Flow Chart of Bale Management

Bale management is the first step of spinning. 40% yarn quality come from bale management. Good bale management give good result in yarn manufacturing. Good mixing depends on good bale management.

Flow chart of Bale management

Raw cotton => Bale-Moisture % test => Collect sample (Every bale) => Sample testing => Classify bale => Bale law down => Mixing

flow chart of bale management

Flow Chart of Bale Management

*Ideal Moisture percentage for cotton fibre 7.5% to 8.0%.
*There three testing of bale sample. HVI, AFIS and trash content

Some properties to determine of cotton bale:

  • Length
  • Strength
  • Fineness
  • Maturity
  • Uniformity
  • Rd (Reflectance/Brightness/Whiteness) + b (Yellowness)
  • Trash content
    *According to test result same properties of bale should lay down for mixing.

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A.M. Amirul Islam (Washim)

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Flow Chart of Rotor Yarn Manufacturing

Rotor spinning is known also open end spinning or break spinning. Now it is become very popular spinning.

 Features of Rotor spinning process

  • Yarn Coarser than carded or combed yarn
  • Low count. Generally 20 count, highest 40s
  • Yarn Use for coarser fabric
  • Low manufacturing coast.
  • Produced by low graded fiber
  • High productivity
  • Less wastage percentage
  • No need of Simplex machine
  • Less labor
  • High capital cost
  • Mainly use to manufacturing Denim jeans fabric
  • Low price
  • Machine speed very high

Flow chart of Rotor yarn manufacturing/ Open end spinning process

flow chart of rotor yarn manufacturing

Flow Chart of Rotor Yarn Manufacturing

*Rotor spinning process eliminates some process of spinning.

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A.M. Amirul Islam (Washim)

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Process Sequence of Fabric Cutting

In garments manufacturing fabric cutting means to cut out the garments pieces from lays of the fabric with the help of cutting template or marker. Cutting is one the major step to make a complete garment. For cutting of fabric generally the marker is applied to the top ply of a lay.

Process Sequence of Fabric Cutting Section

In garments manufacturing industry the term cutting is used in different meaning. Here the term cutting is used in the sense of cutting room which indicates an area which normally includes the activities of marker planning, spreading and preparation for sewing.

Stages of fabric cutting

Generally fabric cutting is carried out with two stages. They are as follows:

  1. Cutting (Separating the individual pieces.)
  2. Final cutting ( accurate cutting of the individual shapes)

Objectives of Cutting

  • To separate fabric parts from the spread of lay according to the dimension of the marker.
  • To make the garments according to required design and shape.
  • To prepare garments pieces to go forward with next process of garments manufacturing.
process sequence of fabric cutting section

Cutting Section in a Garment Factory

Requirement of fabric cutting

To achieve the required objectives by cutting of fabric in garments manufacturing process, the following requirements must be fulfilled.

  • Precision of cut.
  • Clean edges
  • Unscorhed , infused edges
  • Support of the lay
  • Consistent cutting

Different types of fabric cutting

There are mainly three types of cutting techniques. They are as follows:

  1. Completely by manual
    1. By hand operated Scissor.
  1. Manually operated powered knife
    1. Straight knife
    2. Band blade
    3. Round blade
    4. Die cutter
    5. Notcher
    6. Drill
  1. Computerized technique
    1. Knife cutting
    2. Cutting by water jet
    3. Laser cutting
    4. Plasma torch cutting

Flow Chart of fabric cutting

flow chart of fabric cutting

Flow Chart of Fabric Cutting

Working procedure in fabric cutting section

  1. By following production planning at first sample is collected from sample section with pattern and garments approved.
  2. Lay order sheet/ratio sheet fill up by cutting section
    1. e Item, fabric width, color etc.
  3. After putting all information in order sheet then send to CAD section for marker making. Or if it is to do manually than make marker manually.
  4. Checking marker after getting marker.
  5. Sending fabric requisition from cutting section to store for cutting according to plan.
  6. Receiving fabric in cutting table as per marker and cutting plan.
  7. Matching fabric to trim card by merchandiser approved fabric.
  8. Then starting layering manually or with machine.
  9. Completing layering then spread marker upon on the fabric.
  10. Marker checking by quality people & keep all document of style , size wise report to send to store & sewing section.
  11. Before cutting attaching clamp and gum tape on the layer.
  12. If there is any drill mark in marker then need to drill.
  13. Starting cutting by cutter man.
  14. Then dividing group and ratio wise.
  15. Make bundle chart as per lay order sheet and sending for bundle card printing.
  16. Numbering as per bundle chart wise.
  17. Panel checking.
  18. If there is any fault need to replace cut bundle roll and shade wise then bundle and send to sewing section.
  19. If there is any fusing or embroidery then send for this process.

So, hopefully it was helpful for you to understand. If you like it do not forget to put down your valuable comment and share on facebook

Written by

Engineer Sheikh Nurja

B.Sc engineer of textile

Merchandiser at buying house

Carded Yarn Manufacturing Process

Carded Yarn

Carded yarn is formed by carding operation without combing. This yarn made from short staple spinning. Generally less 60s count yarn manufactured without bombing machine. But in particular time 60s or 80s count yarn manufactured without combing. There lots of short fibre in carded yarn, which produced less strength, yarns than combing.

Features of Carded Yarn

  • Low quality yarn
  • Herded hand fillings
  • Low strength
  • Short fibre percentage is high
  • Little hairy yarn
  • Low count yarn(10-45)
  • Less water absorbency
  • Produced lower quality fabric
  • Low production coast
  • Irregularity
  • Dyeing & Knitting wastage very high

Carded yarn manufacturing process

The manufacturing sequence of carded yarn is followed by blow room, carding, draw frame, simplex of speed frame, ring frame and finally winding.

carded yarn manufacturing process

Carded Yarn Manufacturing Process

Process flow chart of Modern Carded Yarn Manufacturing

Modern carded manufacturing process is followed by mixing, blow room, carding, breaker draw frame, finisher draw frame, simplex or roving frame, ring spinning, winding (Auto cone), heat setting and finally packing.

modern carded manufacturing process

Flow Chart of Modern Carded Yarn Manufacturing

Mixing

Mixing depends on cotton grading, micro near value and other properties of raw cotton, how much will be use.

Blow Room

This process removes up to 70 trash or foreign matters of cotton. The delivery product of blow room is chute/lap.

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A.M. Amirul Islam (Washim)

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Flow Chart of Knitting

Knitting is the process where yarn is manipulated to make cloth. Knitting can be done by hand or with the help of a machine. In other words, knitting is a technique of producing two-dimensional fabrics into one-dimensional yarn.

knitting

Knitting

Knitted fabric consists of a number of consecutive rows of loops, called stitches. As each row progresses, a new loop is pulled through an existing loop. The active stitches are held on a needle until another loop can be passed through them. This process eventually results in a fabric, often used for blankets or garments.

Flow Chart of knitting

Normal process/ flow chart of knitting/sequence of knitting started with yarn in cone package form, place the yarn package in the creel, feeding the yarn in the feeder, set the m/c as per design & GSM, knitting, withdraw the roll fabric and weighing, roll making, inspection, numbering and finally dispatch.

flow chart of knitting

Flow Chart of Knitting

*One set of yarn (warp or weft) can produce knit fabrics.

*No need to sizing warps yarn. Knitting is quite different from weaving.

Written by

A.M. Amirul Islam (Washim)

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Classification and Objects of Scouring

Classification and Objects of Scouring

Scouring

Desized textile materials till contain oil, fats and waxes which are removed by alkali or detergent is called scouring.

Classification and Objects of ScouringObjects of scouring/Objectives of Scouring

  1. To remove natural and added oils, fat and wax’s from the textile materials.
  2. Improve hydrophylicity.
  3. Improve absorbency.
  4. Prepare for the next process.
  5. To get uniform bleaching result.

Flow chart of scouring

Flow chart of scouring

Flow Chart of Scouring

Scouring Process

There are two types of scouring process-

  • Hand Scouring
  • Machine Scouring

Hand Scouring

In this process fabric is boiled in an open trough with NaOH common soda and t.r oil for after a few hours. But be careful so that fabric does not come in contact with air otherwise fabric strength can be reduced. After that wash with cold water sour with dilute HCl to remove alkali from the fabric.

Machine Scouring

Now a day’s various types of machines are available for scouring with alkali. This alkali treatment can be divided into three categories.

  • Lime acid soda process.
  • Caustic soda process.
  • Soap soda process.

Written by

Engineer Sheikh Nurja

B.Sc engineer of textile

Merchandiser at buying house

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Combed Yarn

The combed yarn is a yarn which is produced by the combing process. This yarn is finer than carded yarn. Generally combing produced 60 counts or more than 60 count yarn. But sometimes 32 counts or 40 counts yarn also produced by combing process. It is high-quality yarn and it is more expensive compared with carded yarn because its combining process is time intensive.

Combed Yarn

Functional steps of Combed yarn manufacturing process

Functional steps related with this manufacturing process are blown room, carding, pre-comb drawing frame, lap frame, combing, post-comb drawing frame, simplex, and finally ring frame.

Functional steps of Combed yarn manufacturing process

Combed Yarn Manufacturing Process

Features of combed yarn

There are several features of combed yarn can be identified these are given below shortly:

  1. Higher count yarn
  2. Combed Yarn is finer than carded yarn
  3. Produced excluding short fiber
  4. Regular yarn
  5. High-quality yarn
  6. Uniform yarn
  7. Smooth yarn
  8. Good water absorbency
  9. Less hairy
  10. Normally naps free
  11. Costly Production
  12. High price
  13. Higher breaking strength
  14. Lustrous

Written by

A.M. Amirul Islam (Washim)

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Flow Chart of Apparel Manufacturing Process

Flow chart of apparel Manufacturing Process /Garments Manufacturing Process

Garments manufacturing process is related with several process that starts with the receiving of order and make shipment to the ultimate buyer. The process flow chart is based on the type of product and it can be different from one another.

Flow chart of apparel/garments manufacturing process consists of design/sketch, pattern design, sample making, production pattern, grading, marker making, spreading, cutting, sorting/bonding, sewing/assembling, inspection, pressing/finishing, final inspection, packing and finally dispatch to the buyer.

flow chart of apparel manufacturing process

Flow Chart of Apparel Manufacturing Process

Written by

A.M. Amirul Islam (Washim)

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Working Flow Chart of Textile Industry

Working Flow Chart of Textile Industry

Textile industry produces textile materials. Different sectors of this industry are spinning, weaving, knitting, dyeing, and garments. Basically the working flow chart of textile industry consists of getting a buyer order, understanding buyer requirements, brought raw material, set program, start production, processing step by step, finishing (if need), testing product, qualified product according to buyer requirement and finally make delivery to buyer according to the buyer requirements. I made a common flow chart to show how they work which is given bellow:

working flow chart of textile industry

Working Flow Chart of Textile Industry

  • Buyer requirement refers which process will be done, how to do that, Quality of the product. Everything they provide with the order. They control manufacturing process.
  • Raw materials are relative word. Spinning raw material is textile fibre, for weaving yarn, for wet processing Grey fabric. So feed material is raw material any kinds of textile production.
  • Industry has to provide to buyer the latest update of their production order in proper time.

Written by

A.M. Amirul Islam (Washim)

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Flow Chart of Weaving

What can be the flow chart of weaving?

Weaving is a process of producing fabric in which two separate sets of yarns are interlaced at right angles to form a fabric or cloth. In a weaving factory basically woven fabric are made. Basically the process of making woven fabric is known as weaving.

Weaving

Weaving

Flow chart of weaving

The process of weaving related with yarn form spinning, doubling & twisting, winding, creeling, warping, sizing, drawing-in/drafting-in, denting, looming, ltying-in, weaving and grey fabric. This process is shown in the following chart:

flow chart of weaving

Flow Chart of Weaving

  • Winding is the process of transferring yarn or thread from one type of package to another to type of package.
  • Sizing is the method of adapting material size on yarn. It is mainly used to twist yarn to attach the fiber together.
  • Warping is the process of using lengthwise yarns that are seized to form a frame or loom.
  • The denting plan indicates how each of yarn is pinched through a dent in the reed.

Written by

A.M. Amirul Islam (Washim)
E-mail: [email protected]
Cell : +8801929643301