : 700 KW
7. Voltage (max & min) : 400V-380V
8. Frequency : 50Hz
9. Power Factor : -0.98
10. Battery Voltage : 26V
Gas:
Gas is mainly used for steam production in Boiler. The gas is used from DESCO. Generally,
36m3 gases are required to produce 1-ton steam.
Water:
Continuous supply of water for BEXIMCO is ensured by a 4-inch diameter from BEXIMCO
own supply line &Water storage tank.
Steam:
Pure steam with required temperature must be produced to meet the continuous demand
of steam in different sections.
Steam Boilers are used in EOS Textile Mills Ltd.
Steam Boiler:
Brand Name : CLEAVER BROOKS
Origin : Made in USA
No. of Boiler : 4
Capacity : 5, 10, 12.5, 15 Ton
Power : 350-600 HP
Brand Name : TIZAN
General Parameter:
Boiler Water PH : 9-11
TDS : 2500 (maximum)
Steam Pressure : 70-80 PSI
Maximum Steam Pressure : 150PSI
No. of Input Water Motor : 2
Temperature : 300F
Power Management:
1. 5 Ton Boiler used in Bleaching Department for Desizing& Scouring
2. 10 Ton Boiler is used for Bleaching Department
3. 12.5 Ton Boiler is used in Sizing & Dyeing Department
Compressor:
Natural gas is drawn by pipe through the filters above the compressor & the air is
compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to
reduce the temperature of compressed air. Thus the cold water becomes slightly hot & goes
through outlet pipe to the overhead reservoir. At the other hand the cooled compressed air
along with some vapors are transferred to the reservoir where the vapors are condensed
and outlets drop by drop.
The moist compressed air is transferred to the dryer & a slight warm compressed air is
delivered to required sections of EOS.
Machine No.-1
Name : Ingersoll Rand Air Compressor Centac
Model : 20V35M*3
Serial No : C12093
Year : 2005
Country : Brazil
Capacity : 90 Nm3/m
Machine No.-2
Name : Ingersoll Rand Air Compressor Cen.
Model : 20V33M3
Serial No : M92-6612
Year : 1992
Country : USA
Intake temperature : 35 deg.C
8.3 Source of utility:

Electrically : REB & Generator.
Steam : Boiler.
Water : DEPZ Authority.
Compressed air : Compressor.
Temperature control : Chiller.
Gas : DESCO.
8.4 Cost of different utilities:

1. Electricity : 2laks BDT(appr.)
2. Gas : 2laks BDT(appr.)
3. Water : Not found
8.5 Remarks:
Utility services are the heart of a textile processing mill. It should need proper maintenance
to run the mill efficiently
CHAPTER NINE
STORE & INVENTORY CONTROL
In BEXIMCO Textile Mills Ltd. there are different inventory systems for different raw
materials.
Inventory system of raw material:
9.1 Fabrics Store:

All the grey fabrics are stored in the fabric store, near CFDL. Different types of fabrics arc
listed in the sheet according to the fabric types, quantity & consumer’s requirements.
Fabrics GSM, shrinkage, diameter & other properties are also taken into consideration. The
Figure: 9.1: Fabric Store
Figure: 9.2: Fabric Wearehouse
9.2 Dyes & chemicals store:

Various types of dyes & chemicals are stored here according to the dyes & chemical
company. Different types of dyes & chemicals are listed in a sheet. In the sheet the stored
quantity of dyes & chemicals is also included. Every day the sheet is updated & a copy of this
sheet is supplied to the Manager (production), Dye house & lab section.
9.4 Spares:
The required amounts of spares of different machines are stored in the mechanical store
room. All spares are listed in a sheet which is controlled by the mechanical & maintenance
personnel. Spares are arranged in the store room according to their size, quantity &
requirements. There are shelves in the store room to keep the small spare parts.
9.5 Finished goods:
The Crescent Fashion & Design Ltd. supplies its finished garments to different buyers. So,
finished garments are stored for short time/long time in the ware house. All the delivered
finished garments are noted on the tally paper according to the buyer name, color, style, DPI
& considering other technical parameters.
Frequency of inventory control:
1.Monthly inventory control
2.Annual inventory control
Scope of inventory control:

1. Raw materials
a) Fabric store
b) Others chemicals store
c) Grey fabrics
2. Finished fabric
3. Spare parts
4. General store
a) Capital equipment
b) Accessories
9.6 Inventory system for raw materials:
a) Raw materials partially received from production planning & directly from head
office.
b) Material Receiving & Inspection Report (MRIR) is prepared. Received quantity is
mentioned.
c) Submitted to QC department. Some are OK & few rejected.
d) Entry of data of goods in DATATEX.
e) Goods are arranged according to OK or rejected Groups.
f) Department gives store requisition to warehouse.
g) As per requisition materials supplied & this record is noted down.
Stages of grey fabric inventory control
a) After weaving production
b) Grey inspection
c) Warehouse
d) Batch preparation
e) Dye house.
Stages of finished fabric inventory control

a) Finishing section
b) After final inspection
c) Warehouse
9.7 Remarks:
The inventory system of Crescent Fashion & Design Ltd. covers the demand. The space is
noticed sufficient considerably. The department is computer oriented & connected by ERP.
CHAPTER TEN
COST ANALYSIS
Costing system mainly describes how the cost of the final product is fixed by the company.
According to buyer/customer requirement at first the fabric is collected from local and
foreign suppliers. Then it is calculated how much dyestuff and chemical is required till the
end of the processing of that specific fabric. After that, the final cost is fixed including some
profit. Then the unit price is offered to the buyer for approval. If the buyer approves it, all
the transaction of money is carried out by bank.
10.1 Cost of the product:

Costing of the product is done by the consideration of the following factors:
1. Fabric consumption
2. Sewing thread consumption
3. Cost of Making (CM)
4. Cost of Making with Trims (CMT)
5. Office and administrative cost
6. Company profit
10.2 Remarks
The costing of product is a secret matter of the industry. They are not interested to flash up
the cost related data. So, we could not collect the price of the product and costing of the
product.
CHAPTER ELEVEN
MARKETING ACTIVITIES
The Crescent Fashion& Design Ltd. is a 100% export oriented industry. All the goods
produced in this industry are exported into various foreign countries.
11.1 Consumer of the product:

1. Calvin Klein
2. C & A
3. Inditex (Zara, Bershka, P&B)
4. American Eagle
5. Phillips Van Heusen
6. NEXT
7. Marks & Spencer
8. Michael Kors
9. Pull & Bear
10. US Polo
11.2 Duties & responsibilities of marketing officer:

Dealing with the buyer & convince the buyer is the main duty of marketing officer. A
marketing officer also has some other duties.
The main duties & responsibilities of a marketing officer are:
1. To prepare cost sheet by dealing with the buyer
2. To take different steps by discussing with the high officials & merchandisers
3. To maintain a regular & good relationship between commercial officer &
merchandisers
Actually the responsibilities & duties of marketing officer begins from getting order of buyer
& ends after receiving foods by the buyer. So, he should be always smart, energetic &
sincere.
11.3 Remarks.
Crescent Fashion & Design Ltd. has a well learned marketing & merchandising team. They
always communicate with the buyers. Crescent Fashion & Design Ltd. has some fixed buyers.
The marketing section also looks the quality & quantity buyers.
CHAPTER TWELVE
EFFLUENT TREATMENT PLANT
The effluent generated from different sections of a textile mill must be treated before they
are discharged to environment.
12.1 Characteristics of raw effluents:

Volume : 3600 cubic meter/day
Peak flow : 225 cub met/hr
PH : 10-12.5
BOD : 500-800 PPM
Requirement of dischargeable effluent as per World Bank:

PH : 6-8
BOD : <50
COD : <250
SS : <100
TDS : Not stated
Color : Clear
12.2 Chemicals used & their colors:
Table:12.1: Chemical used & their color

Chemicals used Appearance
Ferrous sulphate Granular solid, greenish color
Lime White bulk form
Polyacrylate White granular solid
Na-hypochlorite Clear liquid
Hydrochloric acid Clear liquid
12.3 Product quality check:

Following chemical tests are carried out to check the quality:
1. BOD
2. COD
3. Total suspended solids
4. Total dissolved solids
5. Color
6. PH
12.4 Flow chart of effluent treatment:

Raw effluent
↓
Skin chamber
↓
Collection Sump
↓
Pump station
↓
Aeration tank
↓
Setting tank
↓
Clear water, pH check
↓
Sand filter
↓
Carbon filter
↓
Drain
12.5 Sludge separation:
Sludge of DAF
↓
Sludge thickening plant
↓
Sludge drying
12.6 Typical output of the plant:
Raw effluent treated : 15000 LPH

Raw effluent color : Black
Raw effluent pH : 11
Treated effluent color : Light greenish
Treated effluent pH : 8.5
Treated effluent temp. : 38 C
To0tal suspended solids: 35 PPM
IMPACT OF THE INTERNSHIP

1. I have earned some knowledge about the quality management system of
different sections of the industry.
2. I have identified the process sequence of different units and prepare report of
every quality check that gives me the better idea about running of a production.
3. I have learned some knowledge about how to manage production at different
section(cutting,sewing,finishing) as well as I have learned that how to be a
resources utilizes as an IE Executive.
CONCLUSION
I have completed my internship successfully by the grace of Allah. This Internship sendme to
the expected destiny of practical life.The completion of the two months Internship at
Beximco Apparel Ltd. I have got the impression that factory is one of the most modern
export oriented factory in Bangladesh.
Limitations of the Report:
1. Because of secrecy act, the data on costing and marketing activities has not been
supplied hence data is not provided.
2. Ihad a very limited time. In spite of our willing to study more details it was not
possible to do so.
3. Some of the points in different chapter are not described properly for the
restriction & security reason of the industry.
Lastly, what special in this report is that the information, data & process description very
much subjective & practical. So, one can easily have an idea about the Beximco Apparel Ltd.
at a single look on it

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BGMEA University of Fashion and Technology

BEXIMCO INDUSTRIAL PARK

This Internship Report Submitted in Partial Fulfillment of the

Department of Knitwear Manufacturing & Technology

Examiner 1(Supervisor): ZahidHasanSignature:

Examiner 2(External Member): Signature:

Examiner 3(External Member): Signature:

under the supervision Of Mr. YogeshwaranRamanathan, Manager , Mechandisingof

Beximco Textile & Apparel Division From 1April 2021 to 1 jun,2021.

BGMEA University of Fashion and Technology(BUFT).

Special thanks goes to our enthusiasticProf.Dr.Nazamuddin, Vice Chancellor BUFT &

Special thanks to my enthusiastic supervisorZahidHasan, Lecturer, DepartmentKMT ,BUFT

Industrial Summary Report ....................................................................................................... ………...ii

List of Figures ....................................................................................................................................... vi

List of Tables........................................................................................................................................ vii

1.2 History of BEXIMCO Groups.................................................................................................18

1.4 Company Profile.....................................................................................................................19

1.5 Project Description..................................................................................................................20

1.6 BEXIMCO Textile Division...................................................................................................21

1.7 BEXIMCO group contact information..................................................................................23

1.8 Mission & Vision....................................................................................................................24

2.2 Organogram of cutting.............................................................................................................30

2.3 Organogram of production......................................................................................................30

2.4 Total Employees summary ....................................................................................................31

2.5 Commitment to the Environment............................................................................................31

2.6 Others Facilities......................................................................................................................32

2.7 Management Body..................................................................................................................33

2.8 Board of Directors…………………………………………………………………………...34

3.1 Section 1: Padma Textile Mills Ltd. (Plant 2).........................................................................37

3.2 Section 2 : BEXIMCO Textile Ltd.(weaving & Dyeing)…………………………..…………………………………………..39

3.2.5 Wet processing.....................................................................................................................44

3.3 Section 3: BEXIMCO Denim Ltd...........................................................................................56

3.3.2 Dyeing (Yarn dye)................................................................................................................57

3.4 Section 4: Printing & Embroidery...........................................................................................59

3.5 Section 5: Crescent Fashion & Design Ltd. (Apparel Manufacturing)...................................60

3.6 Section 6: RR Washing Limited..............................................................................................61

4.1 Section 1: Padma Textile Mills Ltd. (Plant 2).........................................................................62

4.2 Section 2: BEXIMCO Textile Ltd...........................................................................................63

4.3 Section 3: BEXIMCO Denim Ltd...........................................................................................64

4.4 Section 4: Printing & Embroidery...........................................................................................64

4.5 Section 5: Crescent Fashion & Design Ltd. (Apparel Manufacturing)...................................67

4.6 Section 6: RR Washing Limited..............................................................................................68

PRODUCTION PLANNING SEQUENCE & OPERATION..........................................................71

5.1 Section 1: Padma Textile Mills Ltd. (Plant 2).........................................................................71

5.1.1 Production parameters..........................................................................................................71

5.1.2 Production flow chart of carded yarn...................................................................................71

5.1.2 Production flow chart of combed yarn.................................................................................72

5.2 Section 2: BEXIMCO Textile Ltd...........................................................................................73

5.2.1.1 Production parameters.......................................................................................................73

5.2.1.2 Winding flow chart............................................................................................................73

5.2.1.3 Flow chart of warping process...........................................................................................74

5.2.1.4 Flow chart of weaving (warp yarn):..................................................................................74

5.2.1.5 Flow chart of weaving (weft yarn)....................................................................................74

5.2.2 Wet processing.....................................................................................................................75

5.2.2.1 Production parameters.......................................................................................................75

5.2.2.2 Production process of wet processing...............................................................................75

5.2.2.3 Flow chart of pretreatment................................................................................................76

5.2.2.4 Flow chart of dyeing..........................................................................................................76

5.2.2.6 Flow chart of finishing......................................................................................................77