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; zahur@apexholdings.com
Shahriar Ahmed, Director Operations; shahriar@apexholdings.com
Marketing & Merchandizing
For knitwear:
Ershad Ullah Khan, GM; ershad@apexknitting.com
MD. Mushahed Alam, Manager; mushahed@apexknitting.com
Belal Hossain, Manager; belal@apextextileprinting.com
,
For Lingerie and Underwear:
Shahnaz Begum Zharna (Ms), AGM; zharna@apexlingerie.com
Nasima Begum (Ms), AGM; nasima@apexlingerie.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 “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 threads
The 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 clinic 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 / men’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 2.3 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
Ladies
Pcs / month
400,000 - 450,000
1,500,000 – 1,600,000
200,000 - 250,000
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
Ladies Bra;
standard
Pcs/month
Ladies Bra;
fashion
Pcs/month
500,000- 550,000
600,000- 650,000
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 sack / 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 1.2
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
Ladies apparel
Pcs / month
400,000 - 450,000
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 - 700,000
Ladies underwear
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 to 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 relaxation.
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 inspection.
Page 6 of
Profile of the Textile Complex of Apex Holdings Sections 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 department
Page 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 sections
Flat 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-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.
 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 fabrics 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
Yarn dyeing, winding & spooling
4. Embroidery:
Capacity 15,000 pieces/ day
 Solid Embroidery: 9 color machines
 Appliqué
 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 procedure. 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.
10. 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 treats 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 etc
We 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 production 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