Tag: Production

Optimization of Ring Frame Process Parameters for Better Yarn Quality and Production

Introduction 

Although
the new spinning technologies have solved the problem of production and
automation to a greater extent, the ring spinning still dominates over
others and is likely to continue as a most widely used form of spinning,
because it exhibits significant advantages in terms of yarn strength
and flexibility in comparison with the new spinning processes.
Increasing ring spindle speed with the existing machines in
consideration of yarn quality and running performance is…



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Concepts of Production and Productivity of Apparel/Garments Industry

 Concepts of Production & Productivity of Apparel/Garments Industry

Author: Saiful Islam
Department of Textile Engineering
Ahsanullah University of Science & Technology (AUST)
Email: saifulsabuz.tex23@gmail.com
Facebook: Saiful Islam

 

Introduction:
In earlier days clothing was only a basic necessity, used to cover the body and to protect from the climatic changes. Over the time people became concerned about the comfort of wearing and also the durability of…



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Fabric Faults/Defects Produced During Weaving, Knitting and Non-woven Fabric Production

Faults in Fabric

Fabric Faults in Weaving:

Warp way defect.
Weft way defect.
Fabric faults common to both warp and weft.

Warp way defect:

Warp stitching.
Long float.
Wrong warp.
Missing warp.
Double warp
Reed mark.
Knot in the warp.
Tight warp.
Slack warp.
Warp steak.
Selvedge effect;
Curly/wavy effect.
Corded selvedge.
Weft breaks or cuts at the selvedge.
Loops in the selvedge.




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Factors for Production of Knitted Fabrics | Methods for Increasing the Production of Knitted Fabrics

Considerable Points to Produce Knitted Fabrics:

When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows- 

 

Type of Fabric or design of Fabric.
Finished G.S.M.
Yarn count
Types of yarn (combed or carded)
Diameter of the fabric.
Stitch length
Color depth.

Methods of…



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High Absorbent Nonwovens | Production Process of High Absorbent Nonwovens

ABSTRACT:

NONWOVEN fabric is a fabric-like material made from long fibres, bonded together by chemical, mechanical, thermal or solvent treatment. The term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. NONWOVEN materials typically lack strength unless reinforced by a backing. In recent years, NONWOVENS have become an alternative to polyurethane foam. Non-woven fabric is manufactured by putting small fibres together in…



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Textile Learner


Airbags for Automobiles | Materials and Properties of Airbags | Production Process of Airbag

AIR BAGS FOR AUTOMOBILES

Author : Moin.S Khan

DKTE’s Textile and Engineering institute, Ichalkaranji, Maharashtra, India

INTRODUCTION

The term automobile means all kind of textile component e.g. fibers, filament, yarn and fabric used in transportation like cars, train, buses, air planes and marine vehicles. Over 15-20 different kinds of fabric are used in automobiles. Automotive textiles are engineered fabrics to meet the challenges of an increasingly competitive automobile…



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Textile Learner


Function/Responsibilities of Deputy General Manager (DGM), Production Manager, Sewing In Charge, Finishing In Charge in Radymade Garment (RMG) Industry

Deputy General Manager (DGM):

Job summary: Overall supervision of Garment Section.

Responsibilities:

Rmg Industry
Has the responsibilities for running the garment department including production planning, operation control, measuring and monitoring of product and the process.
Establishing and maintaining identification and traceability requirement.
Inspection test status, taking corrective and preventive action.
Controlling nonconforming products at intermediate and final…



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Textile Learner


Production of Cotton Fiber From Field to Mill

Cotton: Cotton, the purest form of cellulose found in the nature is the seed hair of the plants of the genus Gossypium. It is classified as natural, cellulosic, mono-cellular, staple fiber. Cotton has been cultivated for more than 5000 years. Archeologists found that it was grown and used for textile purposes in the Indus Valley well before 2100 BC, and in Mexico by 3500 BC Cotton has been of service to mankind for so long that its versatility is almost unlimited and new uses are constantly…



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Nonwoven | Applications of Nonwovens | Production of Nonwovens

Introduction of Nonwoven


An average person is unlikely to be familiar with the term Nonwovens and a few decades back there were no experts in this field. When the consumer hears the term Nonwovens it makes him think of something, which is not like traditional woven fabrics, something modern, advanced, hygienic, but he is not aware of any specific types of materials among those which carry the same name. But now the precise meaning of the term is somewhat clearer to the experts. According to the experts, Nonwovens is a class of textiles/sheet products, unique in industry, which is defined in the negative; that is, they are defined in what they are not. Nonwovens fabrics are different than the conventional textile fabrics and paper. Nonwovens are not based on yarns and (with frequent exceptions) do not contain yarns. They are based on webs of individual fibers. Nonwovens are different than paper in that nonwovens usually consist entirely or at least contain a sizeable proportion of long fibers and/or they are bonded intermittently along the length of the fibers. Although paper consists of fiber webs, the fibers are bonded to each other so completely that the entire sheet comprises one unit. In nonwovens we have webs of fibers where fibers are not as rigidly bonded and to a large degree act as individuals [1].

The definitions of the nonwovens most commonly used nowadays are those by the Association of the Nonwovens Fabrics Industry (INDA) and the European Disposables and Nonwovens Association (EDANA).

1.1.INDA definition:

Nonwovens are a sheet, web, or bat of natural and/or man-made fibers or filaments, excluding paper, that have not been converted into yarns, and that are bonded to each other by any of several means.

The various methods for bonding are:

a) Adding an adhesive
b) Thermally fusing the fibers or filaments to each other or to the other meltable fibers or powders.
c) Fusing fibers by first dissolving, and then resolidifying their surfaces.
d) Creating physical tangles or tuft among the fibers.
e) Stitching the fibers or filaments in place.

1.2.EDANA definition:

Nonwovens are a manufactured sheet, web or bat of directionally or randomly oriented fibers, bonded by friction, and/or cohesion and/or adhesion, excluding paper or products which are woven, knitted, tufted stitch bonded incorporating binding yarns or filaments, or felted by wet milling, whether or not additionally needled. The fibers may be of natural or man-made origin. They may be staple or continuous or be formed in situ.

2.Uses of Nonwovens

Nonwovens find numerous applications ranging from baby diapers to industrial high performance textiles. Some of the important areas where nonwovens are treated as primary alternative for traditional textiles as Geotextiles, materials for building, thermal and sound insulating materials, hygienic and health care textiles and automotive industries. Nonwovens are also used in cover stocks, agriculture, aerospace, home furnishings etc. Although it is not possible to list all the applications of nonwovens, some of the important applications are listed in Table 1 [2].

 

Table 1 – Products That Use Nonwovens
Agriculture  and    Landscaping 
Home Furnishings
Industrial/Military
Crop Covers
Furniture construction sheeting
Coated fabrics
Turf protection products
Insulators, arms and back
Filters
Nursery overwintering
Cushion ticking
Semiconductor polishing pads
Weed control fabrics
Dust covers
Wipers
Root bags
Decking
Clean room apparel
Containers
Skirt linings
Air conditioning filters
Capillary matting
Pull strips
Military clothing
Bedding construction sheeting
Abrasives
Automotive
Quilt backing
Cable insulation
Trunk applications
Dust covers
Reinforced plastics
Floor covers
Flanging
Tapes
Side liners
Spring wrap
Protective clothing, lab coats
Front and back liners
Insulators
Sorbents
Wheelhouse covers
Quilt backings
Lubricating pads
Rear shelf trim panel covers
Blankets
Flame barriers
Seat applications
Wallcovering backings
Packaging
Listings
Acoustical wallcoverings
Conveyor belts
Cover slip sheets
Upholstery backings
Display felts
Foam reinforcements
Pillows, pillow cases
Papermaker felts
Transmission oil filters
Window treatments
Noise absorbent felt
Door trim panel carpets
Drapery components
Door trim panel padding
Carpet backings, carpets, and
Leisure, Travel
Vinyl, landau cover backings
Pads
Sleeping bags
Molded headliner substrates
Mattress pad components
Tarpaulins, tents
Hood silencer pads
Artificial leather, luggage
Dash insulators
Health Care
Airline headrests, pillow cases
Carpet tufting fabric and under
Surgical: caps, gowns, masks,
Padding
Shoe covers
Personal Care and Hygiene
Sponges, dressings, wipes
Diapers
Clothing
Orthopedic padding
Sanitary napkins, tampons
Interlinings
Bandages, tapes
Training pants
Clothing and glove insulation
Dental bibs
Incontinence products
Bra and shoulder padding
Drapes, wraps, packs
Dry and wet wipes
Handbag components
Sterile packaging
Cosmetic applicators, removers
Shoe components
Bed linen, underpads
Lens tissue
Contamination control gowns
Hand warmers
Construction
Electrodes
Vacuum cleaner bags
Roofing and tile underlayment
Examination gowns
Tea, coffee bags
Acoustical ceilings
Filters for IV solutions, blood
Buff pads
Insulation
Oxygenators and kidney
House wrap
Dialyzers
School, Office
Pipe wrap
Transdermal drug delivery
Bookcovers
Mailing envelopes, labels
Geotextiles
Household
Maps, signs, pennants
Asphalt overlay
Wipes, wet, dry polishing
Floppy disk liners
Road and railroad beds
Aprons
Towels
Soil stabilization
Scouring pads
Promotional items
Drainage
Fabric softener sheets
Pen nibs
Dam and stream embankments
Dust cloths, mops
Golf and tennis courts
Tea and coffee bags
Artificial turf
Placemats, napkins
Sedimentation and erosion
Ironing board pads
Control
Washcloths
Pond liners
Tablecloths
Source: The Nonwoven Fabrics Handbook, Association for the Nonwoven Fabrics Industry, Cary, North Carolina

 

 3.PRODUCTION AND SHIPMENTS OF NONWOVENS

The Nonwoven industry is one of the fastest growing industries in the world. It is rapidly developing a sophisticated and diverse market. It has been exhibiting an average growth of about 10% over the past twenty years and should continue this rate of growth in the next ten years. The technology in Nonwoven industry has been improved significantly in nearly all available major manufacturing processes, including those of spun bond, meltblown, needle punched, spunlaced, wet laid and dry laid fabrication. The most important point in rapid development and commercial acceptance of nonwovens is the ability to produce materials of special properties in less time and at reasonable prices. The relative production speeds of various textile technologies are compared in Table 2 [3,4].

Table 2 Relative production rates of different Textile technologies
Technology
Relative Production Rate
Weaving
1-6
Knitting
3-16
Nonwovens – web forming:
-Carding
-Spunbond
-Wet-laid
120-400
200-2000
2300
Nonwovens – bonding
-Stitchbonding
-Needling
-Calendaring
-Hot air bonding
40
30-500
2000
5000


A large number of fibers are available n the market, but the Nonwovens market is mainly dominated by three fibers, namely polyolefin’s, polyester, and rayon. These three fiber types make up a substantial part of the overall Nonwovens markets for fibers [5]. The North American Nonwovens industry is the largest in the world and accounts for almost one third of the worldwide sales of roll goods – around $ 2.8 billion – in 1997, according to estimates from the Association of the Nonwovens Fabrics Industry (INDA). A major portion of the polyolefin and polyester fiber in the U.S. market is consumed by the Nonwovens industry. Last year (1998), 57% of the polyolefin share was consumed by the Nonwovens industry and only 43% was consumed by all the other industries, in spite of the fact that polyolefin’s are the major raw products for the packaging industry. Even in the case of polyesters, the share has increased to 14%. The major share of polyester fiber goes to high loft industry.

 Table 3 U.S. shipments of olefin staple: Nonwovens Vs Other Markets, 1989-1998
YEAR
Total U.S.
Shipped to Nonwovens
All Other
1989
363
195
168
1990
388
233
155
1991
438
272
166
1992
441
259
182
1993
466
276
190
1994
489
280
209
1995
458
267
191
1996
515
295
220
1997
542
314
229
1998
596
339
257
CAGR, 1989/98
5.6%
6.4%
4.9%
       Source: Fiber Economics Bureau and Trade Estimates, CAGR- Compound annual growth rate.

Table 4: Relative production of differnet textile technologies

YEAR
Total U.S.
Shipped to Nonwovens
All Other
1989
2261
272
1989
1990
2015
240
1775
1991
2128
237
1891
1992
2191
244
1947
1993
2158
263
1895
1994
2221
280
1941
1995
2100
280
1820
1996
2016
285
1731
1997
2250
285
1965
1998
2105
292
1813
CAGR, 1989/98
-0.7%
0.8%
-1.0%
 Source: Fiber Economics Bureau and Trade Estimates

 The production of Nonwovens amounts to approximately 20% of the total production of textiles and this percentage grows year by year. The world production of Nonwovens is shown in Table 5[6]. The growth rates of Nonwovens production are extremely high, when compared with the conventional textiles industry.
Table 5. World Production of Nonwovens [6]
2001(tons)
2002(tons)

West Europe

1,115,700
1,203,100
USA
1,024,000
1,074,000
Japan
298000
296000
China
417000
477000
Other AFMA Members
238700
244700
Others
560000
620000
Total
3,653,400
3,915,500

Table 6. Leading producers of Nonwovens [7]

Worldwide Sales
Company
Country
(Millions USD)
Freudenberg
Germany
1,117
DuPont
USA
800
PGI
USA
600
BBA Group
UK
500
Kimberly-Clark
USA
482
Veratec
USA
300
Japan Vilene
Japan
295
Dexter
USA
284
Hoechst
Germany
189
Asahi
Japan
172
Toyobo
Japan
155
Akzo Nobel
The Netherlands
150
Lantor
The Netherlands
132
Walkisoft
Finland
128
Amoco
USA
125

With the nonwovens successfully moving into more technical end-uses, the fiber requirements have also become more important with regard to the fiber properties. The cooperation between fiber supplier and fabric producers is now seen as important criteria for more advancement to come about in the nonwovens field.

References 
 
The Nonwoven Fabrics Handbook, Association of the Nonwoven Fabrics Industry, Cary, NC

Textile Learner


An Abridged Look at Production in the Garment Industry

If you have a passion for garments as a segment of the business landscape, the challenge and rewards are there. As a business possibility, the garment business is rather broad. One has to make a decision early on as to what segment of the industry he should take on. There is this long stretch of varied activities in the industry from a plain home-based one-machine operator to a full-blown retailer you would find in shopping malls. Very simply, one may reduce the segmentation to principal activities like production or retailing.

Once a decision has been reached to entertain production as the main sphere of business activity, attention needs to focus on looking for a low-cost production site making sure that the flow of materials to the site is unimpeded. Next would be the initial machinery to have. Considering that the cost of a sewing machine is relatively affordable, the choice may not be that difficult.

A superior region with begin is to speak with several garment-making providers inside the same region for idle sewing machines which might be purchased very inexpensively. You are able to additionally benefit from these operators’ experience when they might share along with you certain trade tips with better a possibilities of achievement. If required, there are constantly traders of chosen equipment which will be over happy with service your necessities. This could be within the machines with the needles plus threads plus alternative elements between.

After the production site and equipment, the next area of focus is your staffing. A lot of times, workers would come to you with ample experience so that the time you would need to train them would better be used to address the issue of quality production. A lot of times workers would apply claiming that they are very experienced and have always produced quality products.

Be forewarned to not take their claim because the truth. Consistently reserve the final judgment regarding their expert abilities. Even whenever we feel which we have hired all seamstresses you’d want, constantly have additional employees you are able to call about whenever the amount suddenly rises because they are doing from time with time. Quality checking is a need inside manufacturing. Consistently a unique check before the employees receive too far ahead with bad creation.

Just as soon as your production staff completes the order, if there is nothing against early shipment, endeavor to get the order off your premises to free your space for more orders. Early delivery also creates a very positive impression with your customers for repeat business.

The internet abounds with articles about effective business management in production. Look for subject matters in similar industries that bear on your immediate concerns and apply the knowledge to your situation. Did you find this article helpful? If you did take a look at the step by step tutorial here for added information: http://www.MaverickMoneyMakersFair.com


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