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.

Shed Weaving in Loom | Tappet, Dobby, Jacquard Shedding

Definition of Weaving Shedding:

It is the process by which the warp threads are divided into two layer parts, are above the other, for the passage of the shuttle with a pick of weft. Shed weaving is done due to passing the weft yarn over the warp yarn on the slay race of a weaving loom.

Why Shedding Is Required In Weaving?

You know, in weaving there are three procedures is followed to weave a cloth. At first the warp yarn is separated in two layers. And a shed is created where shuttle is passed by taking the weft yarn. and at last the reed press the last yarn into cloth. This whole matter is called shedding and without it weaving is not possible at all.
Sometimes some modern weaving loom doesn’t need all the three shedding procedures to followed like Air Jet Weaving Process or Water Jet Weaving process. But in traditional Cotton and Jute Mills; we still observe that this Shedding in Weaving Loom is continued.

Classification of Shedding:

Shedding are basically classified in 3 steps. These are Tappet Shedding, Dobby Shedding and Jacquard Shedding.
1. Tappet Shedding. –
a) Positive shedding,
b) Negative Shedding.
2. Dobby Shedding.-
a) Positive dobby shedding,
b) Negative dobby shedding.
3. Jacquard Shedding. –
a) Single lift single cylinder jacquard
b) Single lift double cylinder.
c) Double lift single cylinder.
d) Double lift double cylinder.

Weaving | Parts of Weaving Loom | Pick Spacing of Warp Yarn

What Is Weaving:

Weaving is the process of producing a fabric by the interlacement two sets of yarns.

Parts of Weaving Loom:

1. Weaver’s Beam/ Warp Beam.
2. Back Rest.
3. Lease Rod.
4. Drop Wire.
5. Heald Wire.
6. Heald Shaft.
7. Heald Eye.
8. Top roller with large dia.
9. Top roller with small dia.
10. Sley Sword.
11. Race Board.
12. Reed.
13. Shuttle.
14. Fell of the cloth.
15. Front Rest.
16. Take up Roller.
17. Pressure Roller.
18. Cloth Roller.
19. Rocking Rail.
20. Treadle Lever.
21. Bottom Shaft.
22. Shedding Tappet.
23. Fulcrum.
24. Treadle Bowl.

Pick Spacing in Weaving:

Pick spacing is the distance between two picks or distance between stitch of warp. If P.P.I is 50 then pick spacing will be 1/50″ .

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

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

What Is Loom | Classification Of Loom

Loom is a mechanical device which is used to produce woven fabric by the insertion of warp and weft yarn. In weaving technology; loom is the principle mechanical device for weaving. Various types of loom are used for doing the weaving task. Various types of designed fabric are produced by changing the machine setting.



Loom is a mechanical device which interweaves yarns to fabric, that’s fabrics are suitable for use as dress or industrial uses.

Classification of loom: Fabric is produced by the means of loom. In the very beginning of the fabric manufacturing history, man used hand loom for fabric production. Day by day, the weaving mechanism is changed by the development of loom. In the modern times, the loom which is used for fabric manufacturing, they have high production capacity as well as complex design production capacity.

Loom is classified mainly three types. Classification of Loom is given below:

• Conventional Loom: Conventional Loom is classified as -
  

1. Hand Loom


2. Plain Loom


3. Twill Loom


4. Dobby Loom


5. Jacquard Loom

• Automatic Loom: Automatic loom is classified as -
  

1. Modern Loom


2. Missile Loom or Projectile Loom


3. Rapier Loom


4. Water Jet Loom


5. Air Jet Loom

• Special Loom

Loom is also classified into two types depending on the shuttle:

1. Shuttle Loom: Shuttle loom is that loom where weft yarn is inserting through the warp yarn by the means of shuttle. It the above chart conventional and automatic loom is considered as the shuttle loom. Special types of shuttle loom are short loom, broad loom, pile loom, gauge loom and tri-axial loom etc.


2. Shuttle less Loom: In a shuttle less loom, weft yarn is inserting through the warp yarn by the means of projectile, rapier, air or water. The entire shuttle less loom is called modern loom. This type of loom has more production capacity than the shuttle loom.

In jute fabric manufacturing, shuttle loom is used but in modern cotton textile mill, modern loom is used for fabric production.

Types Of Fabric Weight Measurement System And Their Area Of Application

There are various types of fabric is available in the market, they are woven, knitted or non-woven fabric. Fabrics are differing from one to another depending on the manufacturing techniques. Fabrics are differing depending on the fabric design. Some fabrics are heavy and some are light in weight. So, it is important to determine the fabric weight.

Types of Fabric Weight Measurement System and Their Application: Fabric weight can be measured by the following three ways. They are as follow:

By using formula: Fabric weight can be measured by the formula. Where fabric length, weight and width is known. In this measuring system it is not required to cut the fabric. But it needs to measure the whole fabric. Two formula is given below:

Oz/yd² = 576 M/ (LW)

Oz/yd = 16 M/L

Where,

M= Mass of the fabric roll in Ibs

L= Length in yards

W= Width in inch

By GSM cutter: GSM means Grams per Square Meter. It is most used methods for measuring fabric weight. In these methods, GSM cutter, cutting pad and electric balance is used. It is a quick and authentic method. For measure this above instruments and small amount of fabric sample is required.

By using fabric consumption: Another process is done by using fabric consumption. By these methods, fabric weight can be measurement without any measurement and instruments. Here, fabric consumption is used for calculating the fabric weight directly. The main problem is that, warp and weft crimps are required which varies widely and only an approximate value is used which may not provide exact GSM of the ultimate fabric.

Among the above three methods, GSM cutter system is more comfortable and accurate methods for measure the fabric weight. These methods are used for test the fabric weight in various types of quality testing lab.

Fabric weight measurement is required in weaving, knitting, dyeing and finishing unit of a textile mill. It is an off line quality assurance system.

Density Testing Procedure Of A Textile Fiber

In textile industry; quality control department is responsible to carried out various types of quality test. Density test is one of them. Density test is important for fabric manufacturing.



Density of a textile fiber is important to know. Density is measured by the following steps. Density gradient is prepared as the following:

• Clamp the density gradient glass in a firm vertical stand.


• Pour into the tube 25 ml of tetrachloroetylene.


• Now prepare mixture of xylene and tetrachloroetylene in descending order of percent tetrachloroetylene: 90/10, 80/20, 70/30, 60/40, 50/50, 40/60, 30/70, 20/80 and 10/90.


• Pour 25 ml of each in order carefully down the side of the gradient tube.


• Finally put 25 ml of xylene on top.


• Take short fragments of dyed reference fibers and tie in a knot snipping off loose ends.


• Boil for 2 minutes in xylene solvent to remove moisture and air.


• After about a half hour they should come to the rest in a level representing their density.


• Calibrate glass sphere may be used to determine the actual density at various levels.


• Prepare the unknown fiber in like manner, place in the gradient column and note at what level it floats.

So, that’s all about the density test. We can test the various types of fibers density as the above procedure.

Thread Counting System And Their Application In Fabric Manufacturing

In fabric manufacturing process; thread selection is important to get proper GSM of a fabric. Generally, when consumption of a fabric is done then it is fixed that how many yarn will be use in a fabric production. After producing a fabric, thread per inch in warp and weft direction is measured to be confirming about the number of warp and weft yarn in a fabric.



Thread Counting System and Their Application: Various types of thread counting system are used for measure the number of threads in warp and weft direction of a fabric. Followings are the most used system of thread counting. They are-

1. Counting glass/Pick glass: It is the most used method of thread counting. By this system, counting glass is placed on the fabric surface and thread is count manually by a pin. It can be used to count course per inch and Wales per inch of a knitted fabric. It is widely used method and very handy method.


2. Traversing thread counter: Its measuring system is near similar to pick glass but it somewhat improved instrument where the counting pin is moved by means of a handle. It is used for measuring EPI, PPI, CPI and WPI of a fabric.


3. Fabric dissection method: In this method fabric is cut for doing this measurement. It is a most authentic and reliable thread counting method. This counting method is used where the thread of the fabric is difficult to count by the others measuring system.


4. Taper grating and line rating: This type of thread measuring system is used where-

• The test results are required in a short time.


• Where a large number of fabric samples are required to test in a very short time.


• Where the exact test result is unimportant rather a good approximation is required.


• Normally fashion designers use this type of instruments.

Thread counting system is an off line quality assurance system. We can measure the thread of the fabric by the above measuring system.

How To Identify Warp And Weft Yarn Of A Woven Fabric?

In woven fabric construction; two types of yarn use, they are warp and weft yarn. It is important to know the number of yarn in a woven fabric. To know that, warp and weft yarn is calculate by an EPI and PPI test. For calculating that, we have to identify the warp and weft yarn in a woven fabric. For this reason, I have given some identifying sign for identify the warp and weft yarn of a woven fabric.



Identification of warp and weft of a fabric: Warp and weft yarn has some characteristics by which way we can identify the warp and weft yarn. Followings are the main characteristics of warp and weft yarn of a fabric.

• The selvedge direction is warp direction.


• In most cases, EPI/EPCm is more than PPI/PPCm.


• Normally warp count is finer than weft count.


• Warp yarn is more twisted than weft yarn.


• If any yarn contains any size particle then the sized yarn is warp yarn.


• Normally stripe effect is done in warp direction (both woven and printed fabric).


• Warp yarns are relatively hairy yarn.


• Warp crimp is expected to be less than weft crimp due to high warp tension on the loom.

In woven fabric manufacturing process, warp and weft yarn is used for interlacement for producing woven fabric. After producing a woven fabric, we have to identify the warp and weft yarn.

I think above characteristics will help you to identify the warp and weft direction of a fabric.

Functions Of Different Parts Of A Warping Machine

Warping machine is a simplest machine. Its have different components and they have own functions which is required to know for better operation. Warping machine components are mainly divided into two types; they are

• Creel


• Head stock

Now I like to give a short description about creel and head stock parts and their functions.



Components of creel and their functions:

• Yarn cleaner: Different yarn faults like slubs, neps are removed.


• Stop device: This device help to stop the machine when yarns are broken.


• Indicator: To indicate yarn breakage in the package.


• Tensioner: To keep the yarn in a uniform tension.


• Yarn guide: It helps the yarn to pass in a specific way.


• Flanged bobbin or cone or cheese base and stand: To hold the yarn package.


• Blower or suction fan: To remove durt and dust from the yarn.

Components of head stock and their functions:

• Adjustable or Variable V-Wrath: Warp beam weigth is controlled by this device.


• Measuring and Marking device: It measures the amount of warp yarn on the beam and marks the yarn for definite use.


• Yarn speed controlling device: To control the speed of yarn provided with a meter.


• Pneumatic or Hydraulic pressure unit: Too press the warp beam with the surface contact of driving drum.


• Break assembly: It stops the machine instantly in case of yarn breakage.


• Driving drum: Driving drum control the beams and placed in contact.


• Stop motion: When required length is wound on beam then it used to stop the machine.


• Building device: To control space between driving drum and beam while dyeing or sizing.


• Beam bracket: It used to give support and hold the beam.


• Lease rod: It is used for separation of individually.

It is mentioned that creel is divided into single end and multiple package creel. Magazine creel and travelling creel is called multiple package creels. On the othehand, head stock is divided into fixed head stock and travelling head stock.

So, there are lots of component of warping machine. When one of the components fallen in faults then provide one which have enough quality to give better service.

Comparison Between Sectional Warping And High Speed Warping

Warping is important for weaving process. Warping process are mainly two types they are as follow:

1. Sectional warping or pattern warping.


2. High speed warping or beam warping or direct warping.

This two process have lots of features. It is important to know the advantages and disadvantages of two types. If we have idea about the difference between sectional warping and direct warping then it will be very easy to choose the easiest one for the application. For this reason I like to present the comparison between sectional warping and high speed warping.

Difference between sectional warping and high speed warping:

High Speed Warping	Sectional Warping
To produce common fabric in large quantities (grey fabric).	To produce stripped fabric.
Production speed is high.	Lower production speed.
To produce warp beam from large amount of warp yarn.	To produce warp beam from small amount of warp yarn.
Creel capacity is high.	Lower creel capacity.
Weavers beam is produced after sizing.	Weavers beam can be found immediately after sectional warping.
Higher length of warp sheet is produced.	Lower length of warp sheet is produced.
Cone or cheese bobbin is used.	Flanged bobbin is used.
Single yarn is used.	Fly or twisted yarn is used.
One stage is involved.	Two stages are involved.
High speed is less expensive than sectional warping.	Sectional warping is expensive.
Uniform tension of yarn is obtained.	Uniform tension of each yarn can not be maintained.
Cotton, linen, worsted and woolen yarns are processed by this process.	Mostly used for processed silk and man-made fibers.
High speed warping is more popular and widely used than sectional warping.	Comparatively less used process.

 

What Is Warping | Objects And Importance Of Warping

Warping is the first step of fabric manufacturing process. After winding, warping process is done for making a weavers beam. Weavers beam is produced from a set of yarns of same yarn count or different. In most of the cases we see that different yarn count is used for making sacking fabrics in jute mills. But most of the fabrics are produced from same yarn count. It is noted that all requirements are depends on the fabric structure. Production of Weavers beams depending on the fabric structure. Fabric structure plays an important role in fabric manufacturing process.


In textile language; warping is defined as the parallel winding of yarn from cone or cheese package on to a warp beam. It is needed to confirm that warp beam is make from good warp yarn otherwise weaving performance will be hampered. So it needs to require to provide a good warp beam. Faulty weavers beam is one of the causes of wastage in weaving section.
Objects of warping: Followings are the most common objects of warping:

• To wound up fixed length of yarn on to a warp beam.


• To increase the weavability of yarn.


• To increase the quality of yarn.


• To make re-useable small package.


• To make convenient yarn sheet for next sizing process.


• To increase the production.


• To make dynamic next process.

Importance of warping: Warping process plays an important role in fabric manufacturing. Followings are the most common importance of warping.

• Warp beam are constructed by warping.


• Parallel yarn sheets are constructed by this process.


• Predetermined yarns are wound from the yarn package.


• Small packages are combined by this process.


• Long length of warp yarns is found in this process.


• Various yarn faults like thick and thin place, larger knots are modified by this process.


• Small packages become re-useable by this process.


• Warping accelerates the next sizing process.

So, warping is important for accelerating the next sizing process.

Flow Chart Of Weaving Technology || Fabric Manufacturing Process

In fabric manufacturing technology, three types of fabrics are produced they are woven, knitted and non-woven fabric. We know that; weaving is done for producing woven fabric. Before weaving various types of tasks are done. After spinning process; yarns are divided into two forms one is warp yarn another is weft yarn. Warp yarns are produced by roll winding and weft yarns are produced by cop winding.



Process flow chart of weaving technology: I like to divide this process into two parts one is weavers beam preparation another is weft yarn preparation. Weaving is done by the interlacement of these two types of yarn. Process flow chart of weaving technology is given below:

Spinning bobbin for winding

↓

Roll winding for spool production

↓

Warp yarn preparation

↓

Cone winding or pre-winding

↓

Warping

↓

Sizing

↓

Drafting in or Drawing in

↓

Denting

↓

Looming

↓

Weaving (Interlacement of warp and weft yarn)

Above weaving flow chart is mostly used for cotton and jute fabric. Although these techniques vary depending on the machine which is used for producing fabric but basic concept is same.

What Is Warp Yarn | Properties Of Good Warp Yarn

In woven fabric manufacturing technology two types of yarns are used they are warp and weft yarn. But in knit fabric manufacturing one set of yarns are used. The yarn which is placed in the longitudinal direction of a woven fabric is called warp yarn. Warp yarn is used for make a weaving beam. The yarn which is used for cross interlacement through the warp beam is called weft yarn. Warp yarn count is finer than the weft yarn count.



Warp yarn should have various qualities which ensure the quality of fabric. Number of warp yarn which is used for making a specific fabric that is fixed by the calculation of fabric construction. Following properties should have a warp yarn; they are as follows:

• Cross section of the warp yarn should be uniform.


• Warp yarn should be sufficiently and uniformly strong.


• Warp yarn should be less hairy.


• Warp yarn must be dust free and clean.


• Knots of a warp yarn should be minimum.


• Application of size materials on warp yarn should be standard and knots must be proper otherwise warp yarn face difficulties during passing into the eye.


• Arrangement of warp yarn in the weavers beam should be parallel.


• Warp yarn should be free from naps, slubs and loose fiber.


• Tension of warp yarn in the weavers beam should be uniform.

So, when we will select warp yarn we should remember the above properties of warp yarn. After making weavers beam, it becomes ready for fabric production. It is note that; woven fabrics may be colored or in grey form. Grey fabrics send for dyeing if needed.

 

Process Flow Chart of Denim Mercerization | Cotton Mercerizing Techniques

In fabric market; mercerization plays an important roll. Mercerized fabric is more suitable than the unmercerized fabric. In denim industry, mercerizing process is different than the other mercerizing process. In general mercerizing of cotton is done before dyeing but for the denim mercerizing is done after dyeing and weaving which is described in below.



Process flow chart for cotton mercerizing of denim is given below:

Warping

↓

Dyeing and Sizing

↓

Weaving

↓

Finishing

↓

Washing (In mercerizing machine)

↓

Mercerization

↓

Finishing without Singeing

↓

Inspection

Steps of fabric processing in mercerization machine: In mercerizing machine; the process is done sequencely. The first steps is washing then mercerization is done in same machine. Anyhow following task is done one by one in different stages of the machine part.

Washing:

• Closed Tank-1: Desizing using detergent


• Impregnation Tank: Desizing using detergent


• Stabilization Tank: Water wash


• Closed Tank-2: Water wash


• Closed Tank-3: Water wash


• Closed Tank-4: Water wash


• Closed Tank-5: Water wash

Mercerization:

• Closed Tank-1: Water Wash


• Impregnation Tank: Caustic (NaOH) solution


• Stabilization Tank: Steam supply


• Closed Tank-2: Water wash


• Closed Tank-3: Water wash


• Closed Tank-4: Water wash (80°c)


• Closed Tank-5: Acetic acid (CH₃COOH)


• Temperature in mercerizing- 41°c-43°c


• Caustic (NaOH) concentration in bath- 250 g/l (500 g/l)


• Bath pick-up- 95%

There are a lots of mercerizing machine available in the market. Among all of the mercerizing machine brand; DHALL is most popular for this operation. This machine is manufactured in India. This is the Combi-Soft & Flat Finish Range machine.

So, this denim mercerizing process should be accurate to fulfill the buyers requirement.

 

Yarn Preparation | Necessity Of Yarn Preparation Before Weaving and Knitting

The yarn which is used for weaving or knitting it could be grey or dyed. Yarns are the main element of weaving. Before weaving it needs to prepare. The yarn which is collected from the spinning section can not be used in loom directly. Before using it in loom it is processed by various ways. All of that’s activities are called yarn preparation. Performance of the weaving and knitting section mostly depends on the yarn preparation techniques.



Necessity of yarn preparation: Yarns are prepared for weaving by various ways. The necessity of yarn preparation is given bellow:

• Yarn faults are removed by yarn preparation process.


• By this process yarns are transferred from spinning package to a convenient form of package that will facilities the weaving.


• To clean the yarn for better appearance and performance.


• To have desired length of yarn in package.


• To get better quality fabric.


• During yarn preparation unwanted dust and hairy fibers are removed.

After yarn preparation; yarns are used for making a beam which is called warp yarn and another set of yarn is used for insertion through the warp yarn is called weft yarn.

So, yarn preparation plays an important role for weaving or knitting field.

Process Flow Chart Of Finishing Section In Denim Industry

Denim fabric is courser than as usual woven fabric. Generally courser yarn is used for making denim. After dyeing and weaving, denim fabric is send to the finishing section for adding some properties to the fabric. In finishing section; a sequence of production procedure is maintained.



The finishing process is performed as the following sequence.

Grey Fabric Roll at Feeding Scray

↓

Brushing

↓

J-Box

↓

Gas Singeing (2-Burner)

↓

Brushing

↓

Chemical Box

↓

Squeezing Padded

↓

Skew Roller

↓

Dryer-1 (10 Cylinders)

↓

Rubber Belt

↓

Stenter (Except stretch denim)

↓

Palmer

↓

Cooling Roller and Folder

To perform this operation various machine is used. I like to give a list of machine brand name which could be used in this process.

Machine-1: This is the first machine which is used in the beginning of finishing. The Brand name of the machine is Sperotto Rimer, which is manufactured in Italy.

Singeing unit: In singeing unit; hairy fiber is removed. To perform this Osthoff-Senge singeing machine is used which is manufactured in Germany.

Padder pressure (Air Pressure): During padding following parameter is maintained.

• 7000 Kg (for stretch denim)


• 2000 Kg (except stretch denim)

Machine-2: After passing the machine-1, fabrics passed the machine-2. In here following machines could be used.

• Sanforizing unit manufacturer- MONFORTS (Germany)


• Up to the dryer unit manufacturer- KTM (USA)


• General output speed- 50 m/min.


• Used chemical- Softener (Belsoft). Mixing tank contains 1200 Liter of softener solution which requires 20 kg softener for 1200 Liter.

So, this all about the finishing section of denim industry but the process sequence and machine types could be different depending on the demand of end product requirement.