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Internship Report
On
KDS Textile Ltd: An Analysis of Sustainable
Production & Quality Control

KDS TEXTILE LTD

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UNIVERSITY OF CHITTAGONG

Submitted To:
Dr. Md. Didarul Alam Chowdhury
Chairman & Associate Professor
Department of Applied Chemistry & Chemical Engineering
University of Chittagong

Submitted By:
Kawser Mondle
Id: 19209045
Program: MS
Session: 2022-2023
Department of Applied Chemistry & Chemical Engineering
University of Chittagong

Date of Submission:
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LETTER OF TRANSMITTAL
19th July, 2025
Dr. Md. Didarul Alam Chowdhury
Chairman & Associate Professor
Department of Applied Chemistry & Chemical Engineering
University of Chittagong
Subject: Submission of an internship report on “KDS Textile Ltd: An Analysis of Sustainable
Production & Quality Control”
Dear sir,
With great pleasure, I would like to submit my internship report on “KDS Textile Ltd: An
Analysis of Sustainable Production & Quality Control” that you have approved and assigned as a
compulsory requirement. I have tried my level best to bring out the original scenario of KDS
Textile Ltd. with full of effectiveness and efficiency. I have already learned a lot and have gained
valuable experience and knowledge while collecting the information for the report. It was
certainly a great opportunity for me to work on this in real life work to actualize my theoretical
knowledge of this course in the practical area and some more which is out of this course.
I hope that you would be kind and generous enough to accept my sincere effort and
oblige thereby. If you come across any questions or quarries regarding this report, it will be my
pleasure to clarify your questions.
Sincerely yours,
………………………..
Kawser Mondle
ID: 19209045
MS Program,
Session: 2022-2023
Department of Applied Chemistry & Chemical Engineering
University of Chittagong
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ACKNOWLEDGEMENT

I would like to express my gratitude to all the personnel who were involved directly or indirectly
in the preparation of this report. I apologize to the people whose name that I have not
mentioned but their contribution is highly appreciated by me.
At first, I would like to pay my gratitude to my respected teacher Dr. Md. Didarul Alam
Chowdhury, Associate professor, Department of Department of Applied Chemistry & Chemical
Engineering, University of Chittagong, for his guidelines and cordial cooperation in preparing
this report.
I would like to take the opportunity to thank Manager of Human Resource department of KDS
Textile Ltd. for being cooperative with me. I also want to thank managers of production
department for providing me time to time information, suggestions as well as procedures to
work with my topic.
Finally, I will show my gratitude to all the Management and non-Management staffs who have
helped me during the internship period and the entire persons of the organizations who
somehow have the impact on me in completing my whole report.
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Executive Summary
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Table of Content

Name of Content Page No

Chapter-1 Introduction

1.1 Background of the study

1.2 Objectives of the study

1.3 Scope of the study

1.4 Methodology of the study

1.5 Limitation of the study

Chapter-2 Company Overview

2.1 Overview of KDS

2.2 Corporate information

2.3 Corporate Vision

2.4 Corporate Mission

2.5 Organizational Objectives

2.6 Standard and Quality policy

2.7 Departments of KDS Garments Ltd

2.8 Products of KDS Garments

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CHAPTER ONE
INTRODUCTION
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1.1Background of the Study:

The textile industry acts as a catalyst for the development of Bangladesh. The “Made in
Bangladesh” tag has also brought glory for the country, making it a prestigious brand across the
globe. Bangladesh which was once termed by cynics a “bottomless basket” has now become a
“basket full of wonders”. The country with its limited has been maintaining 6% annual average
GDP growth rate and has brought about remarkable social and human development. The textile
industry of Bangladesh commenced its journey in the late 1970s and within a short period of
time emerged as an important player in the economy in terms of export earnings, employee
generation and poverty alleviation and empowering of women. The sector accounts for 83% of
total export earnings of the country. When our only major export earner “the jute industry”
started losing its golden days, it is the sector that replaced it, and then, to overtake it.

The industry that has been making crucial contribution to rebuilding the country and its
economy is none other than the readymade garment industry which is now the single biggest
export earner of Bangladesh. The apparel industry of Bangladesh started its journey in the1980s
and has come to the position it is in today. KDS Textile industries ltd. is one of the most
renowned business and industrial conglomerates of Bangladesh, based mainly in the port city of
Chittagong but with extensive operations in Dhaka as well. They believe in quality and time and
highly emphasize in maintaining a concerted harmony in its working process and its
environment. The quick expansion of the industry was possible because of the less complicated
technology, cheap and easy way to operate sewing machines and relatively cheap and abundant
female workforce. There is no doubt that Bangladesh is the world’s second largest Readymade
Textile exporter, just behind China. Country’s 81% of exports come from the RMG sector and the
textile and apparel sector contributes around 20% to Bangladesh’s GDP. It employs around 20
million people in the country and is the major driving force of the country’s economy.

As a student of Applied Chemistry I have chosen a Textile industry to do my internship and the
name of the company is KDS Textile Industries Ltd. The report is done on the topic of “KDS
Textile Ltd: An Analysis of Sustainable Production & Quality Control” of KDS textile Industries
Ltd. It is a great opportunity for me having practical knowledge and present situations of textile
industries.
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1.2. Objectives of the Study

Primary Objective: For any science student only curriculum activities are not enough for
handling the real situation. Internship is a part of the Bachelor of MS program that provides a
job experience for the students. Internship program is a perfect match of the theoretical and
practical knowledge. So it is a mandatory requirement for the students of Applied Chemistry &
Chemical Engineering Department, University of Chittagong.

Specific Objectives:

• To find out the production process of the company

• To learn the planning and work study of the company

• To observe the production management system

• To find out the productivity of the company

• To identify the problems regarding of production and operation management

• To recommend some suggestions to overcome the problems related with production process.

1.3. Scope of the Study:

The report is written based on operation and production management of KDS Textile Industries
Ltd. As I was an intern, my scope was very much limited and restricted. I had to maintain some
official formalities for the collection of data regarding my report.

1.4. Methodology of the Report:

This report is the reflection of one-weak internship program in KDS Textile Ltd. All companies
are facing tremendous competition from each other as competitors is increasing as well as
changing buyers demand. So the employees remain very busy to gain a competitive advantage
over competitors. As an intern, I had to collect data and information from that busy
Downloaded by corporate environment. Information collected to furnish this report is both
from primary and secondary sources.
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1.5. Limitations of the Study:

Due to some limitations it’s really tough to prepare report as intended though I have given
utmost effort to prepare this report properly. Such are as follows:

• Strict management policy to share information to external people expect government

authority.

• Large scale investigation was not possible due to Time Constrain.

• The functions and activities of KDS textile Limited are too vast, so they change their strategy
frequently. As a result, it was not possible to collect all updated information.

• Using various terminology or jargon words is sometimes difficult to understand which could
otherwise be incorporated sufficiently in preparing the report.

• The main constrain of the study was insufficiency of information which was required for the
study.
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CHAPTER TWO
COMPANY OVERVIEW
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Overview of KDS

KDS Group is a Bangladeshi one of the largest and most renowned businesses and industrial
conglomerates, founded by Mr. Khalilur Rahman in 1983. The head-quarter of this group is
located in Chittagong. The Group is mainly based in Chittagong. It also has wider business
operations in Dhaka. KDS has overseas offices and agencies in India, Hong Kong, Europe, and
North America.

KDS Textile Ltd., part of the well-known KDS Group, is a modern textile manufacturer located in
Chattogram, Bangladesh. The company produces a variety of knit fabrics like single jersey, rib,
fleece, and interlock for global brands.

It operates with advanced machinery and an integrated production process covering knitting,
dyeing, and finishing. KDS Textile places strong emphasis on quality control and sustainability,
using environment-friendly chemicals and running effluent treatment plants to reduce pollution.

The company contributes significantly to Bangladesh’s export sector and is known for its
commitment to operational excellence, worker welfare, and environmental responsibility —
helping strengthen Bangladesh’s position in the global textile industry.
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2.2. Corporate Information

• Established: 2003 (Textile Mill)
• Location: Chattogram
• Focus: Knit fabric production
• Employees: ~200
• Machines: 92 knitting machines
• Fabric Capacity: ~3,000 tons/year
• Products: Solid & stripe knits, including jersey, rib, interlock, pique, and fleece
• Export-Oriented: Yes; for apparel use (T-shirts, underwear, swimwear)
• BGMEA Reg. No.: 3763

2.3 Corporate Vision:

• Delighting our customers
• Sustain performance
• Achieving excellence in process and technology
• Building culture of cost consciousness
• Leveraging through competent people
• Leadership through innovation
• Trust in new product design

2.4. Corporate Mission:

To consistently produce and deliver a diverse range of high-quality knit fabrics using advanced
technology and sustainable practices, ensuring timely supply to global apparel manufacturers,
thereby contributing to the success of our clients and promoting environmental responsibility
within the textile industry.

2.5 Organizational Objectives:

• To participate in the economic development of the country
• To create employment opportunity
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• To play positive role behind the rapid development of the industry

• To assure quality and customer services
• Successfully facing the challenges of Garments sector for 21st century.

2.6 Standard and Quality Policy:

To meet customer’s need, expressed and implied by maintaining consistency in quality through
continuous up-gradation of technology and human endeavor for maximizing return on
investment to the stakeholders. Also, highly committed to comply with the requirements of ISO
9001:2008 international standards and pursuance of consistent improvement of the
effectiveness of quality management system.

2.7. Departments of KDS Textile Ltd.

Core production department:

• Knitting Department

• Dyeing & Finishing Department

o Dyeing

o Printing (if applicable)

o Finishing (compacting, brushing, mercerizing, etc.)

• Quality Control / Quality Assurance (QC/QA) Department

• Research & Development (R&D) Department

• ETP Department (Effluent Treatment Plant)

2.8. Products of KDS Textile Ltd:

Based on available information, the key products of KDS Textile Mills Ltd. are:

• Various types of knit fabrics: This is their core product.

• Solid shade knit fabrics: Fabrics dyed in a single, consistent color.

• Striped knit fabrics: Fabrics with various stripe patterns.

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CHAPTER THREE
OPERATION & PRODUCTION
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3.1. Introduction
KDS Textile is a well-known company that imports various types of yarn, primarily cotton yarn
and polyester yarn. Alongside these two, they also import other specialized types of yarn, which
ensures the diversity and quality of their textile products.

Upon arrival at the factory, the imported yarns undergo a thorough Quality Check. This step is
crucial because it significantly influences the final product's quality. During this quality
assessment, the yarn's strength, durability, colorfastness, and other characteristics are
meticulously examined to prevent any defective yarn from entering the production process. After
strict quality control, the yarns that pass the inspection are then sent for the Winding process.

3.2. Winding

Winding is the process of transferring yarn or thread from one package (e.g., bobbin, hank,
skein) to another (usually a cone, spool, or pirn) to prepare it for subsequent processes like
weaving, knitting, dyeing, and finishing.

3.2.1. Objectives of winding:

• To transfer yarn from one package to another suitable package, this can be conveniently
used for weaving purpose.
• To remove yarn faults like hairiness, neps, slubs and foreign matters.
• To clean yarn.
• To improve the quality of yarn.
• To get a suitable package.
• To store the yarn.
• To make easier the next process.
• To preparing soft package of yarn dyeing.
• To dye the yearn

3.2.2. Common winding processes used in the textile industry :

• Precision winding
• Cross winding
• Hard winding
• Soft winding
• Parallel winding
• Conical winding
• Splicing winding, etc.
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3.2.3. In KDS Textile, two main types of winding processes are used:

(1) Soft Winding

• Mainly done before dyeing or bleaching, where yarn is wound softly.

• The package contains air gaps so dye or chemicals can penetrate easily into the inner
layers.

• Lower tension helps protect the yarn from damage.

• This type of package is often called a pressure-less package because it ensures better
dye penetration.

Procedure:

Flow Chart of Soft Winding Process

Yarn in ring bobbin

Guide

Tension
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Flyer

Yarn clearer device

Stopping device

Traversing guide

Winding

(2) Hard Winding

• After dyeing, the yarn is wound tightly into firm packages to prepare it for fabric
production.
• Usually done in cone or cheese form.
• Yarn becomes compact, making it easier to transport and run on knitting machines.
• The volume of the package is less, so it is easier to store and handle.
• Since the tension difference between the outer and inner layers is minimal, it helps in
smooth processing.
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Flow Chart of Winding Process

Yarn in ring bobbin

Guide

Tension

Drum

Yarn clearer device

Stopping device

Traversing guide

Winding

3.3. Knitting:

Knitting is a method by which yarn is manipulated to create a textile or fabric. It involves using
two or more needles to interlock loops of yarn, forming a series of connected stitches. The
resulting fabric is flexible, elastic, and can be used for a wide variety of purposes, from clothing
and accessories to home decor items.

KDS Textile Mills Ltd. utilize European technology to produce high-quality fabrics for the global
market. They specialize in knitting various fabric types, including single jersey, rib, pique, fleece,
terry, and double jersey, using machines from brands like Mayer & Cie and Santoni. Their
production process is known for its flexibility and speed, allowing them to deliver fabrics with
short lead times.
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3.3.1. Flow chart of Knitting process:

Send to store

Knit Fabric Production Process

1. PO Receive (Purchase Order Receive)

• The process begins with receiving a purchase order from the buyer.

• This includes quantity, specifications, fabric type, and delivery schedule.

2. Yarn Receive

• Based on the PO requirements, the correct type and quantity of yarn are sourced and
received.

• Yarn is checked for quality and specification compliance.

3. Yarn Creeling

• Yarn packages are loaded onto the creel of the knitting machine.

• Creeling ensures smooth unwinding of yarn during knitting without breaks.

4. Fabric Knit Down

• A small batch of fabric is knitted as a sample (knit down) to match the required design,
construction, and GSM.
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• It’s usually sent for buyer approval before bulk knitting.

5. Fabric Inspection

• The fabric is inspected for defects such as holes, streaks, or uneven dyeing.

• Inspection follows standard methods (e.g., 4-point system) to ensure quality before
proceeding.

6. Roll Making

• After inspection, acceptable fabric is rolled properly using rolling machines.

• Each roll is labeled with length, width, weight, and inspection details.

7. Send to Greige Store

• The rolled greige (raw, unfinished) fabric is stored in the greige fabric store.

• It remains there until scheduled for wet processing (dyeing, finishing).

3.3.2. In KDS Textile, two main types of knitting machines are used:

1) Circular Knitting Machine

• These machines knit fabrics in a tubular form (like a big roll).

• They have multiple needles arranged in a circular cylinder.

• Mostly used to produce single jersey, rib, interlock, and various structured fabrics.

• Very high production speed and suitable for bulk production.

• Fabric comes out as a seamless tube, which can later be cut and opened.
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2) Flat Knitting Machine:

• These machines knit fabrics in flat, open-width form.

• Needles are arranged in a straight line on flat beds.
• Mainly used for making collars, sweater panels, jacquard designs, and shaped garments.
• Allows more complex and customized patterns.
• Production speed is generally lower than circular knitting, but offers more design
flexibility.
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CHAPTER FOUR
SHADE DEVELOPMENT
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4.1. Shade Development

Shade development in the textile industry refers to the process of achieving a specific color on a
fabric or garment according to a desired standard, often dictated by a buyer or design. This
process involves matching the color of dyed or printed materials to a pre-defined shade, and
managing variations that can occur during dyeing or printing.

Here is the example of a desired standard that dictated by a buyer

First, experienced lab technicians create an initial recipe of dyes and chemicals that matches the
buyer’s target shade, often using the help of Computer Color Matching (CCM) software. Then,
according to this recipe, small fabric swatches are dyed in lab-scale machines or IR dyeing
machines, following the same temperature, time, and chemical ratio as in bulk production.

After dyeing, the fabric goes through proper washing and finishing processes to remove excess
dye and make the color durable. Then, the dry sample is compared to the target sample under
different light sources to check for metamerism — a condition where two colors appear the
same under one light but different under another. If the first lab dip does not exactly match the
target shade, the recipe is adjusted, and new lab dips are created. This process is repeated until
a satisfactory match is achieved.

Finally, several copies of the approved lab dip are sent to the buyer for approval. If the buyer is
satisfied after checking under various light sources, they approve one copy, which becomes the
“Lab Dip Approved” sample and serves as the standard for bulk production. After that, the lab-
scale recipe is scaled up for production machines so that dyes and chemicals are applied in the
correct proportion. Through this entire process, consistent, high-quality, and durable color is
ensured in production.
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4.2. Bleaching

Before dyeing, the fabric must undergo proper processes such as singeing, desizing, scouring,
bleaching, and mercerizing, which increase the fabric's absorbency and remove unwanted
impurities. This is essential for uniform dye uptake.

4.2.1. Bleaching Process: For Cotton Fabric Before Shade Development

Bleaching is a process that removes natural pigments (such as pectin, natural waxes, and other
undesirable substances) from cotton fabric, making it white and increasing its absorbency. This
is an essential step before dyeing, as it ensures that the dye will be uniform and bright. In
industrial settings, hydrogen peroxide bleaching is the most common and environmentally
friendly method.

The bleaching process is generally completed through the following steps:

1. Fabric Preparation: Before bleaching, the fabric must undergo several preliminary steps:

• Singeing: If necessary, excess fibers or fuzz on the fabric surface are burned off to make
it smooth. This prevents pilling on the finished fabric.

• Desizing: This step involves removing the sizing agents (like starch) used to strengthen
the warp yarns during weaving. This increases the fabric's absorbency.

• Scouring: This is an integral part of bleaching. Natural fats, oils, waxes, and other
contaminants are removed using caustic soda (NaOH) and detergents. This cleans the
fabric and helps the bleaching agent work effectively in the subsequent step."

4.2.2. Chemical that used in bleaching process and their function

1. ALBAFLUID C –
➤ A stabilizer or chemical assistant that helps maintain the effectiveness of hydrogen
peroxide during the bleaching process.

2. CLARITE ONE – 12 GM
➤ A scouring agent used to remove oils, waxes, and dust from the fabric surface.

3. CAUSTIC SODA – 24 GM
➤ Used to clean and remove stains from fabric. It is essential in both scouring and
bleaching.

4. HYDROGEN PEROXIDE – 48 GM
➤ The main bleaching agent. Used to lighten fabric color or remove stains.
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5. CLARITE CBB – 4.8 GM

➤ A chelating agent or stabilizer that reacts with metallic ions in water or fabric to make
bleaching more effective.

6. ALBAFLOW JET – 1.2 GM

➤ A lubricant or fiber protection agent used to make the fabric smoother and reduce
friction during processing.

7. PERSOTEX DBN – 6.0 GM

➤ An oxygen-based bleach booster or activator that enhances the effectiveness of
hydrogen peroxide.
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