Friday, November 22, 2013

About winding and objects of winding

Winding: The process of transferring yarns from ring, bobbin, hank into a suitable package is called winding. It may be electrical or mechanical. 
Objects of winding:
         i.            To transfer yarn from one package to another suitable package, this can be conviently used for used for weaving process.
       ii.            To remove yarns fault like hairiness, naps, slabs, foreign matters.
    iii.            To clean yarn.
    iv.            To increase the quality of yarn.
       v.            To get a suitable package.
    vi.            To store the yarn. 

Thursday, November 21, 2013

Process lay out of yarn manufacturing system with modern blow room line

Process lay out of yarn manufacturing system with modern blow room line:


Mixing, blending,lint,linters and bale management

Mixing: Mixing could be thought of combining of fibres together in somewhat haphazard proportion whose physical properties are partially known so that, the resultant mixture has only generally known average physical properties which are not easily reproducible.

Blending: Blending is based on the measurement of important fibre properties i.e, length, strength, cleanliness, e.t.c. Quantatively proportioning and combining the compatiable properties of the resultant blend can be predicted and reproducible.

Importance of mixing and blending:
  • To give the required characteristics to the end product.
  • To compensate for variation in the characteristics of the raw mtls.
  • To hold down raw material cost.
  • To achieve uniform quality.
  • To use waste cotton in mixing.
  • To meet functions and end use requirements.
Lint: The seed free cotton which is gotten after ginning is called ginning.
Linters: After ginning some short fibres are remained with the surface of the cotton seed which is called linters.
Bale management: The choice of cotton bales according to the fibre characteristics in order to achieve acceptable and economical processing condition and a constant yarn quality is called bale management.
Objects of bale management:
  • An evening out of the quality characteristics of a yarn.
  • A mean of avoiding quality jumps.
  • A possibility of reducing cost as a result of an improved knowledge of the fibre characteristics.



Flow chart of wet processing for cotton and blended fabric

Wet processing: The processes used are desizing, scouring, bleaching, dyeing, printing and finishing which are combinely called wet processing. The total wet processing can be divided into three groups. Such as:
  •  Pre-treatment process.
  • Dyeing or printing process.
  •  Finishing process.

Flowchart of wet processing for cotton fabric:


Flow chart of wet processing for blended fabric:
 

Wednesday, November 20, 2013

Some terms and definitions of yarn manufacturing

Filament: Man-made fibre of very great length, e.g, several km.
Filament yarn: Man-made fibre comprising one or more filament.
Mono filament yarn: Filament yarn consisting of one filament with a thickness up-to .1mm.
Multi filament yarn: Filament yarn comprising many filaments up to 30000 tex.
Micro-fibre:The textile committee, Germany defines a micro-fibre as a fibre finer than 1.2 dtex for polyester and finer than 1.0 dtex for polyamide.
Ultra fine fibre: An ultrafine fibre is specified as a fibre of less than 0.5 d (denier)
Super ultrafine fibre: A fibre of less than 0.1 d is referred to as a super ultra-fine fibre.

Yarn

Yarn:A yarn is an assembly of fibres that are laid or twisted together to form continuous strand.

Yarns may be made from either staple fibres or filament fibres. Staple fibres are twisted into yarns, filament fibres need little or no twist to hold them together in yarn.

Classification of yarns on the basis of processing: 
  I.            Carded or Karded yarn. 
  II.            Combed yarn.

III.            Semi-combed yarn. 

Carded or Karded yarn: It is an inferior quality of yarn. In processing this yarn, no comber is used. It contains more short fibres and naps.The process flowchart of carded yarn is as follows:


Combed yarn: It is a superior quality of yarn. In manufacturing combed yarn comber is used. So this yarn contains almost no naps or short fibres.The process flowchart of combed yarn is as follows:

Semi combed yarn: It is a medium quality of yarn. It is manufactured by mixing some combed slivers. For example, 50% combed sliver means if there are 8 slivers 4 carded and 4 combed slivers are mixed at post comb draw frame to produce this type of yarn.The process flow chart is as follow:

 

Some terms and definitions of yarn manufacturing

 Some terms and definitions of yarn manufacturing
Filament: Man-made fibre of very great length, e.g, several km.
Filament yarn: Man-made fibre comprising one or more filament.
Mono filament yarn: Filament yarn consisting of one filament with a thickness up-to .1mm.
Multi filament yarn: Filament yarn comprising many filaments up to 30000 tex.
Micro-fibre:The textile committee, Germany defines a micro-fibre as a fibre finer than 1.2 dtex for polyester and finer than 1.0 dtex for polyamide.
Ultra fine fibre: An ultrafine fibre is specified as a fibre of less than 0.5 d (denier)
Super ultrafine fibre: A fibre of less than 0.1 d is referred to as a super ultra-fine fibre.

Garments Production Process

Garments Production Process: 
Stepwise garments manufacturing sequence on industrial basis is given below:
Design / Sketch
Pattern Design
Sample Making
Production Pattern
Grading
Marker Making
Spreading
Cutting
Sorting/Bundling
Sewing/Assembling
Inspection
Pressing/ Finishing
Final Inspection
Packing
Despatch