The textile manufacturing process includes several steps. There is spinning, followed by dyeing, weaving, printing, and finishing. The garment manufacturing stage is the final step in this process and is carried out in production units. This results in finished products. Garment manufacturing refers to the conversion of raw materials into finished products. A textile manufacturing business must ensure that the pre-production process is carried out efficiently to achieve the desired production.
Garment manufacturing or Garment production follows a specific sequence. This includes cutting, marking and stitching. The design stage for ready apparel begins first. This is followed by the final product. The garment is then subject to different processing steps before being shipped.
Let’s take a look at the various stages of garment manufacturing.
How to obtain the fabrics for the garment manufacturing process:
The garments arrive in bulk from overseas. Fabric is delivered in large bolts with cardboard. Sometimes, the fabric may arrive in piles or plastic center tubes. These fabrics are then shipped in huge shipping containers, and unloaded by a forklift. These factories have a warehouse where the fabric can be stored between its arrival and when it is being manufactured.
It is significant to relax the fabric. This relaxation process focuses on relaxing fabric that has been processed through many stages. The fabric is then being transformed into a finished product. This allows the fabric to shrink so that shrinkage is minimal during consumer use. The garment manufacturing process used either a manual or mechanical relaxation method.
Manual fabric relaxation involves loading the fabric onto a spinner and then manually feeding it using equipment that relaxes the fabric while it is being pulled through. The same process is used for mechanical fabric relaxing, but it’s done in an automated way.
Manufacturers may also offer quality assurance to ensure that the process meets customer standards. This involves manually checking each bolt of fabric with a backlit surface. It identifies any manufacturing defects, such as color inconsistency or flaws.
Spreading Cutting and Form Layout
After the fabric has been relaxed, it is then processed for spreading and cutting garments. The fabric is first to cut into uniform piles, which can then be done manually or using computer-controlled software. The fabric is then spread to:
- Fabric defects to be marked up by operators
- During cutting, control the tension and slack.
- Each ply should be aligned correctly on top of the others.
The fabric type, spread technique, cutting method, and garment size will affect the number of plies.
The same pattern/forms are then laid on top of the spread. The fabric is then cut to the same shape as the garment forms using either method.
There are some steps and rules that must be followed to lay a foundation.
Initially, workers lay large pieces of fabric which are then arranged in smaller pieces. These smaller pieces can be used to secure the fabric. This will result in significant economic savings. This will result in a significant savings of money due to simultaneous work laid and hundreds of layers being cut.
Many rules will ensure the fabric is used correctly and cost-efficient.
- The fabric’s margin must be equal to the length of the garments.
- The right grain must be where the pattern is to be placed.
- The parts are placed on the border/boundary of each fold.
- Laying is done on the opposite side.
When laying paper patterns, the design of the fabric must be in the correct direction. A dress with an upside-down pattern is not recommended.
Marking the Fabrics
You can either use a computerized marking tool or manually. The individual first choose the full-size patterns and then places them on the marker paper. If done correctly, this could be very cost-effective.
Marking paper is a printed piece of paper that has signs on it to indicate where each component is located and if they are following the required grain lines. To ensure that the marker stays in its designated place, workers attach pins or staples to the fabric. Some manufacturers use adhesive paper to seal the top layer.
These machines are essential in preparing fabric for cutting. Fabric inlays are approximately 100 layers that are laid by a spreading machine before entering the cutting room. To ensure authenticity, this process is overseen by the appropriate individual.
When fabrics are cut and spread, this is a very significant operation in the cutting area. The most vital operation in the cutting room is cutting. Once the fabric is cut, there are a few ways to correct serious mistakes.
The outcome of the sewing room may be affected by any garment problems that are generated in the cutting area. Once all fabric components have been accounted for, the next step is to move the cutting room function to a sewing room.
Screen Printing and Embroidery
Screen printing and embroidery are both possible if the customer requests them. These are done at offsite facilities. Automated equipment is used to embroider. A production line may have between 10 and 20 embroidery stations. Customers can request embroidery to add logos or other embellishments to fabric, such as on sports t-shirts.
Screen printing involves the application of paint-based graphics onto the fabric. This can be done using both textile dryers and presses. To set ink, the garments with screen-printed pieces are dried. The process can be automated in different ways or largely done manually. Screen printing, like embroidery, can also be determined by the customer to print brand information and size information instead of attaching tags.
After the cut garments have been affixed according to the size, pattern, and quantity determined by the sewn units, stitching or sewing can be performed.
The sewists take a bundle of fabric cuts and begin sewing. They pass the finished fabric to another operator.
If there is a manufacturing defect, quality assurance will be performed at the end. If necessary, the garment can be reprocessed or repaired at designated sewing stations. This labor-intensive process turns pieces of garments into designer versions.
The customer can choose how to stitch. To finish the sewing operation, computerized sewing machines can be used.
Laundry and Checking
The end of each sewing line is checked for any defects. The garment must be inspected by workers to avoid any manufacturing defects.
A clothing manufacturer must meet a certain standard for garment quality. This reduces the number of garments that customers refuse to buy. Workers can spot any stains or spots caused by previous processes at the time of the check. The previous processes used markers to mark the garments. All fabrics are then taken to the factory for washing.
Fusing & Pressing
The final appearance of the garments’ manufacturing process is determined by the two critical stages of fusion and pressing. Once a garment has been assembled and sewn, it can be moved to the ironing section for a final press. Fussing is what applies the foundation to the garments while pressing seals them. The machinery required to finish fussing and pressing includes hand irons with vacuum table, carousel machines, scissors presses, as well as a steam dolly.
SHIPPING AND PACKAGING
The last step is to fold, tag, size and pack the garments according to customer specifications. The garments are then placed in cardboard boxes and shipped to the client’s distribution centers. If a large amount of hanging or boxed garments must be transported, the boxes can be packed in cartons that could be sealed with paper or plastic Manual.
This process of garment manufacturing demonstrates how each unit is processed at different stages. Garment manufacturing is different than other processes such as spinning and dyeing. In the textile manufacturing process, we get the finished products rather than semi-finished ones.
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