Procedure of Bale management | Function of the Blow room

Procedure of Bale management:

    1. Sample collection of each bale.
    2. Given ID No. on individual bale and sample.
    3. Conditioning the sample for standard MR%.
    4. Sample test by HVI (High Volume Instrument).
    5. Input data in BIAS (Bale Inventory and Analysis System).
    6. Prepared mixing plan.
    7. Prepared lay down plan.

Function of the Blow room: 

The most function of the blow room are given blow-

         Opening the fibers.
  Cleaning the fibers.
  Dust removing from fibers.
  Blending of different fibers.
  Mixing of fibers.
  To remove contamination. Here contamination means color fiber.
  To remove heavy & foreign materials.

Ring | Automatic Cone Winding | Concept of Bale Management | Necessity of bale management

Ring:

The end-product of ring department is yarn. Yarn is the continuous strand of fibers, which has received its final shape. It may be finer (wt/yard is less) or coarser (wt/yard is more) as per requirement of customer. However it is many times lighter in wt/yard as compared to that of roving from which it is produced.

The machine which produces yarn takes roving and reduces it by roller drawing, twisting as needed and winds the products accurately in a special form of bobbin for further use in auto cone.

 Automatic Cone Winding:

The completion of package from yarn to cone is done in this department. The yarn produced at the ring frame is obtained on a ring bobbin, which is not the final shape to present the yarn to the customer. Therefore it is essential to present the yarn to the customer in a reasonable package which is usually a cone produced on a winding machine. This cone
Contains the yarn in weight usually ranging from 2 lbs to 6 lbs. Yarn bag is commonly understood of weight of 100 lbs

Concept of Bale Management:

Bale management is the process of inventory control and selection of bale according to  fibre properties and also to mix fibre homogeneously to get consistent production and  quality of yarn, which is extremely important for production of yarn. For bale management, all of the bale are tested and almost similar category are arrange for homogeneously mixing.

Necessity of bale management:

Bale management very essential for the following objects-
By bale management consistency yarn quality found.
  A means of avoiding quality jumps.
  Cost saving by bale management.

Mixing | Blow Room | Carding

Mixing:

Mixing is define in which cotton bales are brought from go down and blending is performed in different ratios as per requirement. It is also called mixing and blending. A mixing of cotton blend is usually prepared keeping in view the required parameters of yarn being manufactured on the basis of cotton characteristics. Another important job performed in this department to condition the cotton bale by lay down before opening and cleaning.

Blow Room:

The main function of this department is to open and clean the cotton by beaters, condensers, air current, conveyor belts, hoppers etc. The impurities dropped under blow room machinery at different steps are called dropping-II and it varies in quantity or %age depending upon the cleaning efficiency and cotton density processed at that spot.
The end product of blow room is lap. It is made on Scutcher. It is a roll of uniform sheet of cleaned cotton wrapped after calendaring with sufficient pressure.
There is also another system in which opened and cleaned cotton is directly fed to the carding section from blow room, without lap formation. This system is called chute feed system.

Carding:

Carding may be defined as the reduction of an entangled mass of fibre to a filmy web by working them between two closely spaced, relatively moving surface clothed with sharp wire points.

Combing | Drawing | Roving

Combing:

Before combing the material, a number of slivers are doubled and drafted in a parallel position to form a ribbon lap as a feeding material on the combing machine. The ribbon lap is then processed on the comber for the removal of short fibers (noil), neps and others impurities.

Drawing:

Drawing is the process of progressively passing or sliding fibers by each other, causing a reduction in the size of the strand, but not breaking its continuity. In processing cotton, the action is obtained by using several pairs of rolls running at speed gradually increasing from back to front.

Purpose of all roller drawing is to straighten the fibers & removing hook point being treated and to reduce the size of the strand, which they compose. The straightening is important because it arranges the fibers more nearly parallel to each other and to the direction of the strand when the fibers are well straightened; the arrangement helps in producing uniform, strong and smooth yarn.

Roving:

A roving, the product of roving frame, may be defined as a continuous, slightly twisted strand of cotton fibers, which has not received its final reduction. The machine which produces roving takes sliver or other roving and reduces them by roller drawing twisting them slightly as needed, and winds the product accurately in a special form of bobbin.

The purpose of the roving operation is to attenuation drawn the sliver for a suitable size for spinning

Properties of textile supply water

Water has versatile usages in textile wet processing industry-from preparation of finishing use of water is essential in every stage of textile process. The quality of water is a dominating factor for success of wet treatment. Industrial process water hold different type of element ,sometimes pollute severely. Water mainly contains the carbonates, bicarbonates, sulfates, and chlorides of calcium, magnesium of sodium. Contaminated water can adversely affect the expecting standard of textile wet processes. The process needs a standard specification aspect of use. Textile dye house consume huge amount of water and this water must be maintain the minimum standard quality.

Common Agent | Detergent | Lubricant | Anti-foaming |Anti-creasing | Leveling agent

Detergent

Detergent is one kind of surface active agent but the reserve is not always true. The surfactants which have tendency power and the number of carbon in aliphatic chain are not less than 9. Usually used in textile to clean the materials by removing undesirable substances. These products are either soap or synthetic detergent.

Lubricant 

The chemical compounds use to prevent contact between solid surfaces in relative motion in order to reduce friction wear overhearing and rusting. They are good coolants, provide the appropriate range of viscosity and are thermally stable.

Anti foaming agent

Anti foaming agent are other types of surfactants which are able to prevent or reduce foam. Usually anti foaming agent used in dyeing bath and in printing paste to hinder the foam generation .Excess foam   Generation can create adverse effect in processing and product.

Ant creasing agent 

Usually used in dye bath or in finishing stage to prevent creasing of fabric or garments.

Leveling agent

Leveling agent is used in textile coloration process to achieve uniform dyeing over the whole substrate by controlling the rate of dyeing. Generally it is non ionic surfactants types compound either fiber substantive or dye substantive. It is available in market in liquid form.

Basic Qualification of Merchandiser

-Knowledge on duty rates and customs regulations
-Good command in English.
-Adequate knowledge on technical terms, accurate and efficient communication skill
--Good knowledge of raw materials (Fiber, Yarn, Fabric, Garments and accessories required)
-Sufficient knowledge of Dyeing, Printing, Finishing, Washing, Embroidery, Garments manufacturing etc.
-Adequate idea about color fastness of fabrics, garments and accessories.
-Knowledge on used raw materials and garments inspection systems
-Good knowledge of Exporting and Importing countries
-Knowledge of shipping and Banking documentation and regulations
-Order procedures of international buyers
-Adequate knowledge of factory profile
-Computer literacy and e-mails & internet.
-Excellent power of motivation to improve public relations
-Excellent behaviors and personality and intelligent

Quality of Trimmings

The important qualities of trimmings are-
Life time: The life time of trimmings should be equal or higher than that of the garments.
Shrinkage: The shrink ability of the garments and the trimmings should be checked earlier.
Color fastness: The fastness properties of accessories should be good.
Rust: To avoid this problem, the metal trimmings should be electroplated or they should be made up of non – rusting materials.
Comfort ability: Trimmings should not create any uncomfortable feeling to the wearer. 

Golden Rules for Merchandising

-Be flexible dealing with any buyer for orders and styles
-Do not overload the factory with excessive order
-When the order is start in the floor; Keep constant attention to see what is happening
-Never push any order to its extreme then disaster is imminent
-Approval must be secured in all situations
-Before run  production ensure that you are well equipped
-Accept order in staggering and balancing through the year
-Try to avoid accepting any order of rare and unusual in nature
-Do not accept any order with high risk 

Trims and Accessories

Trims: The raw materials which are sewn with main fabric are called trims

Accessories:  The materials, which are used to make a garment attractive for sale and packing, including trims, other than fabrics are called accessories.

Scouring

 Scouring is the first process carried out with room temperature or at suitable higher temperatures with the addition of suitable wetting agents, alkali and so on. Scouring removes all the  pectins , waxes, and makes the textile material hydrophilic condition  or water absorbent. See also scouring wool .                                                                                                                                                        Textile fibers which have been desized and are about to be bleached are scoured with a boiling alkaline caustic solution containing a surfactant and a solubilizing agent such as amin. This process provides fibers with a substantially reduced impurity level and an end product which is substantially more cond Textile fibers which have been desized and are about to be bleached are scoured with a boiling alkaline caustic solution containing a surfactant and a solubilizing agent such as amino tri(methylene phosphonic acid). This process provides fibers with a substantially reduced impurity level and an end product which is substantially more conducive to a subsequent dyeing process.ucive to a subsequent dyeing process.

Documents need for export of textile product

1 forwarding letter  from garments factory.
2 Packing list from exporter
3 Invoice from exporter
4 Master bill of lading
5 House bill of lading
6 Bill of exchange
7 GSL from EPB
8 USA  or CANADA invoice
9 Attested copy of export L/C for custom
10 Sample garments for custom
11 Pass book for custom
12 EPB clearance for custom
13 Bank certificate for shipping agent
14 Export registration certificate for custom
15 Export delivery application for custom
16 Certificate origin from DCCI/ BGMEA
17 Country origin declaration for USA
18 Inspection certificate
19 Sample approval certificate
20 EXP from bank

Fabric

Fabric is a soft or flexible textile materials which is composed of knitting, weaving, netting, crocheting , braiding etc. Actually fabrics is the input materials for cloth or garments. By the using of fabrics we protect  our self  from the diverse climate condition and the identification and decoration of our personality .fabrics are produces by different way , but the most way of fabric production are weaving and knitting . In the knitting, fabrics are produced by connected of loops in the warp and weft  direction . Here  loops are produced by by the help of needle, sinker and cam.  Here  needle produce the loop , cam is to give the motion for needle up and down , sinker hold down the loop. These are principal element of weft knitting machine elements .there are two types of knitting machine is used to produce knit fabric. One more elements is extra require for warp knitting that is guide.  GSM , Stitch length are the key factor for knit fabrics. The fabric weight is controlled by controlling of GSM  and stitch length of the knit fabrics.

Knit Fabric producing  machine,

Mercerization | mercerizing

A  treatment of cotton yarn or fabric to increase the luster and smoothness and give  tension in a cold sodium hydroxide ( coustic soda) solution . To increase the absorbency  of yarn as well as fabric . It is mainly used for  cellulose woven fabric  like hemp ,cotton etc.  Actually it is very expensive process.

Objective | important | benefit

1. To increase strength of the textile materials.
2. To increase  luster.
3. To increase dye affinity.
4.To increase dimensional stability.
5.It is suitable for deep shade.

Textile Dyeing Principal

Textile Dyeing is one kinds of  distribution or allocation  process in which the dyes or pigments are distributed at least two phase s system i.e. the dye/pigment bath or solution and the textile material or cloths.  By this process dyeing is done in a dye bath. Dye bath or dyeing machine contains a solution of dyes , chemical and other auxiliaries. Dyes and pigment are the main coloring materials in  textiles dyeing process.

dyeing is generally done for  textile material .Textile materials could be natural or man-made,depending on types of textile materials ,dyes, chemical and dyeing process varies. In the  textile dyeing of textile materials  make a bonding  between dyes and textile materials. after dyeing dyes fixed with textile materials. performance of textile materials depend on dyeing performance. If textile industry authority want to overcome  different quality test of textile materials then we need to give deep concern on dyeing process.
Dyeing process is dependent on  by following factor

1.Textile materials:
Textile materials are the Main elements of  the textile dyeing dyeing .Dyeing process varies for different  textile  materials like cotton, nylon,wool, silk, polyester, viscose,polyester etc.

2.Dyes/ pigments:
Dyes/ pigments are the main coloring materials for textile coloration  process. dyes varies depending on their chemical structure. Textile dyes may be varies for different textile materials like natural or man made materials.

3. Chemical and Auxiliaries:
Chemical is the main portion of textile dyeing process and without  chemical dyeing process is not done. Caustic soda, soda ash, hydrose, acetic acid, Hydrogen peroxide etc are the main chemical in the textile industry .

4. Machine for pre treatment and dyeing :
Different types of machine can be used in the dyeing industry for different textile material processing.

5.Utilities:
It must required for dyeing . Water, boiler, Gas are the main utilities in the textile industry.