Weaving

To manufacture the textile fabrics, weaving is the most popular method which is widely used. Two or more sets of yarns are interlaced with one another at the right angle. In the lengthwise direction the warp yarns are run and this is also called ends. And the weft yarns are run in the clockwise direction and this is also known as picks.

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Non Precision Winding

Non precision winding is one kind of packages which consists a single thread which is laid on the package. This is placed on an appreciable helix angle. For that the yarn layer gives more stability and cross one another.

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Types of Winding

The types of winding are given below.

According to density the winding are two types. These are,

1. Precision winding.

2. Non precision winding.

According to type of package the winding are five types. These are,

1. Cone winding package.

2. Pirn winding package.

3. Flange winding package.

4. Cheese winding package.

5. Cop winding package.

According to the build of the package the winding are three types. These are,

1. Parallel winding package.

2. Near parallel winding package.

3. Cross parallel winding package.

According to methods of drive the winding are two types. These are,

1. Positive or direct drive.

2. Negative or direct drive

According to the future of automation the winding are two types. These are,

1. Conventional winding.

2. Modern winding.

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Difference between Precision Winding and Non Precision Winding

The difference between Precision winding and Non Precision Winding are given below,

Precision Winding	Non Precision Winding
1. Number of coils remains constant from the first layer up to the full diameter of package.	1. Number of coils per traverse of yarn guide decrease with increase in package diameter.
2. No air gaps.	2. Air gaps are found here.
3. Winding angle is 90º or near 90º.	3. Winding angle is less than 80º.
4. Bobbin can be wound by one or more yarn.	4. Bobbin can be wound by only one yarn.
5. Less stable package.	5. More stable package.
6. Flanged bobbin is needed.	6. Flanged bobbin is not needed.
7. Yarn tension is relatively more at the time of winding.	7. Yarn tension is relatively less at the time of winding.
8. Yarn package density is more.	8. Yarn density is less in the package.
9. Yarn coil is arranged in the parallel or near parallel.	9. Yarn coil is arranged in traversal.
10. Yarn withdrawal from the package takes more time and it is relatively difficult.	10. Yarn withdrawal from the package takes less time and it is comparatively difficult.

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Balloon size

Balloon size depends on:

1. Yarn count: During the operation of unwinding the centrifugal force is acted. During winding the stronger centrifugal forces is produced if the yarn is coarse. Here is formed the larges balloon size.

2. Yarn winding/unwinding rate: If the winding/unwinding speed is higher, then there must are higher centrifugal forces will be produced.

3. Size of the package: The height of the balloon will be larger if the package is larger of the lift.

4. Lift of the package: There larger balloon will be formed if the package is higher of the lift.

5. Position of the guide: If distance is larger between yarn guide and yarn package then there must be formed larger balloon.

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Tensioning Device

Thick spots or slubs are detected by tensioning device. Yarns break are also a cause of tensioning device. It’s a device mainly worked as a detector.

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Why cotton fiber is very popular?

The reasons of why cotton fiber is very popular are given below:

1. Capacity to absorb moisture: Removing of wax coating from the fiber during processing of cotton readily absorbs moisture and that time the cotton allows the moisture to evaporate. Evaporation makes the cotton fiber very comfortable to wear, because cotton allows the human body to breath. Strength: When we dry the cotton its take more time than other fibers. However, the cotton fiber is very stronger when the condition is wet than dry. It means we can wash frequently any kind of cotton products.

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Fancy Yarn

Which yarns have deliberate imperfections are known as fancy yarn. Now a day’s fancy yarn is very demandable yarn because its defect frees yarn which is considered to be premium product. The production procedure of fancy yarn is different than normal yarn. Fancy yarn is very demandable due to its special aesthetic which imparts new characteristics. Normally fancy yarns used to make high fashion garments and also carpets, curtains, upholstery fabrics and many more.

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Zone of Garments

The zone of garments means to indicate the important part of garments. Zone of garments are divided into two types. These are,

1. Zone-A.
2. Zone-B.

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Cotton Color

To determine the cotton color there are two parameters. These are:

1. Degree of reflectance (Rd)

2. Yellowness (+b).

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Cellulose

Cellulose is a polymer. Polymer means many unit of monomer. Here poly means mono and mer means unit. Many thousands units of glucose molecule are used to made it. To form one molecule of cellulose, 10000 molecules of glucose may need in a chain. Molecular arrangement can vary to leads the cellulose which is different types. To make up cotton fiber there are millions of molecules are needed. 

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Modal

The own right for man made cellulose fiber the Modal is a generic name. To make high quality wooden pulps the modal is manufactured. Modal is very strong and stable. Modal is also soft. If we washed this it’s again became shown its softness. For clothing modal is ideal as it can breathe. More than 50% humidity than cotton the modal can absorb. Modal keep the skin dry and comfortable.

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Difference between Melt, Dry and Wet spinning

The difference between melt spinning, dry spinning and wet spinning is given below:

Parameter	Melt spinning	Dry spinning	Wet spinning
1. Investment cost	Low	High	Low
2. Hazard	Non-toxic	Toxic	Toxic
3. Heat of spg	High	Very high	Low
4. Spinneret holes	2000	300-900	20000-75000
5. Spg speed	2500-3000ft/min	2500-3000ft/min	150-300ft/min
6. Productivity	High	High	Low
7. Solvent	Not required	Only volatile organic solvent	Beth organic & inorganic solvent can be use
8. Example	Polyester, Nylon-6	Cellulose, Acetate. PAN	Viscose rayon

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Cotton History

The most common fiber is cotton which is widely used in this world. To attain commercial importance the cotton is the last natural fiber. The Greek historian Herodotus in the fifth century he reported that among the valuable products in India was the wild plant that bears fleece as its fruit.

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Cotton

In hot climates countries the cotton is grown up widely in the world. Cotton is a vegetable cellulosic fiber. Cotton fiber is non-allergenic and also moisture absorbency is very high and cotton dries quickly.Cotton fiber gives us a cooling effect when we wear any kind of garments which is made from cotton fiber. Cotton fiber is very stronger when wet than dry. Cotton washing is very easy. At first cotton is treated with caustic soda and then stretched. Stretching makes cotton fabric smoother, stronger and also less prone to shrinkage. 

In about 75 countries the cotton is cultivated with an area of about 32 million hectares. About 175 to 225 days are needed to cultivate the cotton. Cotton can be harvested in two seasons. The seasons are winter and summer.

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Spinning

Spinning: Spinning is three types. These are:

1.     Melt spinning.

2.     Dry spinning.

3.     Wet spinning.

Melt Spinning: The process of spinning by which fiber or filament is produced from melted polymer chips by extruding though spinning continuous filament produced here.

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Knitting Faults

Here are some knitting faults:

1. Fabric barre or stripe.

2. Press off.

3. Miss stitch/ drop stitch.

4. Needle mark.

5. Sinker mark.

6. Oil stain.

7. Crease mark.

8. Hole.

9. Excessive slubs and entanglement in the fabric.

10. Spirility.

11. Pin hole.

12. Broken needle.

13. Tight course.

14. Missing yarn.

15. Fine yarn.

16. Coarse yarn.

17. Colored fly. Etc.

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Linen History

From Flax the Linen is made, Ancient Egyptians firstly used linen. Linen was a symbol of purity for the Egyptians because earliest linen cloth color was usually white. Linen was used for not only clothing and household articles but also linen used in religious practices.

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Washing Faults

Some washing faults are given below:

1. Color shade variation.

2. Crease marks.

3. After wash hole.

4. Very dark and very light.

5. Bleach spot.

6. Bottom hem and course edge destroy.

7. Running shading.

8. Over blasting/ low blasting.

9. Over grinding / low grinding.

10. Bad smell due to poor neutralization.

11. Poor hand feel.

12. To high hairiness.

13. Poor brightness.

14. High or low affect / abrasion on garments.

15. Spot on garments.

16. Out of range/ level of pH value of garments.

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Washing Plants Chemicals

Chemical Used in Washing Plant:

Here is the list of Chemicals which is used in washing plant:

1. Enzyme.

2. Acetic acid.

3. Detergent.

4. Antistain.

5. Bleaching powder.

6. Sodium hyposulfite.

7. Caustic soda.

8. Soda ash.

9. Sodium bicarbonate.

10. Potassium permanganate.

11. Cationic/ nonionic flax softener.

12. Micro emulsion silicon.

13. Salt (sodium chloride).

14. Buffer.

15. Hydrogen peroxide.

16. Stabilizer.

17. Fixing agent.

18. Catanizer.

19. Optical brightener.

20. Resin.

21. Sodium metabisulphite.

22. Desizing agent.

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Some Knit Fabric Structure

Fabric structure of some knit garments:

1. Single jersey: Face side of single jersey shows wales wise straight lines, on the other hand, back side shows course wise wavy lines.

2. Polo pique: Face side looks like honey comb and back side looks like wales wise straight lines.

3. Back pique: There are diagonally floating effect on the face side and hole on the back side.

4. Normal rib: Both sides of the fabric are looks similar.

5. Interlock: Both sides of the fabric are looks similar but less stretchable than rib.

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Batch Plan

Production planning for dyeing is called Batch Plan. According to the batch number, color, width, style and construction the batch plan is made. For easy understand, this section gives some ‘T’ cards. ‘T’ cards are serialized according to the priority of delivery. The batches and ‘T’ cards are also serialized as to dye light shade at first and lastly the dark shades, since faulty shade and can be converted to dark color later.

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Caustic Wash

Generally Caustic wash is done on printed garments, sulphur dye, reactive dye or direct dyed garments. Reasons required for caustic wash.

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