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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
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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.
Combed Cotton Yarn SpinningCombed Cotton Yarn Spinning
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
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
KnittingKnitting
Yarns are knitted into fabrics Yarns are knitted into fabrics with different fabrication.with different fabrication.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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.
Piece Dyed Fabric ProductionPiece Dyed Fabric Production
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
Yarn Dyeing ProcessYarn Dyeing Process
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 Dyeing ProcessYarn Dyeing Process
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.
Yarn Dyeing ProcessYarn Dyeing Process
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.
Yarn Dyeing ProcessYarn Dyeing Process
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.
Yarn Dyeing ProcessYarn Dyeing Process
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
Printing ProcessPrinting Process
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.
Printing ProcessPrinting Process
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.
Printing ProcessPrinting Process
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.
Printing ProcessPrinting Process
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.
Printing ProcessPrinting Process
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.