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Process Control in Textile Manufacturing

Book Description

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.

  • Provides an important overview of the fundamentals and applications of process control methods
  • Discusses key issues associated with process control and principles of control systems in textile manufacturing, before addressing testing and statistical quality control
  • Explores process control in the manufacture of knitted, woven, nonwoven textiles and colouration and finishing, with a discussion on process control in apparel manufacturing

Table of Contents

  1. Cover image
  2. Title page
  3. Table of Contents
  4. Copyright
  5. Contributor contact details
  6. Woodhead Publishing Series in Textiles
  7. Foreword
  8. Part I: General issues
    1. Chapter 1: Basics of process control in textile manufacturing
      1. Abstract:
      2. 1.1 Introduction
      3. 1.2 Process mapping, analysis and control
      4. 1.3 Statistical process control (SPC) and improving processes
      5. 1.4 Future trends
    2. Chapter 2: Basic principles of control systems in textile manufacturing
      1. Abstract:
      2. 2.1 Introduction
      3. 2.2 Components of control systems
      4. 2.3 The control system design process
      5. 2.4 Digital control systems
      6. 2.5 Intelligent control systems using soft computing
      7. 2.6 Application of control systems in textile processing
    3. Chapter 3: Testing and statistical quality control in textile manufacturing
      1. Abstract:
      2. 3.1 Introduction: statistical quality control
      3. 3.2 Basic measurement concepts in statistical quality control
      4. 3.3 Interpretations: critical difference
      5. 3.4 Interpretations: ‘t’ tests, ‘F’ tests and the chi-square method
      6. 3.5 Decision-making using control charts
      7. 3.6 Decision-making: hypothesis testing
      8. 3.7 Decision-making: significance testing
      9. 3.8 Testing fibre and yarn properties
      10. 3.9 Testing fabric properties
      11. Raw material
  9. Part II: Process control in fibre production and yarn manufacture
    1. Chapter 4: Process and quality control in cultivating natural textile fibres
      1. Abstract:
      2. 4.1 Introduction
      3. 4.2 Control of cotton fibre quality
      4. 4.3 Indexes for cotton fibre quality
      5. 4.4 Process control in harvesting
      6. 4.5 Control of natural lignocellulosic/bast fibre quality: climatic conditions
      7. 4.6 Process control in production
      8. 4.7 Evaluating fibre quality
      9. 4.8 Future trends
    2. Chapter 5: Process control in the manufacturing of synthetic textile fibres
      1. Abstract:
      2. 5.1 Introduction
      3. 5.2 Process control in polymerisation and fibre spinning
      4. 5.3 Post-spinning process control: drawing and heat setting
      5. 5.4 Key control points in synthetic fibre manufacture
      6. 5.5 Future trends
    3. Chapter 6: Process control in blowroom and carding operations
      1. Abstract:
      2. 6.1 Introduction to blowroom operations
      3. 6.2 General process control in the blowroom
      4. 6.3 Process control in blowroom processes
      5. 6.4 Process control in carding: control of process parameters
      6. 6.5 Process control in carding: control of card clothing, wire maintenance and card waste
      7. 6.6 Yarn count issues and other common process control problems for blowroom and carding operations
    4. Chapter 7: Process control in drawing, combing and speed frame operations
      1. Abstract:
      2. 7.1 Introduction
      3. 7.2 Process control in drawing: key elements
      4. 7.3 The impact of drawing on yarn quality
      5. 7.4 Process control in drawing: common problems
      6. 7.5 Process control in combing: key elements
      7. 7.6 Process control in combing: the impact of combing on yarn quality and common problems arising from the process
      8. 7.7 Process control in speed frame operations: key elements
      9. 7.8 Process control in speed frame operations: the impact of speed frame operations on yarn quality and common defects related to the process
      10. 7.9 Conclusions and future trends
      11. 7.10 Acknowledgement
    5. Chapter 8: Process control in ring and rotor spinning
      1. Abstract:
      2. 8.1 Introduction
      3. 8.2 Factors affecting spinning tension in ring spinning
      4. 8.3 Control of end breakage rate in ring spinning
      5. 8.4 Factors affecting end breakage rates in ring spinning
      6. 8.5 Control of fly generation and twist variations in ring spinning
      7. 8.6 Process control in rotor spinning
      8. 8.7 Control of end breakage rate and twist loss in rotor spinning
      9. 8.8 Future trends
    6. Chapter 9: Maintenance of yarn spinning machines
      1. Abstract:
      2. 9.1 Introduction
      3. 9.2 Maintenance of spinning preparatory machines
      4. 9.3 Maintenance of ring and rotor spinning machines
      5. 9.4 Future trends
      6. 9.5 Sources for further information and advice
  10. Part III: Process control in fabric manufacture, coloration and finishing
    1. Chapter 10: Process control in knitting
      1. Abstract:
      2. 10.1 Introduction
      3. 10.2 Key control points in knitting
      4. 10.3 Quality control of knitted fabrics
      5. 10.4 Control of knitted loop length
      6. 10.5 Common faults in knitted fabrics
      7. 10.6 Other process control factors in knitting
      8. 10.7 Future trends: online quality control
    2. Chapter 11: Process control in weaving
      1. Abstract:
      2. 11.1 Introduction
      3. 11.2 Controlling loom productivity, efficiency and fabric quality
      4. 11.3 Online process control, quality control and monitoring in weaving
      5. 11.4 Cost control in weaving
    3. Chapter 12: Process control in nonwovens production
      1. Abstract:
      2. 12.1 Introduction
      3. 12.2 Needle punching: process variables and process control
      4. 12.3 Hydroentanglement: process variables and process control
      5. 12.4 Melt blowing: process variables and process control
      6. 12.5 Spunbonding: process variables and process control
      7. 12.6 Future trends
      8. 12.7 Sources of further information
      9. 12.8 Acknowledgement
    4. Chapter 13: Process control in dyeing of textiles
      1. Abstract:
      2. 13.1 Introduction
      3. 13.2 Dyeing of cotton
      4. 13.3 Dyeing of synthetic materials
      5. 13.4 Dyeing of blends
      6. 13.5 Process control in batchwise dyeing machines
      7. 13.6 Process control in continuous dyeing machines
    5. Chapter 14: Process control in printing of textiles
      1. Abstract:
      2. 14.1 Introduction
      3. 14.2 Direct printing
      4. 14.3 Discharge, resist and heat transfer printing
      5. 14.4 Process control in roller and screen printing machines
      6. 14.5 Inkjet printing and its process control
      7. 14.6 Product safety and low-carbon production
      8. 14.7 Sources of further information
    6. Chapter 15: Process control in finishing of textiles
      1. Abstract:
      2. 15.1 Introduction
      3. 15.2 Instrumental process control
      4. 15.3 Textile finishing processes and process control in finishing
      5. 15.4 Process control in basic finishing machines
      6. 15.5 Process control in stenter machines
      7. 15.6 Calendering process
      8. 15.7 Surface raising and pre-shrinking finishes
      9. 15.8 Finishing with alkali
      10. 15.9 Softeners
      11. 15.10 Resin finishes
      12. 15.11 Protection from fire damage and water penetration
      13. 15.12 Anti-pilling finish
      14. 15.13 Other types of finishing: antistatic, soil release, antimicrobial and UV protection
      15. 15.14 Wool treatment and enzyme finishes
      16. 15.15 Low-liquor finishing
      17. 15.16 Plasma treatments
      18. 15.17 Future trends
    7. Chapter 16: Process control in apparel manufacturing
      1. Abstract:
      2. 16.1 Introduction
      3. 16.2 Process control in spreading, pattern making and cutting
      4. 16.3 Process control in sewing
      5. 16.4 Causes of damage to the fabric during sewing
      6. 16.5 Control of fusing and pressing operations, storage and packaging
      7. 16.6 Quality evaluation of apparel: testing for tailorability
      8. 16.7 Quality evaluation of apparel: testing for sewability
      9. 16.8 Quality evaluation of accessories
  11. Index