KNITTING DEPERTMENT

KNITTING DEPARTMENT
The Fibre Quality achieved over years of consistent and market oriented business policies has prompted GTN Industries to invest in high-end fabric manufacture in knitted fabrics. The Company has 24 and 28 gauge Terrot knitting machines capable of knitting Jersey Pique, Interlock, Rib, Mini Jacquards and Auto-stripe patterns. The fabric knitting systems are supported adequately by Collar Knitting Machines from Shima Seiki. GTN also knits high quality lycra fabrics providing the knitting division versatility, success and wider customer base.

Various type of knitting machine

I.

Lakshmi Terrot machine Features: M/C type- 4-Track. Model- S296 DIA-30 GAUGE-28 No. Of machine- 2 for polyester+2 for cotton No. Of needles-2640 No of sinker-2640 No. Of feeder-96 Lycra attach-no. Terrot machine Features: M/c type- m/j Model-S3P172 DIA-30 Gauge -28 No. Of machine-2 No. of needle- 2628 No. Of sinker-2628 No. Of feeder-72 Production capacity-12.5kg/shift. Lycra attach no.

II.

III.

Pauling machine Features: M/C type- 4-track Model-XS3B/C DIA- 30 Gauge-24 Flexibility- 16 & 20 No. Of machine-1 No. Of needles-2256 No. Of sinker- 2256 No. Of feeder-90 Production capacity-125kg/shift. Lycra attach- yes

IV.

Pauling machine Features: M/C type- 4-track Model-XS3B/C DIA- 30 Gauge-24 Flexibility- 16 & 20 No. Of machine-1 No. Of needles-2256 No. Of sinker- 2256 No. Of feeder-90 Production capacity-125kg/shift. Lycra attach- yes

V.

Shima seiki Features: M/c type-S/J Model- SFE202T DIA- 80 inch Gauge -14 No. Of machine-1 No. Of needle- 1120 No. Of sinker-1120 No. Of feeder-6 Lycra attach-yes.

VI.

Matsuya knitting machine Features: M/C type-S/j Model-MC-172S/J DIA-68inch Gauge-14 No. Of machine-2 No. of needle-952 No. Of sinker-952 No. Of feeder-6 Lycra attach-yes

VII.

Kauo heno knitting machine Features: M/C type- Plain Model- KH-323DJ DIA- 60Gauge-14 No. Of machine-2 No. of needle-840 No. Of sinker- 840 No. Of feeder-6 Lycra attach-yes

Fabric design in GTN

Types of design of fabrica. Single jersey structure b. Interlock knit structure c. Rib knit structure a. Single jersey fabric Single jersey is the simplest weft knitted structure that it is possible to produce on the one set of the needle. The production rate is very high because of the stitch simplicity and its cost is low because of machine simplicity. The loops have a V-shaped loop appearance on technical face side and show semi-circular loops on the technical back side. The stitch length can be varied with cam setting giving more courses per unit length with short stitch length and vice versa. The properties such as rigidity, air permeability, weight per unit length, bursting strength changes with stitch length. The fabric can be unroved from either end or if stitch is broken, the wale will disintegrate causing the stitches in that line to undo or ladder.

b. Interlock fabric

Interlock is popular double jersey structure produced on a cylinder and dial circular weft knitting machine. Interlock is a reversible fabric, which has similar smooth appearance on each side. It does not curl at edges. The fabric is less extensible due to interlocking structures knitted in two separate planes by sinker loop. Fabric is thick, stronger; less elastic hence is nearer to woven structure. The fabric becomes costlier due to less production. The structure does not curl at the edges when cut and are more ladder resistant than either of the single jersey or the rib structure.

c. Rib knit structure

The term rib is used to describe a knitted fabric with vertical rows of loops meshed in the opposite direction to each other. Rib fabric is generally produced on V-bed or circular knitting machine. It is reversible structure with face and back side having same appearance. The does not curl at the edges due to balanced structure. It has maximum extensibility width way and hence rib trimmings are most suitable for neck bands, collars, arm bands. The structure is more opaque than a jersey and hence this structure is used in swim wears.

Technology/Process Description: GTN industries manufactures t-shirts, polo-shirts, ladies-apparels, men's-wears, children and kids wears in 100% cotton knitted and blended items . It is fully equipped with latest machinery for production. The manufacturing process is as follows: Production process:

Yarn

Knitting

Dyeing

Compacting

Printing &eembrEmbroidery

Shrinkage Testing, Color Fastness Testing, GSM Testing

Cutting

Stitching

Checking

Products: GTN industries produce different items in knitted garments as: 1. T-shirts, basics-round-neck, Polo-shirts, Sweat-shirts etc. 2. Ladies-tops, ladies-wears, night-wears etc. 3. Children and Kids-wears in 100% cotton and blend

. Broad Profile of Project Offer: Project Capacity per day Land Requirements/ Requirements Plant & Machinery Equipment Building To Manufacture Knitted fabric 2800 kg 5000Sq. M

and

Test Circular knitting machine, flat bed knitting machine, Auto striper knitting machine, mini jacquard knitting machine, 15 HP 6 Months 70

Electrical Installation Implementation Period Manpower Required Raw Materials Required Profitability / Equipment

Knitting Machine, Machine, testing lab 4%

Stain

Remover

Preventive Maintenance for KNITTING MACHINES

Maintenance of knitting machinery: The machine breakdown is 0.06% in the GTN in industries. PREVENTIVE MAINTENANCE helps for less breakdown of machinery For the newly purchased machine 3-4 years there is no maintenance problem Only older machines undergoes for the maintenance activity MAINTENANCE DEPT. takes care of the maintenance of machinery, it purchases all the material required for the machinery. MAINTENANCE DEPT. prepared for frequent and emergency breakdown of machinery

QUALITY CONTROL

QUALITY STRETEGY AT GTN

GTN IND. Ltd would achieve the highest level of customer satisfaction by their stated & perceived requirements, maintaining consistency & timely delivery.

GTN Endeavours continual up gradation of product quality & technology supported by R&D efforts in a cost-effective manner.

To meet the changing global demands & stay ahead in competition. GTN would adapt/innovate methods in its manufacturing activity.

GTN would inculcate a sense of quality awareness at all levels by using appropriate training and motivation techniques.

GTN would aim at preserving the environment conditions by adapting ecofriendly measures in its manufacturing & other activities.

QUALITY ASSURANCE DEPARMENT Quality procedure:

PURCHASING PROCESS: 1. Selecting the suppliers depending upon the ability to supply the product with organization requirements.

2. It also includes criteria for selection, evaluation, re-evaluation.

3. Records of supplier evaluation, rating & the necessary follow up action.

PURCHASING INFORMATION: Org have documented information to describe product to be purchased include require for approval, required for qualification of personnel, where necessary & other related information. The documentation also specifies the need for ensuring adequacy of specified purchasing information before placing order with the supplier.

VERIFICATION OF PURCHASED PRODUCT

The organization has documented the methods for verification of incoming products. The type and level of verification may vary depending upon the effect of the purchased product on sequent product realization or the final product. In case the organization required to perform verification at the suppliers premises, the necessary verification arrangements are previously agreed upon including the methods of product release.

IMPROVEMENT: The organization Endeavour to continually improve the effectiveness of management system) through the following. QMS(Quality

Quality policy & objectives

Internal quality audit results

Analysis of data

Corrective and preventive actions

Management reviews

Customer feedback reports

CORRECTIVE ACTION: The organization established a procedure to deal with corrective action to eliminate the cause of non-conformity. This intern alia include review of non-conformities, determining the cause of non-conformities evaluating the need for action to ensure these do not occur, determining & effectively implementing the actions and recording the actions taken. Actions taken are reviewed for effectiveness.

INTERNAL COMMUNICATION: The organization realizes that internal communication plays a vial role ensuring the smooth & effective functioning of the QMS. The organization ensures that information required to be communicated to persons who need to have then are effectively done. A separate procedure addressing the means for this has been established.

MANAGEMENT REVIEW:

The management of the organization conduct management reviews once in every month. The reviews ensure that the system is effectively functioning , is suitable adequate & serves the purpose in view. The review also addresses the opportunities for improvement as may be brought in from different levels/functions. The management review meetings are recorded & actions initiated by concerned persons.

In the quality assurance department testing of the fibers, hanks, and yarns is done for the end product quality .It includes three stages they are, 1. Incoming inspection 2. Process control inspection 3. Final inspection 1. INCOMING INSPECTION: Incoming inspection includes the raw materials, stores, materials, i.e. incoming goods are inspected thoroughly so, that no faults cant be occurred in the product with the raw material or with machine etc.

2. .Process control inspection :

3. FINAL INSPECTION: Final inspection include the testing of hank ,fiber and yarn .every processing element like carding ,combing, simplex etc.is undergoes into

checking whether it is acquired quality according to the specification . Fibers, hanks, yarns are tested by using different Instruments. The results of the testing instruments used by GTN industries are accepted by worldwide.

QUALITY MANUAL MANAGEMENT RESPONSIBILITY

RESOURCE MANAGEMENT

PRODUCT REALIZATION

MEASUREMENT ANALYSIS & IMPROVEMENT

PRODUCT CUSTOMER SATISFACTION

CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

YARN TESTING In the quality assurance department the parameters of yarn checked are COUNT STRENGTH CSP (Count Strength product) ELONGATION CMT ( classimate faults in yarn) CV (count variation) IMPERFECTION I. Thin Places 2. Thick places 3. Neps There are Two types of tests done in the Q&A Dept. Yarn testing Fiber testing

YARN TESTING:: USTER CLASSIMAT QUANTUM: Procedure: By using USTER CLASSIMAT QUANTUM We can check cleared and uncleared yarn, providing perfect classification of thick and thin places, as well as checking infrequently occurring yarn defects and, recently, foreign fibers in the yarn. Classifying foreign fibers into 27 classes according to the FOREIGNCLASS classification system which is recognized worldwide. USTER CLASSIMAT QUANTUM allows the distinction to be made between organic and non-organic foreign matter

Defining customized classes allows targeted monitoring of individual faults in the desired size, for thick and thin places as well as for foreign fibers. Determining infrequently occurring yarn faults in 23 classes of thick and 4 classes of thin places.

USTER STATISTICS Compare measuring results with the international quality benchmarks directly on the screen.

USTER CLASSIMAT QUANTUM Testing charts:

ELECTRONIC WRAP REEL:

Brand: STATEX Procedure:

Reels up to 10 yarn skeins Number of revolutions can be preselected from 1 to 200 by the operator through keyboard with LED display

The reel starts gently and smoothly to increase normal speed under microprocessor control, before reaching the preselected measuring length, it slows down and approach the end of the measurement slowly and stops at accurate position, which ensures uniform winding without any stretch

Stainless steel reel for accurate length measurement and better stability Separate yarn stand is provided to accommodate 10 cops It is designed for adjustable pre-tension mechanism facilitates tension as per ASTM standard to suit individual yarn through common selector. This advanced pretension mechanism ensures uniform tension throughout winding

MODEL

E1.5/10C

E1.5Y/20C

E1M/10C

E1M/20C

Reel circumference No. of skein yarns 10 20 10 20

1.5 YARDS 1.5 YARDS 1 METRE 1 METRE

USTER TENSORAPID : The USTER TENSORAPID gives all the known measured values in tensile testing and offers improved analysis of the yarn quality. The results determine the tested yarns suitability for knitting or weaving. The software package with USTER TENSORAPID calculate the following additional characteristics: Yield Elasticity-tension point definition by behavior either of strength or yarns stretch

Retardation and relaxation tests A range of specially designed clamps and accessories guarantees optimal, reliable and reproducible testing of yarns, hanks, slivers and also fabric strips.

The clamps can be arranged horizontally or vertically, depending on the material being tested. With a horizontal clamping position, the danger of clamp breaks with critical yarns can be avoided, since a considerable percentage of the stress will be absorbed by the frictional surface.

USTER TENSORAPID Testing chart

Time Br.(S) Test1 Test2 Test3

to B-Force (cN)

Elongation(%)

Rkm (kgf*Nm)

B-Work (cN.cm)

Overall Results Mean Value

S +/CV% Q95% +/Min. value Max.Value

Brand : STATEX
ELECTRONIC TWIST TESTER:

Electronic Twist Tester is used to test single yarn and double yarn. Specimen length adjustable from 0 to 20 inch or 0 to 50 cms. Procedure:

Provision to test S and Z twist Results are displayed in TPI and TPM. Minimum number of control switches for complete use

It is used to test heavy yarns and Multi twisted yarns Scale provided to measure elongation of test results Automatic counter start/stop using optical sensor Pre-tension weight available up to 250 grams Suitable for both Microprocessor Twist Tester and Electronic Twist Tester

FIBER TESTING:
USTER HVI SPECTRUM: Brand: USTER PROCEDURE: In this instrument except Trash and Neps all the parameters are checked. For the measure of micronaire study 10gm sample is collected for the testing. The USTER HVI SPECTRUM provides with the required information of Standard measurements of fiber length, uniformity, strength, micronaire, color and trash to assist in selecting the right cotton for end product Growers, ginners, traders and spinners specify, evaluate and select cotton according to the quality standards of USTER HVI the only accepted standard worldwide. The USTER HVI SPECTRUM is the only HVI instrument that is Equipped with a patented moisture probe. Knowing the moisture .Content of the cotton at the time of testing. The USTER BALE MANAGER is software provides information about the cotton quality, allows customization for the bale selection process, and stores historic information on laydowns that have already been consumed.

USTER HVI SPECTRUM Testing sheet:

Bale ID SCI Grade Mic Mat Len Amt Unf SFI Str Elg Moist Rd +b C Grade CNT

MEAN] STD DEV: % CV:

BALANCES&WEIGHING SCALES:

PROCEDURE: Afcoset balances are peerless in accuracy and reliability. Selectable weighing modes Kg, counting or percentage. Large and easy read out display mounted on tall column Outstanding Accuracy up to 1/10000 displayed count resolution. Optional RS232 allows connection to computer

Defects of YARN:
There are two types of yarn defects are defined they are as follows 1. Frequently occurring faults

Thin Places Thick Places Neps

2. Randomly occurring Faults Long Thin Long Thick