Factory : SQUARE Textiles Limited Sardaganj , Kashimpur , Gazipur Bangladesh University of Textiles (BUTex)

1. SQUARE Textiles Limited
Sardagonj , Kashimpur , Gazipur
Dhaka , Bangladesh

2. Presenting Students
 Md. Saidur Rahman
ID : 2011-1-146
 Taukir Kabir Tusar
ID : 2011-1-169
Bangladesh University of Textiles (BUTex)

4. Special Thanks To
 Dr. Hosne Ara Begum
Associate Professor
Head of the department of Yarn Manufacturing
Engineering (YME)
Bangladesh University of Textiles (BUTex)
 Dr. Mohammad Ali
Associate Professor
Head of the department of Industrial Production &
Engineering (IPE)
Bangladesh University of Textiles (BUTex)

5. Thanks for creating friendly
training environment
 Mr. Suresh Chandra Bala
General Manager (Production)
SQUARE Textiles Limited
 Mr. Golam Rabbani
Assistant General Manager (Production)
Unit -01
SQUARE Textiles Limited
 Mr. Shihab Uddin Khan
Production Officer
Unit – 01
SQUARE Textiles Limited
& All officials , employees & workers

6. Company Profile
 Company Name : SQUARE Textiles Limited & SQUARE Yarns Limited
 Year of Esablishment :
Unit 01 : 1995
Unit 02: 1998
Unit 03: 2000
SYL : 2006
 Address :
 Corporate Office : Square Centre
48 , Mohakhali Commercial Area
Dhaka
 Head Office : Mascot Plaza (10th floor)
107/A , Sonargoan Janapath Road
Sector -07
Uttara , Dhaka
 Factory : : Vill –Sadarganj , Post -Kashimpur
Thana – Kashimpur
District - Gazipur

7. No of spindles (Ring and Rotors)
 Ring Section
Unit 01 - 36816
Unit 02 – 23184
SYL - 41328 (SQUARE Yarns Limited)
 Total -101328
 Rotor Section
Unit 02 - 768 ( Autocoro Heads )
Unit 03 – 3192 ( Autocoro Heads )
 Total - 4960

8. Different Departments
 Production Department
 Quality Assurance Department
 Utility Department
 Maintenance Department
 HR & Administration Department
 Civil Department
 Store Department
 IT Department
 Marketing Sales Department
 Planning & Procurement Department
 Finance & Accounting

9. Product Mix
 Unit 01 : Card Hosiery & Comb Hosiery , organic , siro
, slub , inject , core spun , duo spun , 100% manmade
(viscose , modal , polyester)
 Unit 02 : Card Hosiery & Comb Hosiery , compact ,
organic & rotor card woven
 Unit 03 : Rotor card woven
 SYL : Blended (PC , CVC , melange, combed)

10. Flow Chart of various yarn
manufacturing process
Ring yarn (Carded)
Blowroom
Carding
Drawframe
Simplex
Ringframe

11. Flow Chart of various yarn
manufacturing process
Ring yarn (Combed) cont.
Blowroom
Carding
Breaker Drawframe / Pre comb
drawframe
Lap former
Comber

12. Flow Chart of various yarn
manufacturing process
Ring yarn (Combed)
Finisher Draw frame / Post
Comb Draw frame
Simplex
Ring frame
Winding
Conditioning

13. Flow Chart of various yarn
manufacturing process
Rotor yarn (Carded)
Blowroom
Carding
Drawframe
Rotor Frame
Conditioning

14. Segment 1
MachineDescription

15. Blowroom Line
 Machine Name : Unifloc
 Model No : A10 & A11
 Company : Rieter
 Origin : Switzerland
 Production : 1100 kg/hr
 Machine Speed : 5-20 m/min Fig : Unifloc A11
 Take up depth : 4-10 mm
 No of m/cs : 4
 Function : To open the bales into smaller and lighter
tuffs or floc.

16. Blowroom Line
 Machine Name : Uniclean
 Model No : B11
 Company : Rieter
 Origin : Switzerland
 Production : 1100 kg/hr
 Cleaning Intensity : 0-1
 Relative waste amount : 1-10 Fig : Uniclean B11
 No of m/cs : 4
 Function : To remove dust , trash , foreign matters ,
seed contents etc. from fiber flock

17. Blowroom Line
 Machine Name : Unimix
 Model No : B7/3 & B70
 Company : Rieter
 Origin : Switzerland
 Production : 500 kg/hr
 Efficiency : 75-80%
Fig : Unimix B70
 No of m/cs : 4
 Object : Homogeneous & Effective mixing of fibres

18. Blowroom Line
 Machine Name : Uniflex
 Model No : B50 , B60 & B70
 Company : Rieter
 Origin : Switzerland
 Production : 450-500 kg/hr
 Efficiency : 75-80%
 No of m/c : 4 Fig : Uniflex B60
 Function: to optimize waste extraction to suit his
requirements without any mechanical intervention
(VARIO set )

19. Blowroom Line
 Machine Name : The Cotton Sorter
 Model No : SP-FPU ,
HRS-120 &
ED-351_1200T & Jossi
 Company : Truzschler , Loptex & Jossi
 Origin : Germany , Italy & Switzerland
 Production : 400-450 kg/hr
 Efficiency : 75-80%
Fig : SP-FPU
 No of m/cs : 3
 Object : To sort out the Poly propylene (PP) contaminents
from fibre using optical method

20. Blowroom Line
 Machine Name : Condenser
 Model No : LA5/6 , A20 & A21
 Company : LAKSHMI & Rieter
 Origin : India & Switzerland
 No of m/cs : 7
 Function : To control the width of the
fibre strand Fig :Condenser A21

21. Carding Section
 Machine Name : Carding Machine
 Model No : C50 , C51, C60
 Company : Rieter
 Origin : Switzerland
 Flat speed : 0.22-0.29m/min
 Cylinder Speed 450-550 rpm
 No of m/cs : 64
Fig : Carding C60
 Function : To individualize , parallalize , cleaning ,
reduction of neps , aligning , blending & elimination of
short fibres

22. Drawing Section
 Machine Name : Breaker Draw frame
 Model No : SB-2 , RSB-1, RSB-951
SB-D-10 , SB-D -40
 Company : Rieter
 Origin : Switzerland
 Drafting system : 4/3
 Doubling Ratio : 5:1 , 6:1 , 8:1
 Delivery speed : 650-800m/min
 No of m/cs : 18
Fig : Breaker Draw frame
 Function : To stretch or straighten the fed card sliver to one
single sliver , blending of different slivers

23. Drawing Section
 Machine Name : Finisher Draw frame
 Model No : SB-2 , RSB-1, RSB-40
RSB-D -45
 Company : Rieter
 Origin : Switzerland
 Drafting system : 3/3 , 4/4
 Doubling Ratio : 5:1 , 8:1
 Delivery Speed : 650-750m/min
 No of m/cs : 24
Fig : Finisher Drawframe
 Function : To arrange the fibres in parallel fashion , to reduce
irregularty of silvers by auto levelling device

24. Lap Formers
 Machine Name : Unilap
 Model No : E5/3 , E30 , E32
 Company : Rieter
 Origin : Switzerland
 Drafting roller : 24 mm
 Calendar Roller : 30 mm
 Delivery Speed : 100 m/min
 No of m/cs : 3
Fig : Unilap E5/3
 Function : forming the interfacing or lap , which is employed to
feed the combing machine , lighter draft is provided here (1.5-
2)

25. Combers
 Machine Name : Comber
 Model No : E60H , E62 , E65
 Company : Rieter
 Origin : Switzerland
 Drafting system : 3/3
 Feed/Nip : 4.7-5.2 mm
 Nip/min : 350-360
 Doubling Ratio : 8:1
 Noil% : 8-15
 Lap length : 220-230m
 Lap weight : 800-1000gr/yds Fig : Comber machine
 No of m/cs : 18
 Function : To produce more smoother , softer sliver by eliminating short fibres

26. Simplex
 Machine Name : Simplex
 Model No : FL-16, FL-100,
ELECTROJET
 Company : TOYOTA ,
Electrojet
 Origin : Japan , Spain
 Flyer rpm : 1100
 No of flyer : 120,120,128
 Drafting system : 4/4 Fig : Simplex Electrojet
 Function : To convert the drawn sliver into much fine sliver
called roving by drafting and slight twist insertion

27. Ring Frame
 Machine Name : Ring frame
 Model No : FA-507A, RX-240 ,
 LR60/AX
 Company : ERFANJI,TOYOTA ,
LAKSHMI
 Origin : China , Japan , India
 Drafting system: 3/3
 No of spindle : 504,1008,1008
 Spindle speed : 18000 rpm
 No of m/cs : 117 Fig : Ring frame
 Function : To convert the roving into yarn of definite/respective
count by creeling , drafting , building , twisting , winding and
doffing operation

28. Rotor Frame
 Machine Name : Rotor frame
 Model No:BT-903, Autocoro 288 ,
 Autocoro 360
 Company : Rieter & Schlafhorst
 Origin : Switzerland & Germany
 Drafting system: No
 No of pos : 192,288,312
 No of m/c : 15 Fig : Rotor frame
 Function : To produce yarn from the low quality fibres
by the process of open end spinning

29. Winding m/c
 Machine Name : Winding m/c
 Model No: AC 338 ,
SAVIO Polar
Muratec , Orion M
 Company : Schlafhorst , SAVIO
Polar , Muratec
 Origin : Germany , Italy , Japan
 No of drum : 64,60,60
 Drum speed : 1100-1400 rpm
 No of m/c : 24
 Automatic splicing system Fig : Winding machine
 Function : To rewound the yarn from ring bobbin into suitable
package

30. Heat Setting
 Machine Name : Heat Setting m/c
 Company : Elgi-Electric
 Origin : India
 Heat set time: 55 minute
 Temp. : 60 degree celcius
 No of m/c : 01
 Pressure : 5kg/cm*cm
Fig : Heat Setting m/c
 Function : To increase yarns moisture content

31. Daily Production of SQUARE
Textiles Limited ( Approx. )
 Unit 01 - 18522 kgs
 Unit 02 - 10385 kgs
 Unit 03 - 5550 kgs
 Unit 03 - 29735 kgs
(autocoro)
 SYL (Ring)- 14951 kgs
 Expansion - 3982 kgs
(Ring)
 Total - 83125 kgs
Approximately 80 Tons per day

32. Different ring attachments used to
produce special yarns
 Slub Attachment
 Core spun yarn attachment
 Lycra(Core) slub attachment
 SIRO attachment
 Slub Attachment
 Inject Yarn Attachment
 Inject Slub Attachment
 Duo core spun Attachment

33. Segment 2
Quality Assurance System

34. What is Quality Assuarance ?
 Quality assurance (QA) refers to the systematic
activities implemented in a quality system so that
quality requirements for a product or service will be
fullfilled .
 It is well knowned by the term “ Quality Control ”

35. Quality Control Equipments
 Machine name Function
 USTER HVI Spectrum Raw cotton inspection ,
 SCI , MIC value , Rd+b
 grading
 USTER HVI 900 Upgrade version of
 previous one , maturity
 and moisture extra
 USTER Tester 5 Yarn and sliver inspection ,
 unevensess , thick –thin place
 hairiness , neps
 Covatest Same as USTER Tester 5
 USTER AFIS Pro Length , UQL , SFC , Spun length
 IFC , maturity , neps, SCN, NRE,
 Trash

36. Quality Control Equipments (cont.)
 Machine name Function
 USTER AFIS Same as USTER AFIS Pro
 Dynajet Yarns weak point test

 Ustertensojet Single yarn strength test

 Zweigle G566 Yarn inspection , hairiness
 Eureka EY12 Warp reel yarn count
Mesdanlab Yarn twist tester
 NTDA Raw material trash ,neps, dust
 analysis
Board Wrapping (MAG) Same as Eureka EY12
 Auto stretch 5c Yarn lea strength tester
 HVI Rapid Conditioning Cabinet Cotton Conditioning

37. Segment 3
Maintenance Department

38. What is maintenance ?
 Maintenance is a procedure by means of which we can
maintain active functioning in operation according to
the behavior utility of a particular element/ substance

39. Maintenance procedure in SQUARE
Textiles Limited
 Maintenance for Blowroom
-Periodic Maintenance
After 10-15 days
 Maintenance for Carding
-Schedule Maintenance
Cleaning of components like cylinder ,
flat , doffer , Fixed carding segment , lubrication of gear , belt cleaning and
alignment checking etc
 Grinding
1st : After 90tons production
2nd : After 80 tons production
3rd : After 70 tons production
4th : After 60 tons production
 4 times grinding possible
 IGS grinding for doffer and cylinder
 Emery fillet grinding for flat

40. Maintenance procedure in SQUARE
Textiles Limited (cont.)
 Mounting
 removal of faulty wires after its lifetime
(300-350 tons production)
 Emery cloth for rust removal of wire
 Acetone wash
 Lakshmi mounting machine for flats
 Graft mounting machine for cylinder ,
doffer & taken in
 Lubricating
 Done in yearly schedule basis

41. Maintenance procedure in SQUARE
Textiles Limited (cont.)
 Maintenance of Lap former , Comber , Drawframe ,
Simplex & Ringframe
- Scheduled Maintenance
Cleaning machine & its parts ,
gear , belts , top, bottom , feed , calendar rollers ,
winding drums , lap , cut , weight plate , suction line
&duct cleaning , cleaning the drafting zone , pressure
roller cleaning , apron resetting, change & resetting as
per requirement etc.
 Lubricating
Gears , rollers etc .

42. Cot Grinding Machine
 Name : Berkol Cot Grinding Machine
 Origin : Switzerland
 Origin: Switzerland
 Per grinding reduce : 0.02 mm
 Stone dia at frist: 200 mm
 Stone dia when out: 150 mm
 Stone auto cleaning: after 100 grinding Fig :Cot Grinding
 Stone is dressing: after 1000 cot grinding Machine
 Grinding rate: 3 cot/ minute

43. Segment 4
Utility

44. What is Utility ?
 Utility is the set of services provided by the
organizations consumed by the public like electricity ,
natural gas , water & sewage

45. Utility Facilities of SQUARE Textiles
Limited
 Utilities Amount
 Electricity (PDB & Generator) 15MW
 Steam (Boiler) 3000 kg

46. HFO Plant (Generator)
 HFO means heavy fuel oil or Furness oil
 Type : 4.1 MW Man Gegilski power plant
 Company : MAGNUS Power PVT ltd
 Capacity : 4.1 MW
 Engine type : V type
 No of cylinder: 16
 There is 5 oil tank in HFO plant
1. Storage tank
2. Buffer tank
3. Day tank
4. Diesel tank
5. Sludge tank.
Fig : MW Mega Gegiski Power Plant

47. A/C Plant
At SQUARE all A/C type is same
 Brand: LUWA
 Origin: Switzerland
 At
 UNIT 1 8 A/C
 UNIT2 4 A/C
 UNIT3 4A/C
 SYL 4A/C
 Total 20 A/C

48. Chillar
 In Square textiles ltd
 Unit 01 has 3 chillars (all 400 tons capacity)
 Unit 02 has 3 chillars( 1 vapour absorption chillar 500 tons
500 tons
1 steam fired chillar 500 tons
1 Hot water absorption chillar 500 tons
 Unit 03 has 3 chillars( 1 hot water and 2 steam
fired – all 260 tons )
 SYL has 1 chillar (direct gas absorption type)
 Total 10 chillars

49. Boiler
 In SQUARE Textiles Limited ,
Type : Exhaust Gas Boiler
Capacity: 2.5 ton
Consume: Natural gas
Safety valve: 2
Wt of safety valve: 9.5 kg/ cm2
Cell & tube type : in cell there is water & in tube
hot water
Exhaust temp: 450/500 ͦ C
Out temp: 200 ͦ C

50. Some other utility things
 Air Compressor
 Dryer
 Water Softening plant
 PLC ( Progammable Logic Control )
 Circuit Breakers