How It's Made Fabrics

Summary

This video script details the intricate process of fabric production. It begins with 700 polyester bobbins, each holding 250,000 meters of thread. The threads are separated, braided, and treated with glue before being woven on a jacquard loom, resulting in a 3.65-meter-wide fabric. The fabric undergoes washing at 80 degrees, dyeing for six hours, and thermal setting at 200 degrees. The final product is a high-quality fabric, showcasing the meticulous craftsmanship involved.

Takeaways

• 🧵 Fabric is produced by braiding thousands of threads, with each mill having 700 bobbins of polyester thread.
• 🔢 Each bobbin contains an impressive 250,000 meters of thread, which is equivalent to 250 kilometers.
• 🌐 The process starts with separating threads and assembling them with a warp unit, creating a total of 7,000 aligned threads.
• 🕸 The warp threads run lengthwise, while weft threads are added transversely to prevent tearing.
• 🧻 Threads are coated with glue to strengthen them, which is later removed with water before dyeing.
• 🔥 The large green cylinders heat and dry the glue on the threads, preparing them for knitting.
• ✂️ A specific design is produced by each thread passing through a blade on a highly precise machine.
• 🌀 A jacquard type loom uses air jets to insert the warp thread, creating a fabric 3.65 meters wide.
• 📏 The loom operates at high speed, making 600 thread intersections per minute.
• 🛠️ If a thread breaks, the machine has a breakage chain plate to stop the process, ensuring quality control.
• 🧼 After weaving, the fabric undergoes washing in a soapy solution at 80 degrees, followed by rinsing.
• 🎨 Dyeing is performed with jets, soaking the fabric in a solution with colorants for about six hours.
• 🔑 An opener machine unfolds and stretches the material before rolling it up on a large roller.
• ♨️ The final step is thermal setting in a high-temperature oven at 200 degrees Celsius for 45 seconds to dry the fabric.

Q & A

What material is used to make the fabric in the script?

The fabric is made from polyester threads.

How many meters of thread does each bobbin contain?

Each bobbin contains 250,000 meters of thread.

What is the purpose of the comb in the fabric-making process?

The comb separates the strands of thread to align them properly before weaving.

How many strands of thread are used in total for the fabric?

In total, there are 7,000 strands of thread used for the fabric.

What is the role of glue in the fabric-making process?

Glue is used to prevent the threads from tearing and to hold them together before dyeing. It is removed with water later.

How does the loom produce a specific design in the fabric?

The loom uses a blade to separate the 700 strands and produce a specific design as the threads pass through it.

What is the width of the fabric produced by the weaving machine?

The fabric reaches a width of 3.65 meters.

How many weft strands are inserted per minute during the weaving process?

600 weft strands are inserted per minute.

What is the purpose of the washing step in the fabric-making process?

Washing is done to clean the fabric in a soapy solution at 80 degrees before dyeing.

How long does the fabric soak in the dye solution during dyeing?

The fabric soaks in the dye solution for about six hours.

What is the final step in the fabric-making process described in the script?

The final step is thermal setting in a high-temperature oven at 200 degrees Celsius for 45 seconds.

Outlines

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🧵 Fabric Production Process

This paragraph details the initial stages of fabric production, starting with the braiding of thousands of polyester threads from 700 bobbins, each containing 250,000 meters of thread. The process involves separating and assembling the threads using various machines, including a warp unit and a comb. The threads are then treated with glue to prevent tearing, which is later removed before dyeing. The paragraph also describes the weaving process on a jacquard loom, where 7,000 strands are used to create a fabric 3.65 meters wide, with 600 weft strands inserted per minute.

Keywords

💡Fabric

Fabric refers to a material made by weaving or knitting fibers together. In the video, fabric is the main product being manufactured, starting from threads made of polyester. The process of creating fabric is central to the video's theme, showcasing the transformation of raw materials into a finished textile product.

💡Bobbins

Bobbins are cylindrical spools used in the textile industry to hold threads for weaving or embroidery. The script mentions that the mill has 700 bobbins of polyester, each containing 250,000 meters of thread, illustrating the scale of production and the importance of bobbins in the thread preparation stage.

💡Warp and Weft

Warp refers to the threads that run lengthwise in the fabric, while weft is the thread that crosses the warp at a 90-degree angle. The script describes how the warp threads are assembled and the weft threads are inserted, which is fundamental to the weaving process and the creation of the fabric's structure.

💡Jacquard Loom

A Jacquard loom is a mechanical device used for weaving complex patterns and designs. The script mentions this type of loom, indicating the production of patterned fabric. The Jacquard loom is a key technology that allows for the creation of intricate designs in woven fabric.

💡Thread Separation

Thread separation is the process of dividing the threads from the bobbins into individual strands. The script describes how the 700 strands are separated and assembled, which is a critical step in preparing the threads for weaving and ensuring the fabric's quality.

💡Glue

In the context of the video, glue is used to hold the threads together before dyeing. The script mentions that the threads pass through a bin of glue to prevent tearing, highlighting a step in the process that ensures the integrity of the threads during production.

💡Dyeing

Dyeing is the process of applying color to fabric. The script describes the dyeing process, where colorants are added to water and the fabric is soaked for several hours. This step is essential for giving the fabric its final color and appearance.

💡Thermal Setting

Thermal setting is a process that uses heat to set the properties of a fabric, such as its shape or color. The script describes the fabric being dried in a high-temperature oven, which is a crucial step for fixing the dye and the fabric's dimensions.

💡Roller

Rollers are used throughout the script to describe various stages of the fabric production process, such as drying the glue on the threads and operating the loom. Rollers are essential machinery in the textile industry for moving, pressing, and processing fabric.

💡Kilometers of Fabric

The script emphasizes the vast quantity of fabric produced, mentioning that a single bobbin contains thread enough to make 250 kilometers of fabric. This highlights the efficiency and scale of industrial textile production.

💡Breakage Chain

The breakage chain is a mechanism in the loom that stops the machine if a thread breaks. The script mentions this as part of the weaving process, indicating the importance of quality control and the machinery's ability to detect and respond to errors in production.

Highlights

Fabric production begins with thousands of braided polyester threads.

Each mill has 700 bobbins, each containing 250,000 meters of thread.

The warp unit separates and assembles 700 strands of thread.

A comb is used to separate the threads further, with a total of 7,000 strands aligned.

Fabric is composed of warp threads assembled lengthwise and weft threads joined transversely at 90 degrees.

Threads pass through a bin of glue to prevent tearing before dyeing.

Rollers eliminate excess glue, which is later removed with water.

700 strands are separated on the loom roller, with each thread passing through a blade for a specific design.

The jacquard loom uses a jet of air to insert the warp thread.

The weaving machine assembles 7,000 strands to reach a width of 3.65 meters.

600 weft strands are inserted per minute, with the blades removing weft strands to insert warp ones.

A comb pushes the weft strands between the two, with a plate to stop the machine if a thread breaks.

A single bobbin produces 250 kilometers of thread.

The loom operates at full speed, making 600 thread intersections per minute.

Washing is done in a soapy solution at 80 degrees, at a speed of 60 meters per minute.

Dyeing is performed with jets, with the fabric soaking in colorant solution for about six hours.

An opener machine unfolds and stretches the material before rolling it up on a large roller.

Thermal setting in a high-temperature oven dries the fabric at 200 degrees Celsius for 45 seconds.

The final roll weighs 1500 kilos, with one bobbin producing 25 kilometers of fabric.

Transcripts

fabric is made from thousands of braided

threads this mill has 700 bobbins of

polyester each bobbin contains 250

thousand meters of thread we begin by

separating the threads this warp unit

takes the seven hundred strands and

assembles them then this comb separates

them

other strands are added and in total

there will be 7,000 of them well aligned

one fabric is composed of threads

braided at 90 degrees the warp threads

are assembled lengthwise while the wet

threads are joined transversely to

prevent the threads from tearing they

pass through a bin of glue these rollers

eliminate the surplus the glue will be

removed with water before dyeing the

threads the glue together threads exit

this machine these large green cylinders

are heated and dry the glue on the

threads knitting will soon begin the 700

strands are newly separated on this loom

roller

each thread must pass through a blade to

produce a specific design this machine

takes the 7,000 strands of thread one by

one and they pass through the blade it's

a highly precise operation

the threads pass through a blade and the

weaving finally begins on this jacquard

type loom roller the warp thread is

inserted by a jet of air

the weaving machine assembles to loom

rollers made of 7,000 strands the fabric

reaches a width of three point six five

meters the dark threads are inserted

into the weave

they insert 600 weft strands per minute

the blades remove the weft strands to

insert the warp ones between the two a

comb pushes the weft

the plate of the breakage chain stops

the machine should a thread break this

bobbin contains 250 thousand meters of

thread that's 250 kilometers

the weft thread is in the insertion

nozzle when a weft is inserted an air

jet nudges it in the loom roller

operates at full tilt it makes 600

thread intersections a minute

weaving is now over we move on to the

following steps washing and dyeing

washing is done in a soapy solution at

80 degrees in a continuous manner at a

speed of 60 meters of fabric a minute

the fabric is rinsed in clear water of

about 30 degrees now it's on to dyeing

this is done with jets up to 12,000

meters of fabric are placed in clean

water into which colorants have been

added the solution is heated in the

fabric soaks here for about six hours

then it will be rinsed in lukewarm water

the fabric is placed in a bin

this machine is called an opener it

unfolds and stretches the material

before rolling it up on an immense

roller

and now the role is almost full

we now move to thermal setting in a

high-temperature oven which dries the

fabric the temperature is 200 degrees

centigrade at the ovens entrance the

fabric circulates here for 45 seconds

this finish roll weighs 1500 kilos the

bobbin that we saw at the beginning has

produced 25 kilometers of fabric