Fabric

  Production planning of woven Fabric

           Introduction:

                                  Production Planning

ü  Taking order form marketing division

ü  Analyzing the orders

ü  Planning for dyeing the yarn

ü  Planning for weaving the fabric

ü  Planning for finishing the fabric

Literature Survey:

                                               Production Planning

            

Sample Taking

Sample construction

(Count, EPI, PPI)

Weaving Construction

(Fabric Design and Analysis)

Yarn consumption

Weaving

Flow chart of Weaving

Winding:

This is a process of transfer of yarns from ring, bobbin, hanks etc, into a convenient from of package containing considerably long length of yarn. This simple transfer of yarn from one package (bobbin) to another large package (cone, spool, pirn) is called winding.

Objects of winding:

ü  To improve the quality of yarn

ü  To get a suitable package

ü  Make continuous supply of yarn in the subsequent process

ü  Removal of thick &thin place from the yarn

ü  Removal of weak places from the  yarn

ü  Removal of slubs

ü  Removal of knots

ü  To store the yarn

Sequence of winding:

Yarn in ring bobbin

Guide

Tension

Yarn clearer device

Stopping device

Traversing guide

Winding

Defects of winding:

ü  Formation of patches on the yarn.

ü  Incorrect winding speed.

ü  Tension variation.

ü  Dirty package.

ü  Incorrect shape of the package.

ü  Piecing up.

ü  Too much knots in the yarn.

ü  Greasy & dirty yarn.

ü  Excessive full bobbin.

Warping:

The parallel winding of yarn from cone or cheese packages on to a warp beam is called warping. Warping is a process of transferring yarn from a predetermined number of single-end packages, such as cones or cheeses, into a sheet of parallel yarns of a specified length and width.

Objects of warping:

ü  To wound up fixed (required) length of yarn on to a warp beam.

ü  To increase the weavability of yarn.

ü  To make dynamic next process.

ü  To increase production.

ü  To increase quality of fabric.

ü  To make re-useable small packages.

ü  To make convenient yarn sheet for sizing process.

Yarn passing diagram

Sizing: The weaving process requires the warp yarn to be strong, smooth and elastic or extensible to a certain degree.  To achieve these properties on the warp yarns,  a protective coating of a polymeric film forming agent ( size ) is applied to the warp yarns prior to weaving. This is called sizing or slashing.

Types of Sizing

1) Conventional aqueous sizing

                (a) Double cylinder sizing     

                (b) Multi cylinder sizing

2) Non conventional sizing

                (a) Dry sizing

                (b) Solvent sizing

                (c) Hot melt sizing

                (d) Foam sizing

Main Purposes of Warp Sizing:

ü  To increase the strength of the yarns

ü   To reduce the yarn hairiness

ü  To increase the abrasion resistance of the yarn against other yarns

ü  To reduce fluff and fly during the weaving machine process for high speed weaving machines.

Before sizing & after sizing Yarn:

Appearance of size spun yarn:

Weaving:

Weaving is the interlacing of two or more threads or pieces of material in order to create a joined structure. Weaving is the process of making cloth, rugs, blankets, and other products by crossing two sets of threads over and under each other. Weavers use threads to spun from natural fibers like cotton, silk, and wool synthetic fibers such as nylon.

Process Flow Chart of Weaving:

Warp Wise Yarn Path

Weavers beam

↓

Back rest roller

↓

Feeler roller

↓

Warp stop motion or drop wire

↓

Heald Eye

↓

Reed

↓

Take Up Roller

Weft Wise Yarn Path

Bobbin Creel

↓

Pre Winder

↓

Programmable Filling Tensioned (P F T)

↓

Fixed Nozzle

↓

Movable Nozzle

↓

Filling Cutter

↓

Relay Nozzle

↓

Filling Detector

↓

Stress Nozzle

↓

Waste Cutter

Case Study: Some use full formula for production planning

Pre calculation:

Total fabric production=

       Total length+ Excess amount of fabric in %

•Total end=EPI × Width of the fabric

• Reed count = EPI- Crimp%

Reed space = Total ends ÷ Reed count

•          Yarn Consumption: Warp yarn= [{ Total ends ÷ (warp count ×  840) + waste% }]

•          Weft yarn = [{ PPI × (reed space + waste)} ÷ weft count × 840]

Warping:

•          NO. Of cone = Total End ÷ NO. of warp beam

•          Cone length =(cone wt. in lbs × count × 840) yds

•          Set length = cone length ÷ No. of warp beam

•          Weaver’s beam: Length of weaver’s beam = length of warp beam + sizing extension

Crimp% calculation:

•          For 40’s yarn:

Sizing beam length = 1800 yds

Waste in head of the beam = 4 yds

Waste in tail of the beam =   9 yds

Total waste of yarn from beam after sizing = (4+ 9) yds

                                                                                         = 13 yds

Actual beam length = (1800 – 13) yds

                                      = 1787 yds

1787 yds sized yarn produce 1590 yds fabric

Less amount of fabric produce due to crimp = (1787 – 1590) yds

                                                                                         = 197 yds

Due to crimp 1787 yds reduce = 197 yds

Due to crimp 1 yds reduce      = 197 ÷ 1787 yds

Due to crimp 100 yds reduce = (197 X 100) ÷ 1787

                                                                = 11.02 %

Actual crimp% for 40’s yarn = 11.02

Above all,  we learned from  this type of topics like:

•          Flow chart of Weaving

•          Winding

•          Warping

•          Sizing

•          Weaving

•          Calculation formula

•          Crimp% calculation






Basic concept about Geo textile

Contents:

GEO TEXTILES Page no:

Front page …………………………………………………………………………….. 1

Contents ……………………………………………………………………………….. 2

Definition of Geo textile ……………………………………………………………… 3

Geo-Textile fabrics come in four basic forms ………………………………………... 3

Materials for Geo textiles .............................................................................................. 3

Geo textile Types and Construction …………………………………………………. 3

Geo textile function …………………………………………………………………. 4

Applications for natural geo textile ………………………………………………….. 4-5

Advantages …………………………………………………………………………..... 5

Conclusion …………………………………………………………………………… 6

Reference ……………………………………………………………………………..

1. Definition of Geo textiles:-

Geo textiles are flat, permeable, polymer-synthetic or natural textile materials which can be non woven, knitted or woven. They are used in contact with soil or other material in civil engineering and building constructions, filter, rain force, protect or drain. Typically made form polypropylene or polyester.

2. Geo-Textile fabrics come in four basic forms:-

1. Woven (look like mail bag sacking) by weaving methods.
2. Non-woven by non woven methods.
3. Needle punched (looks like felt) by needle punching methods.
4. Heat bonded (looks like ironed felt) by heat bonding methods.

3. Materials for Geo textiles:-

Geo textiles are made from-

1. Polypropylene
2. polyester
3. polyethylene
4. polyamide
5. polyvinylidene chloride
6. fibre glass

4. Geo textile Types and Construction:-

According to generation basis:- Firstly Geo textile were being manufactured carpets & industrial section.

Secondly it is although used in geo textile purpose without adopting modern technique.

Thirdly it is used in actual geo textile designed & produced to meet certain end use.

Technical of production basis:-

1. Woven
2. Heat bonded non woven
3. Needle punched non woven
4. Knitted.

5. Geo textile function:-

Separation function:- Separation of two layers of soil with different soil physical properties, such as road from soft base materials.

Filtration function:- Retaining fine particles when water passes from a fine grained to a coarse grained layer, such as when water flows from a sand soil into geo textile wrapped gravel drain.

Drainage function:- to drain liquid or gas in the plane of the fabric which results in draining or venting of the soil, such as a gas vent layer in a landfill cap.

Reinforcement function:- improving the load bearing capacity of a soil Structure, such as a high strength geo textiles to reinforce a retaining wall.

6. Applications for natural geo textile:-

• Soil reinforcement

Soils have relatively low tensile strength so that they are not able to transfer all of forces arising in a structure when it is loaded. The tensile forces created can be transferred using geo synthetics materials geo grids, geo textiles or geo composites. The geo synthetics products used as a reinforcing element, hence the term reinforced soil.

Picture of soil reinforcement

Benefits of use of geo synthetics materials for reinforcement:

• improvement the mechanical properties of soils
• otherwise unsuitable types of soil can be used
• expensive structural designs are avoided
• minimum land take required
• construction time is shorted (earthworks also in winter)
• embankment safety and stability is increased

Improvement of Load-Bearing Capacity

Use of geo synthetics materials represents one of effective methods of improvement of load-bearing capacity, above all wherever mechanical properties of local soil cannot provide the required level of stability and load bearing capacity.

Picture of improvement load bearing capacity

Supporting Structure

If we construct supporting structures or steep embankments of soils, the shear strength of which would be exceeded under normal circumstances, it is possible to achieve the required safety using horizontal reinforcement of the embankment layers with geo synthetics materials (geo grid or geo textile).

Advantages:

• suitable for reinforcement of fine-grained soil
• high tensile strength at low elongation
• high level of microbiological resistance
• high resistance to damage during installation
• low values of creep ensure long-term stability
• easy construction even in wintertime

Conclusion:

Though our country is undeveloped but we can provide the source of geo textiles materials from where we can be naturally development. In our market area where it well be available to highway construction companies, supply companies, drainage material and supply companies and farm supply stores. For better development to our country we need to research and planning then the eligible to big projection. As a result we can invest a huge amount of money where the country and our Geo textiles both are benefited.