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E-grāmata: Process Control in Textile Manufacturing

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Edited by (Indian Institute of Technology, India), Edited by (Department IRO, University of Montreal, Montreal, Quebec, Canada), Edited by (Professor, Department of Textile and Fiber Engineering, IIT Delhi, India), Edited by (Indian Institute of Technology, India)
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Process Control in Textile ManufacturingPalielināt
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Complex raw materials and manufacturing processes mean the textile industry is particularly dependent on good process control to produce high and consistent product quality. Monitoring and controlling process variables during the textile manufacturing process also minimises waste, costs and environmental impact. Process control in textile manufacturing provides an important overview of the fundamentals and applications of process control methods.Part one introduces key issues associated with process control and principles of control systems in textile manufacturing. Testing and statistical quality control are also discussed before part two goes on to consider control in fibre production and yarn manufacture. Chapters review process and quality control in natural and synthetic textile fibre cultivation, blowroom, carding, drawing and combing. Process control in ring and rotor spinning and maintenance of yarn spinning machines are also discussed. Finally part three explores process control in the manufacture of knitted, woven, nonwoven textiles and colouration and finishing, with a final discussion of process control in apparel manufacturing.With its distinguished editors and international team of expert contributors, Process control in textile manufacturing is an essential guide for textile engineers and manufacturers involved in the processing of textiles, as well as academic researchers in this field.
Contributor contact details xi
Woodhead Publishing Series in Textiles xiv
Foreword xix
Part I General issues
1(78)
1 Basics of process control in textile manufacturing
3(11)
V. Jain Vedpal
1.1 Introduction
3(2)
1.2 Process mapping, analysis and control
5(4)
1.3 Statistical process control (SPC) and improving processes
9(2)
1.4 Future trends
11(2)
1.5 References
13(1)
2 Basic principles of control systems in textile manufacturing
14(27)
S. S. Saha
2.1 Introduction
14(4)
2.2 Components of control systems
18(10)
2.3 The control system design process
28(6)
2.4 Digital control systems
34(2)
2.5 Intelligent control systems using soft computing
36(3)
2.6 Application of control systems in textile processing
39(1)
2.7 References
39(2)
3 Testing and statistical quality control in textile manufacturing
41(38)
A. Das
3.1 Introduction: statistical quality control
41(1)
3.2 Basic measurement concepts in statistical quality control
42(6)
3.3 Interpretations: critical difference
48(5)
3.4 Interpretations: `t' tests, `F' tests and the chi-square method
53(4)
3.5 Decision-making using control charts
57(2)
3.6 Decision-making: hypothesis testing
59(2)
3.7 Decision-making: significance testing
61(11)
3.8 Testing fibre and yarn properties
72(3)
3.9 Testing fabric properties
75(3)
3.10 References
78(1)
Part II Process control in fibre production and yarn manufacture
79(162)
4 Process and quality control in cultivating natural textile fibres
81(28)
M. Zimniewska
J. Mankowski
W. Trywianska
4.1 Introduction
81(1)
4.2 Control of cotton fibre quality
81(4)
4.3 Indexes for cotton fibre quality
85(4)
4.4 Process control in harvesting
89(7)
4.5 Control of natural lignocellulosic/bast fibre quality: climatic conditions
96(4)
4.6 Process control in production
100(5)
4.7 Evaluating fibre quality
105(2)
4.8 Future trends
107(1)
4.9 References
107(2)
5 Process control in the manufacturing of synthetic textile fibres
109(23)
B. L. Deopura
A. Chatterjee
N. V. Padaki
5.1 Introduction
109(2)
5.2 Process control in polymerisation and fibre spinning
111(11)
5.3 Post-spinning process control: drawing and heat setting
122(5)
5.4 Key control points in synthetic fibre manufacture
127(3)
5.5 Future trends
130(1)
5.6 References
131(1)
6 Process control in blowroom and carding operations
132(26)
R. Alagirusamy
6.1 Introduction to blowroom operations
132(3)
6.2 General process control in the blowroom
135(2)
6.3 Process control in blowroom processes
137(5)
6.4 Process control in carding: control of process parameters
142(5)
6.5 Process control in carding: control of card clothing, wire maintenance and card waste
147(6)
6.6 Yarn count issues and other common process control problems for blowroom and carding operations
153(4)
6.7 Bibliography
157(1)
7 Process control in drawing, combing and speed frame operations
158(33)
A. Ghosh
A. Majumdar
7.1 Introduction
158(1)
7.2 Process control in drawing: key elements
159(5)
7.3 The impact of drawing on yarn quality
164(2)
7.4 Process control in drawing: common problems
166(5)
7.5 Process control in combing: key elements
171(7)
7.6 Process control in combing: the impact of combing on yarn quality and common problems arising from the process
178(3)
7.7 Process control in speed frame operations: key elements
181(4)
7.8 Process control in speed frame operations: the impact of speed frame operations on yarn quality and common defects related to the process
185(4)
7.9 Conclusions and future trends
189(1)
7.10 Acknowledgement
189(1)
7.11 References
189(2)
8 Process control in ring and rotor spinning
191(34)
P. K. Majumdar
8.1 Introduction
191(4)
8.2 Factors affecting spinning tension in ring spinning
195(7)
8.3 Control of end breakage rate in ring spinning
202(3)
8.4 Factors affecting end breakage rates in ring spinning
205(3)
8.5 Control of fly generation and twist variations in ring spinning
208(5)
8.6 Process control in rotor spinning
213(4)
8.7 Control of end breakage rate and twist loss in rotor spinning
217(3)
8.8 Future trends
220(1)
8.9 References
221(4)
9 Maintenance of yarn spinning machines
225(16)
A. Basu
9.1 Introduction
225(6)
9.2 Maintenance of spinning preparatory machines
231(4)
9.3 Maintenance of ring and rotor spinning machines
235(1)
9.4 Future trends
236(3)
9.5 Sources for further information and advice
239(1)
9.6 References
240(1)
Part III Process control in fabric manufacture, coloration and finishing
241(234)
10 Process control in knitting
243(22)
S. C. Ray
10.1 Introduction
243(1)
10.2 Key control points in knitting
244(4)
10.3 Quality control of knitted fabrics
248(3)
10.4 Control of knitted loop length
251(2)
10.5 Common faults in knitted fabrics
253(6)
10.6 Other process control factors in knitting
259(3)
10.7 Future trends: online quality control
262(2)
10.8 References
264(1)
11 Process control in weaving
265(14)
V. K. Kothari
11.1 Introduction
265(2)
11.2 Controlling loom productivity, efficiency and fabric quality
267(2)
11.3 Online process control, quality control and monitoring in weaving
269(7)
11.4 Cost control in weaving
276(2)
11.5 References
278(1)
12 Process control in nonwovens production
279(21)
D. Moyo
A. Patanaik
R. D. Anandjiwala
12.1 Introduction
279(1)
12.2 Needle punching: process variables and process control
280(5)
12.3 Hydroentanglement: process variables and process control
285(3)
12.4 Melt blowing: process variables and process control
288(4)
12.5 Spunbonding: process variables and process control
292(3)
12.6 Future trends
295(1)
12.7 Sources of further information
296(1)
12.8 Acknowledgement
296(1)
12.9 References
296(4)
13 Process control in dyeing of textiles
300(39)
S. M. Shang
13.1 Introduction
300(2)
13.2 Dyeing of cotton
302(13)
13.3 Dyeing of synthetic materials
315(7)
13.4 Dyeing of blends
322(4)
13.5 Process control in batchwise dyeing machines
326(8)
13.6 Process control in continuous dyeing machines
334(4)
13.7 References
338(1)
14 Process control in printing of textiles
339(24)
S. M. Shang
14.1 Introduction
339(1)
14.2 Direct printing
339(6)
14.3 Discharge, resist and heat transfer printing
345(3)
14.4 Process control in roller and screen printing machines
348(5)
14.5 Inkjet printing and its process control
353(7)
14.6 Product safety and low-carbon production
360(1)
14.7 Sources of further information
361(1)
14.8 References
362(1)
15 Process control in finishing of textiles
363(65)
A. K. Roy Choudhury
15.1 Introduction
363(2)
15.2 Instrumental process control
365(4)
15.3 Textile finishing processes and process control in finishing
369(4)
15.4 Process control in basic finishing machines
373(3)
15.5 Process control in stenter machines
376(4)
15.6 Calendering process
380(5)
15.7 Surface raising and pre-shrinking finishes
385(4)
15.8 Finishing with alkali
389(4)
15.9 Softeners
393(3)
15.10 Resin finishes
396(5)
15.11 Protection from fire damage and water penetration
401(4)
15.12 Anti-pilling finish
405(2)
15.13 Other types of finishing: antistatic, soil release, antimicrobial and UV protection
407(6)
15.14 Wool treatment and enzyme finishes
413(4)
15.15 Low-liquor finishing
417(4)
15.16 Plasma treatments
421(4)
15.17 Future trends
425(1)
15.18 References
425(3)
16 Process control in apparel manufacturing
428(47)
G. Thilagavathi
S. Viju
16.1 Introduction
428(1)
16.2 Process control in spreading, pattern making and cutting
428(4)
16.3 Process control in sewing
432(9)
16.4 Causes of damage to the fabric during sewing
441(8)
16.5 Control of fusing and pressing operations, storage and packaging
449(5)
16.6 Quality evaluation of apparel: testing for tailorability
454(9)
16.7 Quality evaluation of apparel: testing for sewability
463(2)
16.8 Quality evaluation of accessories
465(6)
16.9 References
471(4)
Index 475
Abhijit Majumdar is currently holding the position of R. Jaikumar Chair Professor for Decision Sciences in the Textile and Fibre Engineering department at the Indian Institute of Technology, Delhi, India (IIT Delhi). He has published 145 research papers in international refereed journals. His research areas include protective fibrous materials, operations management, and sustainable supply chains. management. He has authored two textbooks, edited four books, and two monographs. He is the associate editor of the Journal of the Institution of Engineers (India) Series E (Chemical and Textile Engineering) and OPSEARCH. Dr Apurba Das is Associate Professor in the Department of Textile Technology, Indian Institute of Technology (IIT), New Delhi, India. He has wide experience in industries, including research and development and quality management. He has published more than 100 research papers in journals and conferences and written chapters in several books. His main areas of teaching and research interests include clothing comfort, yarn manufacturing, non-conventional spinning techniques, evaluation of textile materials and technical textiles. Dr R. Alagirusamy is Professor in the Department of Textile Technology at Indian Institute of Technology, New Delhi. He has completed his Ph.D. from Georgia Tech, USA. He has authored several chapters in bestsellers in textiles and possesses several research papers published in reputed national and international journals. Prof. V. K. Kothari is a faculty members in the Department of Textile Technology at the prestigious Indian Institute of Technology (IIT), Delhi, India.
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