textiles-100914104937-phpapp02

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Simple Textile Production Process

1Prepared by Muhammad Shoaib Asad Kha

pinning : Process or process used into production of yarns or filaments. The process involves in the ring spinning ya

rmation are

Plucking

•Funtion : The removal of unwanted non-lint or trash from a fiber mix

•Section: BlowRoom (manual / automatic)

•UoM : Lab

Carding

•Function : Straightens, parallels, and cleans cotton fiber

•Section : Carding

•UoM : Sliver (Drum)

Drawing

•Function : Silver are blended, parallel of fiber, reduce thickness of sliver by drafting,

•Section : Drawing

•UoM : Roving Sliver (Drum)

Comber

•Function : Remove short length Fiber. (Pre comber , Comber, then Post Comber)

•Section : Comber

•UoM : Comber roll

Simplex

•Function : reduce the thickness of sliver. Pre process of Ring Spinning Process.

•Section : Roving

•UoM : Roving Bobbin

Ring

•Function : True twist is inserted into parallel fibers by means of a rotating spindle.

•Section : Ring Frame

•UoM : Ring bobbin

Cones

•Function : Transfer yarn from multi ring bobbin to One cone of Standardized weight.

•Section : coner (Auto / Manual)•UoM : Cones > Bags / Cartons

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Weaving: The process of interlacing at least two yarns at right angles to form a fabric.

Warping

•Functional : transfer yarn (cones) into Warper's Beam. Sectional Warping is used for Yarn Dyed Fabrication.

•Section :Warping

•UoM : Warper's Beam

Sizing

•Function : Before weaving to protect the yarns form abrasion in the healds and reed against each other, applystarch mainly, a chemical treatment to mutliple (calculated) warper's beams.

•Section : Sizing

•UoM : Sizer's Beam

•Supporting : Sizing recipe

Drawing In

•Function : in the process of drawing the warp’s thread passes through the eye of heald wire and dent of reed

according weave type / pattern. In case ot running pattern Knotting process is used from Sizer's beams to Loom

•Section : Drawing In (manual / Automatic)

•UoM : Weaver's Beam

Weaving

•Function : Intersection of Warp and Weft yarn in loom for the formation of fabric.

•Section :Loom shed

•UoM : Cloth Roll•Support : Reed of esp count. Weft yarn.

Inspection &Mending

•Function : Inspection fabric, mending if required. Also assign grading to fabric.

•Section : Inpsection hall (manual / automatic)

•UoM : Pieces , with identifucation tag. *Loom number, weaver,* roll number, * grade,*length (yrd/meter),*width (inches/cms),

•Support : Packing on the bases packing instruction in UoM *Roll, *Bale, *pilates.

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rocessing: the Yarn Fabric or Garment treated combination process of Chemical and / or Mechanical process which chang

hysical or chemical state of Textiles (Yarn, Fabric, Garment). The sub-processes are;

retreatment : Preparation process (es) of textiles.

Singeing

•Function : a mechnical process to remove of protruding fibers by direct flame or by infrared radiation or by burring against hotplate

•Section : Pretreatment

•UoM : in length mtr / yrd.

•support : machine & process paramenter. A-frame/trolley to hold material

Desizing

•Function : removal of size (starch) from the fabric (usually in warp) during sizing process in weaving.

•Section : Pretreatment


•support : Desizing Recipe, machine & process paramenter. A-frame/trolley to hold material

Scouring

•Function : the treatment of textile materials of aqueous or other solution in order to remove the natural fats, waxes, proteins andother constituents, as well as dirt, oil and other impurities (by sponification).

•Section : Prtreatment > Bleaching


•support : Scouring Recipe, machine & process paramenter. A-frame/trolley to hold material

Bleaching

•Functional : a process for improving the whiteness if textile material with or without the removal of natural coloring mattersand/or extraneous substances.



•support : Bleaching Recipe, machine & process paramenter. A-frame/trolley to hold material

Mercerizing

•Function : the treatment of cellulosic textile in yarn or fabric form with a concentrated solution of caustic alkali where by the fiberare swollen, the strength and dye affinity of the material are increased



•support : Mercerizing Recipe, machine & process paramenter. A-frame/trolley to hold material

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yeing: the application and fixing of a dye and substrate normally even distribution throughout the substrate,

rinting: the production of design or motif on a substrate by application of a treatment of colorant or other reagent usually in a

aste or ink in a predetermined pattern.

inish a process physical/chemical applied to a substrate to produce a desired effect.

rocess includes;

Yarn Dyeing

Soft winding(Perfurated cones)

Dyeing & Washing

Re-Winding

(Parper Cone)

Fabric Processingof Prepared fabric

Dyeing

Dye

Dry

Cure/Steamed

Wash

Finshing (cehmical/ mechnical)

Printing

Print

cure/Steam

Wash if required

Finshing (cehmical

/ mechnical)

OBA

Finshing (cehmical/ mechnical)

Garment

Finsihing

Treamtment(washing/finishing

Dry

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titching: attaching the multiple panels of textiles through thread/yarn to make a wearable (apparels) or useable (home textiles

aterial

PatternDesign

•Function : create marker/Design of Textile madeups for cutting of fabric.

•Section : Marker (manual / automatic)

•UoM : paper sheet marker•Support : Customer Textile pattern or sample

Layering

•laying the fabric in specific length with multi layers

•Section : Cutting

•UoM : Layers

•Support : Marker / pattern

Cutting

•Function : cut fabric according to pattern/marker setup on fabric.

•Section : Cutting•UoM : Panels

•Support : Marker / pattern

Bundling

•Function : combine panels of each garment in a bundle(s)

•Section : Bunlding

•UoM : Bundle

•Support : Garment pattern

Printing orEmbroidery

•Function : apply design on fabric panel through diferent means like printing, Embroidery.

•Section : Embellishment

•UoM : Bundle

•Support : Embellishment design and instruction/specification. Embroidery thread, Applique, Printing Recipe etc.

Stitching

•Function threading the panel (bundles) of each garment, home textile to finished product.

•Section : Stitching

•UoM : Pcs

•Support : Panel / Bundles, Accesories

Finishing &Packing

•Function : Triming of hanging thread, pressing, inspection and packing

•Section : Stitching Finsihing

•UoM : Cartoon (pcs per cartoon) is can same pcs in one or different in one carton)

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the Textile Processing Flow, the inspection process is not shown it does not means that it is not necessary, it is the most

mportant factor. The role of Inspection is very important at each and every stage of process from Fiber to Dispatch. So

spection may online or offline, both are required and according to the process requirement. The role of Quality Assurance and

uality Control is important to do such tasks. ,

typical Knitwear unit production process with Quality Control step involved

Knitting

Knitting

Dyeing and

Finishing

Pretreatment

Bleaching

CausticSizing

Washing

Dyeing

Finishing

Slitting

Chemical

Finishing

compacting

Rasing

D – R

7

D – R

8

QA – 100

9

QA – 100

6

Flat

Circluar

utting

Cutting

Layer

Marker

Cutting

QA – R

11

Bundling

Embellishment

QA – R

12

Cake

Collection

Bundle

Farmeing

Embroidery/Printing

Finishing

(Clip/Cure)

D – 100

14

Re-bundling

Stitching

Stiching

Finishing

D – 100

16

Pre

D –

1

Dyeing

Washing

Packing

checking

MD

QA – R

20

MD

Clip

LabTesting

Physical

InspectionQA – R

15

D – R

5

QA

1

QA – R17

QA – RX21

NO

NO

QA – 100

13NO

Printing

QA – 100

10

LabTesting

Physical

Inspection

Yarn

arnDyeing

QA – R

1

LAB – R

2

QA – R

3

LAB – R

4

Documents

textiles-100914104937-phpapp02