Quality control | Quality control for the knit fabric dyeing process

Quality control

Quality control in the textile industry involves certain standards or guidelines that guarantee that a product meets certain parameters as well as customer satisfaction. Determine whether your product meets the requirements to use quality control measures. Set up your testing and control practices in every process.

Quality control for the knit fabric dyeing process

For quality control below subsequent processes are followed-

Process control for Batch

i. Need Batch ratio

ii. Nozzle rope length

iii. Nozzle a batch card will be used

iv. Roll mark must be used with a yellow marker.

v. Yarn lot mixing, M/C quality mixing.

vi. Greige fabrics according to dia, GSM, separately will be arranged.

vii. Batch strick will be given.

viii. From turning nozzle to nozzle separate

ix. Before the overlock yellow mark will be checked.

x. Overlock will be done according to the course.

Process control for finishing

i. Dia separation has to do with the squeezer and dryer

ii. Dia mixing has nothing to do with the squeezer and dryer.

iii. Batch cards will be given.

iv. Quality tag will be used.

v. Floor separation like sample rib/Turning/Dryer/Compacting/OK fabric/Not ok fabric.

vi. Before compacting shrinkage has to test.

vii. Dia to dia shrinkage has to be tested.

viii. After cutting GSM have to make a swatch board.

Process control for dyeing

1. Loading (%): According to rope length, reel speed, and cycle time.

2. Loading way and unload side mark.

3. Seam – Left/Right in any roll.

4. M: L for scouring 1: 6/ 1: 8.

5. Water should be treated by the demineralization process.

6. Scouring Temperature and Time should be calculated.

7. Need to do an absorbency-like drop test (1-3cm).

8. Scouring hot wash temperature 95°C in 15 min.

9. Normal wash cold temperature in 10 min.

10. Scouring pH maybe 10/11/12/13.

11. Enzyme pH maybe 4.0/4.5/5/5.5/

12. Enzyme time/temperature should be calculated.

13. Enzyme wash above 80°C in 10 min.

14. Dyeing process number

15. M: L for dyeing 1: 6/1: 8/1: 10/

16. Salt dossing linear/ progressive.

17. Color dossing linear/ progressive.

18. Soda dossing linear/ progressive.

19. Color steam & time should be calculated.

20. Warm wash at 50°C for 10 min.

21. Neutralization at 50°C for 10 min.

22. Soaping temperature around 80-90°C for 10 min.

23. Fixing pH around 5.0

24. Softener used for hand feel good/ medium.

25. Softener pH around (4.5-5.0)

26. Unloading nozzle-wise.

Quality control for shade

1. Knitting: Yarn a lot will be equally distributed according to ratio.

2. Batch: Yarn a lot do not mix into a batch. Dia ratio must be maintained for making a batch. A floor knit greige fabric will be taken very carefully separately.

3. Dyeing: Color addition will not be given to dyeing. Absorbency, leveling agent, progressive dosing, after-bath drain wash, clear wash before soaping, water pH, water TDS, and water hardness, for re-wash sequestering agent addition, will be followed. Every batch must be unloaded by shade confirmation.

4. Squeezing: After squeezing one roll quickly check by drying and compacting. Note down the temperature and other parameters. Online, the shade will be checked and made shade board.

5. Drying: For full batch drying dryer shade continuity will be attached by the dryer operator, authorized by the in-charge.

6. Compacting: For batch finishing, the starting shade will be checked and reconfirmed by the In-charge and finally, be dyeing manager. Then shade board and continuity will be made.