Fabric Process and Shade Grouping
Shade grouping
Mainly denim fabric shade grouping must do after actual blanket wash, as a process 100% (roles cut panel 8-10 Inch) cut out of cut 8*8 size must be attach as a mat. Per mat can include 09 roles part stitch together . Each and every blanket need attach Master roll fabric/Sample yards cut pcs to compare and match the color. Where the site creates their own patterns from the initial sample, in an in-house Pattern Room, the following must be carried out to ensure that all patterns produced are both accurate to requirements and allowances included to allow...
Shrinkage tests for both washing & steam must be carried out on a minimum of 10% of every dye lot. Including all fabric consignments blanket must be wash as per correct stranded wash recipe and color need match with selected control fabric.Records of any Children’s Product Risk Assessment must be available and used where required in pattern construction. If selected controls fabric color must be matching with target
After wash blanket parts separated and can group as per taper sequence. It can be group shade A. B .C. D. E etc.A system is in place to ensure all patterns are fully checked for accuracy before releasing into production and records to demonstrate. Fabric department can identify and records per shade No of rolls representing shade label it as per shade no. Shade A, B,C etc
While start cutting department can must be take shade A -1st and Shade B-2nd shade C-3rd serially. All pattern amendment records are clearly dated. Shade label must be attached correctly in sewing. Washing department wash load by following shade label. Same shade will be load as one load, output also will be looks same.
Shrinkage tests for both washing & steam must be carried out on a minimum of 10% of every dye lot. Including all fabric consignments blanket must be wash as per correct stranded wash recipe and color need match with selected control fabric.Records of any Children’s Product Risk Assessment must be available and used where required in pattern construction. If selected controls fabric color must be matching with target
After wash blanket parts separated and can group as per taper sequence. It can be group shade A. B .C. D. E etc.A system is in place to ensure all patterns are fully checked for accuracy before releasing into production and records to demonstrate. Fabric department can identify and records per shade No of rolls representing shade label it as per shade no. Shade A, B,C etc
While start cutting department can must be take shade A -1st and Shade B-2nd shade C-3rd serially. All pattern amendment records are clearly dated. Shade label must be attached correctly in sewing. Washing department wash load by following shade label. Same shade will be load as one load, output also will be looks same.
- Shrinkage test- Shrinkage cut panel also can cut from initial cut pcs which cut for blanket.
- Physical test
- Color fastness test
- Rubbing test
Note S/S – (Side to side) S/M Side to Middle. Tailing check – Roll Beginning Middle and end shading check. P1A – Dimensional stability check. If you follow blanket/Shade grouping process correctly easy to handle denim and twill fabric in wash stage. Also it will help to reduce color dark light in same bath and shade variations in bulk stage.
Fabric Process
This department mainly deals with the fabric related activities. Fabric Process inspection department is playing a vital role in the organization. An effective Risk Assessment process must be in place for both the design and manufacturing process. This process must identify any risks to the commercial, technical and manufacturing capability of the product and wherever possible either eliminate them or ensure they are managed. For example: - The embellishment on a product does not affect the functionality of the zip fastening. Metal trims on a product to be used in the sun and come into contact with the skin do not conduct the heat of the sun. Cultural or Politcal messagesGenerally the main function of this department is to ensure the quality of fabric whether it is appropriate for the production or not. The basic functions of this department include the following-
- Inspection of fabrics
- Shade grouping
- Shrinkage test
- Physical test
- Color fastness test
- Rubbing test
Objective of the Fabric Process Technology department
- Develop and Source fabric as per customer requirement
- Ensure all kind of fabric quality and supplier approval in development and Bulk stage
- Ensure good quality fabrics are fed for production, lead to a smooth and quality manufacturing, and reduce the no of second garments due to fabric issue.
- Conduct in house and outside testing for both bulk and develop fabric to asses physical and color performance.
- Raise any fabric issue to Supplier and do Claim negotiation for Company losses.
Fabric Development and Sourcing
Record of the shrinkage per batch/dye lot must be maintained and patterns must be amended for different shrinkage bands to control measurements. In addition to the above requirements the following must also be operational: Records of any Risk Assessment available and used where required in pattern construction. Before & After washed measurements are recorded on size chart for laundry wash products. Fabric department is doing all the fabric sourcing and development as per the customer requirement. Fabric department is in contact with very wide fabric supplier base all over the world (Bangladesh, Pakistan, China, India, Turkey, Thailand, Hongkong, Taiwan, Italy, Germany etc). So after getting the requirement from customer we communicate with the suitable suppliers considering the quality of the product, price, volume, lead time etc.- Quality Assurance of All Bulk Fabric and Issue To Production
- Conducting Testing In house and Out side Lab
- Fabric Process department co ordinates all the test which need to be done in our internal lab or third party accredited lab.
- Dimensional Stability
- Promotional Claim (Water and oil Repellency)
- Print Durability
- Smoothness
- Color fastness to wash
- Color fastness to water
- Color fastness to Rubbing
- PH
- Color fastness to Oxidative Bleach
- Color changes after customer wash
- Tensile Strength
- Tearing Strength
- Seam Slippage
- Weight
- Stretch ability and Residual extension
- Abrasion Resistance
- Pull test for any inconsistencies with raw materials
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