Applications of statistical tools in various processing stages of textile production

Fiber Production

Measures of central tendency like process average gives an idea about average staple length of fibre produced in a continuous or batch wise process. Coefficient of variation (CV) of the process signifies about the process control. On the other hand, analysis of time series is helpful in estimating the future production based on the past records. Measures of dispersion such as standard deviation and CV are useful in comparing the performance of two or more fibre-producing units or processes. Significance tests can also be applied to investigate whether significant difference exists between the batches for means or standard
deviations. Analysis of variance can be applied for studying the effect of parameters of fibre production and methods of polymer dissolving.

Textile Testing of Fiber Yarn and Fabrics

Results analysis in textile testing without the applications of statistical tools will be meaningless. In other words every experiment in textile testing include the use of statistical tools like average calculation, computation of SD, CV and application of tests of significance (t-test, z-test and f-test) or analysis of variance (one way, two way or design of experiments). Populations can be very well studied by normal or binomial or Poisson’s distributions. Random sampling errors are used in studying about the population mean and SD at 95% and 99% level of confidence. Application geometric mean for finding out the overall flexural rigidity or Go has an important role in fabric selection for garment manufacture.

A special mention is made in determination of fibre length by bear sorter where all the measures of central tendency and dispersion (mean length, modal length quartile deviation, etc., in the form of frequency distribution) are computed to understand about the cotton sample under consideration for testing its potential in yarn manufacture. On the other hand ball sledge sorter uses weight distribution from which mean and SD are computed. In the case of cotton fibres, the development of cell wall thickening commonly referred as “Maturity” concept can be very well determined using normal distribution and confidence intervals. Several properties are tested for different packages produced from the same material or from the same frame by applying significance tests. Effect of instruments and variables for different types of samples can be
very well studied by using ANOVA. All the fabric properties tested on a single instrument or different instrument can be understood by using design of experiments. In one of the research applications, which include the testing of low stress mechanical properties for nearly 1000 fabrics are studied by ‘Principle Bi component analysis or Bi plot’. Measures of dispersion like coefficient of variation and percentage mean deviation are very much used in evenness measurement.

Yarn Production

There are several stages involved in the cotton yarn production. When fibres are mixed and processed through blow room, within and between lap variations are studied by computing mean, SD and CV lap rejection, and production control are studied by p and x charts. Average measure is used to find the hank of silver in carding, draw frame, combing and average hank of roving in roving frame and average count at ring frame. Generally the spinning mill use ‘average count’ as the count specification if it is producing 4–5 counts. On the other hand the weaving section uses ‘resultant count’ which is nothing but the harmonic mean of the counts produced. Control charts are extensively used in each and every process of yarn production (for example, the process control with respect to thin places, neps, etc.). Application of probability distributions like Poisson, Weibull and binomial for various problems in spinning is found very much advantageous to understand the end breakage concept. In ring spinning section several ring bobbins are collected and tested for CSP and difference between the bobbins and within the bobbins is studied using ‘range’ method. In cone winding section the process control can be checked either by using control chart for averages or chart for number defectives.

Fabric Production

Design of experiments such as latin square design or randomized block design can be used to identify the effect of different size ingredients on wrap breakages on different looms in fabric formation. Most of the suiting fabric constructions involve the use of double yarn which is nothing but the harmonic mean of different counts. Poisson’s and normal distribution can be applied for loom shed for warp breakages. Using statistical techniques the interference loss can also be studied in loom shed. Various weaving parameters such as loom speed, reed and pick can be correlated with corresponding fabric properties and are interpreted in terms of loom parameters. Control charts are used to study the control of process/product quality in fabric production also. For example, selection of defective cones in a pirn winding from a lot (fixed population) or in a production shift n p and p charts are used. The width of the cloth and its control can be understood by x and defectives per unit length and their control is understood by c charts. The testing process includes determination of average tensile strength (and single thread strength also) and the corresponding CV%.

Chemical processing and Garment Production

The scope of statistics is unlimited. For example the effect of n number washes (identical conditions) on m fabrics on a particular fabric property can be easily found by either tests of significance or analysis of variance. Similarly the effect of different detergents on fabric types can be investigated by two-way analysis of variance. Similarly different types of fabrics and the effect of sewing conditions can be studied by ANOVA.
In garment production the control of measurements and its distribution can be well understood by control and polar charts.



by  : Mason Brown

Textiles are fibres that are spun into yarn or made into fabric by weaving, knitting, braiding, and felting. The term is now applicable to natural and synthetic filaments, yarns, and threads as well as to the woven, knitted, felted, tufted, braided, bonded, knotted, and embroidered fabrics. The spinning and weaving were one of the first crafts that is believed to have been practiced as early as the New Stone Age. In ancient Egypt, the earliest textiles were woven from flax in India, Peru, and Cambodia, from cotton in the Southern European; from wool in China.

Textile also includes non-woven fabrics produced by mechanically or chemically bonding fibres. Computerised textile mill with multiple machines run continuously to produce textiles in the modern market. In a mill, the initial stage of processing fibre into fabric is almost entirely coordinated and controlled by computer. Computers are able to execute complex weaving and spinning jobs with great speed and accuracy. Most are equipped with monitoring sensors that will stop production if an error is detected.

The initial stage of textile manufacturing involves the production of the raw material either by farmers who raise cotton, sheep, silkworms, or flax or by chemists who produce fibre from various basic substances by chemical processes. The fibre is spun into yarn, which is then processed into fabric in a weaving or knitting mill. After dyeing and finishing, the woven material is ready for delivery either directly to a manufacturer of textile products to finally get stitched into clothes that we wear.

This book gives you an insight for terminology used in the textile industry. It should be helpful for everyone who is associated with garment, and textile industry.

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The MAIN Shirt: A Textile-Integrated Magnetic Induction Sensor Array

By : Daniel Teichmann,  Andreas Kuhn, Steffen Leonhardt and Marian Walter

Abstract: A system is presented for long-term monitoring of respiration and pulse. It comprises four non-contact sensors based on magnetic eddy current induction that are textile-integrated into a shirt. The sensors are technically characterized by laboratory experiments that investigate the sensitivity and measuring depth, as well as the mutual interaction between adjacent pairs of sensors. The ability of the device to monitor respiration and pulse is demonstrated by measurements in healthy volunteers. The proposed system (called the MAIN (magnetic induction) Shirt) does not need electrodes or any other skin contact. It is wearable, unobtrusive and can easily be integrated into an individual’s daily routine. Therefore, the system appears to be a suitable option for long-term monitoring in a domestic environment or any other unsupervised telemonitoring scenario.



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The MAIN Shirt: A Textile-Integrated Magnetic Induction Sensor Array


By: Mohammad Mirjalili, Niloofar Yaghmaei and Marjan Mirjalili

In the present study, an attempt has been made to impart antimicrobial finishing to the cellulose fabric using nano silver solution at various concentrations (5, 10, 15, 20 and 25 ml) and an eco-friendly crosslinking agent by the exhaustion technique. Curing conditions were varied, keeping curing temperatures at 110°C and 100°C and curing times to 1 and 2 min. To assess the quality of the finished fabric, various properties such as washing fastness and zone of inhibition were studied. The zones of inhibition have been studied using Escherichia coli bacteria to determine antimicrobial activity of the fabric; the surface characteristics of these fabrics have been studied by scanning electron microscopy (SEM).
In the case of the treated commercial cotton fabric product, the zones of inhibition are at a minimum of 14 mm and a maximum of 18 mm for Gram-negative bacteria. SEM study and antibacterial tests of the silver-finished fabrics indicated that, generally, silver nanoparticles were well dispersed on the fabric surface. Antibacterial test was used to estimate the biological activity of the treated fabrics, and Gram-negative bacteria (Escherichia coli) were used for this purpose. The washing fastness of finished textiles was investigated in terms of ISO 105 CO3-1982 standard. The results obtained proved the good and long-lasting bacteriostatic efficacy of silver nanoparticles applied during the finishing of cotton and viscose.

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Antibacterial properties of nano silver finish cellulose fabric


By:  R. Rajendran, C. Balakumar, Hasabo A. Mohammed Ahammed, S. Jayakumar, K. Vaideki and E.M. Rajesh

The application of nanoscale materials and structures, usually ranging from 1 to 100 nanometers (nm), is an emerging area of nanoscience and nanotechnology. Synthesis of noble metal nanoparticles for applications such as catalysis, electronics, textiles, environmental protection, and biotechnology is an area of constant interest. Recently, an awareness of general sanitation, contact disease transmission, and personal protection has led to the development of antimicrobial textiles. The development of antimicrobial cotton fabrics using Zinc oxide nanoparticles has been investigated in this present work. The ZnO nanoparticles were prepared by wet chemical method and were directly applied on to the 100% cotton woven fabric using pad-dry-cure method. The antibacterial activity of the finished fabrics was assessed qualitatively by agar diffusion and parallel streak method, quantitatively by percentage reduction test. The topographical analysis of the treated fabric and untreated fabric were studied and compared. The results show that the finished fabric demonstrated significant antibacterial activity against S. aureus in both qualitative and quantitative tests. The SEM analysis revealed the embedding of ZnO nanoparticles in treated fabrics. The wash durability study of the treated fabric was also carried out and found to withstand up to 25 wash cycles.

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Use of zinc oxide nano particles for production of antimicrobial textiles


By: Gagandeep Singh, Eadaoin M. Joyce*, James Beddow and Timothy J. Mason

Growing resistance of microorganisms to potent antibiotics has renewed a great interest towards investigating bactericidal properties of nanoparticles and their nanocomposites as an alternative. In the present work studies have been carried out to investigate the antibacterial properties of ZnO nanoparticles (NPs). Various tests were performed to assess the antibacterial activity of cotton fabrics coated with ZnO nanoparticles against Gram positive Staphylococcus aureus and Gram negative Escherichia coli. The antibacterial activities of the fabrics were assessed semi-quantitatively by the agar diffusion method and the shake flask method (nutrient broth) and quantitatively by the shake flask method (saline) and the absorption method (ISO 20743:2007). The results showed a significant antibacterial activity of ZnO nanoparticles coated onto fabrics against both bacteria, with a slightly higher activity against Staphylococcus aureus as compared to Escherichia coli.

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Over the decades there have been several papers on the coloration of cotton-based textiles. The number of articles dealing with the processing of cotton, including preparation, dyeing, and finishing, may be in the thousands. An investigation of the possible causes of problems occurring in the coloration of textiles revealed that a comprehensive review of case studies and scientific analysis would be a welcome addition to the already rich pool of knowledge in this area.

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A Review of Technology of Personal Heating Garments

by: Faming Wang, Chuansi Gao, Kalev Kuklane and Ingvar Holmér

Modern technology makes garments smart, which can help a wearer to manage in specific situations by improving the functionality of the garments. The personal heating garment (PHG) widens the operating temperature range of the garment and improves its protection against the cold. This paper describes several kinds of PHGs worldwide; their advantages and disadvantages are also addressed. Some challenges and suggestions are finally addressed with regard to the development of PHGs.

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A Review of Technology of Personal Heating Garments