Fusing t shirt heat press machine for garments is very much important to maintain the quality of the products. The press machine carries out fusing by holding the fabric & the fusible interlining between the conveyor belts while heating. To check the uniformity of the fusing area in the fusing area in the fusing machine the following method or procedure should be followed.
For Conveyor TypeHeat Press Machine
Three stripes of fabrics & fusible interlining should be taken; Length-42” (inch)—each pieces
The fabrics & interlining (taken before) should be fed into the fusing machine.
In t shirt heat press machine, machine bed should be divided into three zones ( like zone A,B&C) to identity the lack of uniformity in fusing bond.
After fusing three samples each of them to be tested for the fusing bond strength & fusing quality by pulling the interlining apart from the fabrics.
A visual inspection to be carried out in order to ascertain the sharing of the interlining glue with the corresponding fabrics stripes.
Conveyor Type Heat Press Machine
For Flat Bed Type Heat Press Machine
Three stripes of fabrics & interlining should be taken; Length-42” (inch)—each pieces
The fabrics & interlining (taken before) should be fed into the fusing machine.
In fusing machine, machine bed should be divided into three zones ( like zone A,B&C) to identity the lack of uniformity in fusing bond.
After fusing three samples each of them to be tested for the fusing bond strength & fusing quality by pulling the interlining apart from the fabrics.
A visual inspection to be carried out in order to ascertain the sharing of the interlining glue with the corresponding fabrics stripes.
To test fusing press machine light color solid T/C fabrics should be used.
This test should be done at least twice a month, & records should be kept in fusing check register. Test will be conducted between 1st to 3rd (First) & 15th to 18th (Second) day of each month.
Quality in-charge will be responsible to ensure the fusing uniformity of the fusing area to test the fusing machine.
Golden Rules to successful fusing
Check compatibility of fusing type with fabric end use.
Carry out tests as per attached test request form.
George approved certificate to confirm agreed standards for production use.
Fusing bed records.
Temperature checks.
Pressure check.
Time check.
Review peel strength
Wash and/or dry clean result of garment part being fused.
A sample of the fabric being fused should be maintained as a reference for the operative.
Heat Press Machine Maintenance
Keep a record of each press.
We have assembled this guide to make it easier for the factories to assure that the bond strength and the fuse line temperature are according to the requirement as stated in the
Vilene test report.
Once agreed compatibility for end use.
Heat Press Machine Maintenance
Daily Maintenance:
Clean the whole machine.
Check and clean the belt with a dried floor cloth when the operation is over.
Raise the scraper three or four times a day in order to clean.
Wipe off dusts using a dry floor mat, before inserting the material.
Check all the screw & nut & Bolt.
Monthly Maintenance:
Check the electrical wiring system.
Check the machine for visual damages
Tools
Spring loaded balance : A spring balance is a basic devise, which cannot be as precise as a computerised bond strength-measuring machine, however the results are close enough for comparison.
Temperature strips : Just proceed according to the instruction as follows
Method: Cut the interlining in a width of 7cm and a length of 17cm in machine direction (MD). Cut the fabric a little bit bigger to avoid contamination of the conveyor belt, also cut a small fabric piece as shown. Insert the little piece between the fabric and the interlining. Add also the temperature strip readingface to fabric. Put it through the fusing press according to the recommended conditions. After fusing cut alongside the temperature strip. Turnover the temperature strip and look for the black square of the highest reading, this is the fuse-line temperature. Here the fuse-line is 121ºC.
Fuse-line temperature reading 121ºC : The fuse-line temperature is the temperature achieved on the adhesive dots during the fusing process. Therefore the temperature strip is used between the fabric and the fusible interlining for correct measuring. It is recommended to always double check the fuse-line temperature prior to production start.
Personal Safety
Proper personal protective equipment i.e. gloves, visors, and aprons must be used.
This machine is used in high temperature, so pay attention to your hands and clothes not to be burned.
Always wait until the machine is fully stationary.
Do not push finger/ hand through the heated chamber.
Avoid wearing loose wears.
First aid equipment such as first aid kit, stretcher, and dressing material box must be stationed in the vicinity.
Carefully observe announce location and operation of fire extinguishers.
Do not operate the equipment in the presence of flammable gases or fumes.
Machine Safety
Switch off the machine.
After maintenance work always tighten released screw, nut-bolt connections.
Do not use compressed air on electric and electronic parts directly.
Confirm that the power plug is properly connected.
Pay sufficient attention not to make contact with the belt and the upper cover whose temperature rises high nor mount things on them.
Don’t put anything to the main unit of the press except the materials to be inserted.
SOP for Different Types of Garments Pressing
Pressing: It is the process of application of Heat or Steam or both on a finished garment to provide a desired appearance and stability to the garment making it appealing to the customers.
Importance of Pressing: Pressing is a very important parameter which affects the appearance of a garment. When any customer walks in a store to purchase a garment, he / she look for a visually appealing garment. Apart from this, pressing also provides dimensional stability to the garment.
When should be Pressing done: Pressing should be done just before Packing of the garment so that it is retained properly till the time it reaches the customer.
Different Types of Garment Pressing: Following are the different types of pressing methods done for garments:
Flat Iron
Steam Iron
Warm Iron
Inside Out Ironing
Ironing for Puckered Appearance
Ironing for Crushed Look
Tie and Dye appearance
Flat Iron: In Flat Ironing, the garment is pressed by the application of heat as well as steam. This results in formation of Crease Marks at the desired point of application. It is done usually for Formal Shirts and Trousers. The figure on the right refers to an example of Flat Ironing.
Flat Iron
Steam Iron: In this method, the garment is pressed only by the application of steam. It provides a Fresh Look to the garment highlighting overall garment. It is generally done for Denims, Skirts and Cargos where we do not want any shine marks. The figure on the right refers to an example of Steam Ironing.
Steam Iron
Warm Iron: In this method, the garment is pressed only by the application of heat. It provides a distinct appearance to the garment. It is done for formal non wash shirts and T-Shirts. The figure on the right refers to an example of Warm Ironing.
Warm Iron
Inside Out Ironing: In this method, the garment is pressed after inverting the garment. It is done to avoid any directional change in appearance. It is done for directional fabrics like Corduroy and Suede. The figure on the right refers to an example of Inside Out Ironing.
Inside Out Ironing
Ironing for Puckered Appearance: In this method, the garment is presses lightly. It provides puckered appearance to the garment. It is done for washed formal & casual shirts.
Ironing for Crushed Look: In this method, the garment is pressed roughly. It provides a natural crushed appearance to the garment. It is done for cargo pants and skirts .
Tie and Dye Appearance: Though Pressing plays an important role in appearance as well as dimensional stability of a garment, it is not necessary that all the garments need to be pressed before packing. Some garments are visually more appealing without any ironing. It is done for stylized skirts and wrinkle free trousers.
Job Summary of a Inspector for Fusing Press Machine
To make a clear understanding of all information regarding quality requirements of fused parts for every style and to collect all information of that style (e.g. Working Instruction, Sealing Sample, Swatch Card etc.) from Supervisor, QC.
To ensure that the fused parts in test run (control parameter of the fusing machine and quality of fused parts) is approved by the Unit-In-Charge, QC before the start of bulk production
To ensure that the control parameters of the fusing machine are tested properly during bulk production by maintenance personnel.
To inspect all fused parts of the garments (100%) according to inspection guideline and to keep records of all non-conformities.
To communicate with relevant workers and Supervisor (QC & Production) about the defect and to give a proper direction for minimizing the defect.
To send back all defect parts to the sewing section for replace cutting via cutting section and to re-inspect all the replaced parts of the garments.
To inspect the quality of interlining pasting in Make Section randomly and to ensure quality requirements.
To keep records of fusing test in fusing register and to ensure that the fused parts in test run are properly preserved.
To collect the information about the defects which are overlooked by them and identified in the Sewing and Finishing Section and take necessary corrective action.
To take care about the cleanliness and hygiene factors of the work place.
To maintain and practice COC (Code of Conduct) and ISO related activities regarding QC for the unit of t shirt heat press machine
Finishing machine for garments is very essential to improve the quality. Factory must have complete department structure with finishing machine comprising of all relevant categories to have smooth operational function. Daily attendance details certified by P.M./Section in charge have been available in each section for management information. Garment finishing machines must be provided with a complete sample for Packing along with all packing trims and approval from Technical department, which is certified by Q.A. Manager.
Finishing:
It is the process of value addition / Improvisation on the garment and making it presentable visually to satisfy the customer’s perspective of Good Quality and Appearance.The following processes constitute the Finishing department:
Thread Trimming
Inside Checking & Quality Checking
Ironing
Top Side Checking, Measurement and Quality Checking
Attaching Finishing and Packing Trims
Packing
Each finishing line consists of 1 Supervisor, 4 Inside Q/C’s, 4 Topside Q/C’s and 1 Hourly Auditor to maintain production as well as quality of the output.
ProductionReceiving: Details to be maintained by finishing department for non wash garments receiving from Production and Washed garments receiving from Washing.
Stores requisition: For trims and others to be prepared by finishing in charge and have to get approval from P.M or F.M to submit to Stores.
Finishing Process –Layout: To be prepared by Work study department and set targets with the approval from P.M.
Hourly production records: To be maintained to monitor hourly targets. Production recorder has to forward it hourly to Finishing in charge through supervisors.
Garment return records / Style reconciliation: To be maintained and style reconciliation reports to be submit to F.M. on completion of each style
Approved Trim Card: This has to be approved by the Merchandiser and certified by Q.A. Manager prior to handing over to Factory.All sections have to follow this for fabric and all trims to be used for particular style.
Finishing Process –Approved Packing Sample: Technical department have to provide a complete packing sample with all trims attached to the garment and with approved folding method. Q.A Manager has to certify this sample before sending to finishing machine department. Also a sample tag should be attached to the garment which includes complete details such as buyer, P.O. number, style number along with the signature of person’s approved and certified.
Approved Packing Sample
Q.C And Q.I. Instruction: Finishing machine of Q/A In charge has to provide complete instructions about the style/garments checking in finishing, Clock wise/sequence checking of garment, about ZONES of the garment to consider defects to be analyzed and clear instructions to be given to Q.C’s and Q.I.’s
Finishing Process –Target Setting: Section Q.C. In charge has to set target for Q.I’s with consultation of I.E. department and has to monitor hourly individual production.
After Wash Checking: Q.I to be instructed by the Q.C about sequence of checking and zones of the garment. This can be illustrated with sketch or photo attached to the Q.C instruction sheet. Then Hourly quality inspection report to be maintained by Q.I’s, entering the observations/ findings and it’s quantities. Finishing Q.C and Finishing supervisor have to note defect and rework quantities hourly basis and assure acceptable quality levels are maintained in this points. Each Q.I.’s identification mark to be attached in an invisible place in each passed garment.
Pressing Quality: Finishing Q.C along with Finishing supervisor has to give instructions for pressing the garment. Q.C is responsible to assure the standard of garment pressing is acceptable.
Finishing Process –Measurements: Waist and inseam of each garment to be measured on table. In addition to these, three pieces of each size covering full size set to be measured by finishing Q.C for all measurement points’ specified. This exercise to be in practice twice a day and report to be submitted to Q.A.M daily. Q/C and Q/I should be instructed clearly about measuring points as per the particular buyer’s measurement guide
Finishing Process –Appearance Check: Finishing Q.C has to instruct Q.I’s to perform this activity in Q.C instruction sheet. General appearance, presentation of the garment and trim placement to be taken care at this point. Each Q.I’s identification label to be attached to the garment at an invisible place.
Finishing Process –A.Q.L. Audit: Independent auditor has to conduct this audit for the quantity accumulated in each two hour intervals per day. Sample quantity for A.Q.L 1.5 to be selected randomly for each lot to do the audit. Result of this audit report is to be submitted to Q.A.M at completion. In the event of any lot is failed, it has to be kept in a separate location for rechecking, avoiding mix up with passed lots.
Pre Final Inspection (Internal): Finishing Q.C in charge has to conduct prefinal inspection at A.Q.L 1.5.It is advisable to conduct first pre final when complete 10% of packing or any style to minimize recheck quantity, incase of inspection failed. Also the advantage of this percentage will be to do correction at a small quantity. Pre final inspection report to be submitted to Q.A.M upon completion. .
Final Inspection (Internal): This inspection to be conducted by Q.A.M at completion of at least 80% of each style before submitting merchandise to buyer’s inspection.
Finishing A.Q.L. Audits – Daily And Monthly Summary: Finishing in charge has to maintain these summaries daily and monthly and submit to Q.A.M. to submit for management review. This is very important as it is a KEY PRODUCTIVITY INDICATOR (K.P.I) in finishing quality
Finishing Process –Finishing Defects/Rejects – Daily And Monthly Summary: Finishing in charge has to maintain these summaries daily and monthly and submit to Q.A.M. to submit for management review. This is very important as it is a KEY PRODUCTIVITY INDICATOR (K.P.I) in finishing machine quality.
Finishing Process –Buyer’s Final Inspection Result Summary – Monthly: Finishing in charge has to maintain summary report for each month and submit to Q.A.M. to submit for management
SOP for Finishing :
First of all, pcs are received from wash lot wise. The Hourly auditor picks up pcs randomly, checks for hand feel and shade; does rough ironing and checks the measurements. If any issues are encountered, it is immediately informed to the Finishing In-charge and the pcs are sent for rewash.
100% process thread trimming is done.
100% process inspection is done by In Side Q/C. Defective garments are sent for alteration / rejection based on the type, size and location of defect.
Ironing is done for In Side pass pcs.
100% process inspection is done by Top Side Q/C for Quality as well as measurement. Defective garments are sent for alteration / rejection based on the type, size and location of defect.
All the pass pcs are attached with Packing trims and packed after shade and size assortment to ensure that each carton should contain same shade garments only.
The hourly auditor does 12 Pcs audit per hour per lot and does 3 pcs measurement checking per hour.
The Internal audit is carried out after this. The auditor checks 32 Pcs twice a day (before lunch and after lunch). The auditor also inspects quality and measurements for each size covering all colors.
100% External inspection is done to confirm the Packing Accuracy.
After This CT PAT (Customs Trade Partnership Against Terrorism) audit is done. After this process, Pre Final inspection is carried out.
Pre Final is done to check the quality and measurement of the packed goods based on AQL 2.5 system per lot.
If any of the above mentioned quality checks fail, the pcs are again sent to the 1st process i.e. Thread Trimming and entire cycle is reworked.
After passing Pre Final, Buyer Inspection is done for quality and measurement of the packed goods based on AQL 2.5 system.
Once, the packed goods pass the Buyer Inspection, the Goods can be shipped.
Reports in Finishing Section: Eight reports are being made in the Finishing Section:
Finishing Quality Inspection Report
Style/ Line OQL Summary
Hourly Final Audit Report
Measurement Chart Fit Audit Report (By Q/C)
Measurement Chart Fit Audit Report (By Auditor)
Inline/ Final Inspection report
Weekly Root Cause Analysis chart
Finishing Q/C, Iron Man and Folding man Counseling report
Finishing Process – Shipment Documents
Autogarment has got a separate commercial department to arrange and prepare the shipping documents foe smooth shipment of goods to our buyer. The commercial department checks all the relevant shipping documents through a checklist before shipment of goods.
Autogarment follows below mentioned procedure to prepare the shipping documents in different stage:
When goods are ready for shipments, immediately PROJECT STITCH contacts the buyer nominated forwarder to get the booking confirmation and stuffing details. On the basis of above PROJECT STITCH starts preparing the shipping the shipping documents.
Goods send to forwarder along with invoice and packing list signed by Commercial Manager.
Prepare and arrange commercial invoice, final packing list, multiple country declaration, and manufacturer certificate, certificate of origin, wearing apparels details and bill of lading send to forwarder. Above documents are checked and signed by Commercial Manager.
Before sending the above documents to forwarder commercial staff in charge of export check and verifies the documents through a set checklist (if any specific buyer has any checklist that is also adhered to) and that checklist includes concerned persons signature for accuracy of the documents. If they find any discrepancy in the documents, they bring it into the notice of the concerned staff for correction or rectification. Only then the documents are put to Commercial Manager for final checking for his signature. The commercial Manager only signs when he finds there is no discrepancy in the documents as finishing process
Fusing machine for garments is very much important to maintain the quality of the products.Fusing press machine for garments is very much important to maintain the quality of the products. The press machine carries out fusing by holding the fabric & the interlining between the conveyor belts while heating. The pieces are then pressed by rollers at the outlet. The required fusing temperature is achieved by bringing the belt into contact with the heating elements
Each day before start of production, the pressure on the left, rihgt and center of the rollers shall be checked by means of the light weight woven fabric strips. One of the strip shall be passed through the T Shirt Heat Press Machine for garments while holding the other and tight. When the end passes out of the press, the strip will be pull to feel the pressure of the rollers.
When we start any order in the sewing floor. We make sure fusing machine parts of the garments. At first we collect the data sheet from the supplier. According to data sheet (like: pressure time: temperature) we adjust the m/c. After adjusting the m/c we check the m/c (1) thermo paper (2) thermo meter. We check the fusing m/c by thermo meter two times in a day that means after lunch and before lunch against every order according to data sheet. 3.bond strength test machine: we doing bond test when test the machine (after lunch before lunch)
Follow the machine direction or warp direction cut the interlining 17 cm x 7 cm.
1 kg = 9.81 newton.
1 kg = 1000 gram
Check Point Fusing Machine
Check Point Fusing Machine
check the physical condition of the pressure roller.
check the set temperature of the heater, by using a thermal strip at different areas of the rubber roller.
check the pressure exerted by the pressure roller of fusing machine for garments
for a flat bed fusing m/c check the bed at different zones.
check for all electrical connections.
check the solid state relay switch
Proper personal protective equipment i.e. gloves, visors, and aprons must be used.
This machine is used in high temperature, so pay attention to your hands and clothes not to be burned.
Always wait until the machine is fully stationary.
Do not push finger/ hand through the heated chamber.
Avoid wearing loose wears.
First aid equipment such as first aid kit, stretcher, and dressing material box must be stationed in the vicinity.
Carefully observe announce location and operation of fire extinguishers.
Do not operate the equipment in the presence of flammable gases or fumes.
Switch off the fusing machine.
After maintenance work always tighten released screw, nut-bolt connections.
Do not use compressed air on electric and electronic parts directly.
Confirm that the power plug is properly connected.
Pay sufficient attention not to make contact with the belt and the upper cover whose temperature rises high nor mount things on them.
Don’t put anything to the main unit of the press except the materials to be inserted.
Classification of fusing:
Top fusing
Semi fusing
Non fused
Corrective Action For Fusing Machine
if the roller is found too hard of bubble inside the roller, repair it or replace it.
if the obtained temperature varies beyond 10 c check the thermocouple of the m/c also the magnetic contractor.
Clean the whole machine.
Check and clean the belt with a dried floor cloth when the operation is over.
Raise the scraper three or four times a day in order to clean.
Inspect the belt cleaner.
Wipe off dusts using a dry floor mat, before inserting the material.
Clean and oil the guides and bearings.
Check all the screw & nut & Bolt.
Check and put oil if necessary on the upper and lower belt.
Check the electrical wiring system.
Check the machine for visual damages.
pass a long fabric between two rollers and pull the fabric by hand & feel the pressure.
if the bed becomes defored, change the bed cushion / foam of the m/c.
take necessary actions for loose connections of wirngs etc.
if the solid state relay does not work take n/a and maintain the fusing machine
Some common fusing problem:
Gum at collar, cuff, Flap, etc.
Crease mark
Fabric fault
Dust / Stain Mark
Foreign Thread
Bauble at collar, cuff, flap, etc
Fusing Machine Operating Procedure
Each day before start of production, the pressure on the left, right and center of the rollers shall be checked by means of the lightweight woven fabric strips. One of the strip shall be passed through the fusing press and while holding the other end tight. When the end passes out of the press, the strip will be pull to feel the pressure of the rollers.
The Fusing machine will be set to conditions recommended for Fusing of the fabric type.
The conveyor belts shall be checked. If there is any adhesive residue contaminating the belts, it will rub off with a soft cloth.
The cover of the cleaning bars will be Turn or changed, depending on how dirty they are. The scraper blades will be cleaned with a cloth.
Once the Fusing machine is ready for operation, the inter-lining will be set in proper position of the fabric, the appropriate time will be set and a test run through the machine will be made.
Fusing Machine Operating Procedure
After the test run, the fabric will be checked for proper fusing by the QC manager. If the proper fusing condition has been achieved, The QC manager will approve the fused part with signature and temperature setting and the process will continue, otherwise adjustments shall be made to temperature and timing to obtain proper fusing. After that, upon approval of the QC manager the fusing shall commence.
Fusing: Fusing is the process of joining interlining with the fabric. The interlining contains adhesive, which melts at a specific temperature (Glue Line Temperature) and Pressure to make bond with the Fabric.
Importance of Fusing: Fusing is one of the most important processes involved in apparel manufacturing which affects the appearance of the garment. It also provides support and strength to the specific parts of the garment.
Parameters for Fusing: There are three parameters involved in the fusing process:
Fusing Temperature
Fusing Pressure
Fusing Time
Initial Procedure: In the Tech Pack, buyer provides the details about the type of interlining to be used and also the quality standards to be maintained.
As per the details mentioned in the Tech Pack, the respective merchandiser communicates with the suppliers for getting the interlining.
The supplier provides the details of the interlining along with Test Report. This Test Report contains the details of the M/C in which the test was done along with the Temperature, Pressure and Time to achieve the Glue Line temperature.
The Technical GM goes through the Test Report along with the details provided in the Tech Pack. He provides the instructions to the Cutting Department to follow during fusing.
Fusing Procedure: The temperature, pressure and time of the Fusing M/C is set as per the instructions received during the Technical Meeting.
Thermo-strip is inserted in the M/C to achieve the Glue Line Temperature (Actual Fusing Temperature). This process is done twice a day; once in the morning 8:10 AM after starting the M/C and once in the afternoon (45 min after lunch).
Once the Glue Line temperature is achieved, Fusing for 10 Pcs (Mock Ups) is done.
2 Pcs are sent to the Lab for testing the Bond strength. This test is done by the Lab In-charge using the following M/C: OHBA SIKI JAPAN.
8 Pcs are sent to the Washing Department, to observe the effects after wash. The after wash Pcs are checked for bubbling, stain marks and strength.
The results from Lab and Washing is sent to the Technical GM. If the results are OK, approval for Bulk Fusing is given. If any deviation is observed, the Technical GM finalizes the correction for the temperature, pressure and time and communicates to the respective GM.
The cutting department follows the instructions provided by the Technical GM to achieve the Buyer Required Standards.
Requirements of Temperature, Pressure and Time for Commonly Used Interlinings:
M/C Type Temperature Pressure Time
OLD Machines 150 Degrees C 2 Kg 15 Sec
New M/C (HASHIMA HP900LC) 120 Degrees C 1.5 Kg 12.5 Sec
Requirements of Temperature and Pressure for KOHLS VT 20SP Interlining:
M/C Type Temperature Pressure Time
New M/C (HASHIMA HP900LC) 100 Degrees C 2.5 Kg 12 Sec
Reports in Fusing Section: Two reports are being made in the Fusing Section:
Fusing M/C Temp & Pressure Checking Report:
This report contains Thermostrip along with Fabric swatch. This report needs to be filled up two times a day (before starting fusing in morning & before starting fusing after lunch).
Fusing M/C Clean Report:
This report is filled up 3 times a day (10:00 AM, 1:00 PM and 4:00 PM).
Classification of Interlining Fabric
jersey
paper fused / paper non fused
cotton fused / cotton non fused
polyester fused / polyester non fused
Tc interlining (non fused)
Features of the interlining fabric
Features of the Interlining Fabric
It’s used for front fuse.
The excellent hand feel and appearancewill keep good sharp.
Hard hand feeling, superior elastic resilience used For high quality men’s suits
Shrink-resistant, good stretch ability and very comfortable.
Can be washed in any condition:
Water-washing and dry washing.
soft hand feeling, best water and oil
Selection of Interlining Fabric
Selection of Interlining Fabric
Right Interlining for right fabric
Fabric thickness, GSM, Construction, Composition
Fusible, Non fusible, Woven, Non Woven doted etc
Product category
Fusing test-Bonding
Bond strength – or the sturdiness of the seal between the fusible interlining and the fabric – should be evaluated after fusing, and after washing or dry cleaning, depending on the recommended care of the garment
A basic idea about fusing:
Cuff, Collar, Flap, Epulate, Band
Fabric Description
Lining Description
Required temperature
Required speed/ time
Required presser
100 % Cotton
Cotton
160-170
10-12
2-2.5 Kg
100 % Cotton
Paper
130-140
10-12
1 Kg
100% Polyester
Paper
Adjust able in test
10-12
Adjust able in test
100% Polyester
Cotton
Adjust able in test
10-12
Adjust able in test
68% Cotton,
27% polyester,
5% Elaston
paper
130-140
10-12
1 Kg
Note: – * if lining is thick then it needs to adjust less heat and time.
* If lining is thin then it needs to adjust more heat and time.
Fabric Description
Lining Description
Required temperature
Required speed/ time
Required presser
100 % Cotton
Cotton
180-185
18-22
8-10 Kg
100% Polyester
Cotton
Adjust able in test
Adjust able in test
Adjust able in test
Almost of order at front placket lining is used cotton lining.
Note: – These above information always not correct but this is a basic idea that can follow. After testing according to fabric and lining nature speed, temperature, presser should be set up.
Preparation for Fusing Press Machine
Fusing Press Machine
Select right fusing press machine
Fusing press machine Calibration
Find require temperature, pressure, speed & time
Test for bonding test, Thermal paper test, & wash test
Interlining shouldn’t be bigger than fabric to avoid the gluing
A model garment is doing all products to be checked 100% with a industrial metal detector prior to shipment after all manufacturing operations have been completed. This check is being carried out after the final examination and packaging of the garment (incl. attachment of swing tickets) but before packing/boxing the goods in the metal free zone and are being the part of the final quality control procedure. Industrial metal detectors are an aid to prevent metal contamination and are the best way to ensure that needle control procedures are effective, but are not to being used to replace an effective needle replacement policy. Metal detection are being implemented within the production process and used in conjunction with the broken needle procedure.
Metal Detector Calibration Procedure:
Machines are being calibrated every working day with this test card, at the beginning and at thend of each inspection lot, as well as when the machine is started up, then every hour and at the end of a working day as well as after any electricity cuts.
If an issue is found with the machine at the next calibration, the goods that were done since the last successful calibration need re-checking, so the smaller the gap between calibrations checks the smaller the quantity of goods that are being re-checked.
If the machine is to be found out of order after a check, it is being arranged for urgent repair and a replacement to cover for the time the machine will be out of order. This is being done through a static metal detector. It is being ensured though, that no orders leave the factory, that is not been checked, especially in case of children swears.
The following metal detector calibration procedure are being adhered to when checking the machine. Please see below diagram for the width across the belt of the metal detector and where the test card should sit when tested at the bottom, center and top position:
CROSS SECTION TUNNEL NEEDLE DETECTOR
TOP A7 A8 A9
CENTRE A4 A5 A6
BOTTOM A1 A2 A3
Metal Detector Calibration Checklist:
Switch on the machine and set the sensitivity level to less than 1.2mm sphere.
Position the test card directly onto the conveyor belt at position A1.
Let the card pass through the search head.
The metal detector is being activated and the alarm is sound.
Repeat the above steps 1-3 with the test card in positions A2 and A3.
Again the detector is being activated and the alarm is sound.
The test card is putting through on its own, we are not put it on a paper or put it through with a garment.
Repeat steps 1-3 with the test card positioned in the middle of a stand (7-8cm high) or on top of a stand that is around 3-4cm high (depending on the height of the gap between conveyor belt and top of machine) at positions A4, A5, A6.
Again the metal detector is being activated and the alarm is in sound. The stand are being a non-detectable block made of plastic material.
Repeat steps 1-3 with the test card on the top of a stand (7-8cm high or as high as the gap allows for) at positions A7, A8, A9 and again the metal detector calibration procedure are being activated and the alarm are in sound.
Records are being kept of all of these checks by using the prescribe form.
In case the machine fails to pass the calibration test, it is immediately being turned off and re-calibrated by an authorised technician. All goods checked after the last calibration is being re-checked once normal operations of the detector have been re-established.
Machines are being calibrated at least every 6 months by the manufacturer.
Calibration certificates are being obtained and being kept for auditing purposes.
If for any reason the detector are being relocated, it is being re-calibrated by the supplier’s authorised technical service.
Regular maintenance (at least annually) of the detector is being carried out by the supplier’s authorised technical service based on the periods set up by them. Records for maintenance and any re-calibration made by the supplier are being kept, in case these need to be provided during any audits.
Metal detection:
When performing the metal detection it is being ensured that products are placed on the moving conveyor belt one by one with sufficient space in between products, so that there is no overlap.
If goods are being shipped e.g. on hangers that are ferrous and cannot be passed through the metal detector, the goods are being taken off the hanger, passed through the metal detector and then re-hung. It is permitted for the hangers to be moved through the metal via a door. This process are controlling by the authorised person and only the correct amount of hangers per order are to be held at any one time, no spare hangers to be stored.
As a general guideline though garments be metal detected as last as possible in the production process and any ferrous metal items are being attached in the metal free zone, such as security tags, hangers etc.
The metal free zone are not being used for general storage and are being tidy. Once product is boxed or hung is to be taken to dispatch.
In case of stone washing the garments are being metal checked prior to washing as the pumice dust contains small metal particles that have an adverse effect to metal detection.
Any garments or part of a garment that are being outsourced for the application of a print, embroidery or any other process are being metal detected upon receipt back into the factory, prior to continuing production. This is to ensure that no whole or broken needle pieces, staples, other stray metals or sharp objects are in the returned pieces.
The factory are making sure that procedures are in place to ensure that all garments including repaired and re-inspected do not go to packing without being checked by the detector.
Clear separation and identification of the garments that are waiting to be checked and that are being checked to be strictly made.
Records are being kept for all garments that are passing through the metal detector and are being completed as product passes through the machine to verify compliance with this requirement.
If the alarm sounds, all garments on the halted conveyor belt are being put into a sealed bag, segregated and locked in a secure rejection box, to be located near the metal detector.
The rejection bin are being taken to a clearly marked area and thoroughly checked for contamination by the assigned person.
If the metal parts are found and the garment passes through the conveyor industrial metal detectors successfully, the garment can be returned to the bulk.
If the metal part cannot be found, the contaminated product are being put into a polybag with details clearly marked on it and then placed inside the rejection bin (s. photo) locked away from the factory floor and THE GARMENT ARE BEING DESTROYED after authorised sign off by the factory manager.
Under NO circumstances can it be returned to stock for shipment.
If a product is metal detected in its packaging, remove the packaging and detect the product and packaging separately as some packaging can contain traces of metal, especially if recycled, e.g. card, therefore may prevent the product being rejected.
The rejection bin are being locked with a designated person holding the key. The bin is having a slit at the top through which the garment can be passed through. The slit is being big enough to let the garment fit through, but small enough to avoid a hand fitting through it.
Any action is being recorded accordingly and any found metal parts are being taped securely to the metal detection failure record by sticky tape confirming source of contaminant and action taken to prevent future contamination.
Records of garment destruction are being kept for a minimum of 5 years for auditing purposes.
After the tested products are packed in a carton, the carton are being marked with a stamp stating date and ‘tested’.
Any products that are being returned from the storage area / warehouse to the sewing/finishing floor are being checked again with the industrial metal detector and the cartons must be re-stamped with date and ‘tested’.
Requirements on the metal detector machine and accessories:
There are 2 types of conveyor metal detectors:
General Purpose Metal Detectors, which detect all metals (use them for garments that do not have any metal components such as zippers, press studs, buckles etc.)
Ferrous Only Metal Detectors (use them to inspect garments that contain approved non-ferrous, non-magnetic components).
We recommend to use metal detectors that detect ferrous metals only, so that garments can be passed through the detector with metal components on such as zippers, press studs, buckles etc.
Please specify when ordering components that they need to be non-ferrous and non-magnetic.
A complete metal detection system comprises of a digital metal detector, conveyor belt, alarm reject system and test warning signal.
Any new metal detectors purchased must have a printer or production data recording facility to record calibration checks, the style numbers of product detected and contaminants detected.
The metal detector should be able to detect a metal part which is equivalent to a diameter of 1.2mm ferrous sphere at any point of the metal detector aperture at the supplied belt speed.
The sphere should be chrome steel of AISI 52100 grade with AFBMA GD 10 size tolerance mounted on a test card. Please only use approved test cards from nominated suppliers/manufacturers, do not make up your own! The test card must be available at all times with the metal detector it belongs to.
In case of garments with accessories, the metal detector must be capable of ignoring a representative sample of non-ferrous accessories and allowing it to pass undetected. In case of garments without accessories, the needle detector must at least ignore a non-ferrous test coin.
A sample to test your machine can be obtained from the machine manufacturer.
When passing the 1.2mm test card with the accessories or the test coin, the needle detector must detect the 1.2mm ferrous test card.
Machines must have an audible alarm with automatic belt stop in case any metal is detected. The conveyor belt must not be able to operate when the detector is faulty or switched off.
The audible alarm and conveyor belt should only be capable of being re-set by a key switch.
Metal detectors must be installed to the manufacturer’s guidelines and the manufacturer must approve the sitting of metal detectors.
Power fluctuation causes false alarms. Therefore the installation of a regulator will minimise the problem.
All metal components must be non-ferrous to pass through a ferrous metal detector.
Non-ferrous (non-detectable) and nickel free metal components (such as snaps, rivets, zippers etc.) should be used at all times and are mandatory for childrenswear to avoid false alarm during the detection. A special coating is applied to these components making them non-ferrous. Therefore it must be ensured that the trim supplier is alerted to deliver non-ferrous components for such garments.
The factory should check that this is the case by checking incoming items with a ferrous detector prior to attaching them in bulk.
Machine Location and Set-up:
The metal detector should be placed at the end of production (after all sewing operations, attachment of swing tickets and packing) in a so called airport system.
The detection machine should be positioned half into the packing area, then shielded and separated by a solid panel/wall (fence is not sufficient, as items can be passed through it), so the product ends on the other side through the machine in an isolated metal free zone/area. This is to eliminate any external interference and to avoid that goods can bypass the metal detection by mistake.
Please see photo for airport system:
Industrial metal detector location
The detector must be installed in a permanent location free of other metal objects like metal frames, doors, shelves etc. to avoid electrical interference.
It is recommended that the factory has at least 2 conveyor metal detectors at all times, to be able to carry on checking in case the one of them breaks down. It needs to be ensured though that any spare detector is in good working order and able to detect a metal part of 1.2mm ferrous sphere.
Best practice can be found in using 2 metal detectors placed at 90 degrees or even through a twin head metal detector. Position across the conveyor belt in a 9 point check.
Only authorised personnel should have a key that controls set-up and calibration of the machine. The key must not be left in the machine.
Only authorised and trained personnel should be operating and maintaining the metal detector. The training should be held by the manufacturer or an approved agent and trained staff should be able to make minor adjustments when needed. Records must be kept of all training, maintenance, servicing and repairs.
The operating personnel should be professionalised as full time workers.
An organisation chart with the names of people in charge and their photograph must be posted at this area (incl. the person in charge of the process as well as any other operators).
The metal detection policy must be translated into the local language, displayed where applicable and the management must ensure that workers fully understand the policy.
The policy should be part of your induction programme for new workers.
Cellular phones and other electronic devices must be kept away from the detector during operation. The supervisor should ensure that the assigned personnel must not wear clothing with pockets and should not wear items of metallic origin (e.g. wrist watches, rings, mobile phones, belts etc.) or carry a cellular phone while operating the machine.
Uniforms for the authorised workers working in the metal free zone should have a different colour to the rest of the factory.
The area the metal checked goods are going into, has to be a secured ‘metal free zone’ (so e.g. no clippers or scissors for cutting gum tape allowed), that is not too open and segregated/separated/isolated to avoid any possible contamination with the ongoing production.
The zone has to be declared and clearly marked as metal free and only authorised personnel should be allowed into the zone. This again should be clearly marked and communicated to everybody and personnel should be identified as authorised, e.g. through different coloured uniforms or ID cards.
The fencing of this zone should be solid, so that it can be avoided that metal objects can be passed through the fence and cause contamination.
Entry to this area must be restricted and monitored. No one should be allowed access carrying any metal tool, e.g. scissors, blades, clippers, needle, stapler and or spare metal components. Unauthorised personnel are prohibited from accessing the metal free area.
Anybody entering the metal free zone should be recorded with name, signature, in-time, out-time, purpose and signatures by person in charge & manager and again when leaving the area.
The entrance to the metal free zone should be locked during breaks and at the end of the day after ensuring that no one is left behind.
All product must pass through the metal detector into the secured ‘metal free zone’.
Once the product has passed through the metal detector, it must be placed in a designated quarantine area within the metal free zone until the following calibration check has been successfully completed, only then can the product be released from the quarantine area for further packing.
Packing can take place in this metal free zone, but no kimbal/tag guns should be used. Hangers can be inserted into garments and or put into the cartons in this area.
Tools which are used in the metal free zone should be numbered, recorded and kept at fixed places. The manager should check quantities of these tools before and after working.
Goods should be stored and kept in a metal free environment after the check is done and cartons are sealed.
Metal detection machine suppliers:
All the below suppliers are recommended and offer full calibration and maintenance service:
Conclusion:
In summary, records that are being kept to support the operation of the metal detector are: – Calibration checks of industrial metal detectors, – Style number, date and time of products metal detected – Contaminants detected and follow-up action taken. These records are being retained for 03 years after shipment in case of any legal claims. Furthermore Personnel Training Records are being kept, listing the responsible people who have received training in needle control and metal detector calibration procedure procedures. All records are fully completed at all times.
Label ironing machine is used to iron on labels or iron on transfer paper in label industry. The label ironing machine to iron on labels is equipped with best top-level AC motor ; SCHHEIDER inverter, torque at extra little speed and accuracy of speed, high flexibility of magnetic flux vector control. Synchronous motor control under open loop mode not only develops static speed accuracy it also saves electricity charge.
Feature of Iron on Name Labels Machine:
Iron on name labels machine is assembled with seamless steel pipe as well as hard chromium plating with benefits of dust free favorable heating transfer
Iron on name labels machine is assembled with imported high class heating pipe & the electronic thermostatic control panel with characteristics of fast temperature rise as well as temperature constancy
Iron on stickers label machine could be used after 10 minutes of electrifying by means of electric heating, it is suitable to operate and it need not additional raw materials
Iron on stickers label machine is equipped with multi tape mode and it is capable to process 6 labels tapes those are different in width at the same time, processing speed for one tape is 10-20m/min
Iron on name tags machine is adopted of always variable transmission box that enables it to regulate the speed as well as quality freely
Iron on name tags machine is adopting of precise electronic auto control that enables it to regulate the temperature smoothly as well as save sufficient electric energy.
Iron on Labels
Specification of the m/c to Iron On Labels for Clothing:
Specifications of the iron label machine to iron on labels for clothing is given below
The compactor machine is used in Textile Factory is a compaction machine used in textile finishing of apparel fabric. The compactor is a textile machinery which is used for knitted fabric like jersey, pique, interlock, plush, rib etc. as well as cotton blended fabric in rope form. The compactor is used for controlling shrinkage of fabric, GSM control and make compaction the fabric in length wise direction to provide over feed to the fabric while processing in presence of steam and able to control the shrinkage. The text compactor is used as finishing machine after dyeing. Open Width Compactor is used after Stenter Machine and Tubuler Compactor Machie is used after Industrial Dryer Machine.
Application of Compactor:
Text compactor is appropriate for compaction fabric for the felt boarding and pre-shrinking process of pure cotton, blended cotton and polyester tubular fabrics, the shrinkage of fabrics can be less than 4%. It also used for textile printing and general textile manufacturing in Textile company.
