Process Control in Textile Manufacturing

Process Control in Textile Manufacturing

1st Edition - November 27, 2012

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  • Editors: A Majumdar, A. Das, R Alagirusamy, V K Kothari
  • Hardcover ISBN: 9780857090270
  • eBook ISBN: 9780857095633

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Description

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.

Key Features

  • 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

Readership

Textile researchers, engineers and manufacturers; fiber and yarn manufacturers, and those involved in textile finishing and dying; Textile academics and students

Table of Contents

  • Contributor contact details

    Woodhead Publishing Series in Textiles

    Foreword

    Part I: General issues

    Chapter 1: Basics of process control in textile manufacturing

    Abstract:

    1.1 Introduction

    1.2 Process mapping, analysis and control

    1.3 Statistical process control (SPC) and improving processes

    1.4 Future trends

    Chapter 2: Basic principles of control systems in textile manufacturing

    Abstract:

    2.1 Introduction

    2.2 Components of control systems

    2.3 The control system design process

    2.4 Digital control systems

    2.5 Intelligent control systems using soft computing

    2.6 Application of control systems in textile processing

    Chapter 3: Testing and statistical quality control in textile manufacturing

    Abstract:

    3.1 Introduction: statistical quality control

    3.2 Basic measurement concepts in statistical quality control

    3.3 Interpretations: critical difference

    3.4 Interpretations: ‘t’ tests, ‘F’ tests and the chi-square method

    3.5 Decision-making using control charts

    3.6 Decision-making: hypothesis testing

    3.7 Decision-making: significance testing

    3.8 Testing fibre and yarn properties

    3.9 Testing fabric properties

    Raw material

    Part II: Process control in fibre production and yarn manufacture

    Chapter 4: Process and quality control in cultivating natural textile fibres

    Abstract:

    4.1 Introduction

    4.2 Control of cotton fibre quality

    4.3 Indexes for cotton fibre quality

    4.4 Process control in harvesting

    4.5 Control of natural lignocellulosic/bast fibre quality: climatic conditions

    4.6 Process control in production

    4.7 Evaluating fibre quality

    4.8 Future trends

    Chapter 5: Process control in the manufacturing of synthetic textile fibres

    Abstract:

    5.1 Introduction

    5.2 Process control in polymerisation and fibre spinning

    5.3 Post-spinning process control: drawing and heat setting

    5.4 Key control points in synthetic fibre manufacture

    5.5 Future trends

    Chapter 6: Process control in blowroom and carding operations

    Abstract:

    6.1 Introduction to blowroom operations

    6.2 General process control in the blowroom

    6.3 Process control in blowroom processes

    6.4 Process control in carding: control of process parameters

    6.5 Process control in carding: control of card clothing, wire maintenance and card waste

    6.6 Yarn count issues and other common process control problems for blowroom and carding operations

    Chapter 7: Process control in drawing, combing and speed frame operations

    Abstract:

    7.1 Introduction

    7.2 Process control in drawing: key elements

    7.3 The impact of drawing on yarn quality

    7.4 Process control in drawing: common problems

    7.5 Process control in combing: key elements

    7.6 Process control in combing: the impact of combing on yarn quality and common problems arising from the process

    7.7 Process control in speed frame operations: key elements

    7.8 Process control in speed frame operations: the impact of speed frame operations on yarn quality and common defects related to the process

    7.9 Conclusions and future trends

    7.10 Acknowledgement

    Chapter 8: Process control in ring and rotor spinning

    Abstract:

    8.1 Introduction

    8.2 Factors affecting spinning tension in ring spinning

    8.3 Control of end breakage rate in ring spinning

    8.4 Factors affecting end breakage rates in ring spinning

    8.5 Control of fly generation and twist variations in ring spinning

    8.6 Process control in rotor spinning

    8.7 Control of end breakage rate and twist loss in rotor spinning

    8.8 Future trends

    Chapter 9: Maintenance of yarn spinning machines

    Abstract:

    9.1 Introduction

    9.2 Maintenance of spinning preparatory machines

    9.3 Maintenance of ring and rotor spinning machines

    9.4 Future trends

    9.5 Sources for further information and advice

    Part III: Process control in fabric manufacture, coloration and finishing

    Chapter 10: Process control in knitting

    Abstract:

    10.1 Introduction

    10.2 Key control points in knitting

    10.3 Quality control of knitted fabrics

    10.4 Control of knitted loop length

    10.5 Common faults in knitted fabrics

    10.6 Other process control factors in knitting

    10.7 Future trends: online quality control

    Chapter 11: Process control in weaving

    Abstract:

    11.1 Introduction

    11.2 Controlling loom productivity, efficiency and fabric quality

    11.3 Online process control, quality control and monitoring in weaving

    11.4 Cost control in weaving

    Chapter 12: Process control in nonwovens production

    Abstract:

    12.1 Introduction

    12.2 Needle punching: process variables and process control

    12.3 Hydroentanglement: process variables and process control

    12.4 Melt blowing: process variables and process control

    12.5 Spunbonding: process variables and process control

    12.6 Future trends

    12.7 Sources of further information

    12.8 Acknowledgement

    Chapter 13: Process control in dyeing of textiles

    Abstract:

    13.1 Introduction

    13.2 Dyeing of cotton

    13.3 Dyeing of synthetic materials

    13.4 Dyeing of blends

    13.5 Process control in batchwise dyeing machines

    13.6 Process control in continuous dyeing machines

    Chapter 14: Process control in printing of textiles

    Abstract:

    14.1 Introduction

    14.2 Direct printing

    14.3 Discharge, resist and heat transfer printing

    14.4 Process control in roller and screen printing machines

    14.5 Inkjet printing and its process control

    14.6 Product safety and low-carbon production

    14.7 Sources of further information

    Chapter 15: Process control in finishing of textiles

    Abstract:

    15.1 Introduction

    15.2 Instrumental process control

    15.3 Textile finishing processes and process control in finishing

    15.4 Process control in basic finishing machines

    15.5 Process control in stenter machines

    15.6 Calendering process

    15.7 Surface raising and pre-shrinking finishes

    15.8 Finishing with alkali

    15.9 Softeners

    15.10 Resin finishes

    15.11 Protection from fire damage and water penetration

    15.12 Anti-pilling finish

    15.13 Other types of finishing: antistatic, soil release, antimicrobial and UV protection

    15.14 Wool treatment and enzyme finishes

    15.15 Low-liquor finishing

    15.16 Plasma treatments

    15.17 Future trends

    Chapter 16: Process control in apparel manufacturing

    Abstract:

    16.1 Introduction

    16.2 Process control in spreading, pattern making and cutting

    16.3 Process control in sewing

    16.4 Causes of damage to the fabric during sewing

    16.5 Control of fusing and pressing operations, storage and packaging

    16.6 Quality evaluation of apparel: testing for tailorability

    16.7 Quality evaluation of apparel: testing for sewability

    16.8 Quality evaluation of accessories

    Index

Product details

  • No. of pages: 512
  • Language: English
  • Copyright: © Woodhead Publishing 2012
  • Published: November 27, 2012
  • Imprint: Woodhead Publishing
  • Hardcover ISBN: 9780857090270
  • eBook ISBN: 9780857095633

About the Editors

A Majumdar

Dr Abhijit Majumdar is a faculty members in the Department of Textile Technology at the prestigious Indian Institute of Technology (IIT), Delhi, India.

Affiliations and Expertise

Indian Institute of Technology, India

A. Das

Dr Apurba Das is Associate Professor in the Department of Textile Technology, Indian Institute of Technology (IIT), New Delhi, India. He has wide experience in industries, including research and development and quality management. He has published more than 100 research papers in journals and conferences and written chapters in several books. His main areas of teaching and research interests include clothing comfort, yarn manufacturing, non-conventional spinning techniques, evaluation of textile materials and technical textiles.

Affiliations and Expertise

Department IRO, University of Montreal, Montreal, Quebec, Canada

R Alagirusamy

Dr R. Alagirusamy is Professor in the Department of Textile Technology at Indian Institute of Technology, New Delhi. He has completed his Ph.D. from Georgia Tech, USA. He has authored several chapters in bestsellers in textiles and possesses several research papers published in reputed national and international journals.

Affiliations and Expertise

Indian Institute of Technology, India

V K Kothari

Prof. V. K. Kothari is a faculty members in the Department of Textile Technology at the prestigious Indian Institute of Technology (IIT), Delhi, India.

Affiliations and Expertise

Indian Institute of Technology, India

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