What is Circular Knitting Machine? | Development of Circular Knitting Machine

Circular Knitting Machine:

A circular knitting machine is the first option for knitted fabric manufacturers. It is widely used everywhere in the knitting industry to produce fabric for its productivity and user-friendliness. It has been designed and manufactured for mass production of knitted fabrics. Huge range of diameter (12 inches to 60 inch) according to manufactures requirement that is perfect for manufacturing outerwear and underwear.

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Working principle of circular knitting machine:

The working process of the circular knitting machine is similarly easy from other knitting machines. I have described it simply. If you see the below figures with concentrated then you will know how to circular knitting machine making fabric from yarn.

Circular Knitting Machine
Circular Knitting Machine

Recent Development of Circular Knitting Machine

Seamless knitting technology

Seamless garment knitting can be performed either on the circular knitting machine or flat (V-bed) knitting machine. Yet, seamless circular knitting machines vary from seamless flat knitting machines in that seamless circular machines create only a single tubular type of garment such as those offered on Santoni machines.

Seamless knitting machines can produce more than one tube and join the tubes collectively on a machine. The complete garments knitted on circular machines may also only need a least cutting operation.

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Also, seamless circular machines need different diameters to make major adjustments in garment size, whereas seamless flat machines can adjust to many garment sizes on the same machine. Consequently, seamless knitting on circular machines is not true seamless knitting. It should be stated that knitting on V-bed seamless machines produces truly seamless garments since they do not need any cutting or sewing. In recent years, Santoni has produced a four-feed single-jersey electronic circular machine, which allows the creation of a shaped garment by reciprocal movement.

To get a higher quality knitted garment, it is crucial to control the manufacturing functions. Designers and manufacturers must communicate effectively to create successful new products in the knitting industry. Designers complain that the designs that they specified are not accurately created, while technicians think that the designers do not understand the technical difficulties in knitting workability. It has been suggested that one way to overcome the communication problem between designers and technicians would be the use of intelligent CAD systems. The CAD system allows designers and manufacturers to specify and assess their design more precisely without expecting great time investment and technical expertise. Diverse computer-controlled systems including CAD/CAM controlled devices have been developed to facilitate communication.

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Companies have been offered new types of CAD systems, which use two different monitors including a technical window and a design window for designers and manufacturers, who require different information for the same design.

Ultrafine gauge knitting machines

Fine knitted fabrics recognized as ‘second skin’ are produced on fine gauge circular knitting machines. Cotton, polyester, and viscose yarns of 90 to 120 Ne are applied to produce fine circular knitted fabrics. The appearance of these fabrics is similar to woven fabrics but they are more flexible.

High-grade circular knitting cylinders provide the ideal complement to the company’s premium range of needles and system parts to create the ideal knitting system from a single reputable supplier. It is only with the guarantee of a consistently high standard of component quality and outstanding durability that circular knitting machines can reach their full potential for high-performance operation on the factory ground. Ensuring the pinpoint precision of individual elements in existing machines not only simplifies the workflow but also increases capacity utilization in production.

Fine gauge automotive fabrics, known as woven-like fabrics, are produced on fine gauge double cylinders in Pai Lung ultra-fine gauge machines. Pile technology is utilized to these machines, where the fine gauge of loop makers is adjusted near to the sinkers.

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Loop transfer technology in circular knitting machines

Stitch transfer is an essential operation, as a higher number of transfer modes means more extra possibilities of obtaining structured designs and shaped fabrics in which the stitch is transferred from one cylinder to the other or within the same cylinder.

The creation of high-quality knitted fabrics – i.e. of homogeneous appearance as a result of a smooth knitting process and the lack of holes and barring – actually depends on the application of certain technical solutions.

As for the type of needle used, Italian machines include latch needles, which operate according to the drowned butt principle. This kind of needle endures in an idle position with its heel completely plunged in the needle bed groove without being involved in the action of cams, and retains the loop, which in this case is not subject to strain. Figures 7.7 and 7.8 confirm novel loop transfer elements of these circular knitting machines. 

Pile and sliver insertion mechanism in circular knitting

A special sliver knitting process locks individual fibers directly into a lightweight knit backing, allowing each fiber to stand upright, free from the backing, to form the soft pile on the face of the fabric. This gives comfort pile fabrics more elastic, warmer, more drapable, and more flexible than fabrics made from yarns. Each fabric originates from premium loose fibers. These fibers carry high-tech microfibre acrylics, polyesters, and mod-acrylics specially developed for fabric, along with natural fibers such as wool.

Each blend is collected for its specific result. By engineering, the fiber mix, an incredibly wide range of colors, density, weight, patterning, texture, and performance features can be produced in comfort knit pile fabrics.

After knitting, the pile fabric is cut to the desired height. It is then put into a series of technical finishing processes specially produced by this kind of knitting process to control the surface texture and special characteristics of the final fabric.

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