#textileengineering #fiber #weaving #spinning #fabricmanufacture #garments #apparel #fabric #fibretofabric #clothing #fibrescience #textiletechnology The textile process Step 1: Fibre production. Step 2: Yarn production. Step 3: Fabric production. Step 4: Pre-treatment. Step 5: Dyeing and printing. Step 6: Finishing treatments. Step 7: Manufacturing, transport, sales and retail.

1. MINI-PROJECT ON FIBRE TO FABRIC FORMING PROCESS
UNDER THESUPERVISION OF
DR. SANAT KUMAR PAL
PREPARED BY
ABDURRAHIM ANSARI (2001120640001)
ABHISHEK MAURYA (2001120640002)
ABHISHEK RAJPUT (2001120640003)
ALOK PATEL (2001120640004)
ALOK PATEL (2001120640005)
VIDYA YADAV (2101120649001)
INDIAN INSTITUTE OF CARPET TECHNOLOGY
(IICT)-BHADOHI
THIRD YEAR CARPET
& TEXTILE
TECHNOLOGY
(2020-24)

2. ACKNOWLEDGEMENT
We would like to express our special thanks and deep sense of gratitude to
our guide & Supervisor DR. SANAT KUMAR PAL Sir to encourage us to
highest peak and to provide the opportunity to prepare the project.
We have good opportunity to do this project on the topic of FIBRE TO
FABRIC FORMING PROCESS which also helped us to know about all type of
fabric making process.
We pay our sincere thanks to Sir whose valuable guidance and kind
supervision given to us throughout the course which shaped the present
work as it’s shown.

3. CONTENTS
(1) SPINNING
1.1 WORSTED SPINNING
1.2 COTTON SPINNING
(2) FABRIC FORMING PROCESS
2.1 WOVEN FABRIC
2.2 KNITTED FABRIC
2.3 NON-WOVEN FABRIC

4. • Woven fabric is any fabric made by
interlacing two or more threads at right angles
to ane another.
Fibre Yarn Fabric
• Process of converting fibre into yarn is called spinning
process
1.1- WORSTED SPINNING PROCESS
1.- SPINNING

5. Worsted Yarn
• Worsted is a high quality type of wool yarn, which have very high fibre alligment and
giving most uniform even yarn.
• Worsted yarns are wonderful for knitters and crocheted of all skill levels.
• Worsted yarn is ideal for garments.
• It is widely popular and ever versatile.
Flow chart of worsted yarn process is as follows :
• Raw wool — Sorting ---Scouring— Opening ---Blending—Oiling—
Carding — Preparatory Gilling — Combing —Finisher Gilling —
Drawing — Roving — Spinning — Winding and Clearing —
Refolding and Rewinding ( If required)

6. Worsted yarn manufacturing process:
• 1. Sheep shearing : sheep shearing is the process by which the woollen
fleece of a sheep is cut off. Cut off wool is called fleece. It is also called
“grease wool” because of all the oil and lanolin in the wool.
• 2. Sorting: sheared wool is sorted according to different colours, quality,
texture, type and they are sorted into different grades according to these
parameters.
3. Scouring : Wool taken directly from the sheep is called “raw” or “grease wool”.
It contains sand, dirt, grease and dried sweat (called suint). The weight of
contaminants accounts for about 30 to 70 percent of the fleece’s total weight. To
remove these contaminants, the wool is scoured in a series of alkaline baths
containing water, soap and soda ash or a similar alkali. Rollers in the scouring
machines squeeze excess water from the fleece, but fleece is not allowed to dry
completely.

7. 4. Worsted Carding : carding is the only process that
can and tangle and individualise the fibres fibres . After
scoring and drying, the vegetable matter is still remain
in the pool. The bulk of these foreign matters are
moved in guarding. Guarding also a cheese intimate
mixing, a fool fibres, which is only possible with
individualised fibres.
5. Preparative Gilling : The preparative gilling is mainly
to align the
Fibres in a parallel direction, further blend the wool
through doubling, and to add moisture and lubricants.
This is done by using a coarser comb. The main
objectives of the gilling machine are to further align
the fibres in card sliver and to blend the slivers from
different cards. A gilling machine is also known as a
gill box, or simply a gill.

8. 6. Worsted Combing : Combing is a critical step in worsted processing.
The combing process removes short fibers, neps, and impurities
(collectively known as noils), further mixes and aligning fibers, and forms
a continuous rope-like comb sliver.
7. Finisher Gilling : Finisher gilling is mainly aimed to remove the mild
entanglement introduced to the combed sliver.

9. 9. Roving :
• Reduction in the linear density of the sliver
• Blending and regularising the sliver
• Improvement of strength and cohesion
• Package formation
8. Drawing :
• Reduction in the linear density(weight) of the top sliver
• Blending and regularising the sliver
• Fibre straightening
10. Spinning : Worsted yarns are normally spun by four different
methods, namely flyer spinning, cap spinning, ring spinning and mule
spinning.

10. Cotton Fibre
Cotton Yarn
1.2- COTTON SPINNING PROCESS

11. Process Sequence of Cotton Spinning :

12.  Ginning
Objectives:
• Ginning is the process in which the cotton fibres are separated from the cotton
seeds.
• Ginning is the first stage of cotton processing .
Types of ginning machine:-
1.Knife roller ginning
2.Saw ginning
3 macarthy ginning
figure : Saw roller ginning machine
A- saw roller, B-grid bar, C- happer feeder , D- feed latice, E- spiked
roller, F – hopper, G- brush roller, H- lint flue,I- cage, J- cage
pressure roller

13.  Blowroom
3.Mixing and blending: To make homogenous mixture of the material.
4.De-dusting: To extract the dust if present.
5.Uniform feed for card: To convert the mass of fibers into thick sheet called lap which should be uniform length and
width wise or to provide output in the form of tufts of optimum size.
Objectives of Blowroom Section:
Objectives of a blowroom line are as follows:
1.Opening: To open the compressed fibers up to very small tufts.
2.Cleaning: To remove the impurities like seed fragments, stem pieces, leaf particles, neps, short fibers, dust and
sand.
Functions and Operations in Blowroom Section:
1.Opening
2.Cleaning
3.Dust Removal
4.Mixing and Blending
5.Even feed of material to the card

14. Modern Blowroom Line:-

15.  Carding
•Carding may be defined as the process of reduction of an entangled mass of
fibre into thin web .
a) Separate the tufts into individual fibres.
b) Remove tyrash particles ,neps,and short fibres from the opened material.And orientation in
lengthwise direction.
• The carding surface have to perform three basic actions.
1. Feeding and opening action
2. Carding action
3. Stripping action

16.  Drawframe
• To remove entanglements between fibres present in card sliver.
•To straighten out and align fibres along sliver axis .
•To reduce mass irregularity.
•To blend and mix fibres .
•To remove micro dust.

17.  Combing
•Elimination of a precisely pre-determined quantity of
short fibres.
•Elimination of remaining impurities.
•Formation of a sliver having the optimal possible quality
parameters.
 Speed Frame
• To draft the sliver to reduce weight per unit length.
•Insertion of protective twist in order to hold the fine
strand of sliver.
•To make conical or tapper shape of the bobbin.
•Wind the twisted roving on to the bobbin.
•Winding of roving onto a package that can be
transported, sorted,donned,on ring spinning machine.

18.  Ring Frame
•To reduce the mass of the material by drafting until the
required fineness is obtained.
•To twist the drafted yarn by twisting to obtain maximum
strength.
•To wind the twisted yarn onto the bobbin by winding .
Process for suitable storage , transportation and further
processing .
 Winding
•To transfer yarn from small package(ring bobbin) to
bigger package(cone,cheese).
• To remove yarn faults like hairiness,neps,slubs,and
foreign matters.
•To improve the uality of yarn.
•This process is also known as post spinning process.

19. There are 3 kinds of fabric forming method,
•Weaving
•Knitting
•Non- woven
The weaving:-
•By interlacing two sets of yarns at right angles into fabric
•A conventional woven fabric is a textile structure formed on a loom when two sets of yarns are
interlaced at right angles.
• The longitudinal yarns are known as the warp and the widthwise as the weft.
The Knitting:-
•By intermeshing the loops of yarn into fabric.
•Normally, the knitted structure consists of one set of yarn, weft or warp, and is divided into weft
knitted fabric and warp knitted fabric.
The Non-woven:-
•By bonding fibers, filaments, yarns or combinations of these into fabric

20. Weaving Preparatory Process:
Yarns are produced by spinning. These yarns can not be used directly in
weaving process. The preparation for weaving requires many steps of process.
This is called weaving preparatory process.
• Warp yarn preparation
• Weft yarn preparation
2.1 -Weaving
Grey warp yarn preparation
Winding
Weaving
Warping
Sizing Looming in
Grey weft preparation
Winding
Pirn Making Weaving

21. Winding:-
• To prepare packages from ring spinning bobbins to suitable packages for next
subsequent process.
• To remove Yarn faults, like slubs ,knots, thick, thin places etc.
•To improve quality of yarn.
Classification of winding machine:-
1. Spindle driven or Precision
winding.
2. Drum driven or Non precision
winding .

22. Drum driven or Non precision winding Spindle driven or Precision winding

23. •To convert the small yarn package (cone,cheese) into a big warper’s beam having desired
width and containing requisite number of ends .
•To maintained uniform tension on individual yarns during warping .
•The yarns are wound on the warper’s beam in the form of a sheet .
•The sheet has specified length and weight. The sheet is called Warp sheet.
Various parts of warping machine:-
• Creel
• Measuring roller
• Open reed
• Head stock
• Warping drum
• Open reed
• Head stock
• Warping drum
Warping:-
Types of warping machine:-
1.Beam warping/direct/high speed warping
2. Sectional warping/indirect warping machine

24. Sectional warping:-
Sectional warping process is used to produce multi colours warp
,stripped effect on fabric Generally ,V- shaped or rectangular creels
are integrated with sectional warping process.
Here a weavers beam is produce,where as sizing beam is produced
in direct warping.

25. Passage of yarn through twin cup cylinder sizing machine
•To improve the strength and abrasion resistance of the yarn.
•To decrease yarn hairiness.
•To compensate the loss of weight during winding and warping
•To produce a compact beam called “sized beam”or weavers beam suitable for loom
Sizing:-

26. The sizing material should be selected in such a way thatit could be easily removed
during the process of de-sizing.Ingredients of size paste
1. Adhesive(rice potato,PVA,PVC,CMC etc).
2. Lubricant/softeners(mineral T.R.O etc).
3. Anti microbial agent(zinc cloride , phenol, carboxylic etc ).
4. Anti foaming agent(benzene pyridine etc)
5. Anti static agent(polythylene gylcol, lissapalNx etc).
6. Hygroscopic agent(glycerine,calcium cloride etc)
7. PH stablizer(7-7.4 neutraze ph)
8. Tinting material( blue)
9. Weighting material(china clay, french chalk etc)
Sizing Material

27. The process of passing the warp ends from
weavers beam through the drop wire, heald eyes
and reed dents in case of tappet and dobby
weaving or through drop wire, harness cords, and
dents in case of Jacquard weaving in a pre-
decided order as decided by required cloth design
is called drawing in.
Looming in / drawing:-
Types of drawing in:-
In Principle, drawing-in process can be divided into
three parts:
1. Manual drawing-in process
2. Mechanical drawing-in process or semi
automatic
3. Fully automatic drawing-in process,
“Warpmaster”

28. Three Basic Motion of Weaving :-
Loom devices:-
A. Heddles , used for shedding ; B. the shuttle used
for picking ; C. the reed
used for beating in

30. 2.2-KNITTING PROCESS

31. KNITTING:-
•Knitting is a process of manufacturing a fabric by inter looping of yarns.
•Knitting is the second most important method of fabric formation.
•It can be defined as a needle technique of fabric formation, in which,
with the help of knitting needles, loops are formed to make a fabric or
garment.
•Fabric can be formed by hand or machine knitting, but the basic
principle remains exactly the same i.e. pulling a new loop through the
old loop.
• Knitted Fabric are popular for their shape fitting property, soft handle,
bulkier nature and high extension at low tension.

32. NEEDLES:-
Needle is the basic element of loop formation.
Two important functions of a needle
•Linking of new yarn loops with knitted loops,
•To carry the knitted loops during the early stage of the stitch
formation cycle.
TYPES OF NEEDLES
a) LATCH NEEDLE
b) SPRING – BEARD NEEDLE
c) COMPOUND NEEDLE
a) LATCH NEEDLE b) SPRING – BEARD NEEDLE C) COMPOUND NEEDLE

33. COMMON KNITTING TERMS
• Wales :- A wale is a vertical column of loops produced by the same needle knitting at
successive knitting cycles. The number of Wales determine the width of the fabric and
they are measured in units of Wales per centimeter.
• Courses :- Courses are rows of loops across the width of the fabric produced by
adjacent needles during the same knitting cycle and are measured in units of
courses per centimeter. The courses determine the length of the fabrics.

34. • Stitch Length:- the stitch length is one of the most important factor controlling the
properties of knitted fabrics. The stitch length, measured in millimeter is the length of
the yarn in the knitted loop. Generally longer the stitch length, the more open and
lighter the fabric.
• Stitch density:- Stitch density is a term frequently used in knitting and represents
the total number of needles loop in a given area. Stitch density is the product of
Courses and Wales per unit length and is measured in units of loops per square
centimeter.
STITCH DENSITY = No. Of Courses X No. Of Wales
Cam (knit, tuck, miss) :
Each needle action is obtained by means of cams acting on the needle butt.
There are three types of cam. (knit, tuck, miss)
 Functions:
 Help to produce knit, tuck & miss loop.
Knit Stitch :
The knit stitch is the basic stitch. It is also called the plain stitch. Knit stitch is formed when the
needle carries out a complete cycle, reaching the maximum height on the looping plane.

35. Tuck Stitch :
A tuck stitch is formed when a knitting needle holds its old loop and then receives a new yarn.
Two loops then collect in the needle hook. The previously formed knitted loop is called the held
loop and the loop which joins it is a tuck loop.
 The tuck loop will always lie at the back of the held loop.
Miss Stitch (NON-KNIT ):
A miss stitch is created when one or more knitting needles are deactivated and do not move
into position to accept the yarn.
The yarn simply passes by and no stitch is formed.
The float will lie freely on the reverse side of the held loop, which is the technical back, and in
the case of rib and interlock structures it will be inside the fabric.

36. Technical Face:
The side of the knitted fabric having all of face of Knit loop is called
Technical face of the fabric.
Technical Back:
The side of knitted fabric consist of back loops is called technical back
of the fabric.
 Sinker
 Sinker is a thin metal plate which is placed at right angle
between the adjoining needles.
 Sinker is used in single jersey circular knitting machine.
 Functions:
 Loop formation.
 Holding down.

37. TYPES OF KNITTING
WEFT KNITTING WARP KNITTING

38. WARP KNITTING
•TRICOT
•RASCHEL
In case the yarns run in length direction, i.e. the direction of fabric
formation during knitting, the process is called warp knitting.
The yarns inside the knitted fabrics are just like the warp yarns in
woven fabrics Such knitted fabrics are called warp knitted fabrics,
and the machine which produces such fabric is known as warp
knitting machine.

39. WEFT KNITTING
If the yarns run in the width or crosswise direction with reference to the direction of fabric
formation during knitting, then the process of knitting is called weft knitting.
ADVANTAGE OF KNITTING
•Fabric can be produced from minimum number of yarns, even only one yarn
•Loop size can be varied to a wide extent and that too very easily.
•The extensibility and stability of the knitted fabric
can be engineered.
•Wastage of yarn during conversion of yarn into fabric
by knitting is negligible.
•The desired porosity or compactness of the fabric can be achieved easily.
•The extensibility and stability of the knitted fabric can be engineered.

40. Features of single jersey circular knitting machine:-
 Single jersey circular knitting machine has normally rotating (clockwise)
 cylindrical one set of needle bed.
 Generally latch needles are used.
 Generally machine gauge is 24. It can be 10 to 36.
Features of rib circular knitting machine-
 In rib circular knitting machine, there are two set of needle.
One set of needles are mounted on a vertical cylinder & other set
of needles are mounted on horizontal dial.
 Generally needle gauge is 18.
Features of interlock circular knitting machine:-
 In interlock circular knitting machine, there are two
needle bed. One set of needles are mounted
on a vertical cylinder & other set of needles are
mounted on horizontal dial.
 The dial needles are face to face between the
cylinder needles.
 Generally needle gauge is 20.

42. Classification of weft knitting machine
According to the frame design & needle bed arrangement :
 Straight bar frame m/cs
 Circular knitting machine.
 Flat knitting machine

43. WOVEN VS KNITTED
APPLICATIONS OF KNITTED FABRICS
•Sportswear(conformity, flexibility)
•Casual wear (comfort)
•Dress wear
•Technical textiles application

46. Conventional(woven) fabric production -
FIBRE YARN FABRIC
Non-Woven production -
FIBRE FABRIC
Thus, it eliminates the yarn production process and makes the
fabric directly from fibres.

48. Characteristics of Non-Woven
• Absorbency
• Filtering
• Flame Retardancy
• Liquid Repellency
• Resilience
• Softness
• Stretch
• Wash Ability

51. 1.Needle Punching
2.Adhesive Bonding
3.Heat Bonding
4.Stitch Bonding

56. General Process of Manufacturing of Non-woven