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Showing posts with label Spinning. Show all posts
Showing posts with label Spinning. Show all posts
Yarn Count: Count is a numerical value, which express the coarseness or fineness (diameter) of the yarn and also indicate the relationship between length and weight (the mass per unit length or the length per unit mass) of that yarn. Therefore, the concept of yarn count has been introduced which specifies a certain ratio of length to weight.

Type of Yarn Count:

One distinguishes between two systems:

Direct Count System:

The weight of a fixed length of yarn is determined. The weight per unit length is the yarn count! The common features of all direct count systems are the length of yarn is fixed and the weight of yarn varies according yo its fineness.

The following formula is used to calculate the yarn count:


       W x l
N = ------
         L
Here,

N= Yarn count or numbering system
W = Weight of the sample at the official regain in the unit of the system. 
L = Length of the sample
l = Unit of length of the sample.




Definition of the above system is as follows :

  • Tex System : No of grams per 1000 meters
  • Denier: No Of grams per 9000 meters
  • Deci Tex : No Of Grams per 10000 meters
  • Millitex : No of milligrams per 1000 meters
  • Kilotex: No Of Kilograms per 1000 meters
  • Jute Count: No Of lb per 14,400 yds

The Tex of a yarn indicates the weight in grams of 1000 meters yarn, thus 40 Tex means 1000 meters of yarn weight 40 gram.

The Denier of a yarn indicates the weight in grams of 9000 meters yarn, thus 150 D means 9000 meters of yarn weight 150 grams and 100 D means 9000 meters of yarn weight 100 gm.

From above discussion it is concluded that higher the yarn number (count) coarser the yarn and lower the umber finer the yarn.


Indirect Count System:

The length of a fixed weight of yarn is measured. The length per unit weight is the yarn count.

The common features of all indirect count systems are the weight of yarn is fixed and the length of yarn varies according to its fineness.

The following formula is used to calculate the yarn count:


        L x w
N = ---------
        W x l

Here,

N= Yarn count or numbering system
W = Weight of the sample at the official regain in the unit of the system. 
L = Length of the sample
l = Unit of length of the sample.
w = Unit of length of the sample



Definition of the above system is as follows:

  • English count system (Ne) : No of 840 yds lengths per pound
  • Metric Count System (Nm) : No of Kilometers per kilogram
  • Woollen Count (YSW) : No of 256 yds lengths per pound
  • Worsted Count, NeK: No of 560 yd lengths per pound
  • Linen count, NeL : No of 300 yd lengths per pound

The English Count, Ne indicates how many hanks of 840 yards length weigh one English pound. Thus, 32Ne means 32 hanks of 849 yards, i.e. 32x840 yards length weight one pound.

The Metric Count, Nm indicates how many hanks of 1000 meters length weigh one kg. Thus 50Nm means 50 hanks of 1000 meters i.e. 50x1000 meters length weigh one kg and 100Nm means 100 hanks of 1000 meters i.e. 100x1000 meters length weigh one kg.

From above discussion it is concluded that higher the yarn number or yarn count finer the yarn and lower the number or count coarser the yarn.

Most important conversion factors:

  • 1 yard = 0.9144 meter
  • 1 meter = 1.0936 yard
  • 1 meter = 39.37 inch
  • 1 cm = 0.3937 inch
  • 1inch = 2.54 cm
  • 1 m2 = 1.1960 yd2
  • 1 gm = 0.0353 oz
  • 1 oz = 28.350 gm
  • 1 lb (pound) = 453.6 gm
  • 1 lb = 0.4536 kg
  • 1 kg = 2.2046 lb (pound)
  • 1 m/kg - 0.4961 yd/lb 
  • 1 yd/lb = 2.0159 m/k

What is Yarn Count? | Yarn Numbering System

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Yarn Count: Count is a numerical value, which express the coarseness or fineness (diameter) of the yarn and also indicate the relationship between length and weight (the mass per unit length or the length per unit mass) of that yarn. Therefore, the concept of yarn count has been introduced which specifies a certain ratio of length to weight.

Type of Yarn Count:

One distinguishes between two systems:

Direct Count System:

The weight of a fixed length of yarn is determined. The weight per unit length is the yarn count! The common features of all direct count systems are the length of yarn is fixed and the weight of yarn varies according yo its fineness.

The following formula is used to calculate the yarn count:


       W x l
N = ------
         L
Here,

N= Yarn count or numbering system
W = Weight of the sample at the official regain in the unit of the system. 
L = Length of the sample
l = Unit of length of the sample.




Definition of the above system is as follows :

  • Tex System : No of grams per 1000 meters
  • Denier: No Of grams per 9000 meters
  • Deci Tex : No Of Grams per 10000 meters
  • Millitex : No of milligrams per 1000 meters
  • Kilotex: No Of Kilograms per 1000 meters
  • Jute Count: No Of lb per 14,400 yds

The Tex of a yarn indicates the weight in grams of 1000 meters yarn, thus 40 Tex means 1000 meters of yarn weight 40 gram.

The Denier of a yarn indicates the weight in grams of 9000 meters yarn, thus 150 D means 9000 meters of yarn weight 150 grams and 100 D means 9000 meters of yarn weight 100 gm.

From above discussion it is concluded that higher the yarn number (count) coarser the yarn and lower the umber finer the yarn.


Indirect Count System:

The length of a fixed weight of yarn is measured. The length per unit weight is the yarn count.

The common features of all indirect count systems are the weight of yarn is fixed and the length of yarn varies according to its fineness.

The following formula is used to calculate the yarn count:


        L x w
N = ---------
        W x l

Here,

N= Yarn count or numbering system
W = Weight of the sample at the official regain in the unit of the system. 
L = Length of the sample
l = Unit of length of the sample.
w = Unit of length of the sample



Definition of the above system is as follows:

  • English count system (Ne) : No of 840 yds lengths per pound
  • Metric Count System (Nm) : No of Kilometers per kilogram
  • Woollen Count (YSW) : No of 256 yds lengths per pound
  • Worsted Count, NeK: No of 560 yd lengths per pound
  • Linen count, NeL : No of 300 yd lengths per pound

The English Count, Ne indicates how many hanks of 840 yards length weigh one English pound. Thus, 32Ne means 32 hanks of 849 yards, i.e. 32x840 yards length weight one pound.

The Metric Count, Nm indicates how many hanks of 1000 meters length weigh one kg. Thus 50Nm means 50 hanks of 1000 meters i.e. 50x1000 meters length weigh one kg and 100Nm means 100 hanks of 1000 meters i.e. 100x1000 meters length weigh one kg.

From above discussion it is concluded that higher the yarn number or yarn count finer the yarn and lower the number or count coarser the yarn.

Most important conversion factors:

  • 1 yard = 0.9144 meter
  • 1 meter = 1.0936 yard
  • 1 meter = 39.37 inch
  • 1 cm = 0.3937 inch
  • 1inch = 2.54 cm
  • 1 m2 = 1.1960 yd2
  • 1 gm = 0.0353 oz
  • 1 oz = 28.350 gm
  • 1 lb (pound) = 453.6 gm
  • 1 lb = 0.4536 kg
  • 1 kg = 2.2046 lb (pound)
  • 1 m/kg - 0.4961 yd/lb 
  • 1 yd/lb = 2.0159 m/k

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 Cotton fiber contains huge amount of dusts, foreign matters, seed and other particles. During spinning of cotton yarn some wastes produce at different stages. Some of them are re-useable and some are not. Now we are mentioning their name and producing area or machines.

DROPPING 1
It is produced in carding machine. In export mill it is not used. But in rotor spinning it is usable.

DROPPING 2
Produced in blow room. In export mill it is not used. But in rotor spinning it is usable.

HARD WASTE 
Produced in ring frame and winding section. It is non usable waste.

MICRO DUST
We collect these dust from A/C plant. It is non usable waste.

FILTER WASTE
 Produced at different section of spinning mill and collect from A/C plant.

DIRTY COTTON
It is produced because of wrong worker handle.

FINE DUST
 It is collected from A/C plant. It is non usable waste.

SWEEPING
 Produced at different section of spinning mill and collect from A/C

PNEUMAFIL
Produced in ring frame. When end breaks form then increase pneumafil. It is usable waste. Mainly it is used in rotor spinning mill. In Outpace spinning mill it is not used. plant. It is non usable waste.

ROVING
Produced in Simplex and Ring frame. These waste is usable. It use again in lay down. It increase because of wrong worker handling and also

BONDA
Produced in Ring frame. If cotton bale contain more short fibre then Bonda waste will be increased. It also depend on high end breaks and also Temperature and RH%. Bonda is usable waste. But it is not used in export spinning mill. Mainly it is used in rotor spinning mill machine fault.

Name of Wastes Produce in Cotton Yarn Spinning | Wastes Name and Producing area of Cotton Spinning

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 Cotton fiber contains huge amount of dusts, foreign matters, seed and other particles. During spinning of cotton yarn some wastes produce at different stages. Some of them are re-useable and some are not. Now we are mentioning their name and producing area or machines.

DROPPING 1
It is produced in carding machine. In export mill it is not used. But in rotor spinning it is usable.

DROPPING 2
Produced in blow room. In export mill it is not used. But in rotor spinning it is usable.

HARD WASTE 
Produced in ring frame and winding section. It is non usable waste.

MICRO DUST
We collect these dust from A/C plant. It is non usable waste.

FILTER WASTE
 Produced at different section of spinning mill and collect from A/C plant.

DIRTY COTTON
It is produced because of wrong worker handle.

FINE DUST
 It is collected from A/C plant. It is non usable waste.

SWEEPING
 Produced at different section of spinning mill and collect from A/C

PNEUMAFIL
Produced in ring frame. When end breaks form then increase pneumafil. It is usable waste. Mainly it is used in rotor spinning mill. In Outpace spinning mill it is not used. plant. It is non usable waste.

ROVING
Produced in Simplex and Ring frame. These waste is usable. It use again in lay down. It increase because of wrong worker handling and also

BONDA
Produced in Ring frame. If cotton bale contain more short fibre then Bonda waste will be increased. It also depend on high end breaks and also Temperature and RH%. Bonda is usable waste. But it is not used in export spinning mill. Mainly it is used in rotor spinning mill machine fault.
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Cotton spinning has now completed a milestone with modern machines where processing time and machines with man power requirement has been reduced. Most of the spinning mills are now established with modern machines but the basic procedures of spinning are followed perfectly. 

Cotton is the most usable natural vegetable fiber which covers almost 60% of total fiber requirement in textile sector. After getting cotton fibers from land it should be processed with ginning machine to separate seeds from raw cotton. Little amount seed must remain with cotton fiber which is considered as trash materials of cotton where other particles also remain. We get yarn from cotton fiber with many of the spinning process and finally there about 70-72% yarns we can collect and rests are removed as wastage. If we make process for 1 kg raw cotton then we will get 750-780 grams cotton yarn. 

Cotton fibers are generally processed to spin for making two types of yarn. Carded yarn and Combed yarn. Now another technique also has been introduced as rotor spinning to make open end cotton yarns.


Process sequence and their brief description now mentioning below for better understanding of cotton yarn spinning.


Bale management:
Bale management can be defined as the judicious selection of bale orcotton fibre in order to achive acceptable economic spinning performance and consistent yarn quality. Bale management is essential for perfect and homogeneous blending. Bale management also
applicable for hossiery process and rotor. Collect samples from 100% bale. The samples are tested in HVI . Then determine all the parameter of fiber colleted. . Quality assurance department again check
whether these bales fulfill the requirements. Then all the bales are arranged under the
Bale Plucker.

Blow Room:
The cotton comes in compact bale form, which are not suitable for processing. So it have to be opened, cleaned and made free of contamination before processing. To obtain consistent parameters throughout the process, the cotton have to be mixed uniformly. All these tasks are carried out in the blow room. At first the bale arrange under the bale plucker. Bale plucker raw cotton in lump form and sends these to multimixer through air transportation for condensor. After the heavy particles being
removed, the cotton is blended and mixed in the four chamber. Then it is taken for fine opener & cleaning. Then the material sent to the carding machine for further processing via chute feed.


Carding:
The carding machine mainly removes the Neps, short fibers and remaining impurities in the cotton fiber and forms carded sliver. Mainly impurities are removed at the taker in and the neps and short fibers are removed by action between the cylinder and flat. It is called the heart of cotton spinning because the quality of a cotton spinning mill is greatly dependent upon the performance of the carding machine. The card slivers are delivered in card sliver cans which are then‐feed to the breaker drawing frame.


Breaker/ Pre‐comb Draw Frame:
In the breaker draw frame 6 carded sliver cans are feed at a time and are drafted to one drawn sliver. By this, the fibers in the sliver becomes more oriented, parallelized and the irregularity of the strand decreases. Produced drawn sliver cans are then either fed to the finisher if it is card process or feed to the lap former if it is combed process.

Lap Former:
For combing, the material have to be presented to the comber machine is a lap form. So to convert the slivers into mini laps, the lap former is used. Here 26 drawn sliver cans are doubled and drafted together to form lap. The lap is then feed to the comber machine.


Comber:
The comber machine mainly combs out the lap and removes any kind of neps, short fiber or other impurities present in it. It also parallelizes the strand to the maximum degree. As a result the yarn produced from this sliver possesses better quality and aesthetic properties. The produced combed sliver is then feed to the finisher / postcomb drawing machine.


Finisher / Post‐comb Drawing Frame:
The finisher is the last machine where the irregularities in the strand can be modified easily and any fault after this will pass on to the yarn. So this machine is of great importance. That is why this machine is equipped with an auto‐leveler. The auto‐leveler continuously scans the incoming slivers and increases or decreases he draft in the drafting zone to minimize any thick or thin place. 6 breaker or comber sliver cans are feed together. This machine is monitored continuously very carefully. The produced finisher sliver cans are then feed to the simplex machine.


Simplex:

In the ring frame, if the yarn is produced directly form sliver, then a very high amount of draft will be necessary, which will be un‐manageable. That is why the material is gradually drafted and an intermediate strand named roving is produced. A slight amount of twist is also inserted in the roving to ensure breakage free winding and unwinding of it on the roving bobbin. Then the ravings are feed to the ring frame.


Ring Frame:
In the ring frame, finally the yarn is produced by drafting the roving. Here twist is inserted in the yarn to obtain required strength. Twist is inserted by means of ring traveler. The number of turns that the spindle rotates at one revolution of the front roller is the number of twist that are inserted on the unit length of yarn. Then the yarn are wound on ring bobbins. When the bobbins are full, they are doffed from the machine automatically mechanism.


Auto Coner:
The auto coner is a machine for automatic winding of yarn on cross wound packages. The yarn is wound on paper cones. It represents an autonomous, compact winding machine, which is equipped with a splicer and electronic yarn clearer in each winding unit. The EYC continuous scans the yarn for faults using either capacitative or optical principle or both. When a fault is found then it cuts it out. Then a upper and lower arm catches the yarn and brings the two ends to the splicer where they are joined together. The joining is done by means of compressed air. Thus the finished cones are produced which are then heat set and packed in required form of packaging.


Heat Setting Machine:
Heat setting is mainly done to stabilize the twist in the twisted yarn, reduce hairiness and increase the moisture content in the yarn packages. The yarn cones are arranged on trolleys. Maximum 6 trolleys can be fed to the machine. After that the machine door is closed. Then vacuum is created inside the machine and water at 60°C is sprayed inside the chamber. Due to negative pressure, the water becomes steam. There the yarn packages are heat set in the steam for 45 min

Cotton Spinning Process Overview | Short Staple Spinning - Blowroom to Ringframe Process Sequence

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Cotton spinning has now completed a milestone with modern machines where processing time and machines with man power requirement has been reduced. Most of the spinning mills are now established with modern machines but the basic procedures of spinning are followed perfectly. 

Cotton is the most usable natural vegetable fiber which covers almost 60% of total fiber requirement in textile sector. After getting cotton fibers from land it should be processed with ginning machine to separate seeds from raw cotton. Little amount seed must remain with cotton fiber which is considered as trash materials of cotton where other particles also remain. We get yarn from cotton fiber with many of the spinning process and finally there about 70-72% yarns we can collect and rests are removed as wastage. If we make process for 1 kg raw cotton then we will get 750-780 grams cotton yarn. 

Cotton fibers are generally processed to spin for making two types of yarn. Carded yarn and Combed yarn. Now another technique also has been introduced as rotor spinning to make open end cotton yarns.


Process sequence and their brief description now mentioning below for better understanding of cotton yarn spinning.


Bale management:
Bale management can be defined as the judicious selection of bale orcotton fibre in order to achive acceptable economic spinning performance and consistent yarn quality. Bale management is essential for perfect and homogeneous blending. Bale management also
applicable for hossiery process and rotor. Collect samples from 100% bale. The samples are tested in HVI . Then determine all the parameter of fiber colleted. . Quality assurance department again check
whether these bales fulfill the requirements. Then all the bales are arranged under the
Bale Plucker.

Blow Room:
The cotton comes in compact bale form, which are not suitable for processing. So it have to be opened, cleaned and made free of contamination before processing. To obtain consistent parameters throughout the process, the cotton have to be mixed uniformly. All these tasks are carried out in the blow room. At first the bale arrange under the bale plucker. Bale plucker raw cotton in lump form and sends these to multimixer through air transportation for condensor. After the heavy particles being
removed, the cotton is blended and mixed in the four chamber. Then it is taken for fine opener & cleaning. Then the material sent to the carding machine for further processing via chute feed.


Carding:
The carding machine mainly removes the Neps, short fibers and remaining impurities in the cotton fiber and forms carded sliver. Mainly impurities are removed at the taker in and the neps and short fibers are removed by action between the cylinder and flat. It is called the heart of cotton spinning because the quality of a cotton spinning mill is greatly dependent upon the performance of the carding machine. The card slivers are delivered in card sliver cans which are then‐feed to the breaker drawing frame.


Breaker/ Pre‐comb Draw Frame:
In the breaker draw frame 6 carded sliver cans are feed at a time and are drafted to one drawn sliver. By this, the fibers in the sliver becomes more oriented, parallelized and the irregularity of the strand decreases. Produced drawn sliver cans are then either fed to the finisher if it is card process or feed to the lap former if it is combed process.

Lap Former:
For combing, the material have to be presented to the comber machine is a lap form. So to convert the slivers into mini laps, the lap former is used. Here 26 drawn sliver cans are doubled and drafted together to form lap. The lap is then feed to the comber machine.


Comber:
The comber machine mainly combs out the lap and removes any kind of neps, short fiber or other impurities present in it. It also parallelizes the strand to the maximum degree. As a result the yarn produced from this sliver possesses better quality and aesthetic properties. The produced combed sliver is then feed to the finisher / postcomb drawing machine.


Finisher / Post‐comb Drawing Frame:
The finisher is the last machine where the irregularities in the strand can be modified easily and any fault after this will pass on to the yarn. So this machine is of great importance. That is why this machine is equipped with an auto‐leveler. The auto‐leveler continuously scans the incoming slivers and increases or decreases he draft in the drafting zone to minimize any thick or thin place. 6 breaker or comber sliver cans are feed together. This machine is monitored continuously very carefully. The produced finisher sliver cans are then feed to the simplex machine.


Simplex:

In the ring frame, if the yarn is produced directly form sliver, then a very high amount of draft will be necessary, which will be un‐manageable. That is why the material is gradually drafted and an intermediate strand named roving is produced. A slight amount of twist is also inserted in the roving to ensure breakage free winding and unwinding of it on the roving bobbin. Then the ravings are feed to the ring frame.


Ring Frame:
In the ring frame, finally the yarn is produced by drafting the roving. Here twist is inserted in the yarn to obtain required strength. Twist is inserted by means of ring traveler. The number of turns that the spindle rotates at one revolution of the front roller is the number of twist that are inserted on the unit length of yarn. Then the yarn are wound on ring bobbins. When the bobbins are full, they are doffed from the machine automatically mechanism.


Auto Coner:
The auto coner is a machine for automatic winding of yarn on cross wound packages. The yarn is wound on paper cones. It represents an autonomous, compact winding machine, which is equipped with a splicer and electronic yarn clearer in each winding unit. The EYC continuous scans the yarn for faults using either capacitative or optical principle or both. When a fault is found then it cuts it out. Then a upper and lower arm catches the yarn and brings the two ends to the splicer where they are joined together. The joining is done by means of compressed air. Thus the finished cones are produced which are then heat set and packed in required form of packaging.


Heat Setting Machine:
Heat setting is mainly done to stabilize the twist in the twisted yarn, reduce hairiness and increase the moisture content in the yarn packages. The yarn cones are arranged on trolleys. Maximum 6 trolleys can be fed to the machine. After that the machine door is closed. Then vacuum is created inside the machine and water at 60°C is sprayed inside the chamber. Due to negative pressure, the water becomes steam. There the yarn packages are heat set in the steam for 45 min
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In a word TEXTILE means cloth or to weave. If you think it as a broad sense you would find that it is the combination six differential parts where one is related to another. Garment / cloth is the final product of textile, where each and every step has to be followed some successive processes. From fiber to cloth the whole process is basically run through four main steps as spinning, weaving or knitting, dyeing or printing and garments making. Now I have shared the below process flowcharts for any textile students or readers as to know about the significant and consecutive process of textile.

PROCESS FLOWCHART OF TEXTILE AT A GLANCE


TEXTILE FIBERS    -------     YARN MANUFACTURING     -------      YARN

         YARN    -------     FABRIC MANUFACTURING    -------    GREY FABRICS

GREY FABRICS     -------      WET PROCESSING    -------     FINISHED FABRICS

FINISHED FABRICS   --------    GARMENTS MANUFACTURING    --------    GARMENTS


FLOW CHART OF SPINNING

  BLOW-ROOM

CARDING

DRAWING

LAP FORMING

COMBING

DRAWING

ROVING

RING SPINNING



FLOW CHART OF WEAVING

YARN FROM SPINNING

DOUBLING AND TWISTING

WINDING

CREELING

WARPING

SIZING
DRAWING-IN AND DENTING

LOOMING

LTYING-IN

WEAVING

 

FLOW CHART OF KNITTING

YARN IN CONE FORM

CREELING

FEEDING THE YARN IN THE FEEDER

KNITTING

WITHDRAWING THE ROLLED FABRIC

INSPECTION
NUMBERING

DISPATCHING

FLOW CHART OF DYEING (WOVEN FABRIC)

GREY FABRIC INSPECTION

STITCHING

CROPPING

BRUSHING

SINGEING

DESIZING

SCOURING

BLEACHING

SOURING

WASHING

DRYING

MERCERIZING

DYEING

AFTERTREATMENT

FINISHING

INSPECTION

PACKING

BALING

 

FLOW CHART OF DYEING (KNIT DYEING)

GREY FABRIC INSPECTION

BATCHING

STITCHING

LOAD ON MACHINE

SCOURING

BLEACHING

ENZYME TREATMENT

LEVELING

ELECTROLITING

DYEING

AFTERTREATMENT

FINISHING

INSPECTION

PACKING

BALING

FLOW CHART OF PRINTING

GREY FABRIC INSPECTION

STITCHING

CROPPING

BRUSHING

SINGEING

DESIZING

SCOURING

BLEACHING

SOURING

WASHING

DRYING

MERCERIZING

PRINTING 

AFTERTREATMENT

FINISHING

INSPECTION

PACKING

BALING


FLOW CHART OF GARMENT MANUFACTURING

TECH PACK/ SKETCH

BLOCK PATTERN FROM BUYER

PATTERN MAKING

SAMPLE MAKING

GARMENTS PATTERN

GRADING

MARKER MAKING

SPREADING

CUTTING

SORTING & BUNDLING
EMBROIDERY/PRINTING

STITCHING

INSPECTION
WASHING
FINISHING

IRONING

FINAL INSPECTION
FOLDING

PACKING

DISPATCH


Process Flowchart of Spinning, Weaving, Knitting, Dyeing, Printing and Garments Making

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In a word TEXTILE means cloth or to weave. If you think it as a broad sense you would find that it is the combination six differential parts where one is related to another. Garment / cloth is the final product of textile, where each and every step has to be followed some successive processes. From fiber to cloth the whole process is basically run through four main steps as spinning, weaving or knitting, dyeing or printing and garments making. Now I have shared the below process flowcharts for any textile students or readers as to know about the significant and consecutive process of textile.

PROCESS FLOWCHART OF TEXTILE AT A GLANCE


TEXTILE FIBERS    -------     YARN MANUFACTURING     -------      YARN

         YARN    -------     FABRIC MANUFACTURING    -------    GREY FABRICS

GREY FABRICS     -------      WET PROCESSING    -------     FINISHED FABRICS

FINISHED FABRICS   --------    GARMENTS MANUFACTURING    --------    GARMENTS


FLOW CHART OF SPINNING

  BLOW-ROOM

CARDING

DRAWING

LAP FORMING

COMBING

DRAWING

ROVING

RING SPINNING



FLOW CHART OF WEAVING

YARN FROM SPINNING

DOUBLING AND TWISTING

WINDING

CREELING

WARPING

SIZING
DRAWING-IN AND DENTING

LOOMING

LTYING-IN

WEAVING

 

FLOW CHART OF KNITTING

YARN IN CONE FORM

CREELING

FEEDING THE YARN IN THE FEEDER

KNITTING

WITHDRAWING THE ROLLED FABRIC

INSPECTION
NUMBERING

DISPATCHING

FLOW CHART OF DYEING (WOVEN FABRIC)

GREY FABRIC INSPECTION

STITCHING

CROPPING

BRUSHING

SINGEING

DESIZING

SCOURING

BLEACHING

SOURING

WASHING

DRYING

MERCERIZING

DYEING

AFTERTREATMENT

FINISHING

INSPECTION

PACKING

BALING

 

FLOW CHART OF DYEING (KNIT DYEING)

GREY FABRIC INSPECTION

BATCHING

STITCHING

LOAD ON MACHINE

SCOURING

BLEACHING

ENZYME TREATMENT

LEVELING

ELECTROLITING

DYEING

AFTERTREATMENT

FINISHING

INSPECTION

PACKING

BALING

FLOW CHART OF PRINTING

GREY FABRIC INSPECTION

STITCHING

CROPPING

BRUSHING

SINGEING

DESIZING

SCOURING

BLEACHING

SOURING

WASHING

DRYING

MERCERIZING

PRINTING 

AFTERTREATMENT

FINISHING

INSPECTION

PACKING

BALING


FLOW CHART OF GARMENT MANUFACTURING

TECH PACK/ SKETCH

BLOCK PATTERN FROM BUYER

PATTERN MAKING

SAMPLE MAKING

GARMENTS PATTERN

GRADING

MARKER MAKING

SPREADING

CUTTING

SORTING & BUNDLING
EMBROIDERY/PRINTING

STITCHING

INSPECTION
WASHING
FINISHING

IRONING

FINAL INSPECTION
FOLDING

PACKING

DISPATCH


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Count: Yarns  as well as threads are expressed using number to specify them. Yarn count refers to the thickness of a yarn and is determined by its mass per unit length or length per unit mass. It is important to know various numbering systems and their relationships in understanding yarn and thread size specifications. Yarn counting system is of two types. They are -

Direct Counting System (Length fixed but weight variable):
  • Tex 
  • Denier
  • Jute Count
Indirect Counting System (Weight fixed but length variable):
  • English
  • Metric
  • Worsted
Tex: The yarn number or count in the Tex system is the weight in grams of 1000m or 1 km of yarn.

Denier: The yarn count in the denier system is the weight in grams of 9000m or 9 km of yarn.
Pounds per Spyndle: The yarn count in pounds per spindle is the weight in pounds of 14,400yards of yarn. This counting system is commonly known as jute count.

English: It is defined as the number of hanks (840 yards) per pounds. It is denoted by Ne.

Metric: It is defined as the number of hanks (1000 m) per kg. It is defined by Nm.
Worsted: It is defined as the number of hanks (560 yards) per pounds.

Lea Count  = 48/ (Pounds/Spyndle)


Usually, Metric count is used to describe synthetic, spun and corespun yarn and  thread while English count is used to specify cotton yarn and thread. Filament or spandex yarn and threads are normally expressed with Decitex or Denier.

As these counts are used frequently therefore see the below table for better understanding


Count Conversion Laws:

Using the table below will enable you to perform a simple conversion from one system to another. 


Yarn Count | Thread Numbering System | Count Conversion Laws

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Count: Yarns  as well as threads are expressed using number to specify them. Yarn count refers to the thickness of a yarn and is determined by its mass per unit length or length per unit mass. It is important to know various numbering systems and their relationships in understanding yarn and thread size specifications. Yarn counting system is of two types. They are -

Direct Counting System (Length fixed but weight variable):
  • Tex 
  • Denier
  • Jute Count
Indirect Counting System (Weight fixed but length variable):
  • English
  • Metric
  • Worsted
Tex: The yarn number or count in the Tex system is the weight in grams of 1000m or 1 km of yarn.

Denier: The yarn count in the denier system is the weight in grams of 9000m or 9 km of yarn.
Pounds per Spyndle: The yarn count in pounds per spindle is the weight in pounds of 14,400yards of yarn. This counting system is commonly known as jute count.

English: It is defined as the number of hanks (840 yards) per pounds. It is denoted by Ne.

Metric: It is defined as the number of hanks (1000 m) per kg. It is defined by Nm.
Worsted: It is defined as the number of hanks (560 yards) per pounds.

Lea Count  = 48/ (Pounds/Spyndle)


Usually, Metric count is used to describe synthetic, spun and corespun yarn and  thread while English count is used to specify cotton yarn and thread. Filament or spandex yarn and threads are normally expressed with Decitex or Denier.

As these counts are used frequently therefore see the below table for better understanding


Count Conversion Laws:

Using the table below will enable you to perform a simple conversion from one system to another. 


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 In short staple spinning three types of spinning systems are available in a wide range. In ring spinning carded and combed yarn are produced according to the requirement of yarn quality, price as well as time consumption. Carded yarns are highly used for medium quality and average count, used for all kinds of fabrics.

Flow Chart for Carded Yarn Manufacturing Process:


Fiber → Blow Room   →     Lap
                Lap   →        Carding   →   Card Sliver
Card Sliver →   1st Drawing Frame →   Drawn Sliver
  Drawn Sliver    →     2nd Drawing Frame   → Drawn Sliver
Drawn Sliver →    Simplex   →   Roving
Roving    →   Ring Frame   →   Yarn
Winding
Reeling
Bundling
Bailing

 Comb yarn is very much high quality yarns in comparison with card yarn cause of here more short fiber and naps as well as impurities are removed through the combing action. Superior quality yarns can produce in using combing machine to the machine sequence. In cotton count, higher the number finer the yarns will be. Combed yarns have high count number with best quality in using fabric making.
 
Combed cotton yarn manufacturing process:

Fiber → Blow Room   →     Lap
                Lap   →        Carding   →   Card Sliver
Card Sliver →   Pre-Comb Drawing Frame →   Sliver (Pre-Drawing)
Sliver    →   Lap Former →   Lap
    Lap     →     Comber →       Comb Sliver
Comb Sliver   →     Post-Comb Drawing Frame   → Drawn Sliver (Post-Drawing)
Drawn Sliver →    Simplex   →   Roving
Roving    →   Ring Frame   →   Yarn
Winding
Reeling
Bundling
Bailing

 For high quality fabric making combed yarns are frequently used as to make luxurious garments. Comfort as well as handling appeal is much higher in the case of garments made of combed yarns.
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Short Staple Spinning Flow Chart | Carded and Combed Yarn Manufacturing Processes

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 In short staple spinning three types of spinning systems are available in a wide range. In ring spinning carded and combed yarn are produced according to the requirement of yarn quality, price as well as time consumption. Carded yarns are highly used for medium quality and average count, used for all kinds of fabrics.

Flow Chart for Carded Yarn Manufacturing Process:


Fiber → Blow Room   →     Lap
                Lap   →        Carding   →   Card Sliver
Card Sliver →   1st Drawing Frame →   Drawn Sliver
  Drawn Sliver    →     2nd Drawing Frame   → Drawn Sliver
Drawn Sliver →    Simplex   →   Roving
Roving    →   Ring Frame   →   Yarn
Winding
Reeling
Bundling
Bailing

 Comb yarn is very much high quality yarns in comparison with card yarn cause of here more short fiber and naps as well as impurities are removed through the combing action. Superior quality yarns can produce in using combing machine to the machine sequence. In cotton count, higher the number finer the yarns will be. Combed yarns have high count number with best quality in using fabric making.
 
Combed cotton yarn manufacturing process:

Fiber → Blow Room   →     Lap
                Lap   →        Carding   →   Card Sliver
Card Sliver →   Pre-Comb Drawing Frame →   Sliver (Pre-Drawing)
Sliver    →   Lap Former →   Lap
    Lap     →     Comber →       Comb Sliver
Comb Sliver   →     Post-Comb Drawing Frame   → Drawn Sliver (Post-Drawing)
Drawn Sliver →    Simplex   →   Roving
Roving    →   Ring Frame   →   Yarn
Winding
Reeling
Bundling
Bailing

 For high quality fabric making combed yarns are frequently used as to make luxurious garments. Comfort as well as handling appeal is much higher in the case of garments made of combed yarns.
Remove t


Original text
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