Download - Knitting Depertment
KNITTING DEPERTMENT
KNITTING DEPARTMENT
The Fibre Quality achieved over years of consistent and market oriented business policies has
prompted GTN Industries to invest in high-end fabric manufacture in knitted fabrics. The Company
has 24 and 28 gauge Terrot knitting machines capable of knitting Jersey Pique, Interlock, Rib, Mini
Jacquards and Auto-stripe patterns. The fabric knitting systems are supported adequately by Collar
Knitting Machines from Shima Seiki. GTN also knits high quality lycra fabrics providing the knitting
division versatility, success and wider customer base.
Various type of knitting machine –
I. Lakshmi Terrot machine Features:
M/C type- 4-Track. Model- S296 DIA-30 GAUGE-28 No. Of machine- 2 for polyester+2 for cotton No. Of needles-2640 No of sinker-2640 No. Of feeder-96 Lycra attach-no.
II. Terrot machine Features:
M/c type- m/j Model-S3P172 DIA-30 Gauge -28 No. Of machine-2 No. of needle- 2628 No. Of sinker-2628 No. Of feeder-72 Production capacity-12.5kg/shift. Lycra attach –no.
III. Pauling machine
Features: M/C type- 4-track Model-XS3B/C DIA- 30 Gauge-24 Flexibility- 16 & 20 No. Of machine-1 No. Of needles-2256 No. Of sinker- 2256 No. Of feeder-90 Production capacity-125kg/shift. Lycra attach- yes
IV. Pauling machine
Features: M/C type- 4-track Model-XS3B/C DIA- 30 Gauge-24 Flexibility- 16 & 20 No. Of machine-1 No. Of needles-2256 No. Of sinker- 2256 No. Of feeder-90 Production capacity-125kg/shift. Lycra attach- yes
V. Shima seiki
Features: M/c type-S/J Model- SFE202T DIA- 80 inch Gauge -14 No. Of machine-1 No. Of needle- 1120 No. Of sinker-1120 No. Of feeder-6 Lycra attach-yes.
VI. Matsuya knitting machine
Features: M/C type-S/j Model-MC-172S/J DIA-68inch Gauge-14 No. Of machine-2 No. of needle-952 No. Of sinker-952 No. Of feeder-6 Lycra attach-yes
VII. Kauo heno knitting machine
Features: M/C type- Plain
Model- KH-323DJ
DIA- 60Gauge-14 No. Of machine-2 No. of needle-840 No. Of sinker- 840 No. Of feeder-6 Lycra attach-yes
Fabric design in GTN
Types of design of fabric-
a. Single jersey structure
b. Interlock knit structure
c. Rib knit structure
a. Single jersey fabric
Single jersey is the simplest weft knitted structure that it is possible to
produce on the one set of the needle.
The production rate is very high because of the stitch simplicity and its cost
is low because of machine simplicity.
The loops have a V-shaped loop appearance on technical face side and
show semi-circular loops on the technical back side.
The stitch length can be varied with cam setting giving more courses per unit
length with short stitch length and vice versa. The properties such as rigidity,
air permeability, weight per unit length, bursting strength changes with stitch
length.
The fabric can be unroved from either end or if stitch is broken, the wale will
disintegrate causing the stitches in that line to undo or ladder.
b. Interlock fabric-
Interlock is popular double jersey structure produced on a cylinder and dial
circular weft knitting machine.
Interlock is a reversible fabric, which has similar smooth appearance on
each side.
It does not curl at edges.
The fabric is less extensible due to interlocking structures knitted in two
separate planes by sinker loop.
Fabric is thick, stronger; less elastic hence is nearer to woven structure.
The fabric becomes costlier due to less production.
The structure does not curl at the edges when cut and are more ladder
resistant than either of the single jersey or the rib structure.
c. Rib knit structure
The term rib is used to describe a knitted fabric with vertical rows of loops
meshed in the opposite direction to each other.
Rib fabric is generally produced on V-bed or circular knitting machine.
It is reversible structure with face and back side having same appearance.
The does not curl at the edges due to balanced structure.
It has maximum extensibility width way and hence rib trimmings are most
suitable for neck bands, collars, arm bands.
The structure is more opaque than a jersey and hence this structure is used
in swim wears.
Technology/Process Description:
GTN industries manufactures t-shirts, polo-shirts, ladies-apparels, men's-wears, children and kids wears in 100% cotton knitted and blended items . It is fully equipped with latest machinery for production. The manufacturing process is as follows:
Production process:
Products:
GTN industries produce different items in knitted garments as:
1. T-shirts, basics-round-neck, Polo-shirts,
Sweat-shirts etc.
2. Ladies-tops, ladies-wears, night-wears etc.
3. Children and Kids-wears in 100% cotton and blend
. Broad Profile of Project Offer:
Project To Manufacture Knitted fabric
Capacity per day 2800 kg
Land Requirements/ Building Requirements
5000Sq. M
Plant & Machinery and Test Equipment
Circular knitting machine, flat bed knitting machine, Auto striper knitting machine, mini jacquard knitting machine,
Electrical Installation 15 HP
Implementation Period 6 Months
Manpower Required 70
Raw Materials / Equipment Required
Knitting Machine, Stain Remover Machine, testing lab
Profitability 4%
Preventive Maintenance for KNITTING MACHINES
Maintenance of knitting machinery:
The machine breakdown is 0.06% in the GTN in industries.
PREVENTIVE MAINTENANCE helps for less breakdown of machinery
For the newly purchased machine 3-4 years there is no maintenance problem
Only older machines undergoes for the maintenance activity
MAINTENANCE DEPT. takes care of the maintenance of machinery, it purchases
all the material required for the machinery.
MAINTENANCE DEPT. prepared for frequent and emergency breakdown of
machinery
QUALITY CONTROL
QUALITY STRETEGY AT GTN
GTN IND. Ltd would achieve the highest level of customer satisfaction by their
stated & perceived requirements, maintaining consistency & timely delivery.
GTN Endeavour’s continual up gradation of product quality & technology
supported by R&D efforts in a cost-effective manner.
To meet the changing global demands & stay ahead in competition. GTN would
adapt/innovate methods in its manufacturing activity.
GTN would inculcate a sense of quality awareness at all levels by using
appropriate training and motivation techniques.
GTN would aim at preserving the environment conditions by adapting eco-
friendly measures in its manufacturing & other activities.
QUALITY ASSURANCE DEPARMENT
Quality procedure:
PURCHASING PROCESS:
1. Selecting the suppliers depending upon the ability to supply the product with
organization requirements.
2. It also includes criteria for selection, evaluation, re-evaluation.
3. Records of supplier evaluation, rating & the necessary follow up action.
PURCHASING INFORMATION:
Org have documented information to describe product to be purchased include require for
approval, required for qualification of personnel, where necessary & other related
information.
The documentation also specifies the need for ensuring adequacy of
specified purchasing information before placing order with the supplier.
VERIFICATION OF PURCHASED PRODUCT
The organization has documented the methods for verification of incoming products. The
type and level of verification may vary depending upon the effect of the purchased product
on sequent product realization or the final product.
In case the organization required to perform verification at the supplier’s premises,
the necessary verification arrangements are previously agreed upon including the methods
of product release.
IMPROVEMENT:
The organization Endeavour to continually improve the effectiveness of QMS(Quality
management system) through the following.
Quality policy & objectives
Internal quality audit results
Analysis of data
Corrective and preventive actions
Management reviews
Customer feedback reports
CORRECTIVE ACTION:
The organization established a procedure to deal with corrective action to eliminate the
cause of non-conformity.
This “intern alia” include review of non-conformities, determining the cause
of non-conformities evaluating the need for action to ensure these do not occur,
determining & effectively implementing the actions and recording the actions taken.
Actions taken are reviewed for effectiveness.
INTERNAL COMMUNICATION:
The organization realizes that internal communication plays a vial role ensuring the smooth
& effective functioning of the QMS. The organization ensures that information required to be
communicated to persons who need to have then are effectively done. A separate
procedure addressing the means for this has been established.
MANAGEMENT REVIEW:
The management of the organization conduct management reviews once in every month.
The reviews ensure that the system is effectively functioning , is suitable adequate & serves
the purpose in view. The review also addresses the opportunities for improvement as may
be brought in from different levels/functions. The management review meetings are
recorded & actions initiated by concerned persons.
In the quality assurance department testing of the fibers, hanks, and yarns is done for the
end product quality .It includes three stages they are,
1. Incoming inspection
2. Process control inspection
3. Final inspection
1. INCOMING INSPECTION: Incoming inspection includes the raw materials, stores,
materials, i.e. incoming goods are inspected thoroughly so, that no faults can’t be
occurred in the product with the raw material or with machine etc.
2. .Process control inspection :
3. FINAL INSPECTION: Final inspection include the testing of hank ,fiber and
yarn .every processing element like carding ,combing, simplex etc.is undergoes into
checking whether it is acquired quality according to the specification . Fibers, hanks,
yarns are tested by using different Instruments. The results of the testing
instruments used by GTN industries are accepted by worldwide.
QUALITY MANUAL
MANAGEMENT RESPONSIBILITY
RESOURCE MANAGEMENT
PRODUCT REALIZATION
MEASUREMENT ANALYSIS & IMPROVEMENT
CUSTOMER SATISFACTION
CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM
PRODUCT
YARN TESTING
In the quality assurance department the parameters of yarn checked are
COUNT
STRENGTH
CSP (Count Strength product)
ELONGATION
CMT ( classimate faults in yarn)
CV (count variation)
IMPERFECTION
I. Thin Places 2. Thick places 3. Neps
There are Two types of tests done in the Q&A Dept.
Yarn testing
Fiber testing
YARN TESTING::
USTER CLASSIMAT QUANTUM:
Procedure:
By using USTER CLASSIMAT QUANTUM We can check cleared and uncleared
yarn, providing perfect classification of thick and thin places, as well as checking
infrequently occurring yarn defects and, recently, foreign fibers in the yarn.
Classifying foreign fibers into 27 classes according to the FOREIGNCLASS
classification system which is recognized worldwide.
USTER CLASSIMAT QUANTUM allows the distinction to be made between organic
and non-organic foreign matter
Defining customized classes allows targeted monitoring of individual faults in the
desired size, for thick and thin places as well as for foreign fibers.
Determining infrequently occurring yarn faults in 23 classes of thick and 4 classes of
thin places.
USTER STATISTICS Compare measuring results with the international quality
benchmarks directly on the screen.
USTER CLASSIMAT QUANTUM Testing charts:
ELECTRONIC WRAP REEL:
Brand: STATEX
Procedure:
Reels up to 10 yarn skeins
Number of revolutions can be preselected from 1 to 200 by the operator through
keyboard with LED display
The reel starts gently and smoothly to increase normal speed under microprocessor
control, before reaching the preselected measuring length, it slows down and
approach the end of the measurement slowly and stops at accurate position, which
ensures uniform winding without any stretch
Stainless steel reel for accurate length measurement and better stability
Separate yarn stand is provided to accommodate 10 cops
It is designed for adjustable pre-tension mechanism facilitates tension as per ASTM
standard to suit individual yarn through common selector. This advanced pretension
mechanism ensures uniform tension throughout winding
MODEL E1.5/10C E1.5Y/20C E1M/10C E1M/20C
Reel
circumference 1.5 YARDS 1.5 YARDS 1 METRE 1 METRE
No. of skein
yarns 10 20 10 20
USTER TENSORAPID :
The USTER TENSORAPID gives all the known measured values in tensile testing
and offers improved analysis of the yarn quality. The results determine the tested
yarn’s suitability for knitting or weaving.
The software package with USTER TENSORAPID calculate the following additional
characteristics:
• Elasticity-tension behavior of yarns
• Yield point definition by either strength or stretch
• Retardation and relaxation tests
A range of specially designed clamps and accessories guarantees optimal, reliable
and reproducible testing of yarns, hanks, slivers and also fabric strips.
The clamps can be arranged horizontally or vertically, depending on the material
being tested. With a horizontal clamping position, the danger of clamp breaks with
critical yarns can be avoided, since a considerable percentage of the stress will be
absorbed by the frictional surface.
USTER TENSORAPID Testing chart
Time to Br.(S)
B-Force (cN)
Elongation(%) Rkm
(kgf*Nm)
B-Work
(cN.cm)
Test1
Test2
Test3
Overall Results
Mean Value
S +/-
CV%
Q95% +/-
Min. value
Max.Value
Brand : STATEX
ELECTRONIC TWIST TESTER:
Electronic Twist Tester is used to test single yarn and double yarn. Specimen length
adjustable from 0 to 20 inch or 0 to 50 cms.
Procedure:
Provision to test S and Z twist
Results are displayed in TPI and TPM. Minimum number of control switches for
complete use
It is used to test heavy yarns and Multi twisted yarns
Scale provided to measure elongation of test results
Automatic counter start/stop using optical sensor
Pre-tension weight available up to 250 grams
Suitable for both Microprocessor Twist Tester and Electronic Twist Tester
FIBER TESTING:
USTER HVI SPECTRUM:
Brand: USTER
PROCEDURE:
In this instrument except Trash and Neps all the parameters are checked.
For the measure of micronaire study 10gm sample is collected for the testing.
The USTER HVI SPECTRUM provides with the required information of Standard
measurements of fiber length, uniformity, strength, micronaire, color and trash to
assist in selecting the right cotton for end product
Growers, ginners, traders and spinners specify, evaluate and select cotton
according to the quality standards of USTER HVI – the
only accepted standard worldwide.
The USTER HVI SPECTRUM is the only HVI instrument that is
Equipped with a patented moisture probe. Knowing the moisture .Content of the
cotton at the time of testing.
The USTER BALE MANAGER is software provides information about the cotton
quality, allows customization for the bale selection process, and stores historic
information on laydowns that have already been consumed.
USTER HVI SPECTRUM Testing sheet:
Bale ID
SCI Grade Mic Mat Len Amt Unf SFI Str Elg Moist Rd +b C Grade
CNT
MEAN]
STD DEV:
% CV:
BALANCES&WEIGHING SCALES:
PROCEDURE:
Afcoset balances are peerless in accuracy and reliability.
Selectable weighing modes Kg, counting or percentage.
Large and easy read out display mounted on tall column
Outstanding Accuracy up to 1/10000 displayed count resolution.
Optional RS232 allows connection to computer
Defects of YARN:
There are two types of yarn defects are defined they are as follows
1. Frequently occurring faults
Thin Places
Thick Places
Neps
2. Randomly occurring Faults
Long Thin
Long Thick