Manu Process

Knit Fabric Knit Fabric Process Process ManufacturiManufacturing Tutorialng Tutorial

Prepared by Men’s Knit R & D. June 2009Prepared by Men’s Knit R & D. June 2009

Knit Fabric ProductionKnit Fabric Production

Manufacturing ChainManufacturing Chain

CottonCotton

Yarn Spinning MillsYarn Spinning Mills

Fabric MillsFabric Mills

Garment FactoriesGarment Factories

Retails / BrandsRetails / Brands

Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning

Raw Cotton Quality InspectionRaw Cotton Quality Inspection

BlowingBlowing

CardingCarding

CombingCombing

DrawingDrawing

RovingRoving

Ring SpinningRing Spinning

WindingWinding

Finished Yarn InspectionFinished Yarn Inspection


Raw Cotton Quality InspectionRaw Cotton Quality Inspection

Raw cotton is tested for its Raw cotton is tested for its physical condition and is physical condition and is given quality grade given quality grade according to the degree of according to the degree of whiteness, fineness, whiteness, fineness, strength, contamination and strength, contamination and proportion of immature proportion of immature fiber.fiber.


BlowingBlowing

Raw cotton will be selected, Raw cotton will be selected, cleaned and blended to cleaned and blended to generate uniform fiber generate uniform fiber quality.quality.


CardingCarding

Fibers are fed into carding Fibers are fed into carding machine to eliminate machine to eliminate impurities and dust. The impurities and dust. The cleaned fibers will be cleaned fibers will be aligned in the same aligned in the same orientation and twisted into orientation and twisted into sliver form for combing sliver form for combing operation.operation.


CombingCombing

Combing is a process to Combing is a process to upgrade the appearance and upgrade the appearance and quality of the raw material. quality of the raw material. Slivers will go through Slivers will go through further reduction of short further reduction of short fibers, impurities, neps and fibers, impurities, neps and will be drafted to improve its will be drafted to improve its parallelization. The parallelization. The processed slivers will be processed slivers will be cleaner, finer and more cleaner, finer and more uniform in appearance.uniform in appearance.


DrawingDrawing

Since the evenness of slivers Since the evenness of slivers is critical to production and is critical to production and the final yarn quality, the the final yarn quality, the linear density of slivers will linear density of slivers will be fine-tuned in this process be fine-tuned in this process by doubling and drafting. This by doubling and drafting. This step is the final process of step is the final process of quality improvement in the quality improvement in the spinning mill.spinning mill.


RovingRoving

Slivers are drafted into Slivers are drafted into thinner and stretchier thinner and stretchier strands. The strands are strands. The strands are then winded onto roving then winded onto roving bobbins for storage or for bobbins for storage or for next operation.next operation.


Ring SpinningRing Spinning

After roving, cotton After roving, cotton strands are further drafted strands are further drafted until the required fineness until the required fineness is achieved. To increase is achieved. To increase the strength of yarn, twist the strength of yarn, twist will be inserted during this will be inserted during this production process.production process.


WindingWinding

The yarn produced in the The yarn produced in the spinning process will be spinning process will be spliced and made to be spliced and made to be more suitable for later more suitable for later knitting or dyeing knitting or dyeing operation. Faults and operation. Faults and neps of yarn will also be neps of yarn will also be checked and cleared in checked and cleared in this step to ensure the this step to ensure the final yarn quality.final yarn quality.


Finished Yarn InspectionFinished Yarn Inspection

Samples of finished yarn are Samples of finished yarn are inspected for its quality by inspected for its quality by using the testing equipment. using the testing equipment.

The average quality level of The average quality level of combed yarns is within the combed yarns is within the 5% of Uster-evenness 2001 5% of Uster-evenness 2001 grade.grade.

Piece Dyed Fabric ProductionPiece Dyed Fabric Production

Raw Yarn Quality InspectionRaw Yarn Quality Inspection

KnittingKnitting

Greige InspectionGreige Inspection

Fabric DyeingFabric Dyeing

DryingDrying

Finished Dyed Fabric InspectionFinished Dyed Fabric Inspection

Finishing, Compacting & SettingFinishing, Compacting & Setting

Greige PresettingGreige Presetting


Raw Yarn Quality InspectionRaw Yarn Quality Inspection

Raw yarns are tested for Raw yarns are tested for their physical and their physical and mechanical properties and mechanical properties and are graded according to are graded according to their evenness, tenacity, their evenness, tenacity, elasticity, fiber maturity, elasticity, fiber maturity, contamination, twist level contamination, twist level and hairiness.and hairiness.


KnittingKnitting

Yarns are knitted into fabrics Yarns are knitted into fabrics with different fabrication.with different fabrication.


Greige PresettingGreige Presetting

Presetting is carried out oPresetting is carried out on all greige fabrics that con all greige fabrics that contain spandex or with high ntain spandex or with high polyester content so that tpolyester content so that their dimensional stability cheir dimensional stability can be set before dyeing.an be set before dyeing.


Greige InspectionGreige Inspection

After the fabrics are knitted, After the fabrics are knitted, another 100% inspection is canother 100% inspection is carried out to ensure the greiarried out to ensure the greige fabrics are of the highest ge fabrics are of the highest of quality before delivering tof quality before delivering to the dye house.o the dye house.


Fabric DyeingFabric Dyeing

Fabrics are dyed either Fabrics are dyed either in water jet, air jet or in water jet, air jet or overflow machines overflow machines according to their according to their fabrication and fiber fabrication and fiber composition.composition.


DryingDrying

After dyeing, excessive After dyeing, excessive water is removed from water is removed from the fabrics by mechanical the fabrics by mechanical means so that they can means so that they can be heated set with the be heated set with the best efficiency.best efficiency.


Finishing, Compacting Finishing, Compacting && Heat Setting Heat Setting

Any special wet finishes Any special wet finishes such as anti-UV, oil such as anti-UV, oil repellent, stain release repellent, stain release are added before the are added before the fabrics are heat set or fabrics are heat set or compacted for good compacted for good dimensional stability.dimensional stability.


Final Dyed Fabric InspectionFinal Dyed Fabric Inspection

All finished fabrics are All finished fabrics are then inspected for defects then inspected for defects according to the 10-point according to the 10-point system or any system as system or any system as specified by the end specified by the end buyer. buyer.

Yarn Dyeing ProcessYarn Dyeing Process

Cone WindingCone Winding

Yarn DyeingYarn Dyeing

DryingDrying

Rewinding & WaxingRewinding & Waxing

Dyed Yarn InspectionDyed Yarn Inspection


Cone WindingCone Winding

The greige yarns are re-wound oThe greige yarns are re-wound onto steel or plastic packages for nto steel or plastic packages for dyeing.dyeing.


Yarn DyeingYarn DyeingYarns are either bleached, Yarns are either bleached, optically whitened or dyed optically whitened or dyed to specific colors as the mill to specific colors as the mill ensures stringent color ensures stringent color accuracy of the products accuracy of the products and a consistent ability to and a consistent ability to meet the highest of meet the highest of standards in the industry. standards in the industry.

High efficiency and low High efficiency and low liquor ratio machines are liquor ratio machines are used to ensure efficiency used to ensure efficiency and with the least impact to and with the least impact to the environment.the environment.


Radio Frequency &Radio Frequency & Microwave DryingMicrowave Drying

After dyeing, the yarns are After dyeing, the yarns are dried either by radio dried either by radio frequency or microwave so frequency or microwave so that the change of color due that the change of color due to drying will be minimal.to drying will be minimal.


Re-winding & Waxing Re-winding & Waxing

After drying, yarns are After drying, yarns are then re-wound again onto then re-wound again onto paper cones and at the paper cones and at the same time, sufficient wax same time, sufficient wax are added onto the yarns are added onto the yarns so that the next operation so that the next operation can be carried out with as can be carried out with as little friction as possible.little friction as possible.


Dyed Yarn InspectionDyed Yarn Inspection

Dyed yarn inspection is Dyed yarn inspection is carried out to ensure the carried out to ensure the yarns are fault free and yarns are fault free and ideal for delivery to the ideal for delivery to the customers or for the next customers or for the next operation.operation.

Printing ProcessPrinting Process

White or Dyed Fabric PresettingWhite or Dyed Fabric Presetting

Flat Screen / Rotary Screen PrintingFlat Screen / Rotary Screen Printing

Baking, Steaming, WashingBaking, Steaming, Washing & & DryingDrying

Finishing, Heat Setting, CompactingFinishing, Heat Setting, Compacting

Final Printed Fabric InspectionFinal Printed Fabric Inspection


White or Dyed Fabric PresettingWhite or Dyed Fabric Presetting

After dyeing and drying, After dyeing and drying, fabrics which to be printed fabrics which to be printed will be set with a definite will be set with a definite width.width.


Flat Screen or Rotary Screen PrintingFlat Screen or Rotary Screen Printing

Printing can be done on Printing can be done on either a flat screen machine either a flat screen machine or a rotary screen machines. or a rotary screen machines. Dye can be reactive, Dye can be reactive, pigment, disperse or pigment, disperse or discharge.discharge.


Baking, Steaming, Washing and DryingBaking, Steaming, Washing and Drying

Fabrics printed with Fabrics printed with reactive, disperse and reactive, disperse and discharge printing are discharge printing are baked, steamed, washed baked, steamed, washed and dried to achieve the and dried to achieve the best color yield and best color yield and fastness.fastness.


Finishing, Heat Setting, CompactingFinishing, Heat Setting, Compacting

The fabrics are finally The fabrics are finally treated with different treated with different finishes if necessary and finishes if necessary and then heat set or compact then heat set or compact to achieve the requested to achieve the requested weight and width.weight and width.


Final Printed Fabric InspectionFinal Printed Fabric Inspection

All finished printed All finished printed fabrics are then inspected fabrics are then inspected for defects according to for defects according to the 10-point system or the 10-point system or any system as specified any system as specified by the end buyer.by the end buyer.

Manu Process

Technology

Transcript of Manu Process