Primed Canvas

Standard Quality Control (SQC) Manual

SQC Manual Index:

Production Flow ChartYarn procurement and TFO / twisting. Warping and sizing.............................1

Weaving and grey fabric rolls ………………………………………….2Priming (coating) process and stuffing………………………………………..3 & 4

Technical Specifications:-……………………………………………………………… 5 & 6

Quality Control:

Part 1:-Q.C. flow chart up to weaving stage............................................7 to 8Part 2:-Q.C process during priming................................................................9Part 3:-Inspection systems................................................................ 10 to 15Marking…………………………………………………………………………..…16

CIL Textiles Pvt. Ltd. India

PRODUCTION PROCESS

YARN PROCUREMENT BASED ON REQUIRED SPECS FROM CONSISTENT SOURCE E.G. FOR COATED BUSINESS, YARN IS ALWAYS REQUIRED IN VIRGIN GRADE WITH MINIMUM KITTIES AND DEFECTS.

TFO / TWISTING OF YARN ( IF REQUIRED)

WARPING AND SIZING PROCESS

2

BEAM IS MADE AND SENT TO LOOM FOR WEAVING

GREY FABRIC ROLLS

Grey rolls are made in bigger roll length in order to obtain bigger pc length after finishing as per the requirements of the customer.

3

COATING IS DONE ON ROLLS PASSED FROM GREY STAGE WITH

3 LAYERS OF ACRYLIC JESSO WITH TITANIOM DIOXIDE

4

AFTER COATING , FINAL ROLLS ARE MADE FOR S.Q.C. PASSSED ROLLS ARE SENT FOR SHIPMENT

Shipment is made in duly inspected containers under the Supervision of the plant and then is sealed after stuffing.

5

TECHNICAL SPECIFICATION SHEET

Technical specification for coated (primed) goods:-

QUALITY CODE TOLERANCE 6 OZ /72" 8 OZ /72" 10 OZ /72"

WEAVE PATTERN OXFORD OXFORD OXFORD

COATED WIDTH + - 0.50" 71" 71" 71"

WEIGHT GSM ( OZ )FINISHED 20 gms+- 270 320 405

SELVEDGE CLOSED CLOSED/FRINGE FRINGE/ CLOSED

DEFECT POINTS /100 LINIER MTR 40 40 40

DESCRIPTION DOUBLE PRIMED DOUBLE PRIMED DOUBLE PRIMED

WHITENESS COM WITH APPROVED RANGE

COLOR TEST SHOULD PASS

FEEL OF FABRIC WITH APPROVED RANGE

TEXTURE OF FABRIC WITH APPROVED RANGE

PACKING ROLL

CORE DIA .

inner 60 60 60

outer 71 71 71

Adopter NA NA NA

ROLL SIZE +- 5% 100 YDS ROLL 100 YDS ROLL 100 YDS ROLL

FLAGS ON CUTTABLE DEFECTS MAX 1 PER ROLL MAX 1 PER ROLL MAX 1 PER ROLL

NO. OF SEAMS 2 2 2

FOR PRIMED FABRICS

1) Products are classified based on their end use and norms are fixed accordingly and separate group numbers are given for different product segments.

2) The classifications for qualities which are required to be coated are mentioned below under group C :-

6

TECHNICAL SHEET FOR GREY FABRIC WITH END USE IN COATING/PRIMING

WARP WEFT WARP WEFT Focus Points Allowed Not Allowed

IC-2020 100% Cotton PLAIN 20s 20s 60 60 40 Weight +/- 3 %

PC-1414 50/50 p/c PLAIN 14s 14s 32 28 40 Kitty level /sq inch5

IC-168 8 oz 100% Cotton OXFORD 16s 8s 84 28 40 Fluff Not Allowed

IC-1610 6 oz 100% Cotton OXFORD 16s 10s 80 28 40 Dirt Not Allowed

PC- 1610 50/50 p/c OXFORD 16s 10s 84 28 40 Wrinkle Not Allowed

IC-106 10 oz 100% Cotton OXFORD 10s 6s 74 28 40 CreaseNot Allowed

Reediness Not Allowed

Temple mark Not Allowed

Yarn shade variation Not Allowed

Pinhole Not Allowed

Hole Not Allowed

Contamination Not Allowed

Rub mark Not Allowed

Slubby weft yarn Not Allowed

Hanging thread Not Allowed

Improper mending for

knot, slough off lasing Not Allowed

THREADS /INCH POINTS/100

LINIER MTR

CHARACTERISTICS OF "C" GROUPPRODUCT CLASSIFIED UNDER GROUP 'C' FOR COATING WITH 10 % INSPECTION

CODE FIBER

CONTENTS

WEAVE YARN COUNT

7

PART I

Q.C.Flow chart up to weaving

1) All yarn is ordered based on standard specs required for a particular contract. E.g. for coated business, yarn is always required in virgin grade with minimum kitties and defects.

2) Yarn sample is tested from the yarn lot received to check the required norms as shown below the. Photograph of yarn testing machines used to find strength and actual count of yarn.

TEST REPORT OF YARN

NAME OF MILL

REQUIRED COUNT

ACTUAL COUNT FOUND

C.S.P ( STRENGTH )

APPEARANCE OK/NOT OK

RESULTS OK/NOT OK

DT OF RECEIPT

SIGNATURE

3) After warping & sizing process, production starts in weaving section. Inspection of fabric on running loom is done to see the appearance of fabric and to ensure proper setting for loom .

8

.

If there is any issue which needs to be corrected immediately after start of looms, it is taken care of. e.g. Reed marks , temple marks if observed has to be stopped at this stage itself. Weave pattern is checked.

4) Fabric sample is drawn from initial production for testing the parameters required through instrument shown below Tensile strength for fabric is testing with below instrument. It is done based on cutting strips of 6”x4” grab test method and also by using 5x20 cm strip of fabric.

5) Once a roll is made, it is sent for mending the defects. I.e. if there are any defects which can be

corrected by manual correction, it is done. Like hanging threads are cut, dirt marks are removed using guns. Major defects are cut. Flags are marked.( if required by customer )

6) After mending and checking by internal S.Q.C. final roll is made and if it is under the norms, it is offered for final inspection by the external S.Q.C. which is working independently from production dept. Checking is done randomly for 10 % of the lot .If ok, and then it is dispatched for next process on it. If the defects are below 40 points / 100 linier mtrs, then it is passed from grey stage.

9

PART IIQ.C. Process during Coating (Priming)

1) Coating is done on rolls received duly passed after grey inspection stage.

2) 3 coating of acrylic gesso with Titanium dioxide is used.

3) It is continuously monitored during entire coating process in all 3 stages of coating i.e. 1st coating, 2 nd coating and then final 3 rd coating. In process checks for weight, width is done after each layer of coating.

4) Fabrics from each batch are checked for whiteness, texture and feel as per standards.

5) Coated roll is sent for mending, Checking, cutting and final packing by plant.

6) Again the lot already passed by coating plant is randomly checked by the external S.Q.C.

7) If the lot is given ok based on fixed norms of fewer than 40 points /100 meters, then it is ready for dispatch for exports.

8) Containers are checked before stuffing of goods.

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PART IIIInspection system

1) 4 point American system for inspection is followed.

2) A fixed format for inspection is used for both grey and coated fabric.

3) Format for inspection summary for grey goods is given below :-

defect points…….:- 4 2 4 1 3 1 2 4 3 4 1 1 1 2 2 4 4 1 Total

Roll No QUALITY Mtr Pcs 1

Det

ails(

in m

tr)

Pcs 2

Det

ails(

in m

tr)

Pcs 3

Det

ails(

in m

tr)

width Bad

star

ting

mar

k

Brok

en p

ick

Doub

le pi

ck

Wbk

s

Wbk

s

HANG

ING

THRE

AD

Loos

e en

d m

ende

d

Coar

ser e

ndSl

ough

off

CRAC

K/PA

TTI

Bad

boar

der

Oily

spot

Knot

sCo

lour

/ Ha

irOI

LY W

ARP

& OI

LY W

EFT

FINN

ER W

EFT

FLOA

TSl

ub

Tota

l def

ects

in th

e ro

ll

tota

l poi

nts i

n th

e Rol

l

Poin

ts /

100

mtr

7142 6 oz 72" 211.00 211.00 72" 2 2 2 1 3 2 2 3 4 2 5 28 59 28

7143 248.00 248.00 5 3 1 2 1 2 3 7 3 3 8 38 79 32

7144 302.50 86.50 216 4 2 4 2 3 3 4 1 5 2 6 36 77 25

7145 238.50 158.00 80.5 3 2 1 2 1 4 3 2 1 5 7 3 1 7 42 87 36

7146 357.00 357.00 3 1 3 2 2 2 1 5 8 1 6 4 9 47 103 29

1357.00 0

0

9159 8 oz 72" 237.00 237.00 2 1 2 3 2 4 5 7 3 6 35 74 31

9160 326.00 141.50 184.5 3 2 2 6 1 6 9 5 2 4 40 84 26

9161 317.00 317.00 5 3 9 3 7 1 8 3 5 5 49 97 31

9162 223.00 223.00 4 4 5 2 3 5 5 4 6 38 82 37

9163 296.00 296.00 2 10 3 3 2 2 6 3 7 38 78 26

1399.00 0

0

7288 10 oz 72" 293.00 50.50 242.50 1 3 2 5 1 3 2 4 2 4 2 8 4 6 47 96 33

7290 298.00 102.00 196.00 4 4 6 4 2 1 2 4 3 8 3 5 46 102 34

7291 299.00 101.00 198.00 3 3 1 4 4 3 3 1 1 6 2 1 6 38 84 28

7292 300.50 300.50 3 2 3 2 2 1 2 3 2 5 3 1 4 33 81 27

7293 291.50 291.50 2 6 2 5 1 2 4 2 3 6 2 7 42 90 31

1482.00

Major defects are1) bad starting marks2) warp breakages3) cracks4) oily warp and weft.5) Double picks6) Knots

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4) Format for inspection for coated fabric is given below.

COATING INSPECTION REPORT

ROLL NO: - MTR -

QUALITY

NET WT -

COATED WIDTH : PCS

NAME OF THE INSPECTOR

DATE OF INSPECTION

MTRS

POINTS 1 2 3 4

DEFECT SIZE "0-3"

3-6" 6-9"

9 UP

TOTAL DEFECTS 0 0 0 0 0

POINTS 0 0 0 0

TYPE OF DEFECTS BAD STARTING MARKS ( BSM

)

TOUCH UP

LOOSE END

EXCESS CHEMICALS

CHIPS LINE

WARP BREAKAGE

EXCESS CHEMICALS LINE

CRACK

HANGING THREAD

OILY SPOTS/LINING

FLOTS

KNOTS

WARP BREAKAGE

WRINKLES

LT

5) Each defect is counted based on its size. • For defects up to 3” ,1 point is given• For defects more than 3” and up to 6” 2 points are given • For defects between 6” to 9”, 3 points are given• For defects more than 9” , 4 points are given

6) Cut table defects are cut and are not taken into point calculations.( Or FLAGS are put in if

12

customer wants it in order to get bigger piece length.)

7) Defects are marked in respective column.

8) Total points are calculated and converted to defect points/100 linear mtrs .If defects points are less than 40 points/100 linear mtrs, then it is graded under “Passed” category.

9) Defects shown below are taken in point calculations, if they are small,But if size is bigger in size more than 9” and are multiple, they are cut.

A) BAD STARTING MARKS

B) TOUCH UP

C) LOOSE WARP

D) EXCESS CHEMICALS

13

E) CHIPS LINE F) EXCESS CHEMICAL LINE

G) CRACK H) HANGING THREADS

OILY SPOTS/LINES J) FLOTSa.

14

K) KNOTS L) WARP BREAKAGES

M) WRINKLES N) LT

10) Further apart from points system, S.Q.C. has to check weight of the fabric, appearance, whiteness, feel and weave pattern of fabric ( as per chart shown in technical sheet and base approved samples )

11) For coated fabric, sample cutting from each roll is taken for records.

12) Color test for each coated roll is performed and if it gets passed if there is no penetration on the back side of the fabric under acceptable limits, then only the roll is finally approved for exports

15

Procedure for doing the color test is given below:-

Test equipments:50ml Glass Beaker Hog Hair Brush – B 36 size 10Artist Oil Color French Ultramarine Georgian Oil Color Burnt Sienne System 3 Emerald Green WaterArtist Turpentine Linseed Oil Palette knife or other suitable stirrer.

Test Methods:

Check the surface of the canvas to ensure it matches for whiteness tooth. Check also that any color applied to the surface is free – flowing j.e.does not drag under the brush .

Mix a 10% solution of artist Oil Color French Ultramarine in Turpentine using a palette knife and glass beaker. Apply by brush to the canvas surface and allow to dry .Leave to dry overnight. Check for any penetration of the color thought to the reverse side of the canvas.

Make 10% solution of artist Oil Color French Ultramarine in Linseed Oil. Apply the solution by brush to the canvas surface and allow to dry. Leave to dry three days. Check for any penetration of the color thought to the reverse side of the canvas at twenty four hour intervals.

Using a brush. Apply Georgian Oil color burnt sienna directly from the tube to the canvas surface. Check for the drying of the oil over a period of five days at 24 hour intervals.

Mix a 10% solution and system 3 Emerald Green in water using the beaker. Apply by brush to the canvas surface. After one hour check any penetration of the acrylic in to the surface, any unevenness, and that the color has dried.

( Note: all solutions are freshly made before testing the canvas.)

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9) Marking on final rolls is done as shown in example below.

10) Packaging is done with LDPE layer on the fabric and then LAMINATED HDPE on top

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