Latest Technology Used in Garment Industry
Department of Textiles (Fashion Technology)
DKTE’S Textile & Engineering Institute, Ichalkaranji, India
Intern at Textile Learner
India is one of the top producers of textiles and apparel in the world. About 2% of India’s GDP, or 7% of industry output in value terms, comes from the domestic garment and textile sector. In 2020–21, textile, clothing, and handicraft exports made up 11.4% of all Indian exports. India accounts for 4% of global textile and clothing trade. The present trending technology in textile manufacturing suggests that the future of apparel manufacturing technology is bright. Product design is being transformed by artificial intelligence. Manufacturing supply chains are being streamlined through the use of technology to speed up production, allow direct-to-consumer distribution, rethink in-store and online shopping experiences, and develop customized products for particular consumers. Machine learning, supply chain advancements, rapid data analytics, 3D capabilities, and bespoke production runs are five hot trending technologies in apparel manufacturing today.
Hand-stitched clothing is indispensable in many situations. A qualified professional’s attention to detail can produce a degree of quality that is precious in the fashion industry. The rise of machine learning, on the other hand, is improving garment design by eliminating manual intervention at key phases of production. Robotic manufacturing is supplanting antiquated processes such as traditional sewing machines with cutting-edge technology such as laser cutting machines, buttonhole machines, and fusing machines.
Digitization in single needle lock stitch machine, digitally controlled buttonhole machine, digitally controlled button attaching, digitally feed zig zag machine.
The Digital Sewing Machines can actively respond to changes in sewing objects and materials. These sewing machines can digitize “seam” modification functions, and setup parameters can be saved as a pattern. After correction, the data can be shared to other sewing machines through tablet or smartphone using a specific app (application programme).
The same configuration can be shared with other factories that use the same style to get the same quality seam. This will aid industries in reducing machine setting time during line setup. The factory’s profit is enormous since machine settings will be reduced by 50% to achieve seam quality. The following technology and machine models have been digitalized and used in garment industry, with more to come in the future.
Digitized Single Needle Lock Stitch Machine:
|Speed||4000- 5000 STI / Min|
|Needle||Db×1 #14 , Dp×5 #21|
|Application||Medium To Heavy Weight|
|Stitch Length||5 Mm|
|Power Required||220-240 V|
|Needle Bar Stroke||30.7-36|
Automatic Pocket Setter: For Jeans [model AP-876]
Reduction in the number of required facilities and operators. The AP-876 entirely automates a number of operations involved in pocket setting. The following eight facilities (eight operators) will be needed to complete these activities using the general-purpose machine in order to achieve daily production levels comparable to those of the AP-876.
Iron, steam: two devices (Hips pocket folded). Five one-needle lock stitching devices with automatic thread trimmers (Sew back hip pocket to hip). Bar tacking device: a single device (Bar tack hip pocket edge).
These all operations can be completed by the AP-876 by single operator.
|Max Speed||4000 SPI/MIN|
|Needle||SCHMETZ 134 SERV7 (Nm130)|
|Stitch Length||6.4MM ,4.3MM , 0.1MM|
|Stacking Capacity||64 pieces|
|Sewing Area||250*250 MM|
Lockstitch Automatic Welting Machine:
Welting, such as slacks and working pants, offers outstanding performance and high productivity. It has a high-speed machine head that can sew at a maximum pace of 3,000 stitches per minute. By simply placing the cloth on the welting machine and performing the start operation, even a novice operator may easily sew slacks and work pants.
|Speed||Max 3000 STI/Min|
|Kinds Of Welt||Parallel Double Welt, Parallel Single Welt(Without Flaps)|
|Hook||Vertical-Axis 1.7-Fold Capacity Hook|
|Needle||Dp × 17 Standard #16 (#14~#18), 190r Standard #100 (#100~#11|
|Stitch Length||Standard 2.5mm (2.0~3.4mm)|
Automatic 2-needle Belt-Loop Attaching Machine:
With a machine time of 1.2 seconds prior to the belt loop, higher production is guaranteed. To enable the operator to alter the number of stitches and sewing sizes, the feed mechanism has a computer-controlled X-Y approach.
The device efficiently disposes of each belt-loop splice after initially detecting them. Accordingly, the belt-loop feeding mechanism can finish its belt-loop supply action and supply the next belt-loop well before the machine begins to sew, even while the machine performs the splice-disposal method. As a result, the operator can sew consistently and effectively without affecting cycle time. The machine’s potentiometer locates and perfectly disposes of belt-loop splices by detecting changes in the material thickness.
The change in material thickness that the potentiometer interprets as a splice when changing the material to be sewed can be simply altered and programmed using the teaching feature of the machine.
|Machine head||Computer-controlled, 2-needle, lockstitch bartacking machine|
|Max. sewing speed||2,500sti/min*|
|Needle bar stroke||45.7mm|
|Needle (at the time of delivery)||DP×17 (#21) #19~#21|
|Hook||Horizontal-axis 1.8 fold-capacity shuttle hook|
|Lift of the presser foot||21mm|
Automated Sleeve Placket Attachment Under Computer Control:
Utilizing laser lights, the operator precisely positions the shirt front and placket. The location of the garment is changed for sewing, and the sewing cycle starts automatically. Following sewing, the thread is cut, and the garment is piled automatically. In the event that a thread breaks, the machine halts, bar tacks, and eliminates the need for off-line repairs.
It has a stacker for collecting folded clothing, a 1-needle sewing head with an energy-efficient motor, and a preparation station with a laser marker. These features guarantee the highest positioning accuracy, speed, and efficiency of operations.
On a clear, touch LCD control panel, work parameters and patterns are programmed.
|Feed System||Belt Feed|
|Stitch Length||1.5 -6 MM|
|Needle Bar Stroke||30.7|
|Pressure Foot||By Hand 5.5 Auto 10mm|
|No Of Programs||99 Programs|
The machine operation management system known as JANETS It simple is able to receive the operation information and output amount of the sewing machine transferred from the terminal installed on each sewing machine for monitoring purpose.
- It makes enable to Real-time monitoring of work progress in the line getting a handle on the machine’s state (operation rate, failure rate)
- Using the processing time to enable to grasp the line balance. Enhancement of proper line balance and aid request
- It helps to compare goals and outcomes on a machine-by Machine basis
Three-dimensional (3d) software is another advancement in the subject. It functions in a virtual environment, allowing for 3d visualization of drape and fit on a virtual model or avatar. This technology eliminates the time-consuming procedure of generating physical samples. Some of the new and interesting options available with cad software packages include 3d scanning, mapping, personalized avatars based on certain anthropometric and facial attributes, and tailored clothes. Linking design, manufacturing, and other pre-production procedures like as pattern making, grading, and marking can provide increased productivity, competitiveness, and shorter delivery schedules.
Available 3D CAD software for the clothing manufacturing industry is listed below:
- Modaris 3D Fit from Lectra,
- Accumark Vstitcher from Gerber,
- 3D Runway from Optitex,
- Virtual fashion from Reyes Infografica,
- Design concept from Lectra,
- Haute Couture 3D from PAD System,
- it Simulator from Tukatech
Apart from sewing, finishing room technology is being used in supply chain management by using software’s.
Enterprise resource planning (ERP):
Apparel ERP includes several modules and offers customer-specific solutions. Using a single ERP system, operations such as generating POs, Bills, Fabric identification, inventory management, garment costing, and production scheduling may be digitalized. To name a few ERP system vendors based in India, WFX, Stage, and APPS.
3D Simulation – Here can create 3D garments on the digital platform by using 3D simulation. The pattern can be seen fitting on a dress form.
3D Body Scanner – A 3D body scanner measures the human body. This technology aids in the creation of a first and accurate 3D model as well as comprehensive body measurements. Learn more about 3D body scanners and providers of 3D body scanning solutions.
Virtual fitting room and sample approval – A virtual dress form/virtual human is utilized in a virtual fitting room to assess the garment fit. With the garment fit, even the fall of the cloth may be observed. Using this technology, garment manufacturers can obtain online sample clearance.
In the clothing business, lasers have long been used for laser marking (for surface fading), laser welding. By stimulating the emission of photons from excited atoms and molecules, the apparatus produces a powerful beam of coherent monochromatic light. In the textile business, a CO2 RF discharge stimulated laser source with a wavelength of roughly 10.2-10.8 m is frequently utilized. The conventional methods of fading, abrasion, decorating, marking, engraving, and cutting can be entirely eliminated by laser technology. Modern laser machines have a z-axis that automatically moves up and down to etch a variety of textured and shadowy designs with different layering.
- First, it is a considerably speedier process; second, a beam of light is used to burn away the indigo dye, creating a worn appearance.
- It also produces less air pollution.
- Finally, it necessitates less wear and tear.
Overhead handling system:
An overhead material handling method in which all components of a garment are strung in hangers. The overhead rail is moved by the hanger. This type of system decreases the operator’s material handling. Second, the single-piece flow shortened throughput times. Eton INA, SmartMRT, and Eurotex are examples of solution suppliers.
Some advantages of overhead handling system:
- There is no requirement to bundle clothing parts while feeding
- Needle time increased because, in this system, operators just sew clothing; they do not pick up panels, discard them, bundle sewn clothing, or convey (slide) the bundle to the next operator.
- As a result, this system increases labour (and machine) productivity and provides higher standard of the goods
Product lifecycle management:
Software is an enterprise’s information management system. The PLM system has the ability to integrate people, processes, business systems, and data throughout an extended organization. PLM software enables the end-user to efficiently and economically manage this information across a product’s entire lifecycle, from innovation, design, and manufacture, through commercialization and disposal.
List of PLM Software for the Garment Industry:
- Blue Cherry by CGS INC
- Lectra fashion PLM
- NGC software
- PTC INC
You may also like: Product Life Cycle Management Software in Apparel Industry
Regardless of the size of the business, the above technology can be implemented and used to manage the business, improve performance and accuracy in specific procedures, and so on. This list includes software systems that look at the entire garment supply chain. In practice, not everyone needs to use all of the available technology. Even though many older clothing factories do not have cutting-edge production technologies, they are still profitable.
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Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.