Blog Post


In conversation with Stefan Persson in the first Dhaka H&M office and Bjorn Palmqvist (left) who was the former Regional manager of Hong Kong when I was at H&M. My memory clearly states that he was saying to one of the leading manufacture (Right) that “Dhaka Liaison office is the Best Liaison office in H&M World” That made my chest wide and inspired to work harder motivation was running throughout my body. Stefan Persson is the current Chairman of H&M and this was his first visit to Bangladesh this office as well.

Mamun Kabir Bhuiyan
Managing Director & CEO
Technocraft World Corporation
Technocraft World wide Ltd
Dhaka , Bangladesh

Example of an World Class Lingerie Composite Factory

They were setup as a fully vertical operation for the sole purpose of manufacturing high quality brassiere. ALL specializes in brassieres using mostly in house fabrics, narrow fabrics (elastics) etc. They produce a wide range of styles and designs using a variety of fabrics, lace and accessories based on customer’s requirement. The plant is fully equipped to produce high quality molded and non-molded bra, with or without pad, with or without under-wire and bra with traditional seams.

The total production capacity of the ALL for the different types of bra is 1.8 to 2.0 million pieces of bra per month. The production facility is sufficiently flexible to allow 15-20% additional capacity of any of the items.

Sports Bra
Girls Bra
Ladies Bra;
Ladies Bra;
400,000- 450,000
500,000- 550,000
600,000- 650,000
300,000- 350,000

Facilities within this Textile complex:
They textile complex is the combination of these 3 vertical operations, from fabrics toGarment factories along with Yarn Dyeing Mills. Most of the fabrics and other materials for the garments are produced within the Textile complex. Items like lace, under-wires, ring-slide and some special components are imported. Hangers, poly-bags, printed individual boxes, woven labels etc. are locally available.

Each of the three garments factories; ASKML (knitwear), ALL (Bra) & ATPML (underwear & knitwear) have separate and complete set-ups for garment manufacturing, starting from design- sample-pattern to garment finishing.

1.a. Sample, Pattern and design department:

The department in each of the garment manufacturing units is equipped with CAD (Lectra and/or Garber) systems and between 60 to 80 sewing machines to produce samples according to buyer’s specifications and /or own designs. All samples are fitted on appropriate fitting-forms and on live models before sending to the buyers. From digitized patterns, all production markers are produced with optimum efficiency.

Figure: Sections of sample, pattern & design department

1. b. Cutting department:

The cutting department for each of the sewing floors is equipped with fabric inspection, 8 to 12 cutting tables, straight knife, band knife and stripe fabric pilling or lace pilling setups. The capacities of each cutting departments are carefully matched with the respective sewing capacities, between 60,000 to 100,000 pieces each day. All cut pieces are checked and are prepared into bundles of 20 to 40 pieces. The bundle baskets are sent to the sewing section. Before cutting 100% of the fabrics are inspected and laid for sufficient time on cutting tables for relaxation.

Figure: Sections of the cutting floor

1.c. Sewing department:
All the sewing floors are equipped with modern apparel machineries and attachments. The mechanical department is fully equipped with specialized attachment making within facilities. The lines are laid out in a manner to allow 100% inspection of the garments during production.
Figure: Sewing Floor

1.d. Finishing department:

Completed garments in size lots are cleaned of loose threads, dust etc. in vacuum suction device, as required. Subsequently, the garments are transferred into an enclosed humidity controlled (air conditioned) room, where, for the Bra and underwear, the garments are inspected and for the knitwear’s, the garments are finished with steam iron on vacuum tables. After putting all packaging accessories each piece is checked with needle detector before packing for shipment. For all orders, internal AQL is determined before buyer’s inspection.

Figure: Sections of the finishing floor

1. e. Molding & Laminating:

They mainly use the molding & laminating facility. This section is equipped with foam molding, elastic fabric molding, rigid fabric molding, die-cutting (for both foam & fabric) and fabric-fabric, foam-fabric, fiber fill-fabric Laminating machinery. Foam molding Capacity: 52,000 pairs/day and fabric molding capacity: 70,000 pairs/day.
Figure: Foam & fabric molding section

1.f. Hook & eye tape making:
They mainly uses the hook & eye tape making facility. This section is equipped with fully computerized machinery to produce both hook tape and eye tapes of up to 4 rows. The Hook & eye capacity is about 80,000 pieces/day.

Figure: Hook & eye making setup

2. Fabrics:
A large variety of wide fabrics (circular knit & warp knit), using a wide range of fibers,100% cotton, polyester, nylon, various blends, micro-fibers with or without spandex and yarn dyed or solid dyed fabrics are produced exclusively for the garments units within the textile complex.

2.a. Wide Fabrics:

Circular knit fabrics:
There are a total of 145 circular knitting machines, most of the machines are equipped with Spandex attachments and have extra-gauge cylinders.

Circular knit fabrics can be solid dyed or yarn dyed, with or without Spandex;

      Total Capacity 3 5,000 Kg / day

·         Single Jersey / Pique: Capacity/day:16,500 Kg
·         Interlock / drop needle: Capacity/day: 6,000 Kg
·         Rib / drop needle rib: Capacity/day: 6,000 Kg
·         Engineering stripe (up to 6 colors): Capacity/ day: 1,500 Kg
·         3 thread fleece: Capacity/day: 5,000 Kg

Figure: Sections of circular knitting department

Warp knit fabrics:
Solid dyed or yarn dyed, with or without Spandex

v  Tricot: Double tricot, Charmeuse, mesh, honeycomb, velour, diamond tulle etc 
(from rigid to 30 % elastane); Capacity: 150,000 meters / month

v  Raschel: powernet, satinette, slee knit, one way stretch fabric etc
(from 5% to 35 % elastane); Capacity: 70,000 meters / month

v  Simplex; Various types of Simplex fabrics (up to 35% elastane)
Capacity : 24,000 meters to 30,000 meters / month

Figure: Elastane warping, rigid yarn warping and warp knitting sections

Flat knit fabrics:
 Solid dyed or yarn dyed

v  Collars / cuffs (SHIMA SEIKI); Capacity: 6,000 sets / day

v  Fabrics for styling.

Figure : Flat knitting section

2.b. Dyeing & finishing facilities for wide fabrics:
v  Dyeing machines are suitable for cotton, spandex cotton, polyamide, polyester, viscose, and various blends; Capacity 55,000 Kg / day
v  14 sample dyeing machines which can produce 40 different sample fabrics in every day.
v  This department is equipped with both open width & tubular finishing machinery.
v  Fabric finishing section is equipped with stenter / open-width dryer, tubular-dryer Tumble dryer / open-width compactor / tubular compactor etc. suitable for enzyme finish, silicone finish or any specialized finish (e.g., Teflon coating, antimicrobial coating etc.); Capacity; 50,000 Kg / day.
v  In addition to all the options for the chemical finishing, the department has sued- / peach-finishing machines for mechanical finishes. Capacity: 5,000 Kg/day.
v  For Fleece fabrics, the finishing section is equipped with raising machines, brushing machine and searing machine. Capacity: 10,000 Kg/day.

Figure: Sections of the dye-finishing

2.c. Printed Fabrics:
The printing section can produce about 50,000 meters/day of printed fabrics, with either reactive, disperse, acid or pigment dyes.

The All Over Printing (AOP) section is equipped with:

v  One 12 colors Rotary screen printing setup for knit fabrics with a capacity of about 25,000 meters/day.
v  One 12 colors Flat-Bed printing setup for knit fabrics with a capacity of about 22,000 meters/day.
v  Loop steamer / polymerizer / after print washing
v  Digital engraving
v  Computerized design preparation
v  Fully equipped sample & strike off preparation
v  Color kitchen
v  Screen preparation, sample printing

Figure: Screen preparation, sample printing and 12 color rotary screen printing

Figure: 12 color Flat -bed printing Machine

2.d. Narrow fabrics:
The narrow fabrics section is equipped with all the necessary machinery to produce a wide range of elastic and non-elastic fabrics.

v  Rubber covering (double covering): Capacity: 1200 Kg /day
v  Spandex covering (single covering): Capacity: 540 Kg / day
v  Needle looms (without jacquard): Capacity: 350,000 meters / day
v  Needle looms (Jacquard): Capacity: 50,000 meters/day
v  Narrow fabrics dyeing: Capacity: 350,000 meters / day

Figure: Narrow fabric weaving, knitting & dyeing

3. Yarn dyeing

v  Dyed yarn; cotton, polyester & nylon. Capacity: 13,000 to 15,000 Kg/day

v  Sewing and embroidery threads; Spun polyester, filament polyester / nylon / viscose: Capacity: 45,000 cones / day

Figure: Yarn dyeing section

4. Embroidery:

Capacity 15,000 pieces/ day

v  Solid Embroidery: 9 color machines
v  Embroidery on print
v Sequence / cording / boring

Figure: Embroidery section

5. Placement printing:

Capacity: 60,000 to 100,000 pieces / day in up to 6 colors
v  Pigment / Discharge print
v  Puff / Rubber print
v  Glitter / Flock print
v  Stone attachment
v  Foil printing / metallic shine
v  High density printing
v  Photo print

Figure: Placement printing.

6. Pad printing & label printing:
In keeping with the need of the market, they has setup the facilities to print labels on
label tapes as well as printing labels (particularly care labels on bra and underwear)
on the body of the garments, using both pad printing machines or using transfer print

7. Washing plant:

Capacity 25,000 pcs garment / day
The washing plant is equipped to wash knit garments with various additives enzymes during wash and also during the drying cycle.

Figure: Section of the garment washing plant

8. Packaging & Store:

      All garments are fully inspected & packaged before inspection by buyer or buyer’s agent. A large area is allocated for the proper storage of the boxes before shipment.

Figure: Packaging & Store

9. Quality control & Textile testing

      In addition to the modern machinery & equipment’s, they have constantly worked with a wide range of technical experts from Japan, Philippines, Hong Kong and Sri Lanka to improve the working and quality control procedure. Sewing technicians work constantly with the operators and supervisor to upgrade the quality standards and optimize efficiency.

v  QA department personnel conducts inspection of fabric, cutting, molding, bundle preparation and 100% garment quality inspection and recording at all stages of production as per requirements by the buyer.
v  Fabric weight (density), yarn count & composition
v  Spectral color matching
v  Color Fastness to wash, Rub, light etc.
v  Shrinkage and other dimensional stability
v  Extension and Modulus etc.

Figure: Section of laboratory, Spectral equipment and OEKO-TEX certificate.

In addition, regular testing of yarn, fabrics etc. are conducted at our well-equipped lab, Accredited by World class Buyer.

10. Product Development and Fashion Design Department:

     For the last several years, they product development team has been working with various buyers to develop new fabrics, prints, narrow fabrics, embellishments’ etc. to create new fashion garments for the export market. Based on this experience, in 2010 they setup a new independent department for this purpose, staffed by Textile engineers, fashion designers and a complete sample sewing section. The textile engineers in conjunction with the R&D and fabrics departments develop new fabrics, elastics, prints and other embellishments. Fashion designers use these to develop fashion products for the various export market. This has proven to be very useful to the buyers from USA and Europe and many of them are routinely using this facility.

11. Conformity with International Labour & Environmental Standards:

     Their operations are conducted with awareness for environmental safeguard and we deem it as their obligation to prevent pollution by complying with relevant environmental legislations. They are one of the country’s very first textiles knit composite industries to have its own Effluent Treatment Plant (ETP) with a daily capacity of 8 million liters/day. They fully treats all factory effluent before releasing into the environment. All the factories within the complex are fully compliant with and or certified by;

v  WRAP certified
v  OEKO-TEX Standard 100
v  OE (Organic Exchange Certificate)
v  GSV / CTPAT approved
v  Fare Trade
v  ISO 9000 2001
v  Code of Conduct required by major retail stores of the world.

They follow ethical employment practices and adhere to applicable state, National and International laws on labor employment. They provide a clean, safe and healthy environment, adopt fair labor practices, reward them with wages without any discrimination and they do not interfere in their freedom of association and personal freedom. In addition, they have the Child care center accommodate with 90 children providing food, nursing etc.

12. Delivery time and other Commercial issues
      Typically an order can be made ready for shipment in 30-90 days depending on approvals of the buyer. Prior to the confirmation of an order, order details and buyer’s desired delivery dates are sent to the PPIC (Production Planning and Inventory Control) department. Upon receiving the export Letter of Credit or Contract, There merchandizing and commercial department issues purchase orders for the required raw materials. After supplier confirmation of shipment date(s), PPIC department confirms production plans. The production management team, PPIC department, and QAD coordinate the production and the commercial department oversees the export and documentation.

Stay In Touch


Technocraft Worldwide Ltd.

Technocraft World Corporation

Corporate Office
House # 55,Road # 18 Sector # 03,
Uttara,Dhaka-1230 Bangladesh

Phone: +88-02-8922408