Manu Process
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  • 1. Knit Fabric Process Manufacturing Tutorial Prepared by Men’s Knit R & D. June 2009
  • 2. Knit Fabric Production Manufacturing Chain Cotton Yarn Spinning Mills Fabric Mills Garment Factories Retails / Brands
  • 3. Combed Cotton Yarn Spinning Raw Cotton Quality Inspection Blowing Carding Combing Drawing Roving Ring Spinning Winding Finished Yarn Inspection
  • 4. Combed Cotton Yarn Spinning Raw Cotton Quality Inspection Raw cotton is tested for its physical condition and is given quality grade according to the degree of whiteness, fineness, strength, contamination and proportion of immature fiber.
  • 5. Combed Cotton Yarn Spinning Blowing Raw cotton will be selected, cleaned and blended to generate uniform fiber quality.
  • 6. Combed Cotton Yarn Spinning Carding Fibers are fed into carding machine to eliminate impurities and dust. The cleaned fibers will be aligned in the same orientation and twisted into sliver form for combing operation.
  • 7. Combed Cotton Yarn Spinning Combing Combing is a process to upgrade the appearance and quality of the raw material. Slivers will go through further reduction of short fibers, impurities, neps and will be drafted to improve its parallelization. The processed slivers will be cleaner, finer and more uniform in appearance.
  • 8. Combed Cotton Yarn Spinning Drawing Since the evenness of slivers is critical to production and the final yarn quality, the linear density of slivers will be fine-tuned in this process by doubling and drafting. This step is the final process of quality improvement in the spinning mill.
  • 9. Combed Cotton Yarn Spinning Roving Slivers are drafted into thinner and stretchier strands. The strands are then winded onto roving bobbins for storage or for next operation.
  • 10. Combed Cotton Yarn Spinning Ring Spinning After roving, cotton strands are further drafted until the required fineness is achieved. To increase the strength of yarn, twist will be inserted during this production process.
  • 11. Combed Cotton Yarn Spinning Winding The yarn produced in the spinning process will be spliced and made to be more suitable for later knitting or dyeing operation. Faults and neps of yarn will also be checked and cleared in this step to ensure the final yarn quality.
  • 12. Combed Cotton Yarn Spinning Finished Yarn Inspection Samples of finished yarn are inspected for its quality by using the testing equipment. The average quality level of combed yarns is within the 5% of Uster-evenness 2001 grade.
  • 13. Piece Dyed Fabric Production Raw Yarn Quality Inspection Knitting Greige Inspection Fabric Dyeing Drying Finished Dyed Fabric Inspection Finishing, Compacting & Setting Greige Presetting
  • 14. Piece Dyed Fabric Production Raw Yarn Quality Inspection Raw yarns are tested for their physical and mechanical properties and are graded according to their evenness, tenacity, elasticity, fiber maturity, contamination, twist level and hairiness.
  • 15. Piece Dyed Fabric Production Knitting Yarns are knitted into fabrics with different fabrication.
  • 16. Piece Dyed Fabric Production Greige Presetting Presetting is carried out on all greige fabrics that contain spandex or with high polyester content so that their dimensional stability can be set before dyeing.
  • 17. Piece Dyed Fabric Production Greige Inspection After the fabrics are knitted, another 100% inspection is carried out to ensure the greige fabrics are of the highest of quality before delivering to the dye house.
  • 18. Piece Dyed Fabric Production Fabric Dyeing Fabrics are dyed either in water jet, air jet or overflow machines according to their fabrication and fiber composition.
  • 19. Piece Dyed Fabric Production Drying After dyeing, excessive water is removed from the fabrics by mechanical means so that they can be heated set with the best efficiency.
  • 20. Piece Dyed Fabric Production Finishing, Compacting & Heat Setting Any special wet finishes such as anti-UV, oil repellent, stain release are added before the fabrics are heat set or compacted for good dimensional stability.
  • 21. Piece Dyed Fabric Production Final Dyed Fabric Inspection All finished fabrics are then inspected for defects according to the 10-point system or any system as specified by the end buyer.
  • 22. Yarn Dyeing Process Cone Winding Yarn Dyeing Drying Rewinding & Waxing Dyed Yarn Inspection
  • 23. Yarn Dyeing Process Cone Winding The greige yarns are re-wound onto steel or plastic packages for dyeing.
  • 24. Yarn Dyeing Process Yarn Dyeing Yarns are either bleached, optically whitened or dyed to specific colors as the mill ensures stringent color accuracy of the products and a consistent ability to meet the highest of standards in the industry. High efficiency and low liquor ratio machines are used to ensure efficiency and with the least impact to the environment.
  • 25. Yarn Dyeing Process Radio Frequency & Microwave Drying After dyeing, the yarns are dried either by radio frequency or microwave so that the change of color due to drying will be minimal.
  • 26. Yarn Dyeing Process Re-winding & Waxing After drying, yarns are then re-wound again onto paper cones and at the same time, sufficient wax are added onto the yarns so that the next operation can be carried out with as little friction as possible.
  • 27. Yarn Dyeing Process Dyed Yarn Inspection Dyed yarn inspection is carried out to ensure the yarns are fault free and ideal for delivery to the customers or for the next operation.
  • 28. Printing Process White or Dyed Fabric Presetting Flat Screen / Rotary Screen Printing Baking, Steaming, Washing & Drying Finishing, Heat Setting, Compacting Final Printed Fabric Inspection
  • 29. Printing Process White or Dyed Fabric Presetting After dyeing and drying, fabrics which to be printed will be set with a definite width.
  • 30. Printing Process Flat Screen or Rotary Screen Printing Printing can be done on either a flat screen machine or a rotary screen machines. Dye can be reactive, pigment, disperse or discharge.
  • 31. Printing Process Baking, Steaming, Washing and Drying Fabrics printed with reactive, disperse and discharge printing are baked, steamed, washed and dried to achieve the best color yield and fastness.
  • 32. Printing Process Finishing, Heat Setting, Compacting The fabrics are finally treated with different finishes if necessary and then heat set or compact to achieve the requested weight and width.
  • 33. Printing Process Final Printed Fabric Inspection All finished printed fabrics are then inspected for defects according to the 10-point system or any system as specified by the end buyer.