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How will Fabric Testing Lab Manager Plan the Purchasing of Textile Testing Machine?
The textile industry is very competitive, so customer satisfaction is the key to success in this sector. This is only possible with product quality assurance. For this purpose, textile industries set up a fabric testing laboratory to ensure cloth production according to the customer’s standard.
Fabric testing is the responsibility of the lab manager. So, it is up to the QC manager to plan the purchase of textile testing machines necessary for the lab’s proper functioning. In this article, we will see how a Textile Lab Manager plans to purchase a textile testing machine.
Table of Contents
Determine the Textile Laboratory’s Orientation and Objectives
The textile laboratory is the backbone of the textile industry. It focuses on product quality assurance, research, and development to get better results from competitors while maintaining data, and crucially, meeting customer requirements under environmental regulations.
Textile Laboratory’s Orientation
The first step of the lab head is to assess the laboratory’s orientation, lab layout, equipment list, testing procedures, safety protocols, and quality control standards. He should look out for the space for positioning the types of equipment and keeping records and documentation area.
Textile Laboratory’s Orientation
Laboratory Layout
Understanding of lab layout helps the lab manager to make proper informed decisions. There should be enough space for positioning the new instrument, and working area while maintaining the equipment safety protocols.
Understanding of Equipment Operation
The knowledge of equipment operation helps the technician to maintain the instrument with proper functioning. It also increases the machine’s lifespan, because little knowledge is dangerous which may cause problems in machine handling and operation.
Testing Procedure
There are different standards for the same type of test, for example, ISO, AATCC, and ASTM standards. So lab head should know the exact machine type that is required to follow the customer’s requirement.
Safety Protocols
Each chemical and apparatus that is used in the textile sector has safety protocols. The term Material Safety Data Sheet (MSDS) is used for the chemicals, in which product safety guidelines are mentioned.
Similarly, equipment has safety protocols that should be considered while working on it. These guidelines are given for the safety of workers and machines.
Quality Control Procedures
Lab manager knows the quality control & quality assurance methods and procedures. Testing procedures, analysis reports and requirements to meet the result are basic responsibilities of a lab manager.
Maintain the records of Reports and Documentation
Lab gives the idea and complete track record about how we can improve the quality of our products. It is done after numerous experiments and performing different testing procedures.
So it is very important to keep a record of how the new development was done. Record maintenance is a basic task for a lab manager. It saves time and cost for repeating the tests.
Textile Laboratory’s Objectives
Textile Laboratory’s Objectives
The objectives of the textile lab are testing, product evaluation, product, cost analysis on the basis of treatment processes, and the complete testing analysis of the fabric from the initial stage to the final stage to ensure the fabric requirements as according to the buyer.
Testing: Dyes, Chemicals and Fabric
Textile processing units have big consumption of dyes, pigments, textile chemicals, and softeners. There is a chance of an inappropriate supply of dyes and chemicals. So the testing of dyes, chemicals, and fabric supply is the prime job of the lab.
Textile product quality is based on the greige fabric. A good base produces good results. There is a lot of chance of variation in greige quality, so a proper lab is developed just for Greige testing, whose purpose is to ensure the intake supply of greige fabric according to marking requirements.
Similarly, dyes and chemical testing are very important for the proper functioning of the wet process. Textile chemical lab ensures the intake supply of dyes and chemicals that either it is ok or weaker as compared to the older supply.
If the dyes and chemical supply is equal to the older supply then it is marked OK for use, otherwise it in case of weak results from the older supply, then it is marked as WEAKER, and the supply is rejected and returned to the party.
In this way, the Lab saves a huge amount of money by testing the whole supply of fabric, dyes, and chemicals. This testing is only possible with lab testing equipment which ensures the consistent quality of the product.
Maintaining the Production Parameters
In textile processing industries, the lab sets the production parameters and then ensures that production is performing under set parameters. There are a lot of parameters in wet processing. For example, firstly greige fabric goes for de-sizing, after desizing tagewa rating should be up to 7.
After resizing fabric goes to bleaching, here capillary value should be more than 3 inches, and the fabric goes to the mercerizing machine where the barium activity number should be more than 150 for good mercerization.
Similarly, there are further sets of parameters at each stage of wet processing in dyeing and printing units, these all testing is done by lab staff and through lab equipment.
Compliance
International market buyers demand international standards like ISO, AATCC, ASTM, BSTI, WIRA, DIN, and BSI. The lab setup is developed to ensure the requirement of buyer as according to their demanding standard.
Maintaining & Calibration of Testing Instruments
The Lab Manager ensures the working of lab instruments with proper instrument maintenance, on-time calibration, and cleaning.
Research & Development
The lab helps the technicians to develop the new item for production. You can do experimentation on a small scale to know the possibilities of making required products that can be made under budget by choosing the optimum process.
Existing Textile Testing Instrument Evaluation
Existing Textile Testing Instrument Evaluation
Before purchasing the new machines, a wise lab manager will make a list of inventory. He will see which instruments are available, and whether these are in good working condition or not. You cannot get precise results without the proper maintenance and calibration of instruments. Lab staff training is also important to deal with machines effectively.
1. Inventory List
Make an inventory list of existing machines, and check out the working conditions and precision efficiency of these instruments.
2. Instrument Working Report
An instrument working report should be prepared, if it needs maintenance, then the message should be delivered to higher authorities to take necessary action. Lab machines cannot give precise results without proper maintenance and calibration.
3. Operator Training
The Lab Manager has to see how the operator runs the machine. The proper training of operators is must to ensure the precise results and proper functioning of lab instruments.
4. Gap Analysis
It is based on the objectives and testing standards and clarifies which textile testing instruments need to be added. Once the lab head makes the inventory list and knows which machine is in proper working condition.
They segregate the machines which can be used or either it is so old fashioned that is should be replaced with the latest model for getting the most up-to-date results.
For example, formerly HT dyeing machines were used glycerin as the heating medium. Now HT dyeing machines use Infra red rays as heating medium. So gap analysis should be done either the machine can be upgraded or should be replaced.
Selection of appropriate Textile Testing Instruments
Selection of appropriate Textile Testing Instruments
Textile laboratories deal with the physical testing, chemical testing, and functional testing of the fabric. Common tests are color fastness, perspiration, and moisture absorption test. These tests guide the production and quality assurance department to take necessary actions on time.
1. Back Process Tests
Tagewa rating, Absorbency test, and Degree of Mercerization are the physical testing parameters for the back process. Soaping test after soaper and after finish helps the technician to control the staining before packing.
The shrinkage test is a very common test, especially for winter qualities; it helps the production team control the shrinkage on the mercerizing machine and enter.
2. Color Fastness Tests
Colorfastness test includes the washing color fastness tester, rubbing fastness tester, sweat color fastness tester, and so on.
3. Comfort Tests
Similarly, comfort tests include air permeability tester, water vapor permeability tester, cool feeling tester, and thermal resistance tester.
4. Safety & Performance Tests
Safety and performance testing includes a flammability tester, antibacterial tester, and physical property testing equipment (such as tensile strength tester).
So in this way, the Lab head will select the appropriate Textile Testing Instrument which will be demanding as their working condition because different parameters are used in different textile units.
5. Environmental Monitoring Test
For example, an environmental monitoring test includes an environmental chamber and, a light fastness tester.
Choose the Right Textile Testing Instrument Manufacturer
Choosing the Right Textile Testing Instrument Manufacturer
It is a serious responsibility to choose the right Textile Testing Instrument Manufacturer. After purchasing in case of any issue from the manufacturer side, the lab head will be responsible for making the wrong decision.
So considering such an issue a question arises whether to choose domestic or overseas sourcing of textile testing equipment.
Domestic Sourcing
- Domestic sourcing looks comfortable and easy. In case of any issue, you can easily approach the instrument provider with ease of communication. Local machine providers can give you fast and efficient after-sales services.
- The dark side with local instrument providers is they have high prices with moderate technology. They lack advanced technology because it costs more, which could be a challenging scenario for them.
Overseas sourcing
- Overseas sourcing is beneficial in the case of advanced technology, with a wide range of options. You can choose a machine that can do multiple tests or with a specific niche.
- The other benefit of overseas sourcing is competitive pricing. Overseas manufacturers can give you the optimum pricing range for instruments, with a low budget.
- The problems you may face dealing with overseas are language barriers, differences in regulatory compliance, longer delivery time, and not delayed after-sale services.
How to develop the Textile Test Instrument Procurement Budget and Procurement Plan?
The textile test instrument procurement budget and procurement plan are mandatory before purchasing the instrument. It will help the responsible person to make the right decision.
Procurement Budget
- Firstly you have to know which textile test instrument is required currently, including type and specifications.
- The second step is to take quotations of that instrument from all available sources, like suppliers, manufacturers, distributors, or online retailers.
- Take an overall estimated price of the instrument including, equipment price, shipping, installation, maintenance, and training costs from all parties.
- If you want to buy more than one instrument then you should prioritize the list of equipment on the basis of its use, frequency, and urgency.
- Then allocate the estimated budget for each instrument based on the priority list.
Procurement Plan
- Create a procurement plan by adding the organization’s relevant departments and persons related to the deal.
- From all quotations mark the potential suppliers that are most suitable for the deal according to your company’s policies.
- Make a request for a proposal document that will describe all the requirements and the company’s guidelines regarding payment like cash or in installments.
- Send this request for proposal to the shortlisted suppliers and give them a deadline for submission.
- Now check the most suitable supplier according to pricing, after-sale services, and payment plans.
- Once you select the supplier, and then place an order with proper documentation including delivery time, payment method and ways, and commitment of after-sale services.
Pay attention to the Industry’s Technological Developments
Pay Attention to the Industry’s Technological Developments
Lab managers need to be well aware of the latest technologies, trends, and advancements, due to the competitive market nature. Only textile companies that can survive will give quality fabric at a reasonable price.
Adopt the Latest Textile Industry Trends
It is seen market takes a swing every year regarding dressing sense and trends. So manufacturers have to make decisions and make products based on market requirements.
It is the responsibility of the Lab to ensure the quality of products, using and upgrading the latest technologies and testing instruments.
Digitalization & Automatic Machinery
The textile industry is adopting intelligent and automated machinery for fabric production. For example, Digital printing has bypassed the engraving department, it also reduced labor costs, and even dyes cost.
Keep an eye on the Latest Technology & Advancements
Lab manager has a very responsible job in the textile sector, so they must be informed of the latest trends, advancements & Technologies which will be beneficial for the textile company and teamwork.
For more information on textile testing methods/standards
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