Circular Knitting Underwear Garments Making Plant
Traditional underwear garments were made by sewing two pieces of fabrics (bottom of under-paints and under-paints) together. The multi-layer sowing on bottom of under-paintssite made them uncomfortable to wear. The skin is easily damaged by abrasion with the sowing edges, and suffered from less ventilation from by thicker bottom of under-paints. For texture fitting, both inner and outer layers are synthetic fabrics with less elasticity and coverage; nonetheless, better appearance. Synthetic fabrics were used for better appearance.
We made no-bottom paints-paints are with the advantage of one-shape knitting type. Reduce wearing uneasiness from abrasion by removing sowing edge on the bottom of under-paints. In addition, better appearance without trace of sowing edge on heap while dressed in fitted slacks. Our products gives you more options in dressing slacks, praised by consumers in Taiwan & Japan, and with vast potential on international markets.
The inner layer adopts a special tower texturing with soft/fine/comfortable long fibers, better ventilation and better sweat-absorbing properties. Not only comfortable for wearing but also preventing germ growth. They are definitely good for personal hygiene and health. These products have with excellent elasticity, better fitting without tightness and coverage without folded-edges & dislocations. The new Y-hip and concertina products are with advantages of enhanced curve and abdominal shrinkage effects. The Y-hip product, by special design, at center of the hip knitted for bundle, good ventilation net partition, naturally fit on hip curve plus bilateral bundle, amazingly shape up the hip. Paints’ surface pattern structure was knitted in one time. Use electronic yarn feeder (made-in-Germany) to knit one-shape, concertina and no-bottom under-paints. They are cable to shrink waist and belly with even bundle, and not uncomfortable by excessiveness.
The whole process of knitting machine includes one-shape knitting, organizing, checking, shape setting and finish sewing. The manufacturing technology and equipment are mostly developed and/or made by us to simplify the manufacturing process and to reduce the manufacturing cost.
Wearing the underwear and under-paints made of cotton and/or nature fiber can absorb and expel skin moisture, sweat and secretion. It protects skin hygiene, and causes no adverse effect.
We made no-bottom paints-paints are with the advantage of one-shape knitting type. Reduce wearing uneasiness from abrasion by removing sowing edge on the bottom of under-paints. In addition, better appearance without trace of sowing edge on heap while dressed in fitted slacks. Our products gives you more options in dressing slacks, praised by consumers in Taiwan & Japan, and with vast potential on international markets.
The inner layer adopts a special tower texturing with soft/fine/comfortable long fibers, better ventilation and better sweat-absorbing properties. Not only comfortable for wearing but also preventing germ growth. They are definitely good for personal hygiene and health. These products have with excellent elasticity, better fitting without tightness and coverage without folded-edges & dislocations. The new Y-hip and concertina products are with advantages of enhanced curve and abdominal shrinkage effects. The Y-hip product, by special design, at center of the hip knitted for bundle, good ventilation net partition, naturally fit on hip curve plus bilateral bundle, amazingly shape up the hip. Paints’ surface pattern structure was knitted in one time. Use electronic yarn feeder (made-in-Germany) to knit one-shape, concertina and no-bottom under-paints. They are cable to shrink waist and belly with even bundle, and not uncomfortable by excessiveness.
The whole process of knitting machine includes one-shape knitting, organizing, checking, shape setting and finish sewing. The manufacturing technology and equipment are mostly developed and/or made by us to simplify the manufacturing process and to reduce the manufacturing cost.
Wearing the underwear and under-paints made of cotton and/or nature fiber can absorb and expel skin moisture, sweat and secretion. It protects skin hygiene, and causes no adverse effect.
2 General processing information
2.1 Description of manufacturing process:
Material→Knitting machine output→Dyeing→Shape Setting→Cutting→Sewing→Packaging→Outgoing of finished products
Use nature yarn as the material by patented equipment (no-bottom structure underwear knitting machine) to knit one-shape patterned Y-hip concertina and terry raw cloth. Through low temperature vat to dye, patented shape setting machine to set the shape, and to put in order. The Vertical cutting machine cuts tens of raw clothes each time. Use sewing machine to sew waistband or lace on, and pack them for outgoing.
2.2 Manufacturing Process Chart
2.1 Description of manufacturing process:
Material→Knitting machine output→Dyeing→Shape Setting→Cutting→Sewing→Packaging→Outgoing of finished products
Use nature yarn as the material by patented equipment (no-bottom structure underwear knitting machine) to knit one-shape patterned Y-hip concertina and terry raw cloth. Through low temperature vat to dye, patented shape setting machine to set the shape, and to put in order. The Vertical cutting machine cuts tens of raw clothes each time. Use sewing machine to sew waistband or lace on, and pack them for outgoing.
2.2 Manufacturing Process Chart
3 Description for turnkey equipment:
3.1 Machinery & equipment description
3.1 Machinery & equipment description
No.
|
Description
|
Q’ty
(Unit)
|
Function
|
Remarks
|
1
|
no-bottom paints-paints circle knitting machine (8”)
|
8
|
Knit raw cloth for no-bottom paints-paints
|
Patented Model:
F’22G; 6F
|
2
|
Circle knitting machine for no-bottom under-paints (10”)
|
2
|
Knit no-bottom under-paints raw cloth (male & female XL)
|
Patented Model:
6F’22G
|
3
|
Shape setting machine
|
1
|
Shape setting & sterilizing for cloth
|
Patented Model:
16-18 pieces per minute
|
4
|
Vertical cutting machine
|
1
|
Cut into shape
|
Cuts tens of pieces each time (should be purchased locally)
|
5
|
2-3 needle sewing machine
|
3
|
Sew waistband & lace.
|
Includes electronic lace feeder & special sewing device (Made in Japan)
|
6
|
Overlock stitch sewing machine
|
3
|
Sew borders
|
Should purchased domestically
|
7
|
4-needle overlock sewing machine
|
1
|
Sew borders
|
For no border underwear & under-paints
|
8
|
Overlock sewing machine
|
2
|
Overlock sewing & trade mark
|
Should purchased locally
|
9
|
Small vat dyeing machine
|
2
|
Raw cloth dyeing
| |
10
|
Dryer
|
1
|
Dry dye cloth
|
Dryer
|
11
|
Autoclave
|
1
|
Dyeing
|
 |
No-bottom underwear/under-paints knitting machine
|
 |
| Shape setting machine |
 |
Vertical cutting machine
|
 |
Sewing equipment
|
Needle detector — detect broken needles, in any.
3.3 Packaging specifications:
Standard sea cargo crates
Packaging dimension:
No-bottom underwear knitting machine
|
160*160*185 (CM)
|
Shape setting machine
|
450*150*170 (CM)
|
Cutting machine
|
200*150*170 (CM)
|
Sewing machine
|
130*50*100 (CM)
|
Number of staff & job description(s):
No
|
Part
|
No. Of Staff
|
Job description(s)
|
Remarks
|
1
|
Knitting machine
|
2
|
Maintain & operate knitting machine
|
(One shift)
Non-skilled
|
2
|
Maintenance technicians
|
2
|
Maintenance
|
Knitting machine technicians
|
3
|
Shape setting
|
2─4
|
Put raw cloth in order & shape setting
|
Non-skilled
|
4
|
Cutting
|
2
|
Cutting
|
Non-skilled
|
5
|
Overlock sewing
|
6
|
Overlock, waistband/lace & border sewing
|
Good vision
Sewing experience
|
6
|
QC & Packaging
|
4
|
Final QC & packaging
|
Non-skilled
|
Appendix: Patented Products
No
|
Patent Description
|
Taiwan Patent
|
ChinaPatent
|
Remarks
|
1
|
Multi-function circle knitting machine for no-bottom underwear & under-paints
|
New
53797 |
ZL
93244693.0
|
Can be modified to make topless suits & one-piece underwear
|
2
|
Circle knitting machine no-bottom under-paints with terry
|
48289
|
Patent pending
|
Can be modified to make topless suits & one-piece underwear
|
3
|
Surface pattern circle knitting machine for no-bottom underwear
|
52964
|
ZL
93200693.0 |
Can be modified to make topless suits & one-piece underwear
|
4
|
Auto tubular fabric feeding & shape -setting machine
|
61745
|
ZL
93200193.0 |
Shape setting with high temperature UV sterilization
|
5
|
Circle knitting machine for flexible sport knee & elbow support
|
83285
|
ZL
93207415.4 |
Also for ankle, wrist& lumbar support
|
6
|
Rubber yarn feeding device for circle knitting machine
|
81738
|
ZL
93207510.X |
Directly knit rubber yarn into fabrics
|
7
|
Modified no-bottom under-paints design
|
133388
|
ZL
94220062.4
|
Product pattern
|
8
|
No bottom concertina knitting method
|
Patent pending
|
ZL
98208060.3
|
Product pattern
|
9
|
Yarn feeding device for no-bottom knitting machine
|
Patent pending
|
Patent pending
| |
10
|
Needle structure for circle knitting machine
|
Patent applying
|
Needle improvement for better pattern knitting
| |
11
|
Circle knitting for no border underwear with bra
|
Patent applying
|
Patent applying
|
One-shape knitting for no-border female underwear with bra
|
12
|
Bag type no-bottom male under-paints
|
Patent pending
|
Patent pending
|
One-shape knitting for bag type no-bottom male under-paints
|
Raw material analysis: Prices are based on NT$ on Taiwan market.
Material
|
Price (NT$) / Kg
|
Content (%)
|
60 Combed Cotton
|
165
|
55
|
Fine Nylon
|
150
|
35
|
SPANDEX
|
220
|
10
|
● Raw material is around 40gm for each set of under-paints
● Direct raw material is around NT$7.50
● Content varies with different pattern designs; however, the content for most common design is used.
● Raw material can be adjusted according to customer requirements.
Accessories (for female under-paints)
● Direct raw material is around NT$7.50
● Content varies with different pattern designs; however, the content for most common design is used.
● Raw material can be adjusted according to customer requirements.
Accessories (for female under-paints)
Items
|
Width (cm)
|
Price (NT$) /Yard
|
Yard(s) / Each Use
|
Waistband lace
|
2.5
|
4.00-4.50
|
0.8
|
Bottom-band lace
|
1.2
|
2.00-2.50
|
1.2
|
Remarks:
● May use one-shape knitting to include waistband lace, so to reduce labor cost & time.
● Prices are based Taiwan market (Unit: NT$)
3.7 Power requirement & related facilities
Electricity (minimum): 20HP, 15KW
Water: 2000 Liters/Day
5hp & above air-compressor
Good air-conditioner & ventilation system
3.8 Manufacturing cost & profit analysis
Raw material and dyeing cost for each set of under-paints is around NT$15.00.
Annual capacity is around one million pieces (based on 100-150 Pieces/Unit/Shift, 10 units& 3 shifts per day).
Outgoing price is around NT$65.00 on the market.
3.9 Operation training & technology transfer
This company has a comprehensive operation-training program for operators (of sewing, cutting, mode & model making) and maintenance technicians. Training period is 20 days. The company will continuously provide new technology, design. Older models may be upgraded by replacing improved parts from the company. The company makes no reserve on technology transfer and assisting customers for further developments.
● May use one-shape knitting to include waistband lace, so to reduce labor cost & time.
● Prices are based Taiwan market (Unit: NT$)
3.7 Power requirement & related facilities
Electricity (minimum): 20HP, 15KW
Water: 2000 Liters/Day
5hp & above air-compressor
Good air-conditioner & ventilation system
3.8 Manufacturing cost & profit analysis
Raw material and dyeing cost for each set of under-paints is around NT$15.00.
Annual capacity is around one million pieces (based on 100-150 Pieces/Unit/Shift, 10 units& 3 shifts per day).
Outgoing price is around NT$65.00 on the market.
3.9 Operation training & technology transfer
This company has a comprehensive operation-training program for operators (of sewing, cutting, mode & model making) and maintenance technicians. Training period is 20 days. The company will continuously provide new technology, design. Older models may be upgraded by replacing improved parts from the company. The company makes no reserve on technology transfer and assisting customers for further developments.
4 Supplier Information Chi Ying Machine Enterprise
No. 28-1, Jen-Ai Road, Tu-Cheng City, Taipei, Taiwan
Tel: 886 (2) 22668865 , 886 (2) 22665218
Fax: 886 2 22664825
Contact person: Liu Shiu-Qui Liu Sjiu-Wen
E-MAIL: chiying.tw@msa.hinet.net
No. 28-1, Jen-Ai Road, Tu-Cheng City, Taipei, Taiwan
Tel: 886 (2) 22668865 , 886 (2) 22665218
Fax: 886 2 22664825
Contact person: Liu Shiu-Qui Liu Sjiu-Wen
E-MAIL: chiying.tw@msa.hinet.net
Start a Needle punch non-woven fabric production line
(122) Start a Needle punch non-woven fabric production line
Needle punch non-woven fabric production line is one kind of methods for producing non-woven fabrics.
In the process of producing, instead of using the traditional weaving process of the fabrics, the needle punch bond method uses triangle needles averagely punching in the cotton web to make the fibers directly tangle each other together ; controlling the density, intensity, and function of the fabrics by needle density, needle depth ,needle number, and other physical elements. No water, air, heat and chemicals are needed at all. It is a kind of pure physical and mechanical bonding method, saving energy and non-pollution.
Finished products maintain 100% yield form ram materials. It is the best green products for environmental protection. And finally it still can be 100% recycled by physical disposal, and can be reused.
The products made by needle punch bond method are with 3 dimensions’ (3D)effect, with excellent flexibility, and accessible to extension for processing into mold, Furthermore, it is with good ventilation, which the various traditional fabrics can’t be with. The same equipment can be used for various fiber materials, including artificial fiber, synthetic fiber, recycled fiber, inorganic fiber, and metal fiber. The scope of raw materials that can be used is wide and the products that can be produced are almost limitlessly diversified. According to individual industrial requirement, the fabrics can be made into various materials for their special functions. The range of usage is very extensive. It can be used for livelihood products, industrial products, hi-tech aviation. Industrial products, and even national defense industrial products.
Shoou Shyng (Model 1327) needle punch non-woven fabric production line is one kind of large professional machinery with diversified functions. The raw materials that can be used are the most common, lowest cost, and easiest accessible fibers, such as P.E.T., .P.P., Acrylic, Rayon and Nylons, as long as the fiber number is between 2-3 Din, length between 40-75mm. Either single material or mixed material can be used.
To meet the market requirement and productive logic, this equipment is set for the products of following five categories:
In the process of producing, instead of using the traditional weaving process of the fabrics, the needle punch bond method uses triangle needles averagely punching in the cotton web to make the fibers directly tangle each other together ; controlling the density, intensity, and function of the fabrics by needle density, needle depth ,needle number, and other physical elements. No water, air, heat and chemicals are needed at all. It is a kind of pure physical and mechanical bonding method, saving energy and non-pollution.
Finished products maintain 100% yield form ram materials. It is the best green products for environmental protection. And finally it still can be 100% recycled by physical disposal, and can be reused.
The products made by needle punch bond method are with 3 dimensions’ (3D)effect, with excellent flexibility, and accessible to extension for processing into mold, Furthermore, it is with good ventilation, which the various traditional fabrics can’t be with. The same equipment can be used for various fiber materials, including artificial fiber, synthetic fiber, recycled fiber, inorganic fiber, and metal fiber. The scope of raw materials that can be used is wide and the products that can be produced are almost limitlessly diversified. According to individual industrial requirement, the fabrics can be made into various materials for their special functions. The range of usage is very extensive. It can be used for livelihood products, industrial products, hi-tech aviation. Industrial products, and even national defense industrial products.
Shoou Shyng (Model 1327) needle punch non-woven fabric production line is one kind of large professional machinery with diversified functions. The raw materials that can be used are the most common, lowest cost, and easiest accessible fibers, such as P.E.T., .P.P., Acrylic, Rayon and Nylons, as long as the fiber number is between 2-3 Din, length between 40-75mm. Either single material or mixed material can be used.
To meet the market requirement and productive logic, this equipment is set for the products of following five categories:
1. Felt for garment and doll industries.
2. Base cloth for artificial leather P.U. or P.V.C.
3. Filter materials for air, water and bust.
4. Geotextile for civil engineering.
5. High absorbent cleaning cloth.
2. Base cloth for artificial leather P.U. or P.V.C.
3. Filter materials for air, water and bust.
4. Geotextile for civil engineering.
5. High absorbent cleaning cloth.
Considering for a wide variety of products with the machine equipment and production technique in common is the best condition, and the season and the territory for individual product should be also considered, in order that the production line can be adjusted to the best economic capacity, not to cause investment waste but to increase investment margin.
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2.2. Process Description
(A) Opening & Mixing
To process different type of fibers from bale stage, blended in the correct proportions by means of openers. The fibers are opened and dispersed for the preparation of carding process.
To process different type of fibers from bale stage, blended in the correct proportions by means of openers. The fibers are opened and dispersed for the preparation of carding process.
(B) Feeding
The fibers are blown from the opening machine which supply a predetermined Quantity to Cards by electric auto scale controlled system.
The fibers are blown from the opening machine which supply a predetermined Quantity to Cards by electric auto scale controlled system.
(C) Carding
The fibers fed into the carding machine are snared by the wire of rotating cylinder and fibers are aligned in an essential parallel direction. A web or net is formed on card and removed form the card by doffer to the cross lapper.
The fibers fed into the carding machine are snared by the wire of rotating cylinder and fibers are aligned in an essential parallel direction. A web or net is formed on card and removed form the card by doffer to the cross lapper.
(D) Crosslapping
Fiber webs layered to increase the fabric’s cross directional strength, thickness. weight , width and improve uniformity.
Fiber webs layered to increase the fabric’s cross directional strength, thickness. weight , width and improve uniformity.
(E) Web Feeding
Layered web can be adjusted to meet the standards of any specifications and delivered to needle punching by means of Web Feeder . The Web Feeder is to avoid the layered web to be deforming and tractility.
Layered web can be adjusted to meet the standards of any specifications and delivered to needle punching by means of Web Feeder . The Web Feeder is to avoid the layered web to be deforming and tractility.
(F) Preneedle Punching
The layered web are fed through a series of needle punching machines, the Preneedle Punching is to interlace the various layers each other with lower needle density. It is a preliminary 3D interleaving to entangle the fibers.
The layered web are fed through a series of needle punching machines, the Preneedle Punching is to interlace the various layers each other with lower needle density. It is a preliminary 3D interleaving to entangle the fibers.
(G) First Double Side Finish Needle Punching
The layered web are delivered by means of conveyor and rollers to first double side finish needle punching loom. The operation will make the web becomes the middle high density nonwoven fabric.
The layered web are delivered by means of conveyor and rollers to first double side finish needle punching loom. The operation will make the web becomes the middle high density nonwoven fabric.
(H) Second Double Side Finish Needle Punching
The applications of geotextile and filtration need high tensile and high entanglement nonwoven fabric. Special fibers have developed that permit them to be converted into soft, fine finish fabric to be high density structure.
The applications of geotextile and filtration need high tensile and high entanglement nonwoven fabric. Special fibers have developed that permit them to be converted into soft, fine finish fabric to be high density structure.
(I) Calender
After the fabric has been sufficiently interlaced by two times double side needle punching, the fabric can be fed through calenders to further compress.
After the fabric has been sufficiently interlaced by two times double side needle punching, the fabric can be fed through calenders to further compress.
(J) Slitting, Winding and Edge cutting
Nonwoven roll goods are converted in a variety ways, such as slitting to the widths required for end product converting , edge cutting for end product packing, and rewinding to prepare rolls of appropriate for product converting.
Nonwoven roll goods are converted in a variety ways, such as slitting to the widths required for end product converting , edge cutting for end product packing, and rewinding to prepare rolls of appropriate for product converting.
3. Plant Description
3.1. Production Capacity
A needle punch nonwoven fabric plant equipped with machinery and equipment in this proposal, operating 16 houra (2 shifts) a day, 25 days a month, should be able to produce the needle punched fabric as beiow.
Working With:3.6 Metera
End Product. With: 3.6 Meters
End Product Range of Weight: 150gsM~800gsM
Production Line Speed: 1.5~7.5 Meters/minute
Raw material spec:2d~15d
Maximum Capacity:
P.P 15d-250kg/hour
Polyester 6d-200Kg/hour
Rayon 3d-100Kg/hour
End Product. With: 3.6 Meters
End Product Range of Weight: 150gsM~800gsM
Production Line Speed: 1.5~7.5 Meters/minute
Raw material spec:2d~15d
Maximum Capacity:
P.P 15d-250kg/hour
Polyester 6d-200Kg/hour
Rayon 3d-100Kg/hour
3.2. Manpower Required
Job Classification
|
Person/Shlft
|
| General manager Staff Skilled Machining Operator Maintenance & Inspection |
1
2
4
2
|
| Total: |
9
|
3.3. Machinery & Equipment
Item
|
Set
|
| Bale Opening Machine Fiber Opening Machine Fiber Hopper Carding Machine Crosslapping Machine Preneedle Punching Loom First Double Side Needle Punching Loom Calender Slitting & Winding Machine Edge Cutting Machine |
2
2
1
1
1
1
1
1
1
1
|
3.4. Utilities
Electric Power Machine capacity 300KW , 3 Phases AC
380/220V , 60/50 HZ
380/220V , 60/50 HZ
Air 5 Kg/cm2 x 200 IB/min
3.5. Plant Site Planning
The needle punching non-woven production free industry , no need Water , steam and oil. The plant should be located in a district or an area where the production of various textile with a significant scope of future expansion.
3.6. Area of Land and Building
Item
|
Area Required (M2)
|
| Plant Raw Material Warehouse Finished Product Warehouse Production Line |
3,600
600
600
1800
|
The total area required for needle punching non-woven plant is shown as below.
Model-SPL-1327
Model-SPL-1327
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4. Supplier Information
Shoou Shyng Machinerty Co., Ltd
556-1, Chung Cheng Rd., Hsnchuang, Taipei
Tel: 886-2-29012245 Fax: 886-2-29041366
URL: http://www.shoou-shyng.com
E-mail: shoou@ms29.hinet.net
556-1, Chung Cheng Rd., Hsnchuang, Taipei
Tel: 886-2-29012245 Fax: 886-2-29041366
URL: http://www.shoou-shyng.com
E-mail: shoou@ms29.hinet.net
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