What is knitting? Describe the knitting fabric manufacturing process.

Knitting

The technique by which yarn is manipulated to create a textile or fabric is called knitting. It is used for many types of garment making. Knitting may be done manually or by machine. Knitted fabric consists of a number of consecutive rows of connected loops that intermesh with the next and previous rows.

What is knitting?

Knitting is a process of forming fabric from a single strand of yarn, using two needles. The applied fabric has to pay more than the woven fabric. In other words, knitting is a common term that refers to the mechanics of using a pair of needles & yarn for making fabric. When you look closely at the knitted fabric it is made up of rows of loops that interlock with neighboring rows that is what gives the fabric its stretch. This technique allows the fabric to be shaped for the intended purpose, unlike woven fabric which is flat and needs to be cut to shape. Of course, there are advanced techniques that use multiple needles, or a pair of needles attached by a cord, that allow tubes to be knitted, or textural and multicolored effects can be created by using multiple strands of yarn.

 

Knitting History

The original origins of knitting are unknown, the earliest examples are found in Egyptian pyramids being cotton socks. The first commercial sewing guilds appeared in Western Europe in the early fifteenth century. With the invention of the stocking frame, the people of the country became a craftsman with an early form of the knitting machine, hand-knitted, with easy access to fiber. Similar to quilting, spinning, and needlepoints, hand knitting became a leisure activity for the wealthy. Richard Rutt, an English Roman Catholic priest, and former Anglican bishop wrote a History of the Art of Hand Knitting. His collection of books on knitting is now housed at the Winchester School of Art.

Characteristics or properties of Knitted fabrics

1. Loop length is the key factor to determine and maintain the quality of knitted fabrics.

2. The loop length of knitting is generally measured in millimeters or inches, which is the length of the yarn in the knitted loop. Generally the longer the stitch length, the fabric is more open and lighter.

3. So by setting the loop length or stitch length, it is possible to knit fabric as a particular gsm using different yarn counts and machine gauges.

4. The density of the stitch is the next important parameter set in the knitting and represents the total needle loop in the given area. Stitch density is the product of courses per inch and wales per inch and is measured in units of loops per square inch or cm.

5. The construction of knitted fabrics is the number of loops or stitches per inch.

6. A wale corresponds to the warp of woven fabrics, while a course corresponds to the weft.

7. In General, the fabric which has more wales will shrink less in width, and which has more courses that will shrink less in length.

8. The fabric that has both more wales and courses will have better recovery from stretching, while that with fewer wales and courses will be less rigid, stretch more easily, fit the body contour better but have poor recovery.

9. The knit fabric is defined as the number of courses per inch followed by the number of wales per inch. A 30x30 fabric would contain 30 courses per inch and 30 wales per inch.

10. Each wale is formed by a different knitting needle that knits that wale throughout the length of the fabric.

11. In each course, the adjacent loops are formed by the same thread but by different needles. Therefore most, but not all, horizontally oriented defects are yarn related while most, but not all, vertically oriented defects are needle related.

12. Yarns in thickness, yarn, blend, color, or tension are seen as horizontal lines in different fabrics.

13. Needle damage such as a bent latch or a bent or broken hook is seen as vertical lines or streaks in the fabric.

Quality control in knitting Fabric

1. The main contribution of quality control is saving time and money. If any error occurs, the knitting machine must be stopped to correct the error, which reduces the time, which is uniform in the overall production process.

2. Loop density is the most important factor in defining the quality of the knitted fabric and it is directly related to the fabric presence, field weight per unit, dimensional stability, fabric weight, tensile factor, drape, and many other factors.

3. Quality control in the knitting process are two main causes of inconsistency that lead to fabric defects raw material management before the knitting process and variation in parameters during the knitting process.

4. The selection of yarn with a proper yarn count is important in determining the knitted fabric quality since only the correct yarn count gives optimal knitting performance for a specific machine gauge and structure.

5.  An elastic yarn is easier to knit and results in fewer knitting faults such as drop stitches, holes, and bad selvages.

6. This refers to the irregularity and non-consistency of the yarn, which directly affects the quality and weaving performance of the woven fabric.

7. Quality control during the knitting process and precision in the settings of the knitting machine during the whole knitting process are important to produce a fruitless knitted fabric.

8. By carefully controlling the knitting tension, the variations in loop length can be minimized, and the quality of knitted fabric improved.

9. The length of yarn in one stitch is another important factor that permanently affects the quality of a knitted fabric.

Types of knitting

On the basis of way, there are two types-

a. Weft knitting

b. Warp knitting

Weft knitting

The knitting technique in which the yarn zigzags along the width of the fabric is called warp knitting. In weft knitting, the wales are perpendicular to the course of the yarn.

Weft knitted fabric types-

1. Jersey fabric

2. Double knit

3. Circular knit

4. Fair Isle

5. Cable knit

Warp knitting

Knitting techniques, where yarn zigzags along the length of the fabric, are called warp knitting. That is, instead of a single row or course, follow the adjacent columns or wells related to knitting. Since the individual number of yarns needed to weave a warp strand or end is equal to the number of stitches in a row. Warp knitting is almost always done by a machine without hands.

Warp knitted fabric types-

1. Tricot

2. Milanese knit

3. Raschel knit

Type of knitting machine

On the basis of beds, there are two types-

a. Flatbed knitting M/C

b. Circular bed knitting M/C

The knitting process has three basic tasks

1. The active stitches must be held so they don't drop

2. These stitches must be released after secured

3. New bights of yarn usually have to go through the fabric through active stitches, so that it is secure.

Knit fabrication process

At first, the yarn cone is fitted on a machine creel. Then fitter man set the yarn for needle feed. Here needle is used for making a loop, and the sinker is used for holding yarn. When you look closely at the knitted fabric it is made up of rows of loops that interlock with neighboring rows that is what gives the fabric its stretch. This technique allows the fabric to be shaped for the intended purpose. If any yarn is a break, the instant machine is stopped. Then the yarn joined and the machine ran for fabric making without any faults. Finally, get a roll of fabric, cut off this roll, and then start the machine for getting the next fabric roll. If need spandex fabric, spandex is used with yarn feed.