Basic Things of Spinning, Weaving, Dyeing and Garments

Basic of Textile Engineering! Spinning, Weaving, Knitting, Dyeing, Printing, Finishing, Garment or Apparel are the Parent sections of the Textile Mill. In several of Textile Thesis published in different magazine are found the contemporary articles about the modern mechanism and articles about Spinning, Weaving, Dyeing and Garments Technology. But sometime we need to know about the fundamentals of Textile. Very few of the thesis and articles contain it. So I will try my best to provide you the basic of Textile. And of course I will include everything about Textile successively. So let me start now………
Textile Fibre In Textile industry we have to work with fibre and fibre related components. That means without fibre it’s not possible to make a yarn. If yarn is not possible, making fabric and garments are impossible. So it is seen that Fibre is very important. First of all I will give you some basic knowledge about Textile Fibre. Later… I will tell you elaborately in the certain post that is collected from the various thesis and magazine. Fibres are used to production of Yarn and Fabric called Textile Fibres.
It is essential to know that a Textile Fibre must have some definite characteristics.
These are- 1. Minimum Length. It should be 100 times of long than its diameter. 2. Strength 3. Elongation and Elasticity 4. Moisture absorbency 5. Tendency to be twisted. 6. Fibre Fineness.
Classification of Textile Fibre: 1. Natural Fibre 2. Man-made Fibre Natural Fibre are derived from a) Tree i,e, Seed, Leaf, Bast Fibres b) Animal i,e, Silk, Wool c) Mineral i,e, Asbestos d) Metal Fibre i,e, Gold, Silver Mane-made Fibre are derived from a) Regenerated–Cellulose Base, Protein Base, Mineral Base. b) Synthetic—Organic Base (Polyamide, Polyester, Thermoplastic, Hydrocarbons), Inorganic Base

Textile Classes According To It’s Manufacturing Processing Methods

The whole textile processing; from the fibre to garment are classified in several segments. The classes are 1. Spinning 2. Weaving or Knitting 3. Dyeing or Printing 4. Finishing 5. Garments or Apparels.

The short descriptions of Textile Classes:

Spinning:

It is very initial process amongst the Textile Classes. In spinning section fibre are processed in order to make yarn. Several spinning machines are used here to make a fibre to yarn completely.

Weaving or Knitting:

Two types of fabric are produced in Textile. One is Woven Fabric, another is Knit Fabric. Woven fabric is produced by looms with the interlacement of warp and weft yarns. In knitting section the knit fabric are produced with the loops of yarns. Loops of yarns are bound together by passing one series of loop through other series of loops and form the fabric. Textile Knitting follows some knit structure.

Dyeing or Printing:

Textile Dyeing is a process where the fabric is dyed by different dyestuff mixing with water and other chemicals in a certain temperature. It is the main part of textile classes in the basis of textile trade issue. On the other hand, Printing is done by following a pre-determined design and printing paste is used here. Thickener or gum or printing rubber gum are used to fix the print paste on the fabric according to design.

Finishing:

Finishing is one of the important classes of textiles, where all of the textile processes holds the good appearance. Mercerization, Calendaring and done here.

Garments or Apparels:

After getting a woven or knit fabric it is the time to make the fabric to be wearable. Garments section takes the responsibility to do this. In apparel section the fabric is cut according to marker, pattern and then sewed.

Latch Needle | Characteristics & Uses of Latch Needle

Latch Needle is mostly used needle in the knitting industry today:
Latch Needle Characteristics:
1. Most widely used in weft knitting.
2. More expensive needle than the bearded needle.
3. Self acting or loop controlled.
4. Work at any angle.
5. Needle Depth determines the loop length.
6. Variation of the height of reciprocating produces knit, tuck or miss stitch.
Uses of Latch Needle: Latch needle are widely used in –
1. Double Cylinder Machine,
2. Flat Bar Machine,
3. Single Jersey Circular Knitting Machine,
4. Double Jersey Circular Knitting Machine.

Mechanical Terms of Textile Knitting | Sinker, Jack, Engineering Cam, Knitting Cam

The Sinker of Knitting:

The sinker is the second primary knitting element. It is a thin metal plated with an individual or collective action. It may perform the following functions:-
1. Loop Formation
2. Holding Down
3. Knocking Over.

The Jack of Knitting:

The jack is a secondary weft knitting elements, which may be used to provide versatility of latch needle selection and movement. It is placed below and in the same tricks as the needle and has its own operating butt and ca system. The needle may thus be controlled directly by its butt and cam system or indirectly by the movement of he jack.

Textile Cams:

Cams are the device which converts the rotary machine drive into a suitable reciprocating action for the needles and other elements. Cams are of two types:-
a) Engineering Cam.
b) Knitting Cam.

Engineering Cam:

It is a circular engineering cam. The drive is transmitted and adapted via can followers, levers, pivots and rocker shaft. One complete 360˚ revolution of the drive shaft is equivalent to one knitting cycle.
In warp knitting, four types of cam drive have been employed:-
1. Single acting cams
2. Cam and counter cams
3. Box/ Enclosed cams
4. Counter cams.
Knitting Cam: The angular knitting cam acts directly onto the butts of needles or other elements to produce individual or serial movement in the tricks of latch needle of weft knitting m/c. Two arrangements are exist there:
1. Revolving Cylinder M/cs: The needle butt pass through the stationary cam system and the fabric hanging from the needles revolves with them.
2. Reciprocating Cam carriage flat M/cs: The cams with the yarn feed pass across stationary needle beds.

Design Cams of Weft Knitting Machine

There are three types of design cams are used in weft knitting machine:
a) Knit Cam
b) Tuck Cam
c) Miss Cam

How To Do Mechanical Knitting | Sinker, Jack, Engineering Cam, Knitting Cam

What type of element is used on mechanical knitting? Have you faced such of question? Here I will tell you about the knitting elements by which the mechanical knitting is carried out.

The Sinker:

The sinker is the second primary knitting element. It is a thin metal plated with an individual or collective action. It may perform the following functions:-
Loop Formation
Holding Down
Knocking Over.

The Jack:

The jack is a secondary weft knitting elements, which may be used to provide versatility of latch needle selection and movement. It is placed below and in the same tricks as the needle and has its own operating butt and ca system. The needle may thus be controlled directly by its butt and cam system or indirectly by the movement of he jack.

Knitting Cams:

Cams are the device which converts the rotary machine drive into a suitable reciprocating action for the needles and other elements. Cams are of two types:-


a) Engineering Cam.

b) Knitting Cam.

Engineering Cam in Knitting:

It is a circular engineering cam. The drive is transmitted and adapted via can followers, levers, pivots and rocker shaft. One complete 360˚ revolution of the drive shaft is equivalent to one knitting cycle.

In warp knitting, four types of cam drive have been employed:-
Single acting cams
Cam and counter cams
Box/ Enclosed cams
Counter cams.

Knitting Cam:

The angular knitting cam acts directly onto the butts of needles or other elements to produce individual or serial movement in the tricks of latch needle of weft knitting m/c. Two arrangements are exist there:
Revolving Cylinder M/cs: The needle butt pass through the stationary cam system and the fabric hanging from the needles revolves with them.
Reciprocating Cam carriage flat M/cs: The cams with the yarn feed pass across stationary needle beds.

Design Cams of Weft Knitting Machine

There are three types of design cams are used in weft knitting machine:

a) Knit Cam
b) Tuck Cam
c) Miss Cam

What is Yarn Geometry, Classification & Designation

Basic of Textile Engineering! Spinning, Weaving, Knitting, Dyeing, Printing, Finishing, Garment or Apparel are the Parent sections of the Textile Mill. In several of Textile Thesis published in different magazine are found the contemporary articles about the modern mechanism and articles about Spinning, Weaving, Dyeing and Garments Technology. But sometime we need to know about the fundamentals of Textile. Very few of the thesis and articles contain it. So I will try my best to provide you the basic of Textile. And of course I will include everything about Textile successively. So let me start now………

Textile Fibre In Textile industry we have to work with fibre and fibre related components. That means without fibre it’s not possible to make a yarn. If yarn is not possible, making fabric and garments are impossible. So it is seen that Fibre is very important. First of all I will give you some basic knowledge about Textile Fibre. Later… I will tell you elaborately in the certain post that is collected from the various thesis and magazine. Fibres are used to production of Yarn and Fabric called Textile Fibres.

It is essential to know that a Textile Fibre must have some definite characteristics.

These are- 1. Minimum Length. It should be 100 times of long than its diameter. 2. Strength 3. Elongation and Elasticity 4. Moisture absorbency 5. Tendency to be twisted. 6. Fibre Fineness.

Classification of Textile Fibre: 1. Natural Fibre 2. Man-made Fibre Natural Fibre are derived from a) Tree i,e, Seed, Leaf, Bast Fibres b) Animal i,e, Silk, Wool c) Mineral i,e, Asbestos d) Metal Fibre i,e, Gold, Silver Mane-made Fibre are derived from a) Regenerated–Cellulose Base, Protein Base, Mineral Base. b) Synthetic—Organic Base (Polyamide, Polyester, Thermoplastic, Hydrocarbons), Inorganic Base

CPI And WPI / EPI And PPI Measuring System With The Magnifying Glass Setting Multiplier

In fabric structure; it is important to know, how much yarn is in length wise and width wise. To know the number of yarn in a specific fabric a measurement is done for this. For this yarn in inch is measured by the magnifying glass setting multiplier. It is a off line quality assurance system.



In knit fabric yarn is measure in course and Wales direction. CPI means yarn is in course per inch and WPI means Wales per inch.

Measure the CPI & WPI with the magnifying glass setting multiplier:

1. Take the fabric & marking 1 inch with the ball pen according to the Course & Wales wise of a knitted fabric.


2. Then set the marking point with the multiplier scale & counting the CPI & WPI of knitted fabric in 1inch.


3. Wales per inch and course per inch is counted by the magnifying counting glass.

In woven fabric EPI and PPI is measured to the number of yarn in a fabric. EPI means ends per inch and PPI means picks per inch. Number of yarn in warp direction is measured by EPI and number of Weft yarn in fabric is measured by PPI. In weaving beam is prepared by analyzing the fabric by magnifying glass setting multiplier.

Measure the EPI & PPI with the magnifying glass setting multiplier:

1. Take the woven fabric & marking 1 inch with the ball pen according to the warp & Weft wise of the woven fabric.


2. Then set the marking point with the multiplier scale & counting the EPI & PPI of woven fabric in 1 inch.


3. Ends per inch and Picks per inch are counted by the magnifying counting glass.

So, calculate CPI and WPI for knitted fabrics and EPI and PPI for woven fabrics.

Grey Knit Fabric Inspection System In Batching Section | Quality Assurance

The inspection and grading of fabric quality is one of the important functions of Quality Control in the grey or finished state, the grading of fabric is a difficult task, taking two primary considerations: as the frequency of effects and the seriousness of defects.

The grading has two primary functions: First, to classify the fabrics according to standard qualities based on the end-use and costumer demands and second, to supply information as to the qualities actually being produced.

The Knitted fabric can be classified into three levels of quality, each one have a number of points for defects as follows.

The First quality level             : 40 points per 100 Linear Yards.

The Second quality level         : (40 – 80) points per 100 Linear Yards.

The Third quality level             : 80 points or more per 100 Linear Yards.

General Instructions for the final inspection: Before sending the grey knit fabrics to the dyeing floor, following inspection is done in batching section.

1. All pieces will be graded on the base of 40 points per 100 linear yards Mapping will be done on each piece to insure proper grading. Do not count more than 4 points per one yard.


2. All defects must be recorded and marked in final inspection and an accurate account of points made to insure proper grading.


3. All fabric must meet specifications.


4. At the end of each piece of fabric, the inspector will add up total points and decide whether the piece can be shipped as first quality or not, reworked, placed in lower quality, or cut and upgraded for shipment. Fifteen yards or more can be shipped as first quality.


5. The quality control supervisor must approve the grading of all quality levels and check the lower quality.


6. Major or unsightly defects in the first and last yard of a roll or piece will be cut. All defects of one yard length or more will be cut out of the piece. Defects within the first 2 inches or the last 2 inches of a piece will not be cut out or counted in the grading.


7. Open defects on the back of fabric such as drops, runs and hanging picks are to be included in the grading of fabric.


8. Pieces can be connected together, once each piece must be the same shade.


9. All defects such as runs that extend more than a yard in length will be cut out.


10. Fabric up to 70 inches will be allowed a bow of not more than 1 inch and a Bias of not more than 2 inches.


11. Defects within one inch of the fabric edge will not be counted except on tubular fabrics. All defects will be counted in tubular goods.

Grading Procedure: During inspection, following points are considered.

1. All open defects or major defects counted with 4 points per defect.


2. Surface defects over 9 inch length counted with 4 points per defect.


3. Surface defects 6 to 9 inches length counted with 3 points per defect.


4. Surface defects 3 to 6 inches length counted with 2 points per defect.


5. Surface defects up to 3 inches length counted with one point per defect.


6. Running defects, such as tucks, needle lines, barre, crack marks, are judgment defects

Batching is the process to get ready the fabrics which should be dyed and processed for a particular lot of a particular order.

Four Point Systems For Knit Fabric Quality Measurement

In knit fabric inspection system; most of the companies follow four point systems for measuring the quality of the knit fabric. There are various methods for measuring quality of the knit fabric but among all of the methods four point systems is preferable to the inspector of the quality.



After knitting; knitted fabrics are gathered in front of the checking table and the quality inspector inspect the quality of the knit fabric and listed the faults found in the knit fabric and mark it in the knit fabric.

Most of the knit fabric manufacturing companies maintain the ISO: 9001:2000 standards in case of quality. Therefore, the four point systems are followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inspection at different knitting mills.

Four (4) - Point system for knitting fault inspection: During inspection, if the inspector found any knitting faults then he marks it in the fabric and counts it in the sheet. During inspection, following points are considered.

Knitting fault	Point
Slub	1
Any hole	4
Needle/Sinker line	4
Needle breakage(up to 10)	4
Press off	4
Thick, Thin, Dirt, Oil spot, Contamination up to 3" in length	1
Thick, Thin, Dirt, Oil spot, Contamination up to 6" in length	2
Thick, Thin, Dirt, Oil spot, Contamination up to 9" in length	3
Thick, Thin, Dirt, Oil spot, Contamination above  9" in length	4

Quality (points per 100 square meter) = (Total point X GSM)/ (Roll weightX10)

Quality Classification: After calculation of the quality of the knit fabrics, decision is delivered according to the following way.

1	2	3
<20	20 - 30	>30
OK	Ask	Reject

So, when we will check the quality of the knit fabric, we should follow the four point systems.

 

Quality Assurance System Of Knitting Division | Quality Measurement

Quality Assurance System: In modern times, customers want to get quality and quantities products from the producer in every stage of production. For this reason, it needs to deliver quality product to the buyer. To be ensuring about the quality of the product, a quality control department is work for this. Quality control division is responsible to ensure the quality of the product.

In knitting section; a quality assurance division is involved to check the quality of the knit fabric before dyeing. After collecting fabric rolls from different machines, these fabrics need to inspect thoroughly by the quality inspectors to assure required quality before dyeing. Quality assurance of knitted grey fabric is described here.

Some points are needed to maintain for high quality knit fabric: During production, different points are needed to consider. Here are some of them-

1. Brought good quality yarn.


2. Machines are oiled and greased accordingly.


3. G.S.M, Stitch length, Tensions are controlled accurately.


4. Machines are cleaned every shift and servicing is done after a month.


5. Grey Fabrics are checked by 4 point grading system.

List of equipments for quality control: To ensure the quality of the knit products, following instruments are required.

1. Inspection m/c.


2. Electronic balance


3. GSM cutter.


4. Measuring tape.


5. Scissors.


6. Indication sticker.

Quality assurance procedure in knitting division: In knitting floor; body, rib, collar and cuff are produced. The quality of these products is measured as the following way.

Body & Rib Inspection: After production of single jersey or double jersey knit fabric, it sends to the quality checking table. All rolls are kept in front of the inspection m/c time to time and are inspected over the inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etc are recorded in inspection report to classify the fabric based on the four point system.

Collar & Cuff Inspection:  This type of products are produced in flat bed knitting machine. Collar and cuff are inspected visually under the light box, any major or minor fault in collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly counted and recorded.

After completing inspection, quality of the product is measured in four point system. If the product passes the quality the it sends for dyeing if not it sends to store as a reject fabric.

So, we should be care full about the faults of knitted fabric.

 

What Is Warp And Weft Knitting | Difference Between Warp And Weft Knitting

Knitting is done by set of connected loops from a series of yarn in warp or weft direction. Knitted fabrics are divided into two main types; they are

1. Warp knitting


2. Weft knitting

Warp knitting: In a warp knitted structure each loop in the horizontal direction is made from different thread. Sweater is made by this warp knitting techniques.

Weft knitting: In a weft knitted structure a horizontal row of loops can be made using one thread and the thread runs in the horizontal direction. Most of the knitted fabrics are produced by weft knitting.

Difference between warp and weft knitting: Basically warp and weft knitting process are totally different from one to another. Following are the difference of warp and weft knitting.

Warp Knitting	Weft Knitting
The loops are produced to the length of fabric.	The loops are produced to the width of the fabric.
It is elastic to the length.	It is elastic to the width.
Elasticity of the warp knitted fabrics is less than weft knitting.	Elasticity of the weft knitted fabrics is higher than warp knitting.
Its shrinkage properties is less.	Its shrinkage properties is higher than warp knitted fabrics.
Here courses are needed for each pattern row.	Courses are equal to the pattern.
Yarns are supplied from beam.	Yarns are supplied from cone.
At least one yarn is required for each needle.	Any number of needle.
Creating fabric by this method is suitable to dry wash.	Hand wash is suitable for weft knitting.
Any design is done easily.	All types of design is complex.
It is specially suitable for producing coarse fabric.	It is suitable for producing thin fabric.

What Is Knitting And Weaving | Difference Between Knitting And Weaving

Knitting and weaving are the two different processes to produce knitted and weaved fabric. In modern times both types of fabrics have a great demand in the market. The manufacturing process of this both types is different from one to another.

Knitting: The process in which fabrics are produced by set of connected loops from a series of yarn in weft or warp direction is called knitting. Knitted fabrics are produced by knitting technology. Different types of knitted fabrics are produced by the knitting machine.

Weaving: The process in which fabrics are produced by interlacing two sets of threads according to design is called weaving. Weaved fabrics may be in grey, stripped or colored form. Different types of designed fabrics are produced by the weaving technology.

Difference between knitting and weaving: Although knitting and weaving are the fabric manufacturing techniques but they have a lot of difference. Difference between knitting and weaving are given below.

Knitting	Weaving
knitted fabrics are produced by set of connected loops from a series of yarns.	Woven fabrics are produced by the interlacing two types of threads.
One set of yarn is used in this method.	Two sets of yarn is used for this method.
Do not require sizing.	Sizing is required before weaving.
Yarn preparation is not so necessary.	Yarn preparation is must.
Production capacity of knitting is more.	Production capacity of weaving is less than knitting.
Production cost of knitting is less than weaving cost.	Production cost of weaving is higher than knitting.
About 52% fabrics are produced by knitting technology in textile section.	About 48% fabrics are produced by weaving techniques in textile section.
Knitting is done by loop formation.	Weaving is done by shade formation.
Elastic property of the knit fabrics are higher than woven fabric.	Elastic property of the woven fabrics are less than knitted fabric.
Dimensional stability is lower than woven fabric.	Dimensional stability is higher than knitted fabric.

Process Flow Chart Of Sweater Manufacturing Technology

Sweater is the special types of knitted fabrics. Day by day the demand of sweater fabrics is increasing rapidly. To satisfy the present sweater fabrics demand, various sweater manufacturing companies are trying heart and soul. They are trying to add various modern facilities to the sweater fabrics.



It is important to know the process by which sweater fabrics are manufactured. Sweater manufacturing process is given below:

Import Yarn

↓

Winding

↓

Yarn Distribution

↓

Knitting

↓

First Inspection

↓

Linking

↓

Second Inspection

↓

Light Checking

↓

Third Inspection

↓

Labeling

↓

Ironing

↓

Quality Control

↓

Final Inspection

↓

Packing / Folding

↓

Exporting

This is all about the manufacturing process of sweater fabrics. It is the basic sequence of sweater manufacturing.

 

List Of Top Branded Knitting Machine Of The World | Knitting Machine For Bulk Production

In modern time; various knitting machine manufacturing companies are trying to manufacture such types of machine which is cheap in price and facilities more advantage to the user. They also try to develop the present structure of knitting machine. To open a new floor of knitting or add some new machine in the old floor ones can try for the following knitting machine because most of the machines are using in most of the knitting industry.



We know that knitting machines are divided into three types; they are as follow:

1. Single Jersey Knitting Machine


2. Double Jersey Knitting Machine


3. Flat Bed Knitting Machine

Now I will give some knitting machine name list with their origin country name.

Circular Knitting Machine (Single & Double Jersey Knitting Machine)

• FUKAHARA (Japan)


• ORIZIO (Italy)


• MAYER & CIE (Germany)


• HANMA (China)


• HUPTER (Taiwan)


• JIUNN LONG (Taiwan)


• MASA (Taiwan)


• DONG HO (Taiwan)


• WELL (Taiwan)


• JINHAR (Taiwan)


• PAILUNG (Taiwan)


• LISKY (Taiwan)


• Tayo (Taiwan)


• Hun-lung (Taiwan)


• FUKAHAMA (Taiwan)


• Zentex (Singapore)

Flat Bed knitting Machine

• SHIMA SEKI (Japan)


• STOLL (Germany)


• Jy-leh (Taiwan)


• KAUOHENG (Taiwan)


• JAMES (Taiwan)


• FLYING TIGER (Taiwan)

Before buying a knitting machine following points should be considered:

1. Machine type


2. Brand name


3. Origin country


4. Model no.


5. Diameter in Inch


6. No. of Feeder


7. Gauge


8. No. of Needle

In modern time Engineering Auto Stripe is available for producing multi-color stripe knit fabrics. Engineering Auto Stripe may be 4 colors or 6 colors. It uses when a fabric could not produce in a normal circular knitting machine. Auto stripe knitting machines are available in single jersey and double jersey form.

Flat knitting machines may be semi jacquard, full jacquard or fully computerized. We know that flat knitting machines are use for producing collar and cuff for the knit wear.

All of the machines are not same in price or not same in quality. When you will choose you’re desired one you should give emphasis on the requirements and best quality which will give you more facility in price and quality. One should not choose such types of knitting machine which cause knitting faults. Also we should consider the availability of the knitting machine parts.

So, you can choose one of the knitting machines for your knitting industry.

How To Execute Production Process In A Knitting Mill?

Knitting is the interlocking of one or more yarns through a series of loops. Knitting process is the main activities for producing knit goods. In every mill, there maintains a sequence in production processing. It is a team work. In every steps of a processing every responsive person is responsible for give best production. In a knitting mills production process runs as the following sequence.


→Firstly, knitting manager gets a production sheet from the merchandiser as accordance as consumer requirements then he informs or orders production officer about it. He also gives the schedule for producing targeted production.

→After getting the sample knitting manager analysis the design and draw a cam setting for produce the desired designed fabrics.

→After getting the information, production officer informs technical in charge and knows about machine in which the production will be run.

→Technical in charge calls for leader of mechanical fitter troops; they also take decision about machine for production considering machine condition, machine types, production capacity and maintenance complexity.

→Production officer with experienced mechanical fitter adjust required stitch length and grey G.S.M for getting final G.S.M.

→Supervisor checks daily production regularity and make operator conscious about finishing tin due time. They also maintain daily production report sheet. They are responsible to inform the production of that day to the knitting manager.

→Operators operate machine in high attention as if there were no faults in the fabrics. If he thinks or sure about any fabric faults, then he calls for the mechanical fitter in duty. Mechanical fitter then fixes it if he can or he informs it to the technical in charge. Then technical in charge observer the problem and take necessary steps to remove the problem.

→During production time quality department also check the fabric and if they find any faults they inform it to the technical in charge. Technical in charge also take necessary steps for reduce the knit fabric faults.

→After completing the gray knit fabrics production it sends for quality check. If the fabrics pass the quality then it sends for next process.

Knitting division is very sensitive because performance of dyeing is completely depends on knitting. Any types of mistakes during knitting can be the resultant of rejection. A knitting manager should have deep knowledge about the dyeing, printing and finishing process as well as garment manufacturing. Others who are related with this should have the knowledge about the machine and knitting fabrics design.

So, try this at your professional life. I am sure it will help for getting better production in knitting section.

What Are The Considerable Points For Producing Knit Fabrics?

Knit fabrics are the fashion of new age. Various designed fabrics are produced in knitting machine. Knitting flow chart should follow during operation. During production process following machine parameters are considered.

• Machine diameter


• Machine rpm (revolution per minute)


• No. of feeder in use


• Machine gauge


• Count of yarn


• Required time


• Machine running efficiency

Considerable points to produce knit fabrics: Generally knit fabric production runs according to the order of buyer. When a buyer orders for fabric, they mention some points related to production and end product quality. Before production of knitted fabrics, these factors are needed to consider. Those are as follow:

Type of fabric or design of fabric: Knitted fabrics are various in design. When a buyer order for a product they give a sample or give the specification of the end product. Different designed fabrics are produced by changing the cam setting, needle setting and size of loop shape.

Finished G.S.M: It is technical term that indicates the weight of the fabric per square meter. In knitting section grey fabrics are produced but the programer should make his program for getting the finished G.S.M after dyeing. Some points are considered while setting grey G.S.M; they are enzyme level, color and suided or non suided. G.S.M of the fabric is controlled by the following way:

→Major controlled by VDQ pulley.

→Minor controlled by stitch length adjustment.

→By altering the position of tension pulley, G.S.M of the fabric can be changed. If pulley moves towards the positive directive then the G.S.M is decrease and in the reverse direction G.S.M will increase. This also depends on the machine type.

Yarn Count: Yarn count differ on the finished G.S.M. Higher the yarn count higher the G.S.M of the fabric. Sometimes spandex or lycra is used with the cotton in that’s case yarn count of cotton select with the combination of lycra.

Type of yarn: Different types of yarn is used for knit production. Cotton yarns may be combed or carded. Also synthetic fiber like lycra is used with cotton for some special case. All depends on the buyer requirement.

Diameter of fabric: Diamter of the fabric is another factor. Fabric may be open diameter or tube diameter. Any how grey dia. will be selected with response of finished dia. of the fabric.

Stitch length and color depth: If the depth of color of the fabric is high then loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so G.S.M is adjusted then. Similarly in case of light shade loop length should be relatively smaller. Stitch length vary depending on yarn count and shade of the fabric. If stitch length is not fixed with respond to finished G.S.M then knitting faults appear.

So, we have to consider above points before knit fabrics production.

 

 

Different Parts of Knitting Machine | Functions Of Machine Parts

Knitting machines are mainly two types; they are circular knitting machine and flat bed knitting machine. This two types are hugely use in knitting machine. A knitting machine is composed of lots of parts. Every parts of a machine are important for run the machine smoothly. Every part has a specific function during operation.



Different knitting machine parts and their functions are given below:

• Creel: Creel is called the holder of cone. Cone is placed in a creel for feeding the yarn to the feeder.

• Feeder: Yarn is feed through the feeder. No of feeder is depends on the design of the fabric.

• VDQ Pulley: G.S.M of the knit fabric is controlled by VDQ pulley. VDQ pulley is used for controlling the stitch length of the fabric.

• Guide: Guide is called the supporting element. Guide is used to guide the yarn.

• Sensor: Sensor is an automatic controlling system. When a yarn pass through this sensor than if any yarn break down or any problem occur than it automatically stop by this sensoring system.

• Cylinder: Cylinder is the main parts of a knitting machine. Adjustment of a cylinder is important. Cylinder carries needle, sinker, cam and many more.

• Spreader: Spreader is used to spread the knitted fabric before take up roller. Knit fabrics may be tube or open type. Spreader is adjusted as need.

• Fixation Feeder: This type of feeder is used in electrical auto striper knitting machine to feed the yarn at specific finger.

• Rethom: Rethom is used in electrical auto stripper knitting machine.

Different well known companies are manufacturing such types of knitting machine. Day by day they are trying to add some advance technology two facilities best opportunity. In this sense we can consider auto stripe, which gives more opportunity two produce multi-color long stripe knit fabrics. Different zigzag design also can be produced by an auto stripe machine. It is note that, faulty knitting machine parts create knitting faults. To increase the knitting production we should use latest knitting machine.

So, before buying a knitting machine we have to consider these above points.

Classification of Knitting Machine | Knitting Machines for the Industry

Knitting machines are use to produce knit fabric. Knitted fabrics are produced by the interlocking of one or more yarns through a series of loops by the use of hooked needle. Knitted fabrics are differing from one to another depending on their fabric design. Specific fabrics are produced from specific knitting machine.



Knitting machines are classified as follows:

Weft Knitting Machine

• Flat Bar Knitting Machine

1. Flat Bed


2. V-Bed


3. Single Bed


4. Unidirectional

• Straight Bar Knitting Machine

1. Single Needle


2. Double Needle

• Circular Knitting machine

1. Revolving Cylinder; Sinker Top or Open Top Single Jersey Knitting Machine


2. Revolving Cylinder; Cylinder and Dial Double Jersey Knitting Machine

• Circular Bearded Single

1. Sinker Wheel Knitting Machine


2. Loop Wheel Knitting Machine

Warp Knitting Machine

1. Rachel Knitting Machine


2. Tricot Knitting Machine

In modern times knit fabrics have a large verity. Verities type of knit fabrics is the demand of modern time. Such types of fabrics are produced in the knitting mills.

So, choose your favourite one which is required for producing knit fabrics.

How To Increase Production In Knitting Floor | Knitting Machine Utilization

Knit fabrics are produced from circular knitting machine or flat bed knitting machine. Circular knitting machines are two types, they are single jersey or double jersey knitting machine. This two type’s machine has different cam arrangement settings, which is responsible for design production.



Anyhow, production of knit fabrics depends on various factors. By developing the following factors we can increase the production of knit fabrics.

• Machine Speed: Production per hour depends on the speed of the machine. Higher the machine rpm, faster the movement of needle which increase the production. But we should make sure that, this higher speed will not impose excess tension on yarn. Excess tension on yarn can increase the breakage of yarn which is not desired.

• Number of Feeder: If the number of feeder increases in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. Which is responsible for increasing the production.

• Machine Gauge: Machine gauge also effect the production of knit fabric. Machine gauge vary depending on the type of machine and Manufacturers Company. Higher gauge machine gives higher production.

• Automation System: By imposing automation in the machine, production can be increased. Following automation can be added for higher production.

1. Quick starting and stopping for effective driving system.


2. Automatic machine lubrication system for smooth operation.


3. Photo electric fabric fault detector.

• By imposing other developments: Following development can increase the production.

1. Creel feeding system can increase the production.


2. Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage.


3. By using yarn feed control device.

In modern time different advanced facilities added to the machine features, which will facilities the more production.

Knit Fabric Faults In Production | Causes And Way Of Remedies Of Knitting Faults

Knit fabric is produced from loop formation. So it needs to be careful during production. Different types of faults could be found in knit fabric, which could be the cause of fabric rejection. If we can find out the defects of fabric during production, than we can take steps to remove it from the next knitting production process.



In practical; following knitting faults could be found in the knit fabric. Some knitting faults and their remedies are given bellow:

Hole Mark
Causes:

• During loop formation the yarn breaks in the rejoin of the needle hook.


• Holes are the results of yarn breakage or yarn cracks.


• If the yarn count is not correct on regarding structure, gauge, course and density.


• Badly knots or splicing.


• Badly set of yarn feeder.

Needle Mark
Causes:

• When a needle breaks down then needle marks come along the fabrics.


• If a needle or needle hook is slightly bends then needle mark comes on the fabrics.

Star
Causes:

• Buckling of the needle latch.


• Yarn tension variation during production.


• Low G.S.M fabric production.

Sinker Mark
Causes:

• When sinker corrodes due to abrasion then sometimes it cannot hold a new loop as a result sinker mark comes.


• If sinker head bend then sinker mark comes.

Drop Stitches
Causes:

• If yarn is not properly feed during loop formation.


• Use of defective needle.


• Too loose of take down mechanism.


• If yarn tension is insufficient.


• If yarn feeder is badly set.

Oil Stain
Cause:

• When oil lick through the needle trick then it pass on the fabrics and make a line.

Rush Stain
Cause:

• If any rush in the machine.

Pin Hole
Cause:

• Pin hole may come to fabric due to break down or bend of the latch.

Grease Stain
Causes:

• Improper greasing in the machine


• IF greasing is excess.

Cloth Fall Out
Cause:

• Cloth fall out can occur after a drop stitch especially when an empty needle with an empty needle with close latch runs into the yarn feeder and remove the yarn out of the hook of the following needles.

Barre
Causes:

• Yarn fault is responsible for this fault.


• If different micro near value of fiber content in yarn.


• Different luster and dye affinity of fiber content in yarn.


• During spinning different similar classes of fiber is mixed specially in carded yarn and these fibers have similar characteristics.


• In draw frame different similar classes sliver is mixed and make one sliver.

Yarn Contamination
Causes:

• If yarn contains foreign fiber then it remains in the fabric even after finishing.


• Lot mixing and count mixing is responsible for these faults.

Fly Dust
Cause:

• In knitting section too much lint or short fiber is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attached to the fabric surface tightly during knit fabric manufacturing.

Yarn Faults
Causes: Different yarn faults also are cause for knitting faults.

• Neps


• Slubs


• Yarn count variation


• Thick/Thin place in yarn


• Hairiness

Now, if we want to remove these knitting faults we should be aware before yarn selection and during knitting of fabric. Knitting machine conditions should be perfect. Needle, Sinker, Feeder and other equipments, which is used, should be fault free.

So, Management related person should be aware about the causes of knitting faults and try to reduce the knitting faults.