YARN MANUFACTURING PROCESS Cotton is a divine gift to humans as with out with we could not have dreamed of manufacturing

g comfortable cotton t shirts. Below is the process of manufacturing yarn from cotton. COTTON PLOUGHING PICKING PROCESS First and foremost process of t shirt manufacturing is cotton seeds ploughing and once the harvest by manual plucking. The picked cottons is then sent to Ginning mills for the next process of T shirts manufacturing. Fortunately, Indian cotton is regarded as one of the best in the world and we have abundance of cotton available in our cotton fields. GINNING PROCESS The second process of T-shirt manufacturing is cotton ginning. Here the raw cotton or kapas which is picked from the field. The kapas without seed so generated is called lint. The lint is in loose form. The above lint is pressed and packed in to bales and send to cotton spinning mills.

SPINNING PROCESS Third process of T shirt manufacturing is spinning and this process involves blowing the filtered cotton in to a rotating drum, where they attach themselves to the tail of formed yarn that is continuously blown out of the chamber. The variation in the speed of attachment and the type of machine determines the type of counts produced. Helps in making best quality yarn

KNITTED FABRIC MANUFACTURING PROCESS Every process involved in converting yarn in to knitted fabrics is very crucial and the fabric has to go through all of them to become fit for T-shirt manufacturing KNITTING PROCESS The first process in knitted fabric manufacturing is knitting. Knitting is the process through which the yarn is turned into knitted fabric by joining consecutive row of loops using different types of knitting machines. Broadly, there are three types of knitting, which is jersey, interlock and rib. Each type of knitting process has a variation in the knitting process. Knitting Process is described in detail

DYEING PROCESS The second process in manufacturing knitted fabrics for T-shirts is Dyeing. In the dyeing process, plain knitted fabrics are fed in to the 'soft flow' dyeing machines. Here the knitted fabrics are rolled in to the machine, which contains water mixed with required chemical colors and also maintains a certain temperature. After continuous dipping of the knitted fabric in to the colored water, the knitted fabric turns in to the desired color. DRYER PROCESS Third process in fabric manufacturing for T shirts is Drying the dyed fabric. Our dyeing factories use top of the class drying machines to dry the fabrics. These machines blows hot air to the fabric and the knitted fabrics are then dryed. BALLOON PADDING PROCESS The fourth process in Knitted fabric manufacturing for T-shirts is a process called Balloon padding. The process is required to remove the crinkles that has occurred because of the dyeing process. When the knitted fabric is fed in to balloon padding machine, the machine folds the knitted fabric neatly using the heat from the steam it produces.

COMPACTING PROCESS This is the fifth and the final step involved in manufacturing of knitted fabric for t shirts. This process is required for the knitted fabric because it is necessary to arrest the shrinkage of the fabrics. If this process is not done correctly then the fabric becomes loose and will be unfit for t shirt manufacturing.

PRINTING & SPECIAL FINISHING PROCESS Broadly there are four types of T-shirt printing techniques, namely Manual Table printing, Manual Machine printing, MHM printing, Sublimation printing techniques and various washing and embroidery techniques TABLE PRINTING PROCESS The first step of manual table printing is to make screens for each color that needs to be printed. Once the screens are made, depending on the type of prints and the colors required for the printing, chemicals are mixed at the right proportion to derive at the colors needed. In the mean time, the cut knitted fabric is placed on the concrete table with equal distance between them. Number of rows and number of cut knitted fabric depends upon the capacity of that particular printing. After this, the screens are moved manually by the printer to each piece of knitted fabric and the chemical paste is applied to the fabric and left to be dried.

This process is repeated for each color and the desired print is achieved. Using this method the following types of print can be printed, 1. Water based pigment print; 2. Discharge chemical based print; 3. Reactive chemical based print; 4. Oil based pigment print.

MACHINE PRINTING PROCESS The first step of manual machine printing is to make screens for each color that needs to be printed. Once the screens are made, depending on the type of prints and the colors required for the printing, chemicals are mixed at the right proportion to derive at the colors needed. In the mean time, the cut knitted fabric is placed on the rotating hands of the machine, which is round shaped and which has 6 to 11 rotating hands for each color that needs to be printed. For example, if there is 8 colors in a print, each screen is placed on one of the rotating hands and cut knitted fabric is placed below that. After that, the machine is moved manually by the printers by rotating the hands and then the proportion of chemicals for each colour/screen is applied.In one complete rotation of the machine, a particular print is printed on the cut knitted fabric. Once the printing is done, the fabric is fused for the firmness of the print. Types of print that can be printed using machine is plastisol, foil, glitter, high density, puff, gel and sugar prints. MHM MACHINE PRINTING PROCESS The first step of MHM machine printing is to make screens for each color that needs to be printed. Once the screens are made, depending on the type of prints and the colors required for the printing, chemicals are mixed at the right proportion to derive at the colors needed. The only difference between the Manual machine printing and the MHM machine printing is that in MHM the printing process is fully automated therefore the accuracy of printing is much better and also another advantage is that the number of colors in MHM printing technique can be up to 15. The types of prints that can be done using MHM printing technique is Discharge prints, Multicolored prints and Photo prints. SUBLIMATION PRINTING PROCESS

Sublimation printing process is very similar to computer printing technology. The images that are needed to be printed is fed in to the computer, which is connected to the Sublimation printing machine itself. Once the command is given from the computer the printing machine prints the required print on to the cut knitted fabric using heat transfer technology. One of the most important advantage of sublimation printing is that the clarity of the prints are exceptionally good. We have partnered with sublimation printers in our area thus providing the required print quality as and when our International buyers needs this technique to be utilized in our orders.

EMBROIDERY PROCESS Similar to the printing process, the cut knitted fabric is placed on to the holder of fully automatic embroidery machine. The design to be executed is copied on to a floppy disc, which is inserted in to the embroidery machine. Then the machine starts to automatically embroider the fabric which is placed on to the holder of the machine. We have our own embroidery machines and the capacity of that machine is that it can embroider 9 colors and 10 pieces of cut knitted fabric at a time.printing is that in MHM the printing process is fully automated therefore the accuracy of printing is much better and also another advantage is that the number of colors in MHM printing technique can be up to 15. The types of prints that can be done using MHM printing technique is Discharge prints, Multicolored prints and Photo prints. WASHING PROCESS Washing is done to the garments to derive the different kinds of vintage effects and soft feeling that is required by our international buyers. Different types of washing effects can be obtained by the same washing machine and the reason for that is usage of different chemicals. The process of washing is very simple, garments in bit form or final form is fed in to the drum and the necessary chemicals are added and the drum are allowed to roll. Different washing techniques that can be done are Acid wash, Bio wash, Silicon wash, River wash and Stone wash FINAL PROCESSES IN T SHIRT MANUFACTURING Factories should be approved and audited by Sedez or SA8000 or OEKO Tex Standard 100 for ethical and technical compliance KNITTED FABRIC CUTTING The knitted fabric after all the required processing is bought in to our factory and then it is cut either manually or with machine depending the volume of the order and segregated according to the shades in the colors of the knitted fabric.

SEWING OF THE T-SHIRTS Once the fabric is cut, it is then bought in to the sewing section of our factory and is sewn in to the required garments using Flat lock and Singer machines. The production plan we follow in our factory is Line Production plan and we have supervisors, who are responsible for each line of production. Approved Pre-production samples is hung on to a hanger in each line along with the specs sheets with buyers comments so that supervisors know exactly how the garments should look and can verify if there is any doubt in the production.

CHECKING OF THE T-SHIRTS The good quality t shirts are moved on the next process where the Faulty t-shirts are sent back to correction, if the faults cannot be rectified then those T-shirts are destroyed.

IRONING OF THE T-SHIRTS

100% Checked T shirts are then bought to Ironing, where in the T shirts are ironed using STEAM.

PACKING OF THE T-SHIRTS After the ironing process t shirts are then bought to the packing section, where they are packed according to the needs of our international customers - either flat packed or hanger packed.

INSPECTION AND DISPATCH OF GOODS TO THE PORT Once the packed goods are ready, the goods are then inspected with in the AQL 2.5 level.

http://www.qualityinspection.org/what-is-the-aql/