KNITTING DEPERTMENT

KNITTING DEPARTMENT

The Fibre Quality achieved over years of consistent and market oriented business policies has

prompted GTN Industries to invest in high-end fabric manufacture in knitted fabrics. The Company

has 24 and 28 gauge Terrot knitting machines capable of knitting Jersey Pique, Interlock, Rib, Mini

Jacquards and Auto-stripe patterns. The fabric knitting systems are supported adequately by Collar

Knitting Machines from Shima Seiki. GTN also knits high quality lycra fabrics providing the knitting

division versatility, success and wider customer base.

Various type of knitting machine –

I. Lakshmi Terrot machine Features:

M/C type- 4-Track. Model- S296 DIA-30 GAUGE-28 No. Of machine- 2 for polyester+2 for cotton No. Of needles-2640 No of sinker-2640 No. Of feeder-96 Lycra attach-no.

II. Terrot machine Features:

M/c type- m/j Model-S3P172 DIA-30 Gauge -28 No. Of machine-2 No. of needle- 2628 No. Of sinker-2628 No. Of feeder-72 Production capacity-12.5kg/shift. Lycra attach –no.

III. Pauling machine

Features: M/C type- 4-track Model-XS3B/C DIA- 30 Gauge-24 Flexibility- 16 & 20 No. Of machine-1 No. Of needles-2256 No. Of sinker- 2256 No. Of feeder-90 Production capacity-125kg/shift. Lycra attach- yes

IV. Pauling machine

Features: M/C type- 4-track Model-XS3B/C DIA- 30 Gauge-24 Flexibility- 16 & 20 No. Of machine-1 No. Of needles-2256 No. Of sinker- 2256 No. Of feeder-90 Production capacity-125kg/shift. Lycra attach- yes

V. Shima seiki

Features: M/c type-S/J Model- SFE202T DIA- 80 inch Gauge -14 No. Of machine-1 No. Of needle- 1120 No. Of sinker-1120 No. Of feeder-6 Lycra attach-yes.

VI. Matsuya knitting machine

Features: M/C type-S/j Model-MC-172S/J DIA-68inch Gauge-14 No. Of machine-2 No. of needle-952 No. Of sinker-952 No. Of feeder-6 Lycra attach-yes

VII. Kauo heno knitting machine

Features: M/C type- Plain

Model- KH-323DJ

DIA- 60Gauge-14 No. Of machine-2 No. of needle-840 No. Of sinker- 840 No. Of feeder-6 Lycra attach-yes

Fabric design in GTN

Types of design of fabric-

a. Single jersey structure

b. Interlock knit structure

c. Rib knit structure

a. Single jersey fabric

Single jersey is the simplest weft knitted structure that it is possible to

produce on the one set of the needle.

The production rate is very high because of the stitch simplicity and its cost

is low because of machine simplicity.

The loops have a V-shaped loop appearance on technical face side and

show semi-circular loops on the technical back side.

The stitch length can be varied with cam setting giving more courses per unit

length with short stitch length and vice versa. The properties such as rigidity,

air permeability, weight per unit length, bursting strength changes with stitch

length.

The fabric can be unroved from either end or if stitch is broken, the wale will

disintegrate causing the stitches in that line to undo or ladder.

b. Interlock fabric-

Interlock is popular double jersey structure produced on a cylinder and dial

circular weft knitting machine.

Interlock is a reversible fabric, which has similar smooth appearance on

each side.

It does not curl at edges.

The fabric is less extensible due to interlocking structures knitted in two

separate planes by sinker loop.

Fabric is thick, stronger; less elastic hence is nearer to woven structure.

The fabric becomes costlier due to less production.

The structure does not curl at the edges when cut and are more ladder

resistant than either of the single jersey or the rib structure.

c. Rib knit structure

The term rib is used to describe a knitted fabric with vertical rows of loops

meshed in the opposite direction to each other.

Rib fabric is generally produced on V-bed or circular knitting machine.

It is reversible structure with face and back side having same appearance.

The does not curl at the edges due to balanced structure.

It has maximum extensibility width way and hence rib trimmings are most

suitable for neck bands, collars, arm bands.

The structure is more opaque than a jersey and hence this structure is used

in swim wears.

Technology/Process Description:

GTN industries manufactures t-shirts, polo-shirts, ladies-apparels, men's-wears, children and kids wears in 100% cotton knitted and blended items . It is fully equipped with latest machinery for production. The manufacturing process is as follows:

Production process:

Products:

GTN industries produce different items in knitted garments as:

1. T-shirts, basics-round-neck, Polo-shirts,

Sweat-shirts etc.

2. Ladies-tops, ladies-wears, night-wears etc.

3. Children and Kids-wears in 100% cotton and blend

. Broad Profile of Project Offer:

Project To Manufacture Knitted fabric

Capacity per day 2800 kg

Land Requirements/ Building Requirements

5000Sq. M

Plant & Machinery and Test Equipment

Circular knitting machine, flat bed knitting machine, Auto striper knitting machine, mini jacquard knitting machine,

Electrical Installation 15 HP

Implementation Period 6 Months

Manpower Required 70

Raw Materials / Equipment Required

Knitting Machine, Stain Remover Machine, testing lab

Profitability 4%

Preventive Maintenance for KNITTING MACHINES

Maintenance of knitting machinery:

The machine breakdown is 0.06% in the GTN in industries.

PREVENTIVE MAINTENANCE helps for less breakdown of machinery

For the newly purchased machine 3-4 years there is no maintenance problem

Only older machines undergoes for the maintenance activity

MAINTENANCE DEPT. takes care of the maintenance of machinery, it purchases

all the material required for the machinery.

MAINTENANCE DEPT. prepared for frequent and emergency breakdown of

machinery

QUALITY CONTROL

QUALITY STRETEGY AT GTN

GTN IND. Ltd would achieve the highest level of customer satisfaction by their

stated & perceived requirements, maintaining consistency & timely delivery.

GTN Endeavour’s continual up gradation of product quality & technology

supported by R&D efforts in a cost-effective manner.

To meet the changing global demands & stay ahead in competition. GTN would

adapt/innovate methods in its manufacturing activity.

GTN would inculcate a sense of quality awareness at all levels by using

appropriate training and motivation techniques.

GTN would aim at preserving the environment conditions by adapting eco-

friendly measures in its manufacturing & other activities.

QUALITY ASSURANCE DEPARMENT

Quality procedure:

PURCHASING PROCESS:

1. Selecting the suppliers depending upon the ability to supply the product with

organization requirements.

2. It also includes criteria for selection, evaluation, re-evaluation.

3. Records of supplier evaluation, rating & the necessary follow up action.

PURCHASING INFORMATION:

Org have documented information to describe product to be purchased include require for

approval, required for qualification of personnel, where necessary & other related

information.

The documentation also specifies the need for ensuring adequacy of

specified purchasing information before placing order with the supplier.

VERIFICATION OF PURCHASED PRODUCT

The organization has documented the methods for verification of incoming products. The

type and level of verification may vary depending upon the effect of the purchased product

on sequent product realization or the final product.

In case the organization required to perform verification at the supplier’s premises,

the necessary verification arrangements are previously agreed upon including the methods

of product release.

IMPROVEMENT:

The organization Endeavour to continually improve the effectiveness of QMS(Quality

management system) through the following.

Quality policy & objectives

Internal quality audit results

Analysis of data

Corrective and preventive actions

Management reviews

Customer feedback reports

CORRECTIVE ACTION:

The organization established a procedure to deal with corrective action to eliminate the

cause of non-conformity.

This “intern alia” include review of non-conformities, determining the cause

of non-conformities evaluating the need for action to ensure these do not occur,

determining & effectively implementing the actions and recording the actions taken.

Actions taken are reviewed for effectiveness.

INTERNAL COMMUNICATION:

The organization realizes that internal communication plays a vial role ensuring the smooth

& effective functioning of the QMS. The organization ensures that information required to be

communicated to persons who need to have then are effectively done. A separate

procedure addressing the means for this has been established.

MANAGEMENT REVIEW:

The management of the organization conduct management reviews once in every month.

The reviews ensure that the system is effectively functioning , is suitable adequate & serves

the purpose in view. The review also addresses the opportunities for improvement as may

be brought in from different levels/functions. The management review meetings are

recorded & actions initiated by concerned persons.

In the quality assurance department testing of the fibers, hanks, and yarns is done for the

end product quality .It includes three stages they are,

1. Incoming inspection

2. Process control inspection

3. Final inspection

1. INCOMING INSPECTION: Incoming inspection includes the raw materials, stores,

materials, i.e. incoming goods are inspected thoroughly so, that no faults can’t be

occurred in the product with the raw material or with machine etc.

2. .Process control inspection :

3. FINAL INSPECTION: Final inspection include the testing of hank ,fiber and

yarn .every processing element like carding ,combing, simplex etc.is undergoes into

checking whether it is acquired quality according to the specification . Fibers, hanks,

yarns are tested by using different Instruments. The results of the testing

instruments used by GTN industries are accepted by worldwide.

QUALITY MANUAL

MANAGEMENT RESPONSIBILITY

RESOURCE MANAGEMENT

PRODUCT REALIZATION

MEASUREMENT ANALYSIS & IMPROVEMENT

CUSTOMER SATISFACTION

CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

PRODUCT

YARN TESTING

In the quality assurance department the parameters of yarn checked are

COUNT

STRENGTH

CSP (Count Strength product)

ELONGATION

CMT ( classimate faults in yarn)

CV (count variation)

IMPERFECTION

I. Thin Places 2. Thick places 3. Neps

There are Two types of tests done in the Q&A Dept.

Yarn testing

Fiber testing

YARN TESTING::

USTER CLASSIMAT QUANTUM:

Procedure:

By using USTER CLASSIMAT QUANTUM We can check cleared and uncleared

yarn, providing perfect classification of thick and thin places, as well as checking

infrequently occurring yarn defects and, recently, foreign fibers in the yarn.

Classifying foreign fibers into 27 classes according to the FOREIGNCLASS

classification system which is recognized worldwide.

USTER CLASSIMAT QUANTUM allows the distinction to be made between organic

and non-organic foreign matter

Defining customized classes allows targeted monitoring of individual faults in the

desired size, for thick and thin places as well as for foreign fibers.

Determining infrequently occurring yarn faults in 23 classes of thick and 4 classes of

thin places.

USTER STATISTICS Compare measuring results with the international quality

benchmarks directly on the screen.

USTER CLASSIMAT QUANTUM Testing charts:

ELECTRONIC WRAP REEL:

Brand: STATEX

Procedure:

Reels up to 10 yarn skeins

Number of revolutions can be preselected from 1 to 200 by the operator through

keyboard with LED display

The reel starts gently and smoothly to increase normal speed under microprocessor

control, before reaching the preselected measuring length, it slows down and

approach the end of the measurement slowly and stops at accurate position, which

ensures uniform winding without any stretch

Stainless steel reel for accurate length measurement and better stability

Separate yarn stand is provided to accommodate 10 cops

It is designed for adjustable pre-tension mechanism facilitates tension as per ASTM

standard to suit individual yarn through common selector. This advanced pretension

mechanism ensures uniform tension throughout winding

MODEL E1.5/10C E1.5Y/20C E1M/10C E1M/20C

Reel

circumference 1.5 YARDS 1.5 YARDS 1 METRE 1 METRE

No. of skein

yarns 10 20 10 20

USTER TENSORAPID :

The USTER TENSORAPID gives all the known measured values in tensile testing

and offers improved analysis of the yarn quality. The results determine the tested

yarn’s suitability for knitting or weaving.

The software package with USTER TENSORAPID calculate the following additional

characteristics:

• Elasticity-tension behavior of yarns

• Yield point definition by either strength or stretch

• Retardation and relaxation tests

A range of specially designed clamps and accessories guarantees optimal, reliable

and reproducible testing of yarns, hanks, slivers and also fabric strips.

The clamps can be arranged horizontally or vertically, depending on the material

being tested. With a horizontal clamping position, the danger of clamp breaks with

critical yarns can be avoided, since a considerable percentage of the stress will be

absorbed by the frictional surface.

USTER TENSORAPID Testing chart

Time to Br.(S)

B-Force (cN)

Elongation(%) Rkm

(kgf*Nm)

B-Work

(cN.cm)

Test1

Test2

Test3

Overall Results

Mean Value

S +/-

CV%

Q95% +/-

Min. value

Max.Value

Brand : STATEX

ELECTRONIC TWIST TESTER:

Electronic Twist Tester is used to test single yarn and double yarn. Specimen length

adjustable from 0 to 20 inch or 0 to 50 cms.

Procedure:

Provision to test S and Z twist

Results are displayed in TPI and TPM. Minimum number of control switches for

complete use

It is used to test heavy yarns and Multi twisted yarns

Scale provided to measure elongation of test results

Automatic counter start/stop using optical sensor

Pre-tension weight available up to 250 grams

Suitable for both Microprocessor Twist Tester and Electronic Twist Tester

FIBER TESTING:

USTER HVI SPECTRUM:

Brand: USTER

PROCEDURE:

In this instrument except Trash and Neps all the parameters are checked.

For the measure of micronaire study 10gm sample is collected for the testing.

The USTER HVI SPECTRUM provides with the required information of Standard

measurements of fiber length, uniformity, strength, micronaire, color and trash to

assist in selecting the right cotton for end product

Growers, ginners, traders and spinners specify, evaluate and select cotton

according to the quality standards of USTER HVI – the

only accepted standard worldwide.

The USTER HVI SPECTRUM is the only HVI instrument that is

Equipped with a patented moisture probe. Knowing the moisture .Content of the

cotton at the time of testing.

The USTER BALE MANAGER is software provides information about the cotton

quality, allows customization for the bale selection process, and stores historic

information on laydowns that have already been consumed.

USTER HVI SPECTRUM Testing sheet:

Bale ID

SCI Grade Mic Mat Len Amt Unf SFI Str Elg Moist Rd +b C Grade

CNT

MEAN]

STD DEV:

% CV:

BALANCES&WEIGHING SCALES:

PROCEDURE:

Afcoset balances are peerless in accuracy and reliability.

Selectable weighing modes Kg, counting or percentage.

Large and easy read out display mounted on tall column

Outstanding Accuracy up to 1/10000 displayed count resolution.

Optional RS232 allows connection to computer

Defects of YARN:

There are two types of yarn defects are defined they are as follows

1. Frequently occurring faults

Thin Places

Thick Places

Neps

2. Randomly occurring Faults

Long Thin

Long Thick