Theory and calculation of cover factor

The figure shows projected views of two woven cloths of different construction. At A the warp and the weft threads cover the area of the cloth only partially, but at B the cloth area is covered completely with no spaces left between the adjacent warp yarns, and it will be seen that the relative closeness of yarns in a woven cloth is dependent upon the ratio of yarn diameter, d, to yarn spacing, p. This ratio known as relative cover, can be defined as the proportion of a projected view of a given area of cloth which is covered by threads, and will have a scale from 0 to 1, although it may also be expressed as percentage cover with a scale from 0 to 100 per cent.

d/p = relative cover,
(d x 100)/p = percentage cover

It is preferable to express warp and weft relative cover separately, as the cumulative value of cloth cover does not indicate the comparative importance of each set of yarns which is essential for the determination of certain cloth characteristics.

From the relationship shown above it will be obvious that if d= p. the value of relative cover is one, and this is regarded as the theoretical maximum cover. In practice, however, this value can be exceeded  considerably in any one direction, either through yarn distortion, or, by forcing the threads into different planes, especially if the relative cover of the opposite set of threads is reduced correspondingly.
The relative cover for one thread system can be calculated as follows by considering an area of 100 x 100mm:

Area per thread = 100 x d
Area covered by n threads of one system = n x 100 x d
Therefore, relative cover = (n x 100 x d)/(100 x 100) = (n x d)/100

Example: 

The cloth represented at A is specified as follows: Warp — 25 tex cotton, 267 ends/100 mm; weft—36 tex cotton, 334 picks/100 mm. Find the relative warp and weft cover. (Subscript 1 refers to warp, subscript 2 to weft.)

Warp relative cover = (n1 x d1)/100
= (267 x (25)/(26.7))/100
= 0.50

Weft relative cover = (n2 x d2)/100
= (334 x (36)/(26.7))/100
= 0.75

MIXING (COTTON)

Cotton is a hygroscopic material , hence it easily adopts to the atmospheric airconditions. Air temperature inside the mixing and blowroom area should be more than 25 degree centigrade and the relative humidity(RH%) should be around 45 to 60 %, because high moisture in the fibre leads to poor cleaning and dryness in the  fibre leads to fibre damages which ultimately reduces the spinnability of cotton.

Cotton is a natural fibre. The following properties vary very much between bales (between fibres) fibre micronaire fibre length fibre strength fibre color fibre maturity   Out of these , fibre micronaire, color, maturity and the origin of growth results in dye absorption variation.
There fore it is a good practice to check the maturity , color and micronaire of all the bales and to maintain the following to avoid dye pick up variation and barre in the finished fabric.

BALE MANAGEMENT :

Bale Management

In a particular lot

• Micronaire range of the cotton bales   used should be same for all the mixings of a lot
• Micronaire average of the cotton bales used should be same for all the mixings of a lot
• Range of color of cotton bales used should be same for all the mixings of a lot
• Average of color of cotton bales used should be same for all the mixings of a lot
• Range of matutrity coefficient of cotton bales used should be same for all mixings of a lot
• Average of maturity coefficient of cotton bales used should be same for all mixings of a lot

Please note, In practice people do not consider maturity coefficient since Micronaire variation and maturity variation are related to each other for a particular cotton.

It the cotton received is from different ginners, it is better to maintain the percentage of cotton from different ginners throught the lot, even though the type of cotton is same.

It is not advisable to mix the yarn made of out of two different shipments  of same cotton. For example , the first shipment of west african cotton is in january and the second shipment is in march, it is not advisable to mix the yarn made out of these two different shipments.  If there is no shadevariation after dyeing, then it can be mixed.

According to me, stack mixing is the best way of doing the mixing compared to using automatic bale openers which picks up the material from 40 to 70 bales depending on the length of the machine and bale size, provided  stack mixing is done perfectly. Improper stack mixing will lead to BARRE or SHADE VARIATION  problem.  Stack mixing with Bale opener takes care of short term blending and two mixers in series takes care of long term blending.

why?

• Tuft sizes can be as low as 10 grams and it is the best way of opening the material(nep creation will be less, care has to be taken to reduce recyling in the inclined lattice)
• contaminations can be removed before mixing is made
• The raw material  gets   acclamatised to the required temp and R.H.%, since it is allowed to stay in the room for more than 24 hours and the fibre is opened , the fibre gets conditioned well.

Disadvantages:

• more labour is required
• more space is required
• mixing may not be 100% homogeneous( can be overcome by installing double mixers)

If automatic bale opening machine is used the bales should be arranged as follows:

let us assume that there are five different micronaires and five different colors in the mixing, 50 bales are used in the mxing. 5 to 10 groups should be made by grouping the bales in a mixing so that each group will have average micronaire and average color as that of the overall mixing. The position of a bale for micronaire and color should be fixed for the group and it should repeat in the same order for all the groups

It is always advisable to use a mixing with very low Micronaire range.Preferably .6 to 1.0 . Because:

• It is easy to optimise the process parameters in blow room and cards
• drafting faults will be less
• dyed cloth appearance will be better because of uniform dye pickup etc

It is advisable to use single cotton in a mixing , provided the length, strength micronaire ,maturity coefficient and trash content of the cotton will be suitable for producing the required counts.  Automatic bale opener is a must if more than two cottons are used in the mixing, to avoid BARRE or SHADE VARIATION problem.

It is better to avoid  using the following cottons:

• cottons with inseparable trash (very small size), even though the trash % is less
• sticky cotton (with honey dew or sugar)
• cotton with low maturity co-efficient

Stickiness of cotton consists of two major causes. Honeydew from Whiteflies and aphids and high level of natural plant sugars. The problems with the randomly distributed honey dew contamination often results in  costly production interruptions and requires immediate action often as severe as discontinuing the use of contaminated cottons.An effective way to control cotton   stickiness in processing is to blend sticky and non-sticky cotton.  Sticky cotton percentage should be less than 25%.

Process Flow Chart of Denim Manufacturing | Manufacturing Process of Denim Garments

Flow Chart of Denim Production:

Spinning 
↓ 
Bale Warping 
↓ 
Rope Dyeing 
↓ 
Long Chain Beaming 
↓ 
Sizing 
↓ 
Weaving 
↓ 
Finishing 
↓ 
Inspection & Folding 
↓ 
Packing 
↓ 
Dispatch

Manufacturing of Denim:
The term "Denim" has originated from the city of Nimes in France where "serge de Nimes" was manufactured. Denim is made from a vat dye, the Indigo dye, which is applied to cotton fabric in loosely held form in layers. As far as manufacturing process of denim is concerned, it is similar to that of Grey fabric up to the process of weaving with the only difference that in case of Denim Fabric, it is dyed at the stage of sizing where as in case of Grey Fabric, the decision regarding dyeing stage depends upon the finished product. The details of each process are given below:

Spinning:
The initial stage of denim production is Opening and Blending. Opening begins with baled cotton fiber being separated into small tufts. A blend of cotton fibers is made on each opening line. These bales are selected using USDA High Volume Instrument (HVI) data, and PCCA's unique computer blending software produces optimal yarn strength.

Cotton is delivered by air suction from the Opening and Blending lines, through additional cleaning and blending machines, to the Cards. The major functions of Carding are to remove foreign matter and short fibers, form the cotton into a web and convert the web into a rope-like form known as a sliver.

The drawing process produces a single, uniform sliver from six card slivers. The additional blending, paralleling of fibers and cleaning in this process produces a sliver for Open End and Ring Spinning. For Ring Spinning, however, the sliver must pass through an additional process called Roving.

Cotton Fibers are formed into a yarn by centrifugal action in Open- End Spinning. Individual fibers are laid down in the groove of a fast spinning rotor and twisted into yarn. After the cotton fibers are spun into yarn, the yarn is wound into a large package.

Open End Spinning: 
The Open End Spinning Machines have robots on each side which automatically pieces up (repairs broken ends). On a different track, they have another robot that automatically doffs (removes full packages) and starts up a new package. The size and quality of each yarn end are monitored by the Barco Profile System to ensure uniformity.

Ring Spinning:
In Ring Spinning, the spinning frames receive Roving via a transit system from the roving machine. Yarn is formed from cotton fibers that are twisted together after being drafted by passing between three steel rolls and three rubber rolls. The yarn then is wrapped on a bobbin as it spins on a spindle by use of a traveler. The relationship between roll speeds, traveler speeds and spindle speeds controls the amount of twist in the yarn. Ends down levels and production information are gathered by the Uster Ring Expert System. The spinning frames automatically doff bobbins full of yarn and send them to package winding.

ACG also has the capacity to produce Amsler Open-End yarn, also known as Faux Ring Spun yarn. This technology enables ACG to impart various slub patterns into an Open-End yarn. Denim made from this type of yarn has yarn character and surface interest that cannot be achieved with traditional Open-End yarn.

Fabric Weaving:
a. Grey Yarn on Cones:
Normally yarns received for weaving in cone forms are either from ring spinning or from open end spinning in single or double fold as required. For weaving, yarn used is categorised into:

• Warp yarn
• Weft yarn

Normally for Weaving, yarn used as warp should be sufficiently strong to withstand stress and strains exerted during weaving operations. Hence they are having Count Strength Product(CSP) and further sized to increase its strength. The weft yarn is directly used on weaving machines and in some cases, if required, is rewound also so as to enhance its performance in weaving.

b. Warping on Sectional/ Direct Warping:
The warp yarn is required to be fed into a sheet form to the weaving machines. At warping, the individual cones are put into the creel (the number of cones depends upon fabric construction) and yarn from individual cones is pulled together in sheet form, wound on a barrel called warping beams (for Direct warping) or on weaving beams (for Sectional Warping). Normally if warp sheet is with patterns of different coloured yarns it is processed on sectional warping machine.

c. Sizing of yarn in Set/ Beam to Beam Position:
The object of Sizing is to improve the strength of yarn by chemically binding the fibres with each other and also improve upon its friction resistance capacity by chemically coating the surface of yarn/fibres. Further, number of threads in warpers beam sheet is very less against number of threads required in whole width of fabric. Hence multiplication of sheets by drawing yarns together from many warp beams and again making one sheet is also performed on sizing machine. On sizing, normally, 8-12 % size material on warp thread is applied. This improvement in strength and frictional resistance characteristic of warp yarn is essential because during weaving, yarn has to undergo severe strain & stress as well as frictional operations.

d. Drawing–in:
Weaving is basically interlacement of two sets i.e. warp and weft threads in desired sequence and pattern. To obtain this interlacement, warp yarn sheet is bifurcated & opened in the form of two layers/ sheet and weft thread is inserted between so opened two warp sheets. This operation is called shedding. to perform shedding the warp yarn needs to be passed through heald eyes of the heald shafts, this operation is called as drawing-in.

e. Beam Gaiting or Knotting on Loom:
The drawn weavers beams are fixed on weaving machines, threads are tied and heald shafts are coupled. This operation is called Beam Gaiting. If undrawn warp threads are directly knotted to the threads of finished beams, it is called Knotting. These operations are essential because normally weavers beam can carry only certain length of warp sheet on it and when so woven, whole length is converted to the fabric by weaving machine. Further warp length is required to be fed which can be done by knotting or gaiting other beams on weaving machine.

f. Weaving:
As stated earlier, weaving is interlacing two sets of yarn and making fabric. One set is called warp thread which is in sheet form, the other one is called weft thread which is inserted between two layers of warp sheet by means of a suitable carrier i.e. Shuttle, Projectile, Rapier, Air current, Water current, etc. Depending upon the type of the weaving machines. The different types of technologies available for weaving machines are briefly explained as below:

• Conventional Shuttle Weaving System by Ordinary Looms or Automatic Looms.
• Shuttle less Weaving System by Airjet /Waterjet/Rapier/Projectile

Shuttle loom is a conventional Technology with much less production on account of slow speed and excessive wear and tear of machinery. This shuttle loom technology has now become obsolete. Denim is woven through Shuttle less Weaving System by using 96 ZAX-e Type Tsodakoma Corporation’s Airjet looms or rapier looms or projectile looms. These looms are distinguished by weft insertion method, which is briefly discussed hereunder.

Airjet Looms:
These types of looms adopt the latest development in Weaving Technology where weft insertion is done with the help of compressed air. A very high weft insertion rate up to 1800 metre per minute is achieved. Compared to rapier and projectile looms, these looms are less versatile but are economical and are used in mass textile production unit like denim.

Finishing: 
a. Grey Fabric:
The finally woven fabric or Grey Fabric, as it is popularly called, wound on a cloth roll is taken out from weaving machines at certain intervals and checked on inspection machines for possibilities of any weaving fault. If such faults are seen anywhere in fabric during inspection, certain corrective steps are taken at weaving, warping, sizing, etc so that they can be minimised in subsequent product. This is a quality control exercise.

b. Denim Fabric:
Denim Fabrics woven of 100% cotton would be very strong and durable. Traditionally Blue Denim is warp faced cotton fabric with 3 x 1 twill construction with warp being dyed in a solid colour and weft left un-dyed. The look and quality of the Denim Fabric shall improve after dyeing, the process of which differs from plant to plant. Normally the process of dyeing dictates the technology of Denim manufacturing.

The dyeing for Denim Fabric happens at the sizing stage. Generally there are two most popular methods of dyeing Denim Fabric. They are:

• Rope Dyeing
• Sheet Dyeing

A company can adopt any of the methods. In countries like India Sheet Dyeing Method is commonly used for manufacture of its Denim Fabrics, which has following advantages over Rope Dyeing Method:

• The technology is less capital intensive.
• The technology is a proven one.
• The cost of production is lower.
• The process time is lower.
• The Sheet Dyeing machines are very easy to operate.

The only defect in Sheet dyeing is that their is a problem of center to selvedge shade variation.

c. Sheet Dyeing Process:
This process eliminates a few intermediate processes of the rope dyeing. The yarn sheet is washed with chemicals such as caustic and washing soda and after squeezing the excess water; the yarn sheet is allowed to pass through Dyeing Troughs one time for oxidation and development of dye on yarn. After dyeing, the dyed yarn is washed again with fresh water for two-three times and finalIy squeezed before allowing it to pass through six drying cylinders. The dyed yarn enters the starching device and sizing is done. After sizing, the sized warp beam goes for weaving. After weaving, the woven Denim Fabrics goes for various finishing processes consisting of brushing, singeing, washing, impregnation for dressing and drying. Brushing and singeing should eliminate impurities and help to even the surface of the fabric. Dressing regulates the hand and rigidity of the fabric while compressive shrinking regulates its dimensional stability.

Even today Denim Fabric without Indigo Dyeing is not called authentic Denim. Initially when Denim Fabric entered the fashion market, Denim manufacturers were using Natural Indigo Dye, which was costly and giving a natural finish. Though Synthetic Indigo Dye has gradually replaced Natural Indigo Dye, some unorganised manufacturers still prefer the latter and attract premium after branding them “Natural Dye Used”.

d. Making-Up:
Weaving of fabrics on such multi sizes is not economical, hence a standard width fabrics is then sent to making up. Fabrics are cut into the desired width as per size required on this machine. Denim Fabric and Grey Fabric are thoroughly checked for various types of defects such as:

• Weaving Defects
• Uneven Dyeing
• Bleaching and Dyeing Defect
• Oil Stain
• Patches

Here the final product is categorised quality-wise. The products then found okay are segregated and sent to packaging department whereas defective ones are sent for correction. After inspection, the sets are wrapped with polythene covers and sent for despatch as per buyer’s specifications.

Dispatch:
Rolls and sets so formed and packed as per buyers’ requirements are then sent for final despatches.

Denim Washing | Types of Denim Washing | Process of Denim Washing

Denim Washing:

Denim washing is the aesthetic finish given to the denim fabric to enhance the appeal and to provide strength.

Dry denim, as opposed to washed denim, is a denim fabric that is not washed after being dyed during its production.

Denim washing

Much of the appeal of dry denim lies in the fact that with time the fabric will fade in a manner similar to that which artificially distressed denim attempts to replicate. With dry denim, however, such fading is affected by the body of the person who wears the jeans and the activities of their daily life. This creates what many feel to be a more natural, unique look than pre-distressed denim.

Types of Denim Washing:
Denim washing are two types. These are

1. Mechanical washes:

• Stone wash
• Micro sanding

2. Chemical washes:

• Denim bleaching
• Enzyme wash
• Acid wash

Some Important Steps in the Process of Denim Washing:
 1. Pre treatment ( Desizing, Rinsing, Scouring etc)
2. Enzyme or Stone wash
3. Clean up to adjust the desire effect
4. Bleaching
5. Tinting / Dyeing
6. Sand Blasting
7. Softening & Much more…..

Jute Products Manufacturing Process

Jute Fiber:
Jute fiber is a natural bast fiber. It is one of the most affordable natural fibers and is second only to cotton in amount produced and variety of uses of vegetable fibers. It is harder than other textile fibers. It is environment friendly. Normally jute are used for sacking, burlap, and twine as a backing material for tufted carpets. 

Jute plant

Chemical Composition of Jute: 
Jute is composed of 65% cellulose and 35% natural wages, oils and cements (lignin).

The chemical composition of jute is given below: 

• Cellulose....................................... 65.2%
• Hemicelluloses ...............................22.2%
• Lignin ............................................10.8%
• Water soluble ................................1.5%
• Fat and wax ..................................0.3 - 1.0%

Classification of Jute: In accordance with color jute is two types 

1. White jute (Corchorus capsularis)
2. Tossa jute (Corchorus olitorius)

Classification of jute according to the quality (Geographical distribution according to Bangladesh): 

1. Jat
2. District
3. Northern

Common Defects Found in Jute: Specky Jute:If the Jute Fibers are not rotted and washed properly; the barks of jute adhere to the fibers and causes them speck. Speck in jute is a major defect of jute which lowers the quality of Jute fibers.

Defect in jute

Rooty Jute: 
This kind of Jute Defects occurs due to various reasons such as under retting of the root ends of Jute fibers and if the root portion is not completely under water during ratting.

Croppy Jute: 
If the top end of the fibers is rough, black and hard then stripping is insufficient which causes croppy jute.

Knotty Jute: 
This kind of knotty jute defects is caused by insect bite in the jute plants.

Hunka: 
This type of Jute is hard and barky caused by insufficient removal of hard bark from jute.

Mossy Jute: 
Mossy grows in stagnant of water. The mosses adhere to the Jute fibers causing Mossy Jute.

Glossy Jute: 
Highly lustrous jute fiber sometimes creates problems. This kind of highly lustrous jute fiber is named as Glossy Jute.

Flabby Jute: 
Hairy Jute fiber defects are created due to over retting and careless stripping of Jute.

Runners: 
Long hard and broken ribbon like fibers caused careless stripping and washing.

Dazed Jute Fibers: 
The Jute fibre which has lost it’s strength and luster due to over retting or excessive moisture in it.

Heart Damage: 
This kind of defects caused for badly damage rotten or tendered fibers.

Weak fibers: 
Over retting is the main cause of weak fibers, also due to under drying and sorting in moist condition.

Sticky or Woody: 
In the top end at the jute plant is not stripped properly from the fiber, the brow pieces of the plant remain the fiber ceurecl this defect. It is due to over retting of lower part of the plant is under retting of lower part of the plant is under retting of the top end.

Flow Chart of Jute Spinning:
 Due to its worldwide demand different country manufacture jute goods. Jute goods produce by a line of sequence. Its manufacturing process is completely different from cotton. By the following way jute goods are produced: 

Selection of jute for a batch
                                       ↓ (According to jute grade) 
Piecing up
↓
Softening or Lubricating
                                               ↓ (Application of emulsion on jute) 
Conditioning or Piling
                                           ↓ (Piling of jute for certain time) 
Breaker Card
                                                       ↓ (Inter Card is used between this two) 
Finisher Card
                                            ↓ (It may be half or full circular) 
First Drawing Frame
↓
Second Drawing Frame
↓
Third or Finisher Drawing Frame
↓
Jute spinning
↓
Winding
↓
Beaming
↓
Weaving
↓
Dumping
↓
Calendering
↓
Lapping
↓
Cutting
↓
Hemming
↓
Herackele sewing
↓
Bailing
↓
Export

Selection: 
In the selection process, raw jute bales are opened to find out any defect and to remove the defective portion from the mora by experienced workers. Raw jute bales are of two types i.e. 150 kg weight and 180 kg weight with or without top portion cutting. 

The bales are assorted according to end use like Hessiean weft, Sacking wrap, Sacking weft etc. After selection, jute bales are carried to softning section by workers called Gariwala and Bajawala.

Batch & Batching 
A number of bales of jute selected for the purpose of manufacturing a particular type of yarn in known as batch.

Batching cover all the process preparatory to carding. The main purpose of batching is to add oil and water to make the jute fiber flexible, soft and stiff free.

Softening 
In softening process jute morahs are made soft and pliable. Two methods are used for softening; use of softening machine and use of jute good spreader. Generally an emulsion plant with jute softener machine is used to lubricate and soften the bark and gummy raw jute. The emulsion plant consists of gear pump, motor, vat, jet sprayer, nozzles, emulsion tank and the jacket. In this softening process jute becomes soft and pliable and suitable for carding.

Conditioning or Piling and Pile Breaking Conditioning or piling refers to the rest stage, in which jute is given after the water and oil have been applied. It lasts longer with low grade batching to allow the hard barky root material to become softened before passing on the cards.

The main function of pile breaker is to break the pile and serve it to the carding machines. The softener machine output material carried by pilemen through bile to the pile place for pilling. During piling superficial moisture penetrates inside Fiber and "Thermo fillic" action take place which softener the hard portion of the root. After piling for nearly 24 hours the pile breakers carry the material to the carding machine.

Jute Carding 
The process by which long reeds of jute while passing through high speed pinned roller and broken down into an entangled mass and delivered in the form of ribbon uniform weight per unit length called jute carding.

There are three different carding sections: 

1. breaker carding
2. inner carding
3. finisher carding

Breaker Carding 
In the Breaker carding machine soften jute after piling is feed by hand in suitable weight. The machine by action with different rollers turns out raw jute in the form of jute sliver for finisher carding. In this process root cutting is necessary before feeding the material to the hand feed breaker carding machine.

Finisher Carding Finisher carding machine make the sliver more uniform and regular in length and weight obtained from the Breaker carding machine. Finisher carding machine is identical to the Breaker carding machine, having more pair of rollers, staves, pinning arrangement and speed. Nearly 4 to 12 slivers obtained from Breaker carding machine is fed on this machine. The material thus obtained is send to drawing section.

Jute Drawing: 
Drawing is a process for reducing sliver width and thickness by simultaneously mixing 4 to 6 sliver together. There are three types of Drawing Frame machine. In most mills 3 Drawing passages are used in Hessian and 2 Drawing passages are used in Sacking.

First Drawing The slivers obtained from finisher carding machine is fed with four slivers on to the first drawing frame machine. The first drawing frame machines makes blending, equalising the sliver and doubling two or more slivers, level and provide quality and color. This machines includes delivery roller, pressing roller, retaining roller, faller screw sliders, check spring, back spring, crimpling box etc..

Second Drawing In second drawing, the Second Drawing Frame machine obtain the sliver from the First drawing machine and use six slivers and deliveries per head. The Second Drawing machine makes more uniform sliver and reduce the jute into a suitable size for third drawing.

Third Drawing 
In the third drawing, the Third Drawing frame machine uses the sliver from second drawing. The Third Drawing machine is of high speed makes the sliver more crimpled
and suitable for spinning.

Jute Spinning: Spinning is the process for producing yarn from sliver obtained from Third drawing. The jute spinning frame machine is fitted with slip draft zone and capable of producing quality yarns at high efficiency with auto-doffing arrangements also.

Winding : 
Winding is a process which provides yarn as spools and cops for the requirement of beaming and weaving operations. There are two types of winding : 

1. Spool Winding
2. Cope Winding

Spool Winding 
In Spool Winding yarn is produces for warp (the longitudinal yarn). Spool winding machine consists of a number of spindles. There is wide variation in the number of spindles per machines from one make to another. Productivity of spool winding depends on the surface speed of the spindle and machine utilisation. 

Spool winding machine uses the bobbins contain smaller length of yarn. This machine wound the yarn into bigger packages known as 'spool'. The Spool are used in making sheets of yarn to form warp portion used during interleecment of weaving. 

Cop Winding 
Cop Winding machine obtain yarns from the spinning machines. The spinning bobbins is placed on a suitable pin on top of the cop machine and yarn tension is maintained by means of a small leaver. The yarn on the bobbins are cnverted into hollow cylindrical package said to be cop. The cop is used to form Transverse thread during interlacement of weaving. Generally a cop winding machines consist 120 spindles. 

Beaming : 
Beaming process is follows after spool winding. In Beaming operation yarn from spool is wounded over a beam of proper width and correct number of ends to weave jute cloth. To increase the quality of woven cloth and weaving efficiency, the wrap yarns are coated with starch paste. Adequate moisture is essential in this process.

Quality characteristic of a beam is width of beam - number of ends and weight of stand and there is a continuous passage of yarn through starch solution from spools to the beam. 

Strach solution in water contains tamerine kernel powder (TKP), antiseptic - sodium silica fluride (NaSiF4) and its concentration varies with the quality of yarn. 

Weaving : 
Weaving is a process of interlacement of two series of threads called "wrap" and "weft" yarns to produce the fabric of desired quality. There are separate looms for hessian and sacking in weaving section. The Hessian looms, shuttle which contents cops (weft yarn) is manually changed. The sacking looms are equipped with eco-loader to load a cop automatically into the shuttle.

Dumping : 
Dumping is the process in which the rolled woven cloth is unrolled and water is sprinkled on it continuously to provide desired moisture. Each roll is generally104 yards or 95.976 meters. Damping is done manually. 

Calendering : 
Calendering is a process similar to ironing of fabric. After damping the damped fabric passes through pairs of heavy rollers rendering threads in fabric flattened and improve the quality and appearance. 

Lapping : 
Lapping is the process in which Hessian fabrics are folded into the required size used in "Bale press" operation on the lapping machine. 

Cutting : 
Cutting is the process where the sacking cloth is cut to the required length for making bags for different size such as A-Twill bags and B-twill bags of 100 kg capacity.

Hemming : 
In Hemming process, the raw edges of sacking cloth cut pieces are shown by folding it with sewing machine.

Herackele Sewing : In Herackele sewing the sides of sacking cloth cut pieces are shown to make a complete bag.

Bailing : Bags or Bale processing cloths are pressed compactly according to buyers need.

Export: 
Export jute a goods per buyer requirements 

Advantages and Disadvantages of Jute Fiber:
Advantages of Jute Fiber: 

1. Jute Fiber has great antistatic properties; so that any kind of static charges are not produced during Jute Product making or using.
2. Jute is an insulating fiber and this is why it can be used to make cloth which would be used in electrical works.
3. Temperature is passed in this fiber slowly because of the low thermal conductivity.
4. Moisture Regain properties is good enough (about 13.75%).
5. Produce no irritation in skin.
6. 100% Biodegradable; so it is environment friendly fiber like Cotton.
7. Cheap in market.
8. Available in the market and the overall productivity of Jute Fiber is good.
9. Tensile strength is high.
10. Jute Fabric is highly breathable and comfortable to use.
11. Can be widely used in Agriculture Sector, Textile Sector, Woven Sector, Nonwoven Sector.
12. Jute Fiber can be blended with Natural and Synthetic fibers.
13. Can be died by Basic, Vat, Sulpher and Reactive Dyes.

Disadvantages of Jute Fiber:

1. The crease resistance of Jute is very low.
2. Drape Property is not good enough.
3. Create Shade effect and becomes yellowish if sunlight is used.
4. If Jute is wetted it loses its strength.

Uses/Applications of Jute in Textile & Practical Life: 

1. Jute is a fiber which has almost 1000 different kind of uses. Jute has been taken as most important fiber like as cotton as it can be used in various purposes and easy to cultivate too.
2. Jute sacks are widely used in the practical life and coarse fabric made by Jute has no substitute ever. The wrapping bales or raw cotton also made by Jute.
3. As Jute is completely a biodegradable Fiber; it is suitable for many uses if it is replaced in so called synthetic fiber. Synthetic fiber is very unstable and sometimes impacts badly on the natural environment where Jute is quite good alternatives to use.
4. Jute fiber can be blended with other natural and cellulosic fiber like Cotton and make a quite stable and different blended yarn which is stronger and shiner.
5. Jute is not only used to make yarn or cloth but also it is used to make Jute Pulp and paper. As the people of the world are being so much conscious now and trying to stop the cutting wood or plants to save the nature; Jute is drastically being used as the alternative of Wood in the Paper manufacturing Industry.
6. Jute has a bright history of use in making sackings, carpets for the households and so on, cotton bale and wrapping fabrics for that and various fabric manufacturing industry in order to make mats, curtain, brush and etc.
7. Now a day Jute is not only being used in Textile industry; but also it is used in Automobile Industry, Furniture and bedding industry and Paper Making industry.
8. Jute is also being blended with other fibers to make non-woven, composites and technical textiles. The nomenclature of Jute is “Wood Fiber” which is exclusively being used on the leading manufacturing industries with some promising features.
9. By using Jute we can produce various type of fabric named Hosiery Cloth, Hessian Cloth, Sacking, Scrim, Carpet Backing Cloth, canvas etc.
10. Hessian is lighter than sacking and is used for bags, wrappers, wall covering, geo textiles, upholstery and different home furnishing. By using the Heavy jute fibers the Sacking is to be made.
11. Jute has diversified uses now a days. Some of the exclusive and modern use of Jute is in Espadrilles, Floor coverings, Home textiles, high performance technical textiles, geo textiles, composites, and more.
12. Due to the strong color and light fastness properties; just is widely used in decoration of home. Jute is more durable than any other fiber because of its anti-static properties and low thermal conduction.
13. Most importantly; Jute is a bio-degradable fiber which comes from nature and decomposed on nature too. So it’s an environment friendly fiber for the green people to access the green world