The knitted fabric production process goes through many stages, from individual yarns to finished products that serve human needs. From the initial steps like material preparation and spinning to the knitting and finishing stages, each phase plays a crucial role in producing high-quality knitted fabric.
1. Raw Materials for Knitted Fabric Production
The main raw materials for producing knitted fabric include natural and synthetic yarns. Common natural yarns are cotton, wool, silk, and linen. Cotton yarn is popular for its softness and good absorbency. Wool provides warmth, while silk gives a cool, soft feel. Linen yarn is stiff but very durable and absorbs sweat well.
Synthetic yarns like polyester, nylon, acrylic, and spandex are also widely used in the knitted fabric production process due to their flexibility and ability to meet various technical requirements. Polyester is highly durable and dries quickly, while nylon is very strong and abrasion-resistant. Acrylic is soft and retains heat well, and spandex offers excellent stretch.
Some types of knitted fabric also combine both natural and synthetic yarns to leverage the advantages of both. For example, cotton-polyester blends are often combined to create knitted fabric that is more durable and less prone to wrinkling than 100% cotton fabric.
2. Detailed Knitted Fabric Production Process
The knitted fabric production process includes many complex stages that require high technical skill. Specifically:
Step 1: Material Preparation
The production process begins with material preparation. Before being used, the yarns must undergo a strict quality check. In addition, a thorough cleaning is essential to remove impurities and dirt.
Manufacturers can also blend different types of yarns to create fabric with special features. The blending ratio is carefully measured to ensure uniform quality.
Step 2: Spinning
After the pre-processing stage, the raw yarn is sent to the spinning process. Here, the yarn goes through several steps. The yarn is combed to remove impurities and align the fibers in a specific direction. It is then stretched to form continuous and uniform threads. Finally, the yarn is twisted to enhance its durability and elasticity. The finished yarn is wound onto spools, ready for the next stage of knitting.
Step 3: Knitting
This is the most important stage in the production process. Knitting machines use knitting needles to create interconnected stitches. Each type of knitting machine has its own characteristics and applications. Flat knitting machines typically produce flat fabric pieces, while circular knitting machines create tubular fabric.
The machine operator adjusts technical parameters such as stitch length and fabric weight (GSM) to achieve a final product with the desired quality and thickness. Once the knitting process is complete, the fabric will be pre-inspected to detect and fix any knitting flaws.
Step 4: Fabric Finishing
After knitting, the fabric goes through stages like washing, dyeing, and chemical treatment. The washing process helps remove remaining impurities and cleans the fabric surface. Dyeing gives the product a uniform, long-lasting color. Additionally, the fabric can be treated with chemicals to enhance softness and wrinkle resistance.
Step 5: Quality Inspection
The fabric will be carefully inspected to ensure it meets quality standards before being shipped. Fabric samples are checked for durability, stretch, absorbency, and other characteristics.
3. Knitted Fabric Production Technology
Knitted fabric production technology has made remarkable progress in recent years. Modern knitting machines are equipped with automated control systems and are capable of producing fabric with high precision and speed.
One of the most advanced technologies is seamless knitting. This technology allows for the production of seamless knitted products that do not require separate pieces of fabric to be sewn together. This saves time and production costs while creating products that are more durable and comfortable for the wearer.
3D knitting technology is a new advancement in the knitting industry. This technology allows for the production of products with complex 3D structures, from shirts and pants to shoes, without having to cut and sew fabric pieces. 3D knitted products not only have high durability but also offer customization according to customer requirements.
In addition, chemical treatment and dyeing technologies are also continuously being improved to minimize environmental impact. Environmentally friendly dyes and water-saving dyeing processes are now widely applied in the knitting industry.
4. Inspection and Evaluation of Knitted Fabric Quality
Inspecting and evaluating the quality of knitted fabric is a crucial step in the production process. This is to ensure that the product meets the highest quality standards. The quality inspection process includes several different stages.
- Material Inspection: Yarn rolls are thoroughly checked to ensure there are no flaws such as broken threads, excess fibers, or other defects. After knitting, the fabric is pre-inspected to detect knitting flaws such as loose stitches, broken stitches, or stains.
- Finishing Inspection: The fabric’s properties such as durability, stretch, absorbency, and colorfastness are evaluated using tests like the tensile strength test and elasticity test. In addition, chemical tests are performed to check the fabric’s safety. Fabric samples must be free of toxic chemicals like formaldehyde, phthalates, or heavy metals.
- Pre-packing and Shipping Inspection: A final visual inspection is done to ensure no flaws were missed. Technical specifications are also checked to ensure the product meets customer requirements.
5. VieTextile – High-Quality Knitted Fabric Production Company
This article has specifically described the knitted fabric production process and introduced VieTextile, a reputable provider of knitted fabric production solutions. We hope that this information will equip you with useful knowledge about this common type of fabric.
If you have any questions related to the knitted fabric production process, please do not hesitate to contact VieTextile through the following methods:
- Phone: +84 (0) 901809309
- Email: Info@Vietextile.com
- Office: 82C Quach Dinh Bao, Phu Thanh Ward, Tan Phu District, Ho Chi Minh City
