Daffodil International University

Assignment
Course Title: Quality Control in Textile (With lab)
Course code: TE 311

Submitted to:
Tanvir Ahmed Chowdhury.
Lecturer.
Department of TE.
Daffodil International University.

Submitted by :
Md. Shahidul Islam
Id: 102-23-2015
Section: L3T3(B)
Department of TE
Daffodil International University.

Date of Submission : 25Th, April, Thursday.

 Topic’s
Quality Control & It’s Application
In Knit Composite Industry.

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Quality Control :

Quality control can be defined as the cheking, verification and

regulation of degree of excellence of an attribute or property of something.

The operational techniques and activities that are used to fulfill

requirements of quality.

Quality control department runs by the direction of a quality

assurance manager (most of the cases). Quality of a product is checked in the different
manufacturing stages of a product. During quality assurance they follow different
international quality standard. Q.C department also take help from CCMS for measuring
the quality of a textile material.

Here, This is the flow chart of quality assurance diagram from spinning to garments.
Most of the textile manufacturing company follow it.

Yarn processing

Yarn test

Pass ————- Fail

↓                    ↓

                                    Knitting            Send to spinning mill

Grey fabric inspection

Pass ————– Fail

↓                    ↓

                                    Grey store       Send to store as reject

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 Batch making

Dyeing

Dewatering

Drying / stentering

Compacting

Fabric checking

Lab  Inspection (Shade)

Pass ————– Fail

↓                    ↓

                                    Delivery                Send to store as reject

Send to concern Department

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There are two types of quality assurance system; one is on line quality assurance system
and another is off line quality assurance system. Online Quality Assurance System:
Online quality control comprises with the raw material quality control and the process
control.

Online Quality Assurance System: Online quality control comprises with the raw
material quality control and the process control. On line quality control cosist of –

 Raw Material Control

 Process Control

Raw Material Control: As the quality product depends on the raw material quality so
we must be provided with the best quality raw material with an economical consideration.

 The fabric must be without fault, with proper absorbency, whiteness as per
requirement of the subsequent process. The Greige inspection report gives the
condition of the raw fabric. The information found on a greige report is given
below-

Process Control: The method chosen for the process must be provided with the
necessary accurate parameters. The specific gravity, water level, residual hydrogen per
oxide etc. at each stage should checked.

On line quality control is a system which is performed during manufacturing. During this
checking, if any faults are found in materials, one should take necessary steps to reduce
the fault or to stop the process and take necessary steps to recover it.

So, be careful during quality checking.

Off line quality assurance system:

This type of system consists of quality measuring

system when production process is completed. Here, I have described about the quality
assurance system of dyeing and finishing unit. All the Off-Line tests for finished fabrics
can be grouped as follows:

 Physical tests
 Chemical tests

Physical Tests: Following physical tests are carried out in off line quality assurance
system.

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 1. Threads per inch
2. Fabric weight
3. Width test
4. Tensile strength
5. Tear strength
6. Seam slippage
7. Abrasion resistance
8. Pilling resistance
9. Thermal stability
10. Crease resistance
11. Stretch ability & growth recovery
12. Smoothness appearance

Chemical Tests: Following chemical tests are performed in dyeing and finishing unit of
a textile mill.

1. Fastness to washing.
2. Fastness to light
3. Fastness to heat
4. Fastness to actual laundering
5. Fastness to sea water
6. Fastness to Chlorinated water
7. Fastness to water spotting
8. Fastness to perspiration

Equipments used for test: Various types of machineries and equipment are used during
testing. Following equipments are the main instruments for testing. All of the equipments
are not manufactured by same manufacturing companies. Various machine
manufacturing companies are responsible to provide such types of equipments to the
textile mill.

1. Spectrophotometer with software (Data color)

2. Martindale Abrasion Tester
3. Day light box
4. Sample dyeing machine (2)
5. Iron
6. Electric Balance
7. Crock meter
8. Data color
9. Washing m/c
10. GSM Tester
11. PH meter

So, we should perform off line quality assurance with great care.

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 Quality Control In Knit Composite Industry.

Knitting
Process Flow Chart Of Sweater Manufacturing Technology

Sweater is the special types of knitted fabrics. Day by day the demand of sweater fabrics
is increasing rapidly. To satisfy the present sweater fabrics demand, various sweater
manufacturing companies are trying heart and soul. They are trying to add various
modern facilities to the sweater fabrics.

List Of Top Branded Knitting Machine Of The World | Knitting

Machine For Bulk Production

In modern time; various knitting machine manufacturing companies are trying to

manufacture such types of machine which is cheap in price and facilities more advantage
to the user. They also try to develop the present structure of knitting machine.

How To Execute Production Process In A Knitting Mill?

Knitting is the interlocking of one or more yarns through a series of loops. Knitting
process is the main activities for producing knit goods. In every mill, there maintains a
sequence in production processing. It is a team work. In every steps of a processing every
responsive person is responsible for give best production.

What Are The Considerable Points For Producing Knit Fabrics?

Knit fabrics are the fashion of new age. Various designed fabrics are produced in knitting
machine. Knitting flow chart should follow during operation. During production process
following machine parameters are considered. Machine diameter Machine rpm
(revolution per minute) No. of feeder in use Machine gauge Count of yarn Required time
Machine running efficiency.

Different Parts of Knitting Machine | Functions Of Machine Parts

Knitting machines are mainly two types; they are circular knitting machine and flat bed
knitting machine. This two types are hugely use in knitting machine. A knitting machine
is composed of lots of parts. Every parts of a machine are important for run the machine
smoothly. Every part has a specific function during operation.

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Quality Assurance System Of Knitting Division | Quality Measurement

Quality Assurance System:

In modern times, customers want to get quality and

quantities products from the producer in every stage of production. For this reason, it
needs to deliver quality product to the buyer. To be ensuring about the quality of the
product, a quality control department is work for this. Quality control division is
responsible to ensure the quality of the product.

In knitting section; a quality assurance division is involved

to check the quality of the knit fabric before dyeing. After collecting fabric rolls from
different machines, these fabrics need to inspect thoroughly by the quality inspectors to
assure required quality before dyeing. Quality assurance of knitted grey fabric is
described here.

Some points are needed to maintain for high quality knit fabric:

During production, different points are needed to consider.

Here are some of them-

1. Brought good quality yarn.

2. Machines are oiled and greased accordingly.
3. G.S.M, Stitch length, Tensions are controlled accurately.
4. Machines are cleaned every shift and servicing is done after a month.
5. Grey Fabrics are checked by 4 point grading system.

List of equipments for quality control:

To ensure the quality of the knit products, following

instruments are required.

1. Inspection m/c.
2. Electronic balance
3. GSM cutter.
4. Measuring tape.
5. Scissors.
6. Indication sticker.

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Quality assurance procedure in knitting division:

In knitting floor; body, rib, collar and cuff are produced. The
quality of these products is measured as the following way.

Body & Rib Inspection:

After production of single jersey or double jersey knit fabric, it

sends to the quality checking table. All rolls are kept in front of the inspection m/c time to
time and are inspected over the inspection m/c visually in a pre-set speed against light.
For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly,
holes, oil lines, needle line, slubs etc are recorded in inspection report to classify the
fabric based on the four point system.

Collar & Cuff Inspection:  

This type of products are produced in flat bed knitting machine.

Collar and cuff are inspected visually under the light box, any major or minor fault in
collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round
problem etc properly counted and recorded.

After completing inspection, quality of the product is measured

in four point system. If the product passes the quality the it sends for dyeing if not it
sends to store as a reject fabric.

So, we should be care full about the faults of knitted fabric.

Grey Knit Fabric Inspection System In Batching Section | Quality

Assurance

The inspection and grading of fabric quality is one of the

important functions of Quality Control in the grey or finished state, the grading of fabric
is a difficult task, taking two primary considerations: as the frequency of effects and the
seriousness of defects.

The grading has two primary functions: First, to classify the

fabrics according to standard qualities based on the end-use and costumer demands and
second, to supply information as to the qualities actually being produced.

The Knitted fabric can be classified into three levels of quality,

each one have a number of points for defects as follows.

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The First quality level             : 40 points per 100 Linear Yards.

The Second quality level         : (40 – 80) points per 100 Linear Yards.

The Third quality level             : 80 points or more per 100 Linear Yards.

General Instructions for the final inspection:

Before sending the grey knit fabrics to the dyeing floor,

following inspection is done in batching section.

1. All pieces will be graded on the base of 40 points per 100 linear yards Mapping
will be done on each piece to insure proper grading. Do not count more than 4
points per one yard.
2. All defects must be recorded and marked in final inspection and an accurate
account of points made to insure proper grading.
3. All fabric must meet specifications.
4. At the end of each piece of fabric, the inspector will add up total points and
decide whether the piece can be shipped as first quality or not, reworked, placed
in lower quality, or cut and upgraded for shipment. Fifteen yards or more can be
shipped as first quality.
5. The quality control supervisor must approve the grading of all quality levels and
check the lower quality.
6. Major or unsightly defects in the first and last yard of a roll or piece will be cut.
All defects of one yard length or more will be cut out of the piece. Defects within
the first 2 inches or the last 2 inches of a piece will not be cut out or counted in
the grading.
7. Open defects on the back of fabric such as drops, runs and hanging picks are to be
included in the grading of fabric.
8. Pieces can be connected together, once each piece must be the same shade.
9. All defects such as runs that extend more than a yard in length will be cut out.
10. Fabric up to 70 inches will be allowed a bow of not more than 1 inch and a Bias
of not more than 2 inches.
11. Defects within one inch of the fabric edge will not be counted except on tubular
fabrics. All defects will be counted in tubular goods.

Grading Procedure:

During inspection, following points are considered.

1. All open defects or major defects counted with 4 points per defect.
2. Surface defects over 9 inch length counted with 4 points per defect.
3. Surface defects 6 to 9 inches length counted with 3 points per defect.
4. Surface defects 3 to 6 inches length counted with 2 points per defect.

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 5. Surface defects up to 3 inches length counted with one point per defect.
6. Running defects, such as tucks, needle lines, barre, crack marks, are judgment
defects

Batching is the process to get ready the fabrics which should

be dyed and processed for a particular lot of a particular order.

Knit Dyeing
Process Sequence Of Removal Softener Spots From The Dyed Fabric

Removal of softener spot from the Fabric is a washing

process, which is done in the dyeing bath. Softener spot is a dyeing fault which is
occurred during the application of softener to the fabric in dyeing bath or de-watering
machine.

Process Flow Chart Of Stripping In Dyeing | Cotton Knit Fabric Re-

Process

Knit Dyeing is a critical procedure and it is required to

match the shade of the dyed fabric with the buyer’s approved swatch. Sometimes, it is
found that the dyed fabric shade does not match with the approved swatch then this fabric
is required to re dyeing. This re dyeing process is called stripping.

Process Sequence Of Topping For Cotton fabric | Dyes Adding Process

Topping is defined as the addition of color to the fabric after

completing one dyeing process. Sometimes it is found that the dyed fabrics do not match
with the standard or buyer approved swatch then it needs to re dyeing, this process is
called topping. Tipping sequence is near similar as the full dyeing sequence.

Bleaching And Scouring Process Of Grey Melange Fabric

Pre-treatment is done for grey melange fabric. I have

written about scouring and bleaching process of grey melange yarn in one of my blog
post. Whitening Recipe: Here, I have given a scouring and bleaching process of grey
melange with a whitening recipe.

Process Flow Chart Of Viscose Fabric Dyeing

In dyeing floor, different types of natural, regenerated,

synthetic, blended fabrics are dyed. All of the fibers dyeing procedure are not same. For

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this reason, an textile engineer should have vast knowledge about the different fibers
dyeing process.

Dyeing And Finishing Section

In dyeing and finishing section; various types of quality is
measured by the quality assurance department. They check the shade of finished dyed
goods and measure the fastness properties of the dyed goods. If the dyed goods have
enough fastness properties then they give quality certificate.

Most of the knit dyeing industry assures the quality of the products of dyeing section in
the following three steps:

1. In Laboratory
2. In Dyeing section
3. In Finishing section

Procedures are described below: Now, I like to give a short idea about
the quality assurance procedure of textile materials in different stages of dyeing and
finishing.

In laboratory:

By the following way, quality of the material is measured in laboratory.

1. Swatch card from buyer according to their requirement.

2. Recipe prediction for sample dyeing by manually or CCMS.
3. Sample dyeing until matching with swatch card.
4. Fastness & other tests of the fabric or yarn are done here.

In Dyeing Section:

In dyeing section; quality of the product is checked by the following way.

1. According to the buyer’s sample, sample dyeing is done in sample dyeing

machine in dyeing shed, again matched with the approved sample.
2. If result is OK, then move to bulk production.
3. During dyeing, samples are taken until accurate shade matching. The interval may
be 30-40 minutes.
4. After dyeing sample is collected after softening matching is done.
5. Last of all, sample is collected after fixation & matched.
6. Then allowed the fabrics to be finished.

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In Finishing Section: After passing the dyeing section, different fabric properties are
added in finishing section by applying different finishes.

1. By using a series of finishing machines; correct width, softness and appearance

are maintained according to requirements.
2. Then sampling is done for several times to test GSM, Shrinkage & fastness
properties.
3. Finally fabric is inspected & prepared for delivery.

A quality control department is a busy department if they do their job perfectly. A quality
controller should have enough knowledge about the quality standard of different fastness
measurement process. Otherwise, all will be hampered.

So, be careful about the quality of the textile materials.

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