All the processing stages in textile manufacturing from fiber production to finished fabric are experiencing enhancement in process control and evaluation.
It includes textile fiber production and processing through blow room, carding, drawing, and combing; and fabric production including knitted, woven, nonwoven, and subsequent coloration and finishing and apparel manufacturing. The global textile industry, in yarn and fabric production, has strong presence and experiencing growth. In , the yarn and fabric market was valued at USD The market consumption is forecasted for growth at CAGR of 5.
Apparel production is another important area in textile manufacturing around the textile industry chain. Probably the apparel is what an individual wear for the purpose of body coverage, beautification, or comfort. Apparel and garment terms are used interchangeably.
However, the two terms may be differentiated as apparel is an outerwear clothing and garment is any piece of clothing. The study of apparel manufacturing market includes all the clothing articles except leather, footwear, knitted product, and technical, household, and made-up items.
The worldwide apparel manufacturing market was valued at USD The market enhancement is forecasted to move from to at CAGR of 4. Traditionally, yarn manufacturing comprises a series of processes involved in converting the fiber into yarn.
It was rooted in natural fibers obtained from natural plant or animal sources. Natural fibers are produced with natural impurities that were removed from the yarn in subsequent pretreatment processes. Possibly, cotton is the fiber that has rooted the yarn manufacturing from fiber bale opening, followed by the series of continuous operations of blending, mixing, cleaning, carding, drawing, roving, and spinning. Yarn manufacturing using cotton fibers through a sequence of processing stages may be shown by process flow diagram Figure 4 [ 8 ].
All these operations are mechanical and do not require chemical application. Processing stages in cotton yarn manufacturing [ 8 ]. Each processing stage in yarn manufacturing utilized the machine of specialized nature and provided quality effects in yarn production. The advancement in fiber processing and machine technology for yarn manufacturing is continuous.
The manual picking of cotton fiber is now replaced with machine picking. However, conventional systems of blending, carding, drawing, roving, and spinning are indicated important in the future [ 9 ]. Yarn diameter, hairiness, linear density, permeability, strength properties, etc. Several interesting works on the production of yarn are available that provide details of the material processing and technological control.
Introductory spinning technology is described by Lawrence [ 10 ]. It covers the rudiments of staple-yarn technology, the manufacturing process, the raw materials, and the production processes for short-staple, worsted, semi-worsted, woolen spinning, doubling, and specialty yarn. Some of the useful advanced topics discussed are staple-yarn technology, including new development in fiber preparation technology, carding technology, roller drafting, ring spinning, open-end rotor spinning, and air-jet spinning.
Peter described the yarn production technology in combination with the economics [ 11 ]. The study is useful for yarn manufacturing and its development in the textile industry. Important topics covered include review of yarn production, filament yarn production, carding and prior processes for short-staple fibers, sliver preparation, short-staple spinning, long-staple spinning, post-spinning processes, quality control, and economics of staple-yarn production.
The interlaced fibrous structure mainly used is woven, nonwoven, and knitted. Traditionally, the weaving technology was the principal source for fabric production. The important types of woven fabric produced are the basic weaves, such as plain or tabby, twill, and satin, and the fancy weaves, including pile, jacquard, dobby, and gauze. Knitted fabric is the second major type of fabric used following the woven.
It has a characteristic of accommodating the body contour and provided the ease of movement. It is particularly a comfortable form of fabric structure for sports, casual wear, and undergarment.
Knitted fabrics include weft types and the warp types, raschel, and tricot. Net, lace, and braid are other useful interlaced fabric structures. Nonwoven fabrics are rapidly increasing in market consumption. These fabrics are finding interesting uses in industrial and home applications. Nonwoven fabrics include materials produced by felting and bonding. Laminating processes are also increasing in importance, and fairly recent developments include needle weaving and the sewing-knitting process.
Garment is known as a piece of clothing. Garment design and manufacturing is the combination of art and technology. Garment manufacturing has seen several advancements in design development, computer-aided manufacturing CAD , and automation. However, the older version of garment manufacturing process is still the main theme today—that is, the cutting and joining of at least two pieces of fabric. The sewing machine has the function of joining woven or cut-knitted fabrics.
Garments are mostly produced by sewing the pieces of fabric using a sewing machine. These machines are still based on the primary format used. Today the important topics in the current garment manufacturing industry range over product development, production planning, and material selection.
The selection of garment design, including computer-aided design, spreading, cutting, and sewing; joining techniques; and seamless garment construction are beneficial in meeting the consumer needs. The development in finishing, quality control, and care-labeling of garment are meeting the point-of-sale requirements.
Technical textile is an established domain of interdisciplinary application of textile products. Most of the major industrial sectors are benefiting the function of fiber material. Any technical textile is a fibrous structure or a textile product that is produced for technical performance rather than fashion or aesthetic requirements.
Currently, technical textiles occupy strong market consumption. It is significantly an important sector for industrial development in industrialized and developing countries.
There are 12 types of technical textile with example product application which may be outlined as under: Meditech—sanitary diapers, bandages, sutures, mosquito nets, heart valves, ligaments, etc. BuildTech—ropes, tarpaulin, concrete reinforcement, window blind, wall covering, etc. ProTech—protective gloves, knife and bulletproof vest, flame-retardant and chemical-resistant clothing, etc.
The emergence of technical textile products was realized in the s, in addition to the conventional woven and knitted textile articles. However, since then technical textiles showed phenomenal growth Figure 5 [ 12 ]. Emergence of technical textile products from and its growth with knitted and woven textiles [ 12 ]. More recently, the global technical textile market has shown significant growth in consumption, and it is estimated to continue in the future.
Technical textile market was estimated at USD The CAGR of from to is indicated 5. The selection of any pretreatment process, its composition, and methodology depends upon the end-use requirement of the textile product. A pretreatment process is generally required to introduce two important value additions in textile substrate including: Removing the undesired content from the fiber mass including dust, coloring matters, undesired oils, lint, trash, etc.
Imparting the required level of fiber property for subsequent processing of textile substrate. The required fiber property may include fabric whiteness, absorbency, softness, strength, weight, width, etc. The pretreatment processes performed in conventional textile industry are sizing, desizing, scouring, bleaching, mercerization, washing, and heat setting.
One or more of any of these processes are required for the textile substrate depending upon the end use of the textile. Apparel manufacturing operators often sit for long periods and lean over machines. New ergonomically designed chairs and machines that allow workers to stand during their operation are some of the means that firms use to minimize discomfort for production workers. Another concern for workers is injury caused by repetitive motions.
The implementation of modular units and specially designed equipment reduces such potential health problems by lessening the stress of repetitive motions. Workers sometimes are exposed to hazardous situations that could produce cuts or minor burns if proper safety practices are not observed.
The movement away from traditional piecework systems in apparel manufacturing often results in a significant change in working conditions. Modular manufacturing involves teamwork, increased responsibility, and greater interaction among coworkers than on traditional assembly lines.
In , there were , wage and salary workers in the textile, textile product, and apparel manufacturing industries. The apparel manufacturing segment, particularly cut and sew apparel manufacturing, was the largest of the three employing , workers. Most of the wage and salary workers employed in the textile mills, textile product, and apparel manufacturing industries in were found in California and in the southeastern States.
California, Georgia, and North Carolina, together accounted for about 44 percent of all workers. While most apparel and textile establishments are small, employment is concentrated in mills employing 50 or more persons.
The textile and apparel industries offer employment opportunities in a variety of occupations, but production occupations accounted for 66 percent of all jobs; many of which are unique to the industry table 2. Additional jobs found at the headquarters of some of these textile and apparel companies are generally classified in a separate industry.
Production occupations. As in most manufacturing industries, the process of creating finished products is broken into a number of steps. Workers in these industries usually repeat a small part of the manufacturing process, using tools and machines where needed.
This allows manufacturers to create textile products from raw materials quickly and efficiently. They use computers to lay out the parts and draw in details to indicate the position of pleats, buttonholes, and other features, making adjustments as needed for different sizes. Extruding or forming machine operators set up and operate machines that extrude or force liquid synthetic material, such as rayon, fiberglass, or liquid polymers through small holes and draw out filaments.
Other operators put natural fibers, such as cotton or wool, through carding and combing machines that clean and align them into short lengths. Textile winding, twisting, and drawing-out machine operators make yarn from this material, taking care to repair any breaks. Textile bleaching and dyeing machine operators control machines that wash, bleach, and dye yarn or finished fabrics.
Textile knitting and weaving machine operators place the yarn on machines that weave, knit, loop, or tuft it. Textile cutting machine setters, operators, and tenders use patterns to prepare the pieces from which finished apparel will be made. Sewing machine operators join these pieces together, reinforce seams, and attach buttons, hooks, zippers, and accessories.
In some cases, hand sewers may be employed to do specialty work and make adjustments. Shoe machine operators and tenders tend machines used in making footwear. They perform a variety of functions, such as cutting, joining, and finishing.
Shoe and leather workers and repairers may finish work that cannot be performed by a machine. Others are employed in cobbler shops, where they repair shoes and other leather products, such as luggage. Pressers receive a garment after it has been assembled. Pressers eliminate wrinkles and give shape to finished products. Inspectors, testers, sorters, samplers, and weighers inspect finished products to ensure consistency and quality.
Other occupations. Industrial machinery mechanics inspect machines to make sure they are working properly. They clean, oil, and grease parts and tighten belts on a regular basis. When necessary, they make adjustments or replace worn parts and put the equipment back together. Mechanics are under pressure to fix equipment quickly because breakdowns usually stop or slow production. In addition to making repairs, mechanics help install new machines.
They may enter instructions for computer-controlled machinery and demonstrate the equipment to machine operators. Engineers and engineering technicians account for less than 1 percent of employment in these industries. Some engineers are textile engineers , who specialize in the design of textile machinery or new textile production methods, or the study of fibers. The industries also employ other types of engineers, particularly industrial and mechanical engineers.
Fashion designers are the artists of the apparel industry. They create ideas for a range of products including coats, suits, dresses, hats, and underwear. Fashion designers begin the process by making rough sketches of garments or accessories, often using computer-assisted design CAD software.
This software prints detailed designs from a computer drawing. It can also store fashion styles and colors that can be accessed and easily changed.
Designers then create the pattern pieces that will be used to construct the finished garment. They measure and draw pattern pieces to actual size on paper. Then, they use these pieces to measure and cut pattern pieces in a sample fabric.
Designers sew the pieces together and fit them on a model. They examine the sample garment and make changes until they get the effect they want. Some designers use assistants to cut and sew pattern pieces to their specifications. A high school diploma or GED is sufficient for most entry-level production occupations, although familiarity with computers and some postsecondary training is needed for more technical jobs and to operate sophisticated machinery.
As the production of textiles and apparel items becomes more technologically advanced, education and training is playing a larger role in the workplace. Administrative and professional workers often require more formal postsecondary education. Most production workers in textile and apparel manufacturing are trained on the job. Although a high school diploma is not required for many jobs, some employers prefer it. Extensive on-the-job training has become an integral part of working in today's textile mills.
This training is designed to help workers understand complex automated machinery, recognize problems, and restart machinery when the problem is solved. Some of this training may be obtained at technical schools and community colleges. Basic math and computer skills are important for computer-controlled machine operators so some job applicants are screened through the use of tests, to ensure that they have the necessary skills. Increasingly, training is offered to enable people to work well in a team-oriented environment.
Many firms have established training centers or host seminars that encourage employee self-direction and responsibility and the development of interpersonal skills. Because of the emphasis on teamwork and the small number of management levels in modern textile mills, firms place a premium on workers who show initiative and communicate effectively. Cutters and pressers are trained on the job, while patternmakers and markers usually have technical or trade school training.
All of these workers must understand textile characteristics and have a good sense of three-dimensional space. Traditional cutters need exceptional hand-eye coordination. Patternmakers and markers usually design pattern pieces and layouts on a computer screen, so new entrants seeking these jobs should learn basic computer skills. Those running automatic cutting machines could need technical training, which is available from vocational schools. Sewing machine operators must have good hand-eye coordination and dexterity, as well as an understanding of textile fabrics.
They are trained on the job for a period of several weeks to several months, depending on their previous experience and the function for which they are training. Operators usually begin by performing simple tasks, working their way up to more difficult assemblies and fabrics as they gain experience. Advancement often takes the form of higher wages as workers become more experienced, although operators who have good people and organizational skills may become supervisors.
Operators with high school diplomas and some vocational school training have better chances for advancement. With a meeting set for next week with our buildings and procurement partners, we must determine this week what we want to achieve as a department this year and how our partners can help us get there. I like to have the miscellany out of the way by the time everyone else gets there.
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