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Process control in textile manufacturing

Edited by A Majumdar, A Das, R Alagirusamy and V K Kothari, Indian Institute of Technology, India

Woodhead Publishing Series in Textiles No. 131

 - provides an important overview of the fundamentals and applications of process control methods
 - discusses key issues associated with process control and principles of control systems in textile manufacturing, before addressing testing and statistical quality control
 - explores process control in the manufacture of knitted, woven, nonwoven textiles and colouration and finishing, with a discussion on process control in apparel manufacturing

Complex raw materials and manufacturing processes mean the textile industry is particularly dependent on good process control to produce high and consistent product quality. Monitoring and controlling process variables during the textile manufacturing process also minimises waste, costs and environmental impact. Process control in textile manufacturing provides an important overview of the fundamentals and applications of process control methods.

Part one introduces key issues associated with process control and principles of control systems in textile manufacturing. Testing and statistical quality control are also discussed before part two goes on to consider control in fibre production and yarn manufacture. Chapters review process and quality control in natural and synthetic textile fibre cultivation, blowroom, carding, drawing and combing. Process control in ring and rotor spinning and maintenance of yarn spinning machines are also discussed. Finally part three explores process control in the manufacture of knitted, woven, nonwoven textiles and colouration and finishing, with a final discussion of process control in apparel manufacturing.

With its distinguished editors and international team of expert contributors, Process control in textile manufacturing is an essential guide for textile engineers and manufacturers involved in the processing of textiles, as well as academic researchers in this field.

Published in association with The Textile Institute

£165.00 / US$280.00 / €200.00

An e-book version of this title is available to purchase as part of a Collection or Pick n Mix or by Chapter. Visit Woodhead Publishing Online

About the editors

Dr Abhijit Majumdar, Dr. Apurba Das and Prof. R. Alagirusamy and Prof. V. K. Kothari are faculty members in the Department of Textile Technology at the prestigious Indian Institute of Technology (IIT), Delhi, India.

Titles which may also be of interest:
Fabric testing
Soft computing in textile engineering
Engineering textiles

Contents

PART 1 GENERAL ISSUES
PART 2 PROCESS CONTROL IN FIBRE PRODUCTION AND YARN MANUFACTURE
PART 3 PROCESS CONTROL IN FABRIC MANUFACTURE, COLOURATION AND FINISHING

PART 1 GENERAL ISSUES

Basics of process control in textile manufacturing
Vedpal and V Jain, Indian Institute of Technology Delhi, India
 - Introduction
 - Process mapping, analysis and control
 - Statistical process control (SPC) and improving processes
 - Future trends
 - References

Basic principles of control systems in textile manufacturing
S S Saha, Government College of Engineering and Textile Technology Berhampore, India
 - Introduction
 - Components of control systems
 - The control system design process
 - Digital and intelligent control systems
 - Application of control systems in textile processing
 - References

Testing and statistical quality control in textile manufacturing
A Das, Indian Institute of Technology Delhi, India
 - Introduction: statistical quality control
 - Basic measurement concepts in statistical quality control
 - Interpretations: critical difference
 - Interpretations: ‘t’ tests, ‘F’ tests and the chi-square method
 - Decision making using control charts
 - Decision making: hypothesis testing
 - Decision making: significance testing
 - Testing fibre and yarn properties
 - Testing fabric properties
 - References

PART 2 PROCESS CONTROL IN FIBRE PRODUCTION AND YARN MANUFACTURE

Process and quality control in cultivating natural textile fibres
M Zimniewska and J Mankowski, Institute of Natural Fibres and Medicinal Plants, I Frydrych, Technical University of Lodz and W Trywianska, Gdynia Cotton Association, Poland
 - Introduction
 - Control of cotton fibre quality
 - Indexes for cotton fibre quality
 - Process control in harvesting
 - Control of natural lignocellulosic/bast fibre quality: climatic conditions
 - Process control in production
 - Evaluating fibre quality
 - Future trends
 - References

Process control in the manufacturing of synthetic textile fibres
B L Deopura, Indian Institute of Technology Delhi, A Chatterjee, B R Ambedkar National Institute of Technology and N V Padaki, CSTRI Central Silk Board, India
 - Introduction
 - Process control in polymerization and fiber spinning
 - Post-spinning process control: drawing and heat setting
 - Key control points in synthetic fiber manufacture
 - Future trends
 - References

Process control in blowroom and carding operations
R Alagirusamy, Indian Institute of Technology Delhi, India
 - Introduction to blowroom operations
 - General process control in the blowroom
 - Process control in blowroom processes
 - Process control in carding: control of process parameters
 - Process control in carding: control of card clothing, wire maintenance and card waste
 - Yarn count issues and other common process control problems for blowroom and carding operations
 - References

Process control in drawing, combing and speed frame operations
A Ghosh, Government College of Engineering and Textile Technology, Berhampore and A Majumdar, Indian Institute of Technology Delhi, India
 - Introduction
 - Process control in drawing: key elements
 - The impact of drawing on yarn quality
 - Process control in drawing: common problems
 - Process control in combing: key elements
 - Process control in combing: the impact of combing on yarn quality and common problems arising from the process
 - Process control in speed frame operations: key elements
 - Process control in speed frame operations: the impact of speed frame operations on yarn quality and common defects related to the process
 - Conclusions and future trends
 - Acknowledgement
 - References

Process control in ring and rotor spinning
P K Majumdar, Government College of Engineering and Textile Technology, Serampore, India
 - Introduction
 - Factors affecting spinning tension in ring spinning
 - Control of yarn end breakage rate in ring spinning
 - Factors affecting yarn end breakage rates in ring spinning
 - Control of fly generation and twist variations in ring spinning
 - Process control in rotor spinning
 - Control of yarn end breakage rate and twist loss in rotor spinning
 - Future trends
 - References

Maintenance of yarn spinning machines
A Basu, Central Silk Board, India
 - Introduction
 - Maintenance of spinning preparatory machines
 - Maintenance of ring and rotor spinning machines
 - Future trends
 - Sources of further information and advice
 - References

PART 3 PROCESS CONTROL IN FABRIC MANUFACTURE, COLOURATION AND FINISHING

Process control in knitting
S C Ray, University of Calcutta, India
 - Introduction
 - Key control points in knitting
 - Quality control of knitted fabrics
 - Control of knitted loop length
 - Common faults in knitted fabrics
 - Other process control factors in knitting
 - Future trends: online quality control
 - References

Process control in weaving
V K Kothari, Indian Institute of Technology Delhi, India
 - Introduction
 - Controlling loom productivity, efficiency and fabric quality
 - Online process control, quality control and monitoring in weaving
 - Cost control in weaving
 - References

Process control in nonwoven production
D Moyo, A Patanaik and R D Anandjiwala, CSIR Materials Science and Manufacturing, South Africa
 - Introduction
 - Needle punching: process variables and process control
 - Hydroentanglement: process variables and process control
 - Melt blowing: process variables and process control
 - Spunbonding: process variables and process control
 - Future trends
 - Sources of further information
 - Acknowledgement
 - References

Process control in dyeing of textiles
S M Shang, Hong Kong Polytechnic University, China
 - Introduction
 - Dyeing of cotton
 - Dyeing of synthetic materials
 - Dyeing of blends
 - Process control in batchwise dyeing machines
 - Process control in continuous dyeing machines
 - References

Process control in printing of textiles
S M Shang, Hong Kong Polytechnic University, China
 - Introduction
 - Direct printing
 - Discharge, resist and heat transfer printing
 - Processing control in roller and screen printing machines
 - Inkjet printing and inkjet printing machines
 - Inkjet printing: pretreatment, defect prevention, aftertreatment and future trends
 - Product safety and low-carbon production
 - Sources of further information
 - References

Process control in finishing of textiles
A K Roy Choudhury, Government College of Engineering and Textile Technology, India
 - Introduction
 - Instrumental process control
 - Textile finishing processes and process control in finishing
 - Process control in basic finishing machines
 - Process control in Stenter machines
 - Calendering process
 - Surface raising and pre-shrinking finishes
 - Finishing with alkali
 - Softeners
 - Resin finishes
 - Protection from fire damage and water penetration
 - Anti-pilling finishes
 - Other types of finishing: anti-static, soil release, antimicrobial and UV protection
 - Wool treatment and enzyme finishes
 - Low-liquor finishing
 - Plasma treatments
 - Future trends
 - References

Process control in apparel manufacturing
G Thilagavathi and S Viju, PSG College of Technology, India
 - Introduction
 - Process control in spreading, pattern making and cutting
 - Process control in sewing
 - Causes of damage to fabric during sewing
 - Control of fusing and pressing operations, storage and packaging
 - Quality evaluation of apparel: testing for tailorability
 - Quality evaluation of apparel: testing for sewability
 - Quality evaluation of accessories
 - References