PRODUCTION PROCESS-KNITSPRODUCTION PROCESS-KNITS

By Sunil Talekar, Student handout-SOFT -PuneBy Sunil Talekar, Student handout-SOFT -Pune

PRODUCT DEVELOPMENTPRODUCT DEVELOPMENT• The Product Development section is a window for new The Product Development section is a window for new

buyers in term of pricing, sampling and information buyers in term of pricing, sampling and information collection.collection.

• The department provides assistance on a micro level, The department provides assistance on a micro level, something that is essential to the growth of any something that is essential to the growth of any account.account.

Pre production team works with Pre production team works with well articulated and well thought well articulated and well thought out timings and action calendars out timings and action calendars ensuring that each product is ensuring that each product is ready for production in the true ready for production in the true sense before it gets handed over sense before it gets handed over to production department for to production department for manufacturing.manufacturing.

Effective management of Pre Effective management of Pre Production approvals process is Production approvals process is critical to delivering a great critical to delivering a great quality product on time.quality product on time.

PRE PRODUCTION PROCESSPRE PRODUCTION PROCESS

Fabric is produced on Circular knitting machines, as per Fabric is produced on Circular knitting machines, as per required structure.required structure.

Principal yarns are cotton and cotton blends including Lycra. Principal yarns are cotton and cotton blends including Lycra.

Fabric range is single jersey, pique, interlock 2/3 thread Fabric range is single jersey, pique, interlock 2/3 thread fleece, thermals, waffles, jaquards and feeder / auto stripe fleece, thermals, waffles, jaquards and feeder / auto stripe jersey / interlocks.jersey / interlocks.

PRODUCTION PROCESS KNITTING PRODUCTION PROCESS KNITTING

Trims are made on flat knit machines.Trims are made on flat knit machines.Sometime a database of all fabric development and Sometime a database of all fabric development and production to ensure reproducibility and give a wide production to ensure reproducibility and give a wide choice to the buyers.choice to the buyers.

CIRCULAR KNITTING MACHINECIRCULAR KNITTING MACHINE

FLAT BED KNITTING MACHINEFLAT BED KNITTING MACHINE

FLAT BED KNITTING MACHINEFLAT BED KNITTING MACHINE

PRODUCTION PROCESS DYEINGPRODUCTION PROCESS DYEING• Fabric is dyed using the latest soft flow technology. Fabric is dyed using the latest soft flow technology. • Reactive dyes are used to meet the international standards of dyed Reactive dyes are used to meet the international standards of dyed

fabric performance. fabric performance. • Polyester dyeing is also available along with reliable resource base Polyester dyeing is also available along with reliable resource base

for yarn dyeing. for yarn dyeing.

PRODUCTION PROCESS FABRIC FINISHINGPRODUCTION PROCESS FABRIC FINISHING

Complete finishing range for all types of knitted fabrics, Complete finishing range for all types of knitted fabrics, done on squeezer horizontal dryer, compactor for proper done on squeezer horizontal dryer, compactor for proper fabric handle and ensure fabric stability.fabric handle and ensure fabric stability.

CAD system is used to make precise CAD system is used to make precise patterns and grading as well as patterns and grading as well as planning a lay and markers for planning a lay and markers for efficient and accurate cutting.efficient and accurate cutting.

PATTERN & CUTTINGPATTERN & CUTTING

In line inspection of cut goods is In line inspection of cut goods is carried out before it is transferred carried out before it is transferred to the stitching department.to the stitching department.

PRODUCTION PROCESS- PRINTINGPRODUCTION PROCESS- PRINTING

Printing is being done Printing is being done manually & automatic manually & automatic machines.machines.Printing options are Printing options are •Water based screen Water based screen •PlastisolPlastisol•High Dynasty High Dynasty •FlockingFlocking•FoilFoil•Discharge printDischarge print•Heat transfer.Heat transfer.

• The flock printing is a latest technology to make an artificial velvet surface with Electrostatic The flock printing is a latest technology to make an artificial velvet surface with Electrostatic Flocking Equipment's.Flocking Equipment's.

• This can be done on any kind of fabric & garments on any part of the garments giving very This can be done on any kind of fabric & garments on any part of the garments giving very soft hand feel.soft hand feel.

• The flock printing is done by flock sheets by transfering flock paper on fabric.The flock printing is done by flock sheets by transfering flock paper on fabric.

FLOCKING- PRINTINGFLOCKING- PRINTING

• High density High density screen printing at screen printing at first glance seems first glance seems to be some sort of to be some sort of high-quality puff high-quality puff print. print.

HIGH DENSITY- PRINTINGHIGH DENSITY- PRINTING

FOIL- PRINTINGFOIL- PRINTING

• Foil Sparkles Shimmers are Foil Sparkles Shimmers are used for applications like used for applications like giving flashing effect on giving flashing effect on cloth, enhancing color cloth, enhancing color shade after printing, giving a shade after printing, giving a lamination effect, giving lamination effect, giving transparent effects Giving transparent effects Giving very soft hand feel & color very soft hand feel & color fasteners towards world fasteners towards world class standards & world class standards & world class ECO System.class ECO System.

PUFF- PRINTINGPUFF- PRINTING

WATER BASE- PRINTINGWATER BASE- PRINTING

Appliqués are being Appliqués are being attached by hand attached by hand with gum and then with gum and then embroidery is done embroidery is done by using most by using most advanced Tajima & advanced Tajima & Barrudan machines.Barrudan machines.

PRODUCTION PROCESS-EMBROIDERY PRODUCTION PROCESS-EMBROIDERY

PRODUCTION PROCESS-STITCHINGPRODUCTION PROCESS-STITCHING

• Stitching machines to assemble Stitching machines to assemble polo shirts, pieced garments, polo shirts, pieced garments, rugby, henleys and other styles. rugby, henleys and other styles.

• Time-motion studies, using Time-motion studies, using industrial engineering techniques industrial engineering techniques are used to plan production lines are used to plan production lines for every style that goes into for every style that goes into production. production.

• Unique trolley system to Unique trolley system to transport parts from one stitching transport parts from one stitching station to the other has reduced station to the other has reduced the through-put time from 3 days the through-put time from 3 days to 6 hrs.to 6 hrs.

In finishing all stitched In finishing all stitched garments are being garments are being checked for quality and checked for quality and appearance and then finaly appearance and then finaly after folding and poly after folding and poly packing goes to cartons.packing goes to cartons.

PRODUCTION PROCESS-FINISHING & PACKING.PRODUCTION PROCESS-FINISHING & PACKING.

THANK YOUTHANK YOU