BGMEA University of Fashion & Technology

Industrial training report on

RUPA KNITWEAR PVT
LTD

Submitted By
Name: Shihab Bin
Rahman ID: 191-060-811
Name: Md. Tanvir Islam
ID: 191-083-811
Name: Shahiduzzaman Papon
ID: 191-110-811

Name: Abdullah Al Mahmud

ID: 191-112-811

This internship report is submitted in partial fulfillment of the requirements for the degree of
B.Sc. in the Textile Engineering & Management Department (TEM) in the faculty of
Textile Engineering of BGMEA University of Fashion & Technology (BUFT).

Department of Textile Engineering &

Management BGMEA University of Fashion &
Technology July 2023
 Industrial training report on
RUPA KNITWEAR PVT
LTD

Submitted By
Name: Shihab Bin
Rahman ID: 191-060-811

Name: Md. Tanvir Islam

ID: 191-083-811
Name: Shahiduzzaman Papon
ID: 191-110-811

Name: Abdullah Al Mahmud

ID: 191-112-811

Submitted To

Department of Textile Engineering & Management

In partial fulfillment of the requirements for the degree of Bachelor of Science in
Textile Engineering Management

Supervised By
Md. Mizanur Rahman
Asst. Professor & Head, Dept. of TEM

Department of Textile Engineering &

Management BGMEA University of Fashion &
Technology July 2023
Letter of Transmittal

24th July, 2023

Md. Mizanur Rahman,

Asst. Professor & Head, Dept. of TEM
Department of Textile Engineering &
Management, BGMEA University of Fashion &
Technology
Nishatnagar, Dhaka

Subject: Submission of Internship

Report Dear Sir,

We are extremely indebted for your tremendous support and guidance throughout our long journey
at “Rupa Knitwear Pvt. Ltd.” and our internship period. Being working with you, we have earned
valuable knowledge and were inspired by your innovativeness, which helped enrich our experience
to a greater extent. An internship report on “Rupa Knitwear Pvt. Ltd.” is submitted to you for the
partial fulfillment of the Bachelor of Science in Textile Engineering & Management Degree.

During our internship period, we trained in all departments of Rupa knitwear Pvt. Ltd.; we made
sincere efforts to study related materials, and observe operations performed in the Knitting, Dyeing,
Sample manufacturing, Cutting, Sewing, Finishing, and Merchandising department which are the
sources of collected data to prepare the present report on.

We have to make this report as comprehensive as possible within the time limit. But there may be
some mistakes due to various limitations. For this reason, we beg your sympathetic consideration.
Finally, we pray for your blessing for our successful engineering career.

Thank you

Yours Faithfully
Shihab Bin Rahman (191-060-811)
Md. Tanvir Islam (191-083-811)
Shahiduzzaman Papon (191-110-811)
Abdullah Al Mahmud (191-112-811)
BGMEA University of Fashion & Technology

i
 Declaration of Examiners

The “Rupa Knitwear Pvt. Ltd” internship report is submitted by Shihab Bin Rahman (191-060-811),
Md. Tanvir Islam (191-083-811), Shahiduzzaman Papon (191-110-811), Abdullah Al Mahmud
(191-112-811). The report is accepted as satisfactory in partial fulfillment of the requirement for the
degree of B.Sc. in Textile Engineering Management.

Board of Examiners

Name Signature

Supervisor: Md. Mizanur Rahman ..……………………………………….

Asst. Professor & Head
Department of TEM

Examiner 1: Prof. Dr. Engr. Abu Bakr Siddique ………………………………………….

Dean Faculty, Department of TE

Examiner 2: Dr. Ranajit Kumar Nag ………………………….…………….......

Associate Professor & Head
Department of Textile
Engineering

i
 ACKNOWLEDGEMENT

First of all, I would like to thank Almighty ALLAH to give me the strength and complete
the industrial training and to write this report a number of people have made a significant
contribution to making my training successful. Their advice and suggestions helped me a lot.

Finally, thanks go to my organization supervisor Nizam Uddin, HR, Admin, and other
officials and staff of Rupa Knitwear Pvt. Ltd. for the unbelievable support.

Special thanks go to my enthusiastic Md. Mizanur Rahman Asst. Professor & Head, Dept.
of TEM, has been an amazing experience, not only for this tremendous academic support but
also giving me so many wonderful opportunities.

Special thanks go to Prof. Dr. Abu Bakar Siddique, Dean Faculty of Textile Engineering &
Md. Mizanur Rahman, Asst. Professor & Department Head of Textile Engineering &
Management, BUFT. Who so generously inspired & contributed to this type of project work.

Special thanks go to our enthusiastic Prof. Dr. Engr. Ayub Nabi Khan, Pro Vice
Chancellor, BUFT and Prof. Dr. S.M. Mahfuzur Rahman, Vice Chancellor, BUFT, for
their encouragement and valuable suggestions for continual improvement of the report.

i
 Executive Summary

First, I want to say Thank you Almighty ALLAH to give me the opportunity to help me every
time, and obviously in that training period. During the training period time, the first day on the
knitting floor. After completing knitting, then I am ready for dyeing. But I need some
information about batching. One day I spend in batching room and collect about almost full
information about

the batch card and how to fill this card. Then I was ready for dyeing, but first of all, I went to the
dyeing lab for 2 weeks and then I went to the bulk production dyeing floor. This dyeing has
many opportunities to know about many information and learn. But if a man want to learn about
dyeing properly, he needs more time on the floor. After a good time, I went to the ETP side.
Because I had a presentation about ETP on a regular course. So, I have to learn that time. But I
want to say, this ETP is excited and thinks about the environment, people, and earth. So, It was a
great plant. Then I went to a sample the manufacturing floor learned how skilled full of workers
started sewing a basic T-shirt and l as good information about line and fabric faults. That day
was good and the QC manager was a charming gentleman. Then the next day I went to the bulk
cutting room. Then I went to the main sewing floor, there were many workers sewing together.
After achieveing a good knowledge of sewing floor, now time for the last step of about
production finishing. One day I went to the merchandising department and knew some basics
about merchandise. This is my completed 2-month training experience about Rupa Knitwear
Pvt Ltd.

Keywords: Knitting, Dyeing, Cutting, Sewing, Finishing, Merchandizing.

i
 TABLE OF CONTENTS
Letter of Transmittal i
Declaration of Examiners i
Acknowledgment iii
Executive Summary iv

Chapter 1: Introduction 1
1.1 Introduction 2
1.2 Objective of Industrial Training 3

Chapter 2 Company Profile 4

2.1 Information about company 5
2.2 Factory Location 6
2.3 Pictorial View of Rupa Fabrics Ltd 7
2.4 Mission & Vision 8
2.5 Name of product company export 8
2.6 Major Buyers Name 8

Chapter 3: Knitting 9
3.1 Definition of knitting… 10
3.2 Process flow chart of knitting 10
3.3 Fabric mix with Characteristics 11
3.4 Machine specification of knitting section 12
3.5 Raw materials for knitting 17
3.6 Considerable points to produce knitted fabrics 19
3.6.1 Effect of stitch length on color depth 19
3.6.2 Methods of increasing prodution 20
3.7 Faults & Remedies of knitting fabrics 20
3.8 Batching 24
 Chapter-1
Introduction

1
1.1. Introduction:

Textiles and garments sector is the biggest and fastest growing sector in Bangladesh. It is also
the highest foreign currency earning sector in Bangladesh. Among this sector, knit garment is
growing very rapidly due to smaller investment requirement, greater backward linkage facility
& higher profit than garments. That's why export of knit garments is increasing steadily for last
few years and up to now.

It is not possible to apply theoretical knowledge using practical knowledge in the practical field.
For any technical education there is practical experience almost as important in conjunction with
theoretical knowledge.

Industrial attachment is a process that builds understanding, skills and attitude performer, which
improves his knowledge while increasing productivity and service. Higher education provides
us with extensive theoretical knowledge as well as more practical attachment helps us to be
familiar despite all these industrial attachments with the technical support of modern machines,
peace of mind about the various stages of processing. It also provides us with sufficient practical
knowledge of production management, work study, efficiency, industrial management,
purchasing, utility and maintenance machines and their operating techniques, etc. the above
cannot be successfully achieved using only theoretical knowledge. That's why it should be
completed by the practical knowledge on which it is based.

Industrial attachment makes us dependable to be used to the industrial atmosphere and improve
courage and inspiration to take personal responsibility. Textile education cannot be completed
without industrial training. Because this industrial training minimizes gap between theoretical
and practical knowledge and we get used to it industrial environment. I was given the
opportunity to complete a two-month industrial course training at RUPA FABRICS LTD which
is a 100% export oriented composite knitwear company Dye industry. It has well planned and
equipped fabric and garment dyeing the units also make knitting and making knitwear easier.

2
1.2 Objective of Industrial Training:

 Performed problem-solving activities in the workplace;

 Further developed my communication skills;
 Demonstrated ability to accept responsibility, work independently, manage own
time and schedule work;
 Understand the limitations of a formal work environment and the benefits of
teamwork;
 I appreciate the relevance of my academic work and apply it to new situations;
 I used new tools and techniques to supplement those listed in my study plan;
 Gained experience to understand, discuss and evaluate professional issues related to
textile engineering.

3
 Chapter-2
Company Profile

4
2.1 Information about company

Group : Rupa

Company name : Rupa Fabrics Ltd.

Type : 100% Export Oriented Composite Knit

Year of established : 1992 (Dyeing section-2010)

Investor : Md. Shahidul Islam

Location : Kunia, Barobari, Gazipur.

Certification &awards : ISO 9001:2001

Production capacity : Knitting zone 150 ton per month

Dyeing : 900 ton per month

E-mail address : rupa@citechco.net & rupafash@bol-online.com

Website : www.rupagroup.netPhone

5
2.2. Factory location
Factory : Rupa Fabrics Ltd

 Corporate office: House No-16, Road-30, Gulshan-01,Dhaka-1212.

Google map location of Rupa Fabric Ltd

Fig: 2.1 Factory map location

6
2.3 Pictorial View of Rupa Fabrics Ltd

Fig: 2.2 Pictorial View of Rupa Fabrics Ltd

7
2.4 Mission & Vision:

The mission and vision of Rupa fabrics Ltd. is to produce and deliver high quality ready-to-wear
garments (RMG) to its customers. The main goal is to achieve and increase customer
satisfaction by providing timely delivery of the required quality ready-to-wear and also to
increase the efficiency of the workforce. To achieve these goals, the management of Rupa
fabrics Ltd. decided to accept following To increase awareness of customer requirements
worldwide organization. By providing training to develop employee performance. Collect
feedback from customers regularly to know about their concept about your company and take
appropriate measures in time. Reduce the wastage / reject rate by at least 2% per annum
implements and monitors ISO 9001:2000 quality management.

2.5 Name of product company export

Basic T-Shirt
Long Sleeve
Sweater
T-Shirt
Polo Shirt
Pajama
Ladies, Kids Knitwear& all kinds of knit

2.6 Major Buyers Name

LPP
Texeye
Refinery
Pepco
Givova
Angel Fashion
Versatile Textile LTD.

Besta Apparels etc.

8
Chapter-3
Knitting

9
3.1 Definition of Knitting
Knitting: Knitting is the process of producing fabric by transferring continuous yarns into
interlocking loops, each row of loop hanging from the one immediately preceding it.

3.2. Process flow chart of Knitting section

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via Trip-tape positive feeding arrangement

Tension device

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

Fig: 3.1 Process flow chart of knitting section.

1
3.3. Fabric mix with characteristics

Fabric Specification

Single Jersey or -One set needle in used to make this fabric

Plain Fabric -It’s face & back side is different

-After cutting curling is produced

-Sinker is used to construct this fabric

-Needles are placed on cylinder

Double Jersey -Two set of needles are used to construct this fabric

-Needles are placed on dial and cylinder

-No sinker is used

-After cutting curling is not produced

Rib -It is double jersey fabric

-Used two sets of needles to construct this fabric

-Face & back side are same

-No sinker is used

Lycra Rib -Fabrics contain an elastic type of yarn which is called Lycra

Polo Pique -It’s another name is double cross tuck

-Two course knit -tuck

-Two course tuck-knit

Single Lacoste - It’s another name is single cross tuck

-Knit-tuck then all knit

-tuck knit then all knit

1
 Double Lacoste - It’s another name is back pique

-Two course knit-tuck then one courses all knit

- Two course tuck-knit then one courses all knit

Plain Interlock -It’s double jersey fabric

-Two sets of needles are used to make this fabric

-Needles are placed on dial and cylinder

-Face & back sides are same

CVC Fleece -It is full name is chief valued cotton

-Here cotton percentage is more and polyester percentage is less

-It may be (40% + 60%, 35% + 65% etc.)

100% Polyester -It’s constructed by only polyester yarn

Fabric

Grey Melange -Combination of cotton and viscose yarn is called grey mélange

-Percentage of cotton is more than viscose

-It’s may be (99%+1%, 98%+2%, 95%+5%, 85%+15% etc.)

Table No: 1

3.4. Machine specification of Knitting section

Machine No-01

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

1
 Number of feeder 60F
Día 30
Gauge 18
Number of needle 1700
Safety RPM 6

Machine No-02

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 6F
Día 38
Gauge 24
Number of needle 2856
Safety RPM 23

Machine No-03

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 72F
Día 34
Gauge 24
Number of needle 544
Safety RPM 26

Machine No-04

1
Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 64F
Día 32
Gauge 24
Number of needle 2400
Safety RPM 28
Machine No-05

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 126F
Día 42
Gauge 24
Number of needle 3168
Safety RPM 25

Machine No-06

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 120F
Día 40
Gauge 24
Number of needle 3000
Safety RPM 26

1
 Machine No-07

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 114F
Día 38
Gauge 24G
Number of needle 2856
Safety RPM 27
Machine No-08

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 108F
Día 36
Gauge 24G
Number of needle 2712
Safety RPM 29

Machine No-09

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 112F
Día 38

1
Gauge 24
Number of needle 2544
Safety RPM 30

Machine No-10

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 90F
Día 30
Gauge 24G
Number of needle 2556
Safety RPM 36
Machine No-11

Machine Name Circular Knitting M/C

Brand Pai Lung

Country of Origin Taiwan

Number of feeder 96F
Día 32
Gauge 24G
Number of needle 2400
Safety RPM 32

Machine No-12

Machine Name Circular Knitting M/C

Brand Pai Lung

1
 Country of Origin Taiwan
Number of feeder 90F
Día 30
Gauge 24
Number of needle 2256
Safety RPM 35

Table No: 2-13

Type of yarn Count

Cotton 24S, 26S, 28S, 30S, 32S, 34S, 40S
Polyester 75D, 72D,100D
Spandex yarn 20D,40D, 70D
Grey Mélange (C-90% V-10%) 24S, 26S
PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S
CVC 24S, 26S, 28S, 30S
Table No: 14
3.5 Raw materials for knitting:

1
 Fig: 3.2 Pai Lung Circular Knitting Machine

Fig: 3.3 knitting action Fig: 3.4 dust removal

fan Changing of GSM:
 Major control by QAP pulley.

 Minor control by stitch length adjustment.

 Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley
moves towards the positive direction then the G.S.M. is decrease. And in the reverse
direction G.S.M will increase.
 Other m/c in Knitting Section:

1
 Fig: 3.5 Grey GSM setting cylinder

Production Parameter:

 Machine Diameter;
 Machine rpm (revolution per minute);
 No. of feeds or feeders in use;
 Machine Gauge;
 Count of yarn;
 Required time (M/C running time);
 Machine running efficiency.

Fig: 3.6 Cam with cambox

1
 Fig: 3.7 Cam setting to the cylinder.

3.6 Considerable points to produce knitted fabrics:

When a buyer orders for fabric then they mention some points related to production and quality.
Before production of knitted fabric, these factors are needed to consider. Those are as follows-
- Type of Fabric or design of Fabric.

- Finished G.S.M.

- Yarn count

- Types of yarn (combed or carded)

- Diameter of the fabric.

- Stitch length

- Color depth.

3.6.1. Effect of stitch length on color depth:

If the depth of color of the fabric is high loop length should be higher because in case of fabric
with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted
then. Similarly in case of light shade loop length should be relatively smaller Factors that should
be change in case of fabric design on quality change:

a) Cam setting

b) Set of needle

c) Size of loop shape

3.6.2. Methods of increasing production:

By the following methods the production of knitted fabric can be increased –

2
A. By increasing m/c speed

Higher the m/c speed faster the movement of needle and ultimately production will be
increased but it has to make sure that excess tension is not imposed on yarn because of this high
speed.

B. By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the number of courses
will be increased in one revolution at a time.

C. By using machine of higher gauge:

The more the machine gauge, the more the production is. So by using machine of higher gauge
production can be increased.

E. By imposing other developments:

a) Using creel-feeding system.

b) Applying yarn supply through plastic tube that eliminates the possibilities of yarn
damage.
c) Using yarn feed control device.

d) Using auto lint removal.

3.7 Faults &Remedies of knitting fabrics:

1. Hole Mark

Causes: Holes are the results of yarn breakage or yarn cracks. During loop formation the
yarn breaks in the rejoin of the needle hook.
If the yarn count is not correct on regarding structure, gauge, course and density. Badly
knot or splicing.
Yarn feeder badly set.

2
Remedies: Yarn strength must be sufficient to withstand the stretch as well as uniform.
Use proper count of yarn. Correctly set of yarn feeder. Knot should be given properly.

2. Needle Mark
Causes: When a needle breaks down then needle mark comes along the fabrics.
If a needle or needle hook is slightly bends then needle mark comes on the fabrics.
Remedies: Needle should be straight as well as from broken latch.

3. Sinker Mark
Causes:
When sinker corrode due to abrasion then sometimes cannot hold a new loop as a result
sinker mark comes.
If sinker head bend then sinker mark comes. Remedies:
Sinker should be changed.

4. Star Mark
Causes:
Yarn tension variation during
production Low G.S.M fabric
production.
Remedies:
Maintain same Yarn tension during
production. Use good continuous yarn.

5. Drop Stitches
Causes:
Defective needle.
If yarn is not properly fed during loop formation i.e. not properly laid on to the
needle hook.
Take-down mechanism too loose. Insufficient yarn tension.
Badly set yarn feeder.
Remedies:

2
Needle should be straight & well.

2
 Proper feeding of yarn during loop formation. Correct take up of the fabric & correct
fabric tension. Yarn tension should be properly.

3.8 Batching:

Batching is the process to get ready the fabrics that should be dyed and processed for a Particular
lot of a Particular order.

Batch Management

Primarily Batching is done by dyeing manager taking the above criteria under consideration.
Batch section in charge receives this primary batch plan from dyeing Manager. Sometime
Planning is adjusted according to m/c condition.

Batch process follow-up:

Grey fabric inspection

Batching Fabric Turning

Storing for dyeing

Fig: 3.8 Batch process follow-up

Purpose of Batch Section:

 To receive the grey fabrics roll from knitting section or other source.
 To turn out the tubular fabric in its grey stage and to safe the face side of the fabric from
any type of friction during the time of dyeing.
 To prepare the batch of fabric for dyeing according to the following criteria-
 Order sheet (Receive from buyer)
 Dyeing shade (Color or white, light or Dark)
 M/c available
 Type of fabrics (100% cotton, PC, CVC)

2
  Emergency
 To send the grey fabric to the dyeing floor with batch card.
 To keep records for every previous dyeing.

Criteria of proper batching:

- To use maximum capacity of existing dyeing m/c.

- To minimize the washing time or preparation time & m/c stoppage time.
- To keep the no. of batch as less as possible for same shade.
- To use a particular m/c for dyeing same shade.

Fabrics Faults Identification:

 Hole Mark: Five are acceptable.

 Needle Mark: five are acceptable. Visualize on the face side of the fabric.

 Sinker Mark: These problems are not acceptable. It is Visualize on the back side of the
fabric.
 Patta: acceptable for only white color producing.

 Star Mark: Five are acceptable.

 Thick and thin place.

 Lycra out.

 Loop hole.

 Oil spot.

 Drop Stitches