Preface:
Experiment:
All fabrics knitted underwent the same processing stages after the circular knitting process. Below is a short description of the various processing stages involved subsequently to the manufacture of the various circular knits.
Processing stages of the fabrics:
- Fabric-dyeing was performed in light and dark shades
- Balloon padding
- Relax drying
- Compacting
Then the processed fabrics underwent the standard washing tests to determine shrinkage advantages of compact yarn owing to its unique structural properties.
Washing testing method:
To obtain a reliable result, the washing tests were conducted on a sample size of 25 x 25 cm and 50 x 50 cm of knitted fabrics for all knits in their various shades.
Testing procedure:
All samples underwent a computerized programme of 3 washing cycles at 40C and 3 rinses and eventually tumble dried at 80C. Samples were tested for the shrinkage percent after the tumble-drying process.
(Refer to table 1)
Knit Structure |
Gauge |
Colour |
Washing temperature |
Drying temperature |
Sample size |
Shrinkage % |
|
Length |
Width |
||||||
Single Jersey |
30gg |
White |
40C |
80C |
25 x 25 cm |
-4% |
-4% |
|
|
White |
40C |
80C |
50 x 50 cm |
-4% |
-4% |
|
|
Light Blue |
40C |
80C |
25 x 25 cm |
-4% |
-2% |
|
|
Light Blue |
40C |
80C |
50 x 50 cm |
-2% |
-2% |
1 x 1 Rib |
18gg |
Light Blue |
40C |
80C |
25 x 25 cm |
-2% |
-2% |
|
|
Light Blue |
40C |
80C |
50 x 50 cm |
-4% |
Nil |
|
|
Rose |
40C |
80C |
25 x 25 cm |
-2% |
-2% |
|
|
Rose |
40C |
80C |
50 x 50 cm |
-3% |
-2% |
2 x 2 Rib |
18gg |
Stone |
40C |
80C |
25 x 25 cm |
-4% |
-4% |
|
|
Stone |
40C |
80C |
50 x 50 cm |
-4% |
-5% |
|
|
Dark navy |
40C |
80C |
25 x 25 cm |
-2% |
-2% |
|
|
Dark navy |
40C |
80C |
50 x 50 cm |
-2% |
-5% |
Table 1: Washing tests performed on various knits of different shades to assess the shrinkage percentage after 3 washes and 3 rinses.
Conclusion:
From the above tabulation the reduced shrinkage in the knitted fabrics in different knits and colours is attributed to the structural advantages of compact yarn.
In the case of knitted fabrics manufactured from conventional ring-spun yarn the fabric shrinkage after conducting the washing tests lies between 5-6% depending on the knit structure, whereas with the usage of compact yarn the fabric shrinkage is confined to a range between 3-4% resulting in a reduction by nearly 35-40%.
Due to the significantly lower fabric shrinkage the weight loss, which is considered in the fabric costing, is minimized from around 5% in conventional yarns to 2-3% in compact yarns and thus effecting in a net saving of 2% in fabric weight loss.
General advantages of compact yarn in knitting (physical properties)
- Clearer loop structure with less loop cross-infringing fibres
- Higher brilliancy and softer handle
- Fewer end-breaks
- Low emission of fly and dust
- Usage of un-waxed yarn is feasible
- Reduction in abrasion by 30%
- Reduces the wear and tear of needles and other related components, thus avoiding holes or stripes in the fabric
- Fabric appearance is enhanced due to the uniformity and low yarn hairiness
Structural advantages of compact yarn in knitting contributing to its cost effectiveness
- Significantly lower fabric shrinkage by around 35-40% after fabric processing, resulting in net saving of
- 2% in fabric weight loss
- Dimensional stability is retained after many washes owing to the better pilling resistance
- Fabric gloss after yarn mercerization is retained even after several washes
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