The production process of needle textiles is a systematic industrial process that covers raw material preparation, spinning, weaving/knitting, dyeing and finishing, finishing, garment processing, and finished product inspection. The core links vary significantly depending on the product type (knitting vs. weaving). The following is a complete structured analysis of the process based on Chinese national standards and industry practices:
1、 Basic Process Framework
|Stage | Knitwear Process | Machine Weaving Process|
|1. Raw material preparation | Raw yarn (cotton, polyester, acrylic, etc.) warp and weft, ensure uniform tension, adapt to knitting machine feeding | Raw yarn warp and weft tube, twist and invert, distinguish warp and weft, and prepare for subsequent warp and weft|
|2. Yarn Making and Weaving | Weft Weaving: A single or multiple yarns are fed into a knitting needle from the warp direction to form a loop loop (such as T-shirts, underwear). Warping: Multiple sets of yarns are simultaneously looped along the warp direction, with a stable structure (such as curtains, medical fabrics). | Preparation of warp yarns: Warping → sizing (to improve wear resistance) → threading → weaving on the machine: warp yarns and weft yarns are vertically interwoven to form a woven fabric (such as shirts, trousers)|
|3. Dyeing and finishing treatment | Pre treatment (boiling, bleaching) → Dyeing (reactive/dispersed dyes) → Dehydration → Setting → Pulling/Grinding (depending on product requirements) | Pre treatment (desizing, refining, bleaching) → Dyeing (pad dyeing/roll dyeing) → Printing (circular mesh/digital) → Pre shrinking|
|4. Post functional finishing | Coating treatment for anti pilling, moisture absorption, quick drying, coolness, antibacterial, UV protection, etc. | Anti wrinkle and heat free, waterproof and splash proof, soft, glossy, and frosted treatment|
|5. Finished product inspection | Testing according to GB/T 22848-2022 "Knitted Finished Fabrics": color difference, bursting strength, pH value, formaldehyde content, washing size change rate | Testing according to GB/T 2660-2017 "Shirts", GB/T 2664-2017 "Men's Suits" and other standards: appearance defects, color fastness, size stability|
|6. Finished garment processing | Sewing of raw fabric pieces: cutting → sewing (overlock, lockstithing) → ironing → inspection of fully formed weaving: computerized flat knitting machine "one line finished garment", directly weaving complete pieces of clothing without cutting | cutting → sewing → ironing → inspection → packaging|
Note: Knitwear has natural elasticity due to its coil structure, making it suitable for close fitting clothing; The machine woven fabric has a tight structure and is suitable for stiff clothing. There is a significant difference in the manufacturing process between the two in the "ready to wear" stage.
2、 Industry standards and quality control
Core National Standards:
GB/T 22848-2022 "Knitted Finished Fabrics": applicable to weft knitted and warp knitted fabrics, with added provisions for color difference and drop, unified testing method for bursting strength, and strengthened safety limits for formaldehyde and pH.
FZ/T 73034-2021 "Semi precision Woolen Knitwear": Technical Requirements and Inspection Rules for Wool and Cashmere Blended Knitwear.
GB/T 22849-2024 "Knitted T-shirts" and GB/T 22853-2019 "Knitted sportswear": Set performance indicators for end products.
Environmental Protection and Intelligent Trends:
Color spinning adopts the "dyeing before spinning" process, which saves more than 60% of water compared to traditional "spinning before dyeing", reduces sewage discharge, and achieves green production.
3、 Typical Enterprise Practice Cases
|Enterprise | Process Highlights | Technical Applications|
|Huafu Fashion | Color spinning "three in one" system | Multi fiber color mixing, air flow spinning, vortex spinning technology, with an annual output of 290000 tons of new yarn, covering bases in Zhejiang, Xinjiang, and Vietnam|
|Lutai Textile | Intelligent Printing and Dyeing and Weaving | Automatic Combing Union, Intelligent Color Matching System, Non woven Machine, Achieving "One Click Color Matching and Precise Machine Operation"|
|Qinghe Shared Factory | Fully formed computerized flatbed machine cluster | 1700+flatbed machines achieve "first-line ready to wear", AI design → 3D ready to wear conversion in minutes, saving 50% of manual labor|