Practical Process of RMG Industry

Quality Assurance Test Procedure for Apparel Industries


Quality assurance test:


Yarn quality verification: Applicable test for yarn quality verification are as follows- For color fabric, For white fabric

For color fabric:
Machine - apparatus used:NA
Machine - apparatus manufactured by:NA
Person responsible:Quality assurance executive
Frequency:Every lot report is checked

Procedure:Every lot is accomplishing by a yarn quality report. This report is compared with the ATL yarn quality requirement chart.

Yarn quality of each lot is checked using random sampling by machine available in the padma textile mills ltd

Performance standard: ATL yarn quality requirement chart.

In case of non conformity: Lot is returned
Document - form used :Yarn quality requirement chart

Yarn verification form:Non confirming yarn return form


For white fabric: 
Machine -apparatus used :NA

Machine - apparatus manufactured :NA

Person responsible :Quality assurance executive

Frequency: Every lot report is checked
Procedure: Sample production
Make 200 mt sample fabric from each white lot received.
Carry of subsequence processing: (sinze-desize, scour-bleach and final inspection. Refer to QC confa in Dispo module of T.I.M)
Performance standard: 15 points per 100 linear meters in final inspection.
In case of non conformity:Lot is rejected for white fabric production using yarn contamination test result.
Document -form used :Yarn contamination test result.

Dyes quality verification:Applicable test for dyes quality verification are as follows:
  • Reactive dyes
  • Disperse dyes
  • Vat dyes
  • Pigment dyes
Reactive dyes:


Machine / apparatus used: Dyeing padded, curing chamber.
Machine / apparatus manufactured by: Werner Mathis AG, Switzerland.
Person responsible :Lab assistant (pilot plant
Frequency:every new lot.
Procedure: Self shade with 30 gl solution is prepared and compared with previously approved lot strength of the dyes is determined in this way.
Fastness to water, wash and crock (rubbing) are checked for their acceptable level.
Performance standard: Consistency with previous approved lot
Minimum fastness requirement-Change in color
In case of non conformity:Lot is returned.
Document / form used: Reactive dyes shade continuity register.

Disperse dye: 

Machine / apparatus used:Dyeing padded, curing chamber.
Machine / apparatus manufactured by: Werner Mathis AG, Switzerland.
Person responsible:lab assistant (pilot plant).
Frequency:Every new lot.

Procedure:self shade with 15 g/l solution is prepared and compared with previously approved lot strength of the dyes is determined in this way
Fastness to water, wash and crock (rubbing) are checked for their acceptable level
Performance standard:Consistency with previous approved lot
Minimum fastness requirement-Change in color

In case of non conformity:Lot is returned.

Document / form used:
Disperse dyes shade continuity register.


C. Vat dyes:

Machine / apparatus used:Dyeing padded, curing chamber.

Machine / apparatus manufactured by:Werner Mathis AG, Switzerland.

Person responsible:Lab assistant (pilot plant).
Frequency:Every new lot.

Procedure:Self shade with 10 gl solution is prepared and compared with previously approved lot strength of the dyes is determined in this way.
Fastness to water, wash and crock (rubbing) are checked for their acceptable level.
Performance standard: Consistency with previous approved lo
In case of non conformity:Lot is returned.
Document / form used:Vat dyes shade continuity register.

d. Pigment dyes:

Machine / apparatus used: Dyeing padder, curing chamber.
Machine / apparatus manufactured by :Werner Mathis AG, Switzerland.
Person responsible: Lab assistant (pilot plant).
Frequency: Every new lot.
Procedure: Self shade with 30 gl solution is prepared and compared with previously approved lot strength of the dyes is determined in this way.
Fastness to water, wash and crock (rubbing) are checked for their acceptable level. Heat stability test (fastness to calendaring / ironing is also checked)
Performance standard: Consistency with previous approved lot
In case of non conformity: Lot is returned.
Document / form used: Pigment dyes shade continuity register.
Swatch analysis:Sample analysis procedure:

Given bellow the swatch analysis process followed by ATL QA lab:
Parameter checked: Count, concentration, composition, weave, type of dye used and finished type.
Machine / apparatus used: Pick, counter, weighing machine, gas burner etc.
Machine / apparatus manufactured by: N/A
Person responsible: Lab assistant
Frequency:As and when requisite by marketing department.
Procedure: Applicable test for swatch analysis process are as follows:


Fabric analysis

Refer to the following section for detailed procedure.


In case of non conformity: QA executive is informed in case of non conformity of the swatch analysis report with our procedure range. Marketing division is subsequently notified about inability to replicate the given swatch.
Document / form used: Swatch analysis report.

a. Physical test:

- Marketing division sends swatch to the QA department according to the customer requirement.

1. Construction:

Construction (no of ends and picks) and weave are determined using pick counter

2. Count:

Count is calculate using following formula-

Total length (in ˝) × 0.015

Count =

Weight of sample (in gm)

Total length (cm) × 0.059

=

Weight of sample (in gm)

Warp and weft are taken out, their total length is measured individually and the sample is weighed in grams in a sensitive weighing machine.

Quantitative analysis

a. Chemical analysis (Carbonizing test):

Carbonizing is carried out to determine the percentage of cotton and polyester percent in PC and CVC fabric / yarn.

Sample are deeped in adequate amount of H2SO4 (70 %) for considerable amount of time than taken out washed and dried cotton dissolved in H2SO4 while polyester does not. Percentage of cotton is found out using following formula-

Initial weight – Dye weight (After carbonized)

Cotton % = 100 – × 100

Initial weight

Note: Be careful handling sulfuric acid.

B. Types of dyes determination:

Types of dyes used in the swatch are found out by using some process

1. At first 1-2 drops sodium hypochlorite are used to find out the how much color faded of the fabrics.


2.By using ( 6 g/l hydrous + 4 g/l caustic) chemicals at first have to make 1L solution. The swatch is dipped in the mixer of the above solution at boiling temperature for 5 min until the swatch is dissolved in it. At last fabric is washed.

3. By using N-N dimethyl Formamide:

a. N-N dimethyl formamide is taken

B. Boiling is done

c. Then fabric is washed.

D. At last fabric is dried.

Result:

1. Pigment dye: No change

2. Disperse dye: Slightly change

3. Soluble dye:

a. Caustic + Hydross = unchanged

B.N-N dimethyl formamide= change like faded color.

4. Vat dye:

a. Caustic+ Hydross=Black

b. N-N dimethyl formamide= slightly change

5. Reactive dye:

If color is not totally striped than it indicates reactive dyes.

a. Color is faded or removed by using caustic and hydross

B. N-N Dimethyl formamide = Unchanged, remain like before.

C. Types of finish determination:

Types of finish is determine by hand feel experience.

Offline Quality assurance test
All the offline QA test for finished fabric of Auto Textile limited can be groped as-

Physical test

Chemical test

The detail of all application QA test for finished fabric are discussed in bellow-

Physical test:

The applicable QA physical test for finished fabric is as follows-

Tensile strength test

Tear strength test

Abrasion resistance test

Pilling resistant test

Crease resistant test

a2. Tear strength tester:


Machine used

:

Tearing tester 1653.


Machine manufactured by

:




Person responsible

:

QA lab assistant


Frequency

:

Every order (only for 100% light fabric)


Procedure

:

According to customer’s requirement and / or as specified in the ATL quality stander specification.


Performance standard

:

Both warp and weft 7000 mN minimum or 713 gm minimum or as per the customer requirements.


In case of non conformity

:

To increase tearing strength re-mercerized and re finish.






5.Crease resistance:


Machine used

:

Crease recovery tester.


Machine manufactured by

:

Shirley, England


Person responsible

:

QA lab assistant


Frequency

:

Whenever buyer requirement


Procedure

:

BS EN 22313, AATC 66, ISO 2313.


Performance standard

:

According to buyer given stander.


In case of non conformity

:

Resin finish.



Engr. Kh. Mashiur Rahman Email: garmentspedia@gmail.com















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