Inner fabrics production process

The required raw material for the manufacturing of inner fabrics is cotton yarn.Knitting is done on a flat knitting machine. The knitted fabric passes down ward through the space between the upper edges of the plate, called the throat. In the knitting process, the needles are pushed up and down by the cam attached to a carriage with a yarn guide, which moves over the length of the machine. The width of the fabric can be altered by increasing or decreasing the number of active needles, allowing production of shaped fabrics.

The inner fabrics are produced through knitting of cotton yarn and doesn’t have finishing section, which uses various chemicals unless treatment plant is installed will cause adverse environmental impact.

Silk Yarn Production Process

Raw materials

The main materials are silk fiber, Spools, cops, reels and cons.

Production Process

Hatching of eggs

Sericulture, or the raising of silkworms, involves the incubation of the tiny eggs of the silk worm moth until they hatch and becomes worms. After hatching, the worms are placed under a layer of gauze, on which is spread a layer of finely chopped mulberry leaves. For six weeks, the worms eat almost continuously. At the end of this period, they are ready to spin their cocoons, and branches of trees or shrubs are placed in their rearing houses.

Silk Production

The worms climb these branches and make their cocoons in one continuous thread, taking about eight days for the process. The amount of usable silk

Modern Garment Making Process

Making of men's dress shirt involves the following major steps.

1) Cutting Process

In the cutting process, the cloth is cut to the proper sizes, then is inspected, assorted, and arranged to facilitate flow to the sewing process. Cut cloth must be combined with the interlining, if to be applied. The cutting process consists of the following four processes:

(1) Drawing

A paper pattern is placed on the cloth and the pattern is copied on the cloth.

(2) Cloth Laying

The cloth is spread and piled on the cutting table.

(3) Cutting

The cloth is cut by a knife-type cutting machine or a die cutting machine.

(4) Arrangement

The cut cloth and interlining are inspected, assorted, and bundled, and a slip is attached to the bundle.

2) Sewing Process

In the sewing process, the cut cloth is sewn one by one and the whole cloths are made into the finished product. Generally, each part of shirt is made at different section and the shirt is made in an integrating way. As the workers become specialized the work is mastered in a short time, and efficiency is improved. 80 % of the direct labor of the sewing factory serves for the sewing process.

3) Finishing Process

In the finishing process the completely sewn shirt is inspected, pressed for body finishing and collar finishing, ironed to the proper shape and then folded and packaged.

Integrated Textile Mill process flowsheet

Process Description

The production process of woven mixed fabrics consists of the following three basic processes:

• Spinning: making fibers into a thread, generally referred to as yarn, and
• Weaving: making fabrics on looms.

(i) Spinning

The basic sub processes involved in spinning of natural or synthetic fiber are:

• Opening, blending and cleaning (blow room),
• Carding,
• Drawing, and
• Roving, spinning and winding.

1) Opening, blending and cleaning (blow room)

All staple fibers both natural and synthetic must pass through some form of opening, blending and cleaning to convert compressed bales of fiber into an open sheet for presentation to the carding machine.

2) Carding

The carding machine is the last major cleaning machine in the normal process (excluding combing) and converts the open flock into a condensed sliver reducing its weight per meter to 100^th of the flock weight.

3) Drawing

The draw frame draws several slivers from the card and attenuates them to the dimensions of one thus increasing the uniformity of the product. it may also be used to blend cotton and synthetic slivers in desired proportions.

4) Roving

The objective of roving is to attenuate further and even the sliver, give it some twist to the strength required at this stage, and wind into a bobbin to fit a ring frame creel. This process is eliminated in open-end (rotor) spinning.

5) Spinning

Two main types of spinning are available, i.e., ring spinning and open end or rotor spinning.

(a) Ring spinning

Ring spinning is the final yarn producing stage in conventional spinning. Again ring spinning machines have undergone very little change over the years except a slight increase in speed and higher drafts. Nowadays, automation is common with the tubes being removed automatically and in some cases fed directly to a ‘’ Linked’’ cone winding machine.

(b) Open end or rotor spinning

This is one of the developments over the previous types of spinning. The sliver, either carded or combed, is fed to the rotor chamber revolving at speeds of up to 100,000 revolutions per minutes. Here the off take provides the much higher drafts that are employed.

6) Winding

Three types of windings are to be differentiated: cone winding, Assembly winding, twisting and hank winding.

TEXTILE WALL AND FLOOR COVERING

Process Description

The type of carpet that is envisaged to be produced in the factory has got two main parts; the backing and the face. Each part can be made from different kinds of materials depending on the chosen design and quality. The backing can be jute or cotton. The face is mostly from acrylic. The yarn is put on a creel (a bar with skewers) behind the tufting machine, and then fed into a nylon tube that leads to the tufting needle. The needle pierces the primary backing and pushes the yarn down into a loop. Photoelectric sensors control how deeply the needles plunge into the backing, so the height of the loops can be controlled. A looper, or flat hook, seizes and releases the loop of yarn while the needle pulls back up; the backing is shifted forward and the needle once more pierces the backing further on. To make cut pile, a looper facing the opposite direction is fitted with a knife that acts like a pair of scissors, snipping the loop. This process is carried out by several hundred needles (up to 1,200 across the 12 foot [3.7 ml width), and several hundred rows of stitches are carried out per minute. One tufting machine can thus produce several hundred square yards of carpet a day. The process does not produce wastes that can be harmful to the environment.

SYNTHETIC YARN

1                    Production Process

The production process involves the following sub- processes.

·        Opening, Blending and Cleaning

·        Carding

·        Drawing

·        Roving

·        Spinning

·        Winding

·        Twisting

Opening, blending and cleaning: -All staple fibers must pass through some form of opening, blending and cleaning to convert compressed bales of fiber into an open sheet for presentation to the carding machine.

Carding: - is the last major cleaning and opening operation in the normal process and converts the open flock into a condensed sliver reducing its weight per meter to 100th of the flock weight.

Drawing: - The draw frame draws several slivers from the card and attenuates them to the dimensions of one thus increasing the uniformity of the product.

Roving:- The objective of roving is to attenuate further and to even the sliver, give it some twist to the strength required at this stage, and wind onto a bobbin to fit a ring frame creel. This process is eliminated in open-end [rotor] spinning.

Spinning: - It is the final process in the transformation of fiber into yarn or thread.

Spinning twists fibers of finite length together to form a long, continuous length of thread or yarn. The yarn is finally wound in appropriate container like cone, cops, reel etc. by using winding machine according to the market demand.

The production of yarn starts from dyed fiber as a result no finishing operation is involved which uses many chemicals which requires treatment plant before disposal. So the envisaged plant has no any adverse impact on environment.

SILK GARMENT

Process Description

The major unit operations involved in silk garment making consists of the following.

- Pattern design and pattern making;

- Silk Cloth cutting, grading process by mechanical cutting system and piece bundling;

- Sewing by sewing machine;

- Trimming and inspection;

- Ironing and pressing for finishing process; and

- Button-hole making, buttoning, and fixing of zippers and other accessories are done at all required points.

The silk fabric in different colors/designs is spread on a table and is cut with hand scissors as per required design size and shape of the garments. The cut pieces are stitched by lock/sewing machines. Button holing and stitching, hook attaching etc is done manually. The garments are then pressed and packed in cartons.

Production of silk garment does not have any negative impact on environment.

SILK FABRICS

Production Process

Silk fabric can be produced either by weaving or knitting but knitted silk fabric is envisaged for this project and the process is discussed briefly as follows.

The raw material (Silk Yarn) that has been delivered is wound on a cone, which is most suitable for knitting. The silk yarn is then placed on the knitting machines for knitting in to cloth.

The silk fabric is inspected for knitting damage and other flaws, and sub-standard goods are eliminated.

ADHESIVE TAPE FROM TEXTILES

Production Process

Production of self-adhesive tape is carried out by blending the adhesive mass (synthetic resin and other additives.  The blended mass is then spread over the textile fabric; which has been cut to the required dimension.  After the coating is finished, the product is stayed in a heated chamber in order to allow proper adherence of the mass into the fabric.  The adhesive tape is then rolled on to plastic spools prepared for the purpose.  The product is then wrapped, labels attached and then packed into cartons for dispatching into the market.

The production of adhesive tape is environmentally friendly. There are no by-products and wastes produced are generally minimal.