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Different Types of Yarns: Structure, Features & Applications

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Yarns are the fundamental building blocks of textiles, formed by twisting fibers together to create long, continuous strands. Based on construction and fiber arrangement, yarns can be classified into various types, each with distinct characteristics that influence the performance, texture, strength, and end-use of the fabric. Understanding these yarn types is essential for selecting the right yarn in apparel, home textiles, and technical textile applications. 1. Single Yarn Definition: A single yarn is the most basic form of yarn, composed of a single strand of fibers twisted together. It can be made from natural (e.g., cotton, wool) or synthetic fibers (e.g., polyester, nylon). Characteristics: Simple structure Lightweight and soft Prone to pilling , snagging , and lower durability compared to multi-ply yarns Commonly used in lightweight garments and knitted fabrics 2. Plied Yarn (Twisted Yarn) Definition: A plied yarn is made by twisting two or mor...
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𝗖𝗼𝗺𝗺𝗼𝗻 𝗳𝗮𝘂𝗹𝘁𝘀 𝗶𝗻 𝗸𝗻𝗶𝘁𝘁𝗲𝗱 𝗳𝗮𝗯𝗿𝗶𝗰𝘀 𝗶𝗻𝗰𝗹𝘂𝗱𝗲:

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𝗙𝗮𝗯𝗿𝗶𝗰 𝗙𝗮𝘂𝗹𝘁𝘀 1. 𝗗𝗿𝗼𝗽𝗽𝗲𝗱 𝘀𝘁𝗶𝘁𝗰𝗵𝗲𝘀: Stitches that have been dropped or missed during the knitting process. 2. 𝗬𝗮𝗿𝗻 𝗯𝗿𝗲𝗮𝗸𝘀: Breaks in the yarn that can cause holes or unevenness in the fabric. 3. 𝗡𝗲𝗲𝗱𝗹𝗲 𝗺𝗮𝗿𝗸𝘀: Marks or impressions left on the fabric by the knitting needles. 4. 𝗨𝗻𝗲𝘃𝗲𝗻 𝘁𝗲𝗻𝘀𝗶𝗼𝗻: Inconsistent tension in the yarn can lead to uneven fabric texture or distortion. 5. Holes or runs: Holes or runs in the fabric caused by broken yarns or dropped stitches. 6. 𝗣𝗶𝗹𝗹𝗶𝗻𝗴 𝗼𝗿 𝘀𝗻𝗮𝗴𝗴𝗶𝗻𝗴: Fabric pilling or snagging due to friction or wear. 7. 𝗦𝗵𝗿𝗶𝗻𝗸𝗮𝗴𝗲: Fabric shrinkage due to improper care or processing. 8. 𝗗𝗶𝘀𝘁𝗼𝗿𝘁𝗶𝗼𝗻: Fabric distortion due to uneven knitting or finishing processes. 𝗖𝗮𝘂𝘀𝗲𝘀 1. 𝗠𝗮𝗰𝗵𝗶𝗻𝗲 𝗺𝗮𝗹𝗳𝘂𝗻𝗰𝘁𝗶𝗼𝗻: Issues with the knitting machine, such as needle breakage or yarn feeding problems. 2. 𝗬𝗮𝗿𝗻 𝗾𝘂𝗮𝗹𝗶𝘁𝘆: Poor yarn quality or inconsistent yarn properties...
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Understanding and Solving Bottleneck Operations in Garment Production

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What is a Bottleneck Operation? A bottleneck operation is a point in the production line where work slows down and expected output isn’t achieved. It becomes the slowest process in the line, causing work to pile up before it and delays for the next steps. This blockage can affect the overall flow of production. 📌 Why Identifying Bottlenecks is Important Bottlenecks usually happen when workers face difficulties completing tasks on time . If not addressed, it can: Slow down production Reduce employee efficiency Lower productivity Finding and solving bottlenecks helps improve the production system and boosts overall output. ✅ How to Improve Bottleneck Operations Here are some practical steps to fix or reduce bottlenecks: 1. Add Extra Manpower or Machines One quick solution is to add more workers or machines to the slow operation. However, this also increases the cost , so it's not always the best option. A good manager will try to improve without adding ext...
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Thread consumption (T-shirt)

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  Overlock Machine: Shoulder joint = 10.5*2 = 21 cm Neck joint = 30*2 = 60 cm Sleeve joint = 26*4 = 104 cm Side seam = 33*2 = 66 cm Total = 251 cm Flatlock Machine: Sleeve hem= 17*4 = 68 cm Bottom hem = 48*2 = 96 cm Back neck piping & top stitch = 23*2 = 46 cm Front neck top stitch = 36 cm Total = 246 cm LSA Machine: Care label stitching = 6 cm Main label attach = 5 cm Total = 11 cm SL Machine Type Thread/Needle Used Thread Consumption (per inch of sewing) 1 Plain Machine (m/c) 1 Needle 2.5-3 inches 2 Plain Machine (m/c) 2 Needle 5 inches 3 Overlock 3 Thread 13.25 inches 4 Overlock 4 Thread 22 inches 5 Overlock 5 Thread 24 inches 6 Flat Lock 3 Thread 18 inches 7 ...
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Process Flow Chart of Industrial Engineering (IE)

  Process Flow Chart of Industrial Engineering (IE): Negotiation with  garments merchandiser ↓ Garments analysis ↓ Make P.P meeting if all the required fabrics,  trimmings, and accessories  are in-housed ↓ Production target ↓ Set machine layout ↓ Line setting ↓ Line balancing ↓ Continuous production meeting ↓ Collecting production data ↓ Preparing production report ↓ Production report analysis ↓ Report submitted to the factory manager Talking to the Sales Team (Negotiation with garments merchandiser): Before they even start, the factory's engineering team talks to the people who sell the clothes (the "merchandisers"). They discuss what new clothes need to be made, what they're supposed to look like, and what materials are needed. It's like planning what to cook before you go to the grocery store. Checking the Clothes Design (Garments analysis): Once they know what to make, engineers carefully look at the design of the clothes. They figure out how many pieces it ...
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Knit Fabric Consumption Formula for a Basic Polo-Shirt

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  Ques: H&M forwards a knitted polo shirt item order (10000pcs) to you with the following specification. 100% cotton single jersey fabric for body parts (Body + Sleeve), Half-moon, and Pocket. Where fabric GSM is 160. 1 X 1 Rib fabric for collar and Cuff. Where the fabric GSM is 230 1.       Fabric consumption for Body parts (Body +Sleeve): Here, we will follow the following formula (per dozen),  (in kg)  (in kg) = 2.48 kg per dozen. 2.       Fabric consumption for Collar: (in kg)   =   (in kg) = 0.12 kg per dozen 3.       Fabric consumption for Cuff:  (in kg) = = 0.072 kg per dozen 4. Fabric consumption for Pocket:  (in kg) = = 0.03 kg per dozen 5.Fabric consumption for Half-moon:  (in kg) = = 0.04 kg per dozen Now, the total amount of cotton single jersey fabric needed for this order is (per dozen), ...
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