Knit fabric is one of the most widely used fabrics globally. It is used to make t-shirts, sweaters, leggings, and a variety of other items. What makes these fabrics stand out is that they create clothing that is very smooth, soft, and comfortable. However, when it comes to its production, many people are unaware: How is a knit fabric made?
Interestingly, the knit fabric can be made by hand or by machines. Modern manufacturers utilize dedicated machines for the fast production of knit fabrics. Understanding its production process is very important, especially if you’re in the textile sector. In this article, I will dive into the process of producing knit fabric. Let’s get started!
What is Knit Fabric?
Before discussing the production of knit fabrics, let’s first explore what knit fabric is!
Knit fabric is a popular type of fabric made by interlacing yarns. These interloping help create soft and stretchy fabric. Moreover, this fabric can be made either manually or using machines. They are popular for making t-shirts, sweaters, and leggings.
The interloping of yarn can occur in either a horizontal or vertical direction, depending on the type of knitting used. Horizontal side-by-side knitting, also known as weft knitting, is a very popular technique. On the other hand, vertical knitting is also known as wrap knitting. What makes knit fabric popular is its specific properties. Those include stretchiness, softness, and durability.
T-shirts made with knit fabrics are known for their breathability. Air can pass through these shirts. But the question is HOW? During the knitting and interloping of yarn, small amounts of gas remain in each loop. These gaps are tiny, but they still allow the air to pass through. So, when you wear a knitted T-shirt in the summer, you feel more comfortable due to the small gaps in the fabric.
Remember, the knitted fabric is not new and has been in use for many centuries. In the early days, people used to knit fabrics using needles. The manual knitting process was a slower and more challenging task. However, in 1589, William Lee, an Englishman, created the first-ever knitting machine. It was very basic but was faster than hand knitting.
This laid the foundation for knitting machines. In the 2000s, we saw the emergence of many newer and technologically advanced knitting machines. They are swift and reliable, producing fabrics of the highest quality. All modern manufacturers utilize machines to produce these fabrics. However, hand knitting is still done on a small scale for making sweaters.
How is Knit Fabric Made? Step-by-Step Process
As I said, knitting fabric is popular due to its ease of production. Its manual knitting is slower but relatively more straightforward. Women in many villages still use hand knitting to create this fabric, which they then sell to make a living. However, modern machines help in the large-scale production of these knitted fabrics.
Let’s drill down and discuss its production process in practical steps:
1- Selection of Yarn or Spinning
The first step is to choose the right type of yarn. However, if you don’t have yarn, you’ll have to make it by spinning fibers. I recommend using ready-made yarns as they are very inexpensive and readily available. If you make yarn yourself through spinning, it would make the process a bit slower.
Different types of yarns are available in the market. Those include cotton yarn, polyester yarn, wool yarn, nylon yarn, and the list goes on. You can choose any of these depending on your needs. For example, if you’re making breathable t-shirts, I recommend choosing cotton yarn. Similarly, polyester yarn is suitable for making sweatshirts as it is very durable.
Moreover, the polyester yarn is wrinkle-resistant. It means you can wear polyester fabric multiple times without needing to iron it. Similarly, for winter clothing, opt for wool yarn, as it is renowned for its warmth. In short, select yarn according to your needs and the properties you desire in the fabric.
2- Setup Machines & Preparation of Yarn
The second step is to choose the right machine for the knitting process. Interestingly, a variety of machines are available, each with a specific output. For example, some machines offer bigger yarn sizes and make patterns while knitting the fabric. On the other hand, some machines can only knit without creating a pattern.
Moreover, those machines also vary their gauges. Some knitting machines produce fabric with small gauges. On the other hand, some high-end machines can produce fabrics with chunky gauges, which are suitable for sweaters. Manufacturers also consider many different factors, such as speed, cost, and so on. Additionally, the yarn fed to the machine is prepared.
It is generally waxed and lubricated for feeding. The advantage of waxing yarn is that it does not break when the machine starts to work. Remember, while working, some stress comes on the yarn. If it gets damaged, the production process can be affected and become very slow. Therefore, waxing of yarn is done to speed up the overall knitting process.
3- Knitting – Making Loops to Create Fabric
This is the most crucial step that makes the fabrics. During knitting, the machine takes the yarn and starts to knit the fabrics using its needles. The yarns interloop during knitting to form the fabric. There are two types of knitting that machines can do, which we explain in the upcoming section:
Weft Knitting
In this process, the yarns go side by side and make fabrics. What makes it stand out is that this knitting uses a single yarn at a time. It means the single yarn goes side by side and creates interloops. As a result, it creates fabrics that are highly breathable and soft. Moreover, this weft knitting can be done by hand or using dedicated machines.
Wrap Knitting
It is a less popular type of knitting and requires specialized knitting machines. In this process, multiple yarns are interlooped together. The yarns run vertically (up and down) to each other. Machines of this type have multiple needles that work together. Due to having multiple yarns, they make more durable and heavy fabrics.
Wrap knitting cannot be done by hand and can only be done through machines. So, if you use weft knitting, you’ll get lightweight, breathable, and soft fabrics. On the flip side, weft knitting will give you more durable but less breathable and less stretchy fabrics. You can use any of these knitting processes or machines depending on your needs and requirements.
4- Inspection & Quality Check
This is one of the most critical steps in the production of knit fabrics. As I said, modern manufacturers rely heavily on knitting machines. Most of the time, these machines produce excellent-quality fabrics. However, these machines sometimes malfunction during operation.
As a result, they can produce fabrics with holes, loose threads, or uneven loops. Therefore, every manufacturing unit generally has a quality control assurance team. They check those defects in the fabrics. If any piece has defects, the fabric is sent back to the manufacturing facilities. The labor then manually removes those defects.
For example, if the fabric has uneven loops or loose threads, they will improve these areas. This process removes defects and ensures the production of high-quality fabric. However, if the fabric has a large stain or is of poor quality, it is discarded. However, if the fabric passes a quality check, it is then sent out for the dying process.
5- Dyeing & Finishing
The last step is to dye the knit fabrics. There are two ways of dyeing. You can either dye the fabric before feeding it to the knitting machine. Secondly, you can also dye the fabric after the machines have knitted it. This second method is called piece dyeing. In the dyeing method, the fabric is dipped into the dye.
As a result, the fabric gets a specific color. It is then put into the dyeing machine. This machine creates a bond between dye and fabric. Therefore, the color or dye becomes an integral part of the fabric. Once the fabric is dyed, it then undergoes a finishing process. In this step, the knit fabric is treated to enhance its overall appearance, stretch, and breathability.
The additional treatment also helps to remove wrinkles from the fabrics. Some manufacturers also use heat treatment for the fabrics. This treatment improves the shape of the fabric. After these treatments, the fabrics also become very soft and comfortable. This post-treated fabric is then sent out to garment production.
Characteristics of Knitted Fabrics
As mentioned earlier, knitted fabrics are gaining popularity. In fact, people prefer knit fabric clothing in the summer due to their excellent feel. They are more breathable, which makes them a good option for hot summer days. Here are some key characteristics of this fabric:
- Soft and Comfortable
- Feels gentle on the skin
- Breathable and allows airflow
- Does not wrinkle easily due to pre-shrinking processing
- Stretchy and suitable for making sports and activewear.
- Good durability, meaning it has excellent flow and conformity
Часто задаваемые вопросы
What is a knit fabric made of?
The knit fabric is made of yarn that is interloped together. Different types of yarn can be used, including cotton, wool, nylon, polyester, and so on.
Is knit fabric suitable for hot weather?
Yes, knit fabric is an excellent option for winter clothing. A gap remains during the knitting process. The air can pass through this gap, making them breathable. Therefore, t-shirts are typically made of knitted fabrics and are often worn in the summer.
Can knit fabric shrink after washing?
Yes, knit fabric can shrink, especially when made from cotton yarn. Therefore, those fabrics require ironing. However, some manufacturers use a pre-shrinking process during the finishing stage. This process significantly reduces the shrinking.
Are knit fabrics suitable for sportswear?
The knitted fabric made of cotton, wool, or nylon may not be a perfect fit for sportswear. However, those knit fabrics made of polyester blended with spandex are decent options for sportswear. It offers both durability and stretchiness required for sportswear.
What is the composition of knit fabric?
The knit fabrics can be composed of yarns made from cotton, nylon, wool, and polyester. There is no restriction on what manufacturers can use in making knit fabrics. However, each yarn type gives specific properties to the final knitted fabrics.
Заключение
Knitted fabric has become increasingly popular in the creation of various clothing items. From t-shirts to jerseys and sweaters, their use is very versatile. The knit fabric is typically produced using dedicated knitting machines. They take the yarn, interloop it, and give us the final fabrics. The interloping of yarns can be done either sideways or vertically.
The side-by-side interloping of yarn is called weft knitting. However, vertical interloping is called wrap knitting. Each of these knitting methods has its pros and cons. In the final steps, the fabrics undergo dyeing and undergo a final finishing process. In this article, I’ve explained the whole production steps in easy-to-understand steps.