The Process Of Knitwear Mass Production

Knitwear is a challenging form of clothing manufacturing. The tight tolerances of knit garments mean that even the most minor details need to be correct. As a result, knitwear manufacturers have their own process to ensure knitwear keep coming out perfect. This article will explore the process of mass knitwear production.

First of all, What is Knitwear Manufacturing?

Manufacturing is the process of making products based on plans or instructions. But in the textile industry, manufacturers use the term to encompass all stages of production, from design through to marketing and distribution. In the case of knitwear manufacturing, the process starts with yarn, then moves on to production knitting, and finally, the creation of a finished garment. Although the stages are different depending on the manufacturer and garment type, most use a similar process.

Then let me list out 18 Steps of  knitwear Mass Production

Step 1: Yarn Sourcing

Raw yarn is the primary raw material in knitting production—factory sources yarn package, in the form of Cone or Cheese in hank or spool form. Jiaxing E-son clothing Co., Ltd has its own spinning mill and yarn dyeing unit.

Therefore, this is the main plus point for E-son clothing in knitting production.

The first step in the production process is inspecting the yarn.

We make sure the materials meet our quality standards and are in good condition. This is done by either looking at the yarn from a visual perspective or by having it visually inspected by an inspection specialist.

When we receive the sampling requirement, the first thing that needs to do is to confirm the yarn material and color? Here is our Yarn showcase. These yarn books are from our 50 yarn suppliers. Each kind of yarn has a relative color book for choosing a color. All yarn is available for sampling and mass production directly!  

Step 02: Yarn Waxing  

Knitting is done with a single set of yarn. These yarns need to be waxed to let the hairiness fall on the yarn. It improves production efficiency. It can reduce so many defects such as clogging. Water-soluble wax block improves the hydrophilicity and antistatic ability of the yarn.

Besides, it has an economic benefit in the knitting process. The wax could use as a yarn lubricant. Consequently, it reduces the friction with the machine. The friction coefficient is reduced. Additionally, it improves product quality. Also, the yarn breakage rate is reduced. Overall, the weaving rate is improved, and product quality is improved.

Step 3: Patterning  

Patterning is the process of drawing different components of apparel by standard body measurement or body measurement. It can be made manually or entirely computerized machine.

Before starting production, the pattern needs to be completed. We have own developing sample department. This specialized department helps to come out with the designer’s imagination from the sketching to the actual knit product.

Step 4: Knitting Programming

Programable Knitting machines are used to manufacture complicated shapes from yarns. Although designing patterns for these machines requires extensive experience. We have a number of skillful workers to present the first general visual programming interface. It will create 3D clothing visual with complex surface finishes on automated knitting machines.

An updated version of the stitch mesh data structure is at the center of the interface. The automated system generates knittable augmented stitch meshes from 3D models. That allows the operator to edit these meshes in such a way that preserves their knittability. Moreover, it can schedule the execution order on a knitting machine. A programable knitting system maintains editing operations sufficient to transform any knittable machine stitch patterns with the same orientation on the same surface.

Step 5: Knitting for Shaped Knitwear

The programable knitting machine has shaped knitwear. In this stage, the knitwear is visible as a fabric. A circular knitting machine produces round shape apparel, and a flatbed knitting machine produces flat knitted fabric.

Step 6: Panel Inspection

In this step, experienced operators conduct the checking of panels. A quality inspector checks 100% panels on a flat table. Usually, it is done under the light table. Measurement checking of panels is conducted randomly.

Step 7: Linking

Linking is the process of attaching pieces of fabric after the pieces have been knitted on a flatbed knitting, m/c. Knitted sweater parts are sent to the linking department. Different components of knitwear are joined together utilizing linking m/c. The linking process always requires skilled labor. Mainly it is primarily used for high-end knitted apparel.

Step 8: Waste Yarn Cleaning

Trimming is done in this step to remove the waste yarn. Loose yarns are cleaned in this stage by the trimmer. Manual and automatic method is used to trim loose yarn.  

Step 9: Hand Stitching

In this process, knitting defects are repaired manually by hand stitching. Sometimes it found fault in the knit fabric. Mending is done to reinforce thinning areas in knits. It has to be done by an experienced worker. Firstly, the worker has to choose a darning thread or yarn similar to the colors. It may be a little thinner than the original knit. Therefore, it can cover an area that will not be too thick and bulky compared to the rest of the fabric.

Step 10: Seam & Defect Checking

After mending, again, Quality checking is done on complete knitwear. Knitwear is checked using a light checking machine.

 Stitching defects in knitwear can occur due to the following reasons: Machine is malfunctioning, Inexperienced operator, Not trained enough to stitch and handle particular seam/stitch type, Operators don’t follow proper procedure.

 There are many defects found in knit products. Such as Broken Stitch, Jump Stitch and Skipped stitch, uneven stitch, Stripe or check mismatch, Roping, Pinching, Puckering, Uneven bottom hem, irregular gathering, and uneven seam Margin, Wrong overlock, Needle hole /cut mark.

Step 11: Washing

Different types of washing are conducted according to the requirements of the buyer. Fashionable requires fashionable knitwear. Essential knitwear and washed knitwear have different looks. At present, the washed knitwear item is a hot cake for the young generation. Therefore, different kinds of wash are applied to knit apparel, such as Enzyme Wash, Stone Enzyme Wash, Rubber Ball Wash, Pigment Dye, Tie-Dye, Hot Wash, Softener Silicon Wash, Acid Wash, P.P. Spray, Garment Dye, Cold Dye, Deep Dye, etc.

Step 12: Drying

Knitwear manufacturing processing involves many chemical processes. Drying is a necessary operation. Various Drying Systems are used according to needs Cylinder drying, Float dryer or Loop dryer, Tensionless dryer/Shrink dryer, Stenter machine, Hot air dryer, Radiofrequency Pressure dryer, Infra-red dryer.

The objective of drying is to eliminate exceeding water. Moreover, it helps to achieve the natural moisture content of the fiber. Excessive drying may negatively affect the final appearance and knitwear hand.

Step 13: Label Sewing

The label is an essential trimmings part of apparel. A label is not a piece of fabric. It helps directly communicates with the buyer and consumer as well.

The label carries various information about that apparel, such as brand name, country of origin, types of fabric, types of yarn, special instruction about care, etc. There are two types of labels. One is Main Label, and the other is Sub Label. A sub-Label is not a label, and it consists of different labels such as Care Label, Size Label, Price Label, Composition Label, Special Label, and Flag Label. All of these labels are sewn with knitwear with the appropriate thread.

Step 14: Pressing

Pressing or ironing is the process that helps remove unwanted creases and crinkles and apply creases where necessary. It is the most important finishing process in the knitwear manufacturing sector. It is done by applying heat and pressure with or without steam to remove unnecessary creases and to provide a flat appearance to the knitwear.

Step 15: Inspection

The final inspection is done manually and automatically to control the quality of knitwear. The final checking consists of checking the fabric of knitwear, sewing, button, thread, zipper, final apparel, measurements of clothing with the standard process, etc.

Step 16: Hanging tag  

In every department of knitting, there are arrangements for inspection. The primary objective of the inspection is to identify the faults at the earliest possible steps. It will help to reduce wastage of production time and money.

We provide custom knitwear hang tag for your brands. The branding materials of the hang tags include paper, leather, textile fabric, PVC, rubber, etc. Additionally, surface effects such as Sliver hot-stamping, spot U.V., embossing, etc., are applied on hang tags. Moreover, we can print, hot-stamping, and laser-engrave your brand logo.

Step 17: Packing  

Excellent packaging of knitwear sometimes increases sales from the retailer’s point of view. When you look at mass knit manufacturing for the export market, you need to take care of the final packaging. Good packaging helps transportation products from the manufacturing factory to your retail shop—moreover, easy distribution of color and sizes to the stores.

we ensures every carton doesn’t contain random knitwear pieces; instead, each carton contains apparel of specific sizes and colors of a certain ratio. The different sizes and colors ratio could depend on the location, customer requirement, and order booking.

In a knit production unit, finished knitwear is folded and packed in individual poly bags. Then packed garments are placed into carton boxes. There are two kinds of packing types. These are Single piece packing and Blister Packing.

Step 18: Delivering  

Fabric order delivery is one of the most important stages. If everything is ok, the manufacturer sends the knitwear to the buyer.

If you choose the yarn and color directly from E-son clothing’s look book or send the tech pack info, the sample time will be 3 to 5 days. Bulk delivery will take up to 35 – 40 days.