Ratio Analysis on Spinning Industry Ltd

Profile of Apex Textile Complex Apex Spinning & Knitting Mills Limited Apex Lingerie Limited Apex Textile Printing Mills Limited Apex Yarn Dyeing Limited    Contact persons:    Zahur Ahmed PhD, Managing Director; [email  protected] com Shahriar Ahmed, Director Operations; [email  protected] com    Marketing & Merchandizing For knitwear: Ershad Ullah Khan, GM; [email  protected] com MD. Mushahed Alam, Manager; [email  protected] com Belal Hossain, Manager; [email  protected] com , For Lingerie and Underwear: Shahnaz Begum Zharna (Ms), AGM; [email  protected] om Nasima Begum (Ms), AGM; [email  protected] com Apex Holdings Limited Head office: Rupayan Golden Age (5th & 6th Floor) 99 Gulshan Avenue, Dhaka 1212, Bangladesh Telephone: 880-2-9883358 Fax: +880-2-8810850 or 9861685 WWW. apexknitting. com; apexlingerie. com; apextextileprinting. com Factory: Mouza: Chandora, P. O. : Shafipur, District: Gazipur Profile of the Textile Complex of Apex  Holdings Introduction: Apex Textile Complex consists of four 100% export oriented textile and Garment manufacturing enterprises under the management of Apex Holdings Limited (AHL).Over the years the companies under AHL have built an enviable reputation of being a reliable vendor of consistent high quality, on time delivery and compliance with international labor laws & environmental standards. Companies under AHL have been supplying textiles to several large retail chains in the European Union and north America for the last 20 years and enjoy prominent status with them. Our reputation is based on the simple philosophy that â€Å"consistent high quality, on-time delivery and competitive price are the essence of long term relationship in export business†. The Textile complex is made up of 1.Apex Spinning & Knitting Mills Limited; year of establishment 1991 Vertical operation, Fabric to garments; 2 . 2 – 2 . 3 million pcs/month knit-garments 2. Apex Lingerie Limited; year of establishment 1999 Vertical operation, Fabric to garments; 1. 8 – 2. 0 million pcs/month bra 3. Apex Textile Printing Mills Limited; year of establishment 2006 Vertical operation, Fabric to garments; 1. 0 – 1. 2 million pcs/month knit-garments and 3. 4 to 3. 6 million pcs/month of underwear (men’s & ladies) 4. Apex Yarn Dyeing Limited; year of establishment 2003 Cotton, polyester & nylon yarn dyeing as well as sewing and embroidery threadsThe AHL textile complex is located in a 17 acre fully owned compound, 35 km from Dhaka international airport on Dhaka-Tangail highway. The different units are housed in separate built spaces consisting of about 100,000 square meters. The complex is equipped with prime power (15 MW), steam (45 T/hr), Thermo boiler (75 million BTU), Hot water (from waste heat), Compressed air (2500 cuM/hour), Process water treatment (8. 0 million liter/day), and effluent treatment (8. 0 million liters/day). Along with the production facilities, the complex has a c linic attended by doctors and nurses, childcare facilities.Both these are for workers at free of cost. In addition, there is a large dining area and a subsidized canteen for the workers. 1. Apex Spinning & Knitting Mills Limited Apex Spinning & Knitting Mills Limited (ASKML) is a fully vertical setup to manufacture high quality Knit-garments for Children, Ladies and Men’s, using inhouse fabrics. ASKML is equipped to produce a wide range of solid dyed fabrics and all-over printed fabrics (reactive, disperse, acid and pigments) using a variety of designs provided by the buyer and/or from ASKML’s own design department.The fabric can be circular knit or warp knit, 100% cotton, polyester, nylon or various blends, with or without elastane, yarn dyed or solid dyed, all from in-house source. The 42 sewing lines are equipped to produce garments starting from the basic Page 2 of Profile of the Textile Complex of Apex  Holdings   children’s items to ladies / menâ€℠¢s hooded sport jackets based on designs and specifications and accessories as required by the buyer. The total production capacity of the ASKML is 2. 2 to 2. million pieces per month, as shown below, with sufficient flexibility to allow 25-40% additional capacity of any one of the items. Infants Pcs / month Children’s Pcs / month 1,500,000 – 1,600,000 Ladies Pcs / month 200,000 – 250,000 400,000 – 450,000 2. Apex Lingerie Limited Apex Lingerie Limited (ALL) has been 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.Apex Lingerie Limited produces 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 Pcs/month Girls Bra Pcs/month 500,000- 550,000 Ladies Bra; standard Pcs/month 600,000- 650,000 Ladies Bra; fashion Pcs/month 300,000- 350,000 400,000- 450,000 3. Apex Textile Printing Mills Limited Apex Textile Printing Mills Limited (ATPML) is a fully vertical setup to manufacture high quality Knit-garments and both ladies & men’s underwear using in-house fabrics. High quality knit-garments for infant and children are manufactured in one floor. In the separate two floors men’s and ladies underwear and others intimate apparels are made.Both the sewing floors use in-house fabrics and components manufactured within the Apex textile complex. The plant is equipped with facilities to produce garments starting from the infant sleep sac k / body suits to ladies / men’s hooded sport jackets, based on designs, fabrics and accessories as required by the buyer. The garments can be from basic to complicated cut & sew, with placement prints, embroidery or both. Page 3 of Profile of the Textile Complex of Apex  Holdings   The production capacity of the knitwear section of ATPML is about 1. 0 to 1. million pieces per month of knit garments and that of the underwear floors are about 3. 4 to 3. 6 million pieces per month. The two tables below shows the capacities of the 3 floors in ATPML. The capacities of different types of knit-garment, with sufficient flexibility to allow 25-40% additional capacity of any one of the items. Infants Pcs / month Children’s Pcs / month 400,000 – 450,000 Ladies apparel Pcs / month 300,000 – 350,000 300,000 – 400,000 The table below shows the sewing capacities of underwear in ATPML. Children’s underwear Pcs / month 600,000 – 700,000Ladies und erwear Pcs / month 1,200,000 – 1,250,000 Man’s underwear Pcs / month 1,600,000 – 1,650,000 Facilities within Apex Textile complex: Apex textile complex is the combination of these 3 vertical operations, from fabrics to garment factories along with Apex Yarn Dyeing Mills limited. 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. 1. Garment-making: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 t o produce samples according to buyer’s specifications and /or Apex’s own designs (see page XX). 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. Page 4 of Profile of the Textile Complex of Apex  Holdings 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 re laxation. Sections of the cutting floor Page 5 of Profile of the Textile Complex of Apex  Holdings   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. 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 inspect ion. Page 6 of Profile of the Textile Complex of Apex  HoldingsSections of the finishing floor Another section of the finishing floor 1. e. Molding & Laminating: Apex Lingerie Limited mainly uses 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. Foam & fabric molding section 1. f. Hook & eye tape making: Apex Lingerie Limited mainly uses the hook & eye tape making facility.This section is equipped with fully computerized machinery to Page 7 of Profile of the Textile Complex of Apex  Holdings   produce both hook tape and eye tapes of up to 4 rows. The Hook & eye capacity is about 80,000 pieces/day. 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 Sections of circular knitting departmentPage 8 of Profile of the Textile Complex of Apex  Holdings Warp knit fabrics: Solid dyed or yarn dyed, with or without Spandex Tricot: Double tricot, Charmeuse, mesh, honeycomb, velour, diamond tulle etc (from rigid to 30 % elastane); Capacity: 150,000 meters / month Raschel: powernet, satinette, slee knit, one way stretch fabric etc (from 5% to 35 % elastane); Capacity: 70,000 meters / month Simplex; Various types of Simplex fabrics (up to 35% elastane) Capacity : 24,000 meters to 30,000 meters / month Elastane warping, rigid yarn warping and warp knitting sectionsFlat knit fabrics: Solid dyed or yarn dyed Collars / cuffs (SHIMA SEIKI); Capacity: 6,000 sets / day Fabrics for styling Flat knitting section 2. b. Dyeing & finishing facilities for wide fabrics: Dyeing machines are suitable for cotton, spandex cotton, polyamide, polyester, viscose, and various blends; Capacity 55,000 Kg / day Page 9 of Profile of the Textile Complex of Apex  Holdings   14 sample dyeing machines which can produce 40 different sample fabrics in every day. This department is equipped with both open width & tubular finishing machinery. Fabric finishing section is equipped with stenter / open-wid th 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. 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. For Fleece fabrics, the finishing section is equipped with raising machines, brushing machine and searing machine. Capacity: 10,000 Kg/day.Part of the dyeing department showing a section of the sample dyeing Sections of the dye-finishing Page 10 of Profile of the Textile Complex of Apex  Holdings 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:    †¢ One 12 colors Rotary screen printing setup for knit fabrics with a capacity of about 25,000 meters/day. AND One 12 colors Flat-Bed printing setup for knit fabrics with a capacity of about 22,000 meters/day.Loop steamer / polymerizer / after print washing Digital engraving Computerized design preparation Fully equipped sample & strike off preparation Color kitchen Screen preparation, sample printing †¢ †¢ †¢ †¢ †¢ †¢ †¢ Screen preparation, sample printing and 12 color rotary screen printing Page 11 of Profile of the Textile Complex of Apex  Holdings 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. Rubber covering (double covering): Capacity: 1200 Kg /day Spandex covering (single covering): Capacity: 540 Kg / day Needle looms (without jacquard): Capacity: 3 50,000 meters / day Needle looms (Jacquard): Capacity: 50,000 meters/day Crochet: Capacity: 60,000 meters / day Narrow fa brics dyeing: Capacity: 350,000 meters / day Label printing: Capacity: 200,000 labels / day Narrow fabric weaving, knitting & dyeing Page 12 of Profile of the Textile Complex of Apex  Holdings   3. Yarn dyeing Dyed yarn; cotton, polyester & nylon: Capacity: 13,000 to 15,000 Kg/day Sewing and embroidery threads; Spun polyester, filament polyester / nylon / viscose: Capacity: 45,000 cones / day . Embroidery: Yarn dyeing, winding & spooling Capacity 15,000 pieces/ day Solid Embroidery: 9 color machines Applique Embroidery on print Sequence / cording / boring Embroidery section 5. Placement printing: Capacity: 60,000 to 100,000 pieces / day in up to 6 colors Pigment / Discharge print Puff / Rubber print Page 13 of Profile of the Textile Complex of Apex  Holdings   Glitter / Flock print Stone attachment Foil printing / metallic shine High density printing Photo print Sections of Placement printing department 6. Pad printing & label printing:In keeping with the need of the market, Apex 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 labels. 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. Page 14 of Profile of the Textile Complex of Apex  Holdings 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. Packaging area and storage 9. Quality control & Textile testing In addition to the modern machinery & equipments, Apex has constantly worked with a wide range of technical experts from Japan, Philippines, Hong Kong and Sri Lanka to improve the working and quality control pro cedure. Sewing technicians work constantly with the operators and supervisor to upgrade the quality standards and optimize efficiency. QA department personnel conducts inspection of fabric, cutting, molding, bundle preparation and 100% garment quality inspection and recording at all stages of production. Fabric weight (density), yarn count & composition Spectral color matching Color Fastness to wash, Rub, light etc Shrinkage and other dimensional stability Extension and Modulus etc Page 15 of Profile of the Textile Complex of Apex  Holdings Section of laboratory, Spectral equipment and OEKO-TEX certificate In addition, regular testing of yarn, fabrics etc are conducted at our wellequipped lab, accredited by H&M. 0. Product Development and Fashion Design Department: For the last several years, Apex’s 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 Apex 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: Our operations are conducted with awareness for environmental safeguard and we deem it a s our obligation to prevent pollution by complying with relevant environmental legislations. Apex is 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.Apex Textile complex fully trea ts all factory effluent before releasing into the environment. All the factories within the complex are fully compliant with and or certified by; WRAP certified OEKO-TEX Standard 100 OE (Organic Exchange Certificate) GSV / CTPAT approved Fare Trade ISO 9000 2001 SEDEX Code of Conduct required by major retail stores of the world, e. g. , H&M, Maidenform, Hanes Brands Inc, Vanity Fair, JC Penney, Target, Lindex, Sear-Kmart, Fruit of the loom, Walmart, The Children Place etcWe follow ethical employment practices and adhere to applicable state, National and International laws on labor employment. We provide a clean, safe and healthy environment, adopt fair labor practices, reward them with wages without any discrimination and we do not interfere in their freedom of association and personal    Page 16 of Profile of the Textile Complex of Apex  Holdings   freedom. In addition, we have the Child care center accommodate with 90 children providing food, nursing etc. 12. Buyers of Apex Textile Complex: Our buyers of Knitwear are; H&M, Zara, The Morrison, Oshkosh/Caters, Sainsbury, V a n i t y F a i r .Children Place, O’stin, Buyers of Bra are : Maidenform, H&M, George UK, Vanity Fair, Matalan, Hunkemoller, Charlott, Sears, Next, JC Penney, Kohls, Target, Lindex, Kappahl . Buyers of Underwear are : H&M, George UK, Lindex, Kappahl, DB Apparels, Hema, Next, Pi erre Cardin , 2xist. 13. 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, Apex’s 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 pro duction management team, PPIC department, and QAD coordinate the production and the commercial department oversees the export and documentation. 14. How to execute a new order To start business with any of the factories of Apex Textile Complex, you or your representative can visit our factory to see our production facilities, products and compliance issues, or have the factory audited.In addition, you can send us any of the following along with the sizes & colors you want and target date(s) for the shipment(s). A sample of the item(s) you want. OR A sketch of the item(s) you want with complete measurement chart. OR You can ask us to send you samples from our own collections Our merchandizing department will give you our costing(s) and send counter sample(s) as soon as possible with and options of shipment dates. Page 17 of