Automation in

spreading and
cutting.
(in Textile Industry)
SUBMITTED TO – MS. USHA SUBMITTED BY
YADAV ADITI DANDRIYAL
ARCHANA SINGH
Spreading

 Fabric spreading is a method where piles of fabrics are spread a

specific length and width wise according to the garment marker
measurement.
 The fundamental purpose of spreading machines is to superimpose
layers of fabric in a smooth, tension-free manner for accurate and
efficient cutting.

Types of spreading machines

 Manual
 Semi automatic
 Fully automatic
Manual Method

 Fabric is laid completely by hand.

 With the help of mechanical assistance as
roll cutter.
o The operator clamps the free end of fabric
in line with the end of the spread.
o Pushes the spreader to the other end.
o Cuts off the ply in line with that end.
o Clamps the beginning of the next ply.
o Pushes the spreader to the other end other
end and so on.
Automated Spreading
machines
 The spreading machine is stationed
at one end of the cutting table.
 Fabric roll or folded fabric stack is
loaded on the spreading machine.
 One operator is required when
spreading is done using an auto
spreader.
 The automatic spreading machine
is operated by one operator.
 The same person checks the fabric edge,
remove unnecessary creases on the
fabric layer and collect end bits.
 The fabric spreader reaches to the end
of the marker and starts laying the fabric
on the table.
 When the spreader reaches to other end
of the marker, auto end cutter split the
fabric from roll.
•Intelligent Equipments and Functions:

oTouch panel display - Execute computer order precisely.

oFabric loading sensor - Machine returns to original position once fabric runs
empty.
oEmergency stop device – Brake wires are under two sides of fabric.
oManual /Automatic – To control the amount of fabric feeding freely.
• Fabric Control Device:
 Tensioning Mechanisms - Tensioning involves synchronizing the rate of
spreading with the rate fabric is unrolled. A positive feed system utilizes a
covered roller that is driven and timed to the movement of the machine. It
prevents the momentum of a large roll from continuing to unwind when the
machine slows down or stops. Roller covers of different materials may be
used to give better gripping power for different types.
 Positioning devices – Electronic edge sensors monitor selvages is fabric is
spread.
 Width indicators - Width indicators may sound an alarm to alert the operator
whenever fabric becomes narrower than the established width. Width
variations are analyzed to determine where in the marker they fall, whether
the fabric will still fit the marker, or whether the variation should be treated
as a defect and removed.
 End treatment system – End catcher, roller blade. An overfeed device may
be built into the spreading unit which automatically feeds extra material
when a fold is to be made.
Automatic Turntable:

 Semi-Automatic – May use either catches or a cut off knife mechanism, and is self
powered. Requires the spreader to manually rotate the fabric turntable rack when
spreading F/F , N/O/W and F/O/W , N/E/D modes of spreading.

 Fully Automatic – Capable of rotating the fabric as well.

Fabric defect marking sensors:

 In this system, a reflective label is normally fixed at the selvedge of the fabric during
the fabric preinspection. Automatic spreading machines having this sensor detect
the label as it crosses the electric edge control eye and stops the machine and
allows spreader to trace the defect.
Pin table:
 To match the checks and tripes while
spreading hence each pin is
positioned inside the block on table

Air flotation tables:

 The cutting tables having air jets
fitted at the bottom of the table
facilitates moving the entire spread
to the adjacent cutting area.

Vacuum table:
 The vacuum is applied from the
bottom of the table through small
holes in the table after a polythene
cover is spread over the top of the
entire lay to compress the lay and
stabilise it.
Heavy roll loaders:
 It is used when roll weights surpass 200 lb per roll. It has the capacity to
manage rolls weighing over 1200 lb and these are used to lift the fabric
rolls from the floor to the spreading machine.
Comparison
Manual
 Spreading done manually
 Equipments - Spreading table,
Fabric feeder, Cutting device
 Low cost
 Low Productivity
 Two operators needed
Automated
 Spreading done by machine
 Equipments - Spreading table,
Spreading machine
 Tension control mechanism
present.
 Position mechanism present
 Width indicators present
 End system treatment present
 Fabric defect marking system
present
 High expenses
 High productivity
 One person needed
Cutting
 Cutting is the process which cut out the pattern pieces from specified fabric for making
garments. Using the markers made from graded patterns and in accordance with the
issue plan, fabrics are cut to prepare garment assembly.

Cutting depends on-

 Nature of fabric (grain line shade, twill etc.)
 The thickness of fabric.
 Design characteristics of a finished garment.
 Machines and tables used.
Types of cutting systems

 Manual cutting machines

 Semi automatic cutting machines
 Fully automatic/ Computerized cutting machines

Manual Method Computerized Method

Scissor Knife Cutting
Round knife water jet
Band knife Laser cutting
Straight knife Plasma torch cutting
Manual Cutting

 It is used for cutting one

or two plies
 Not very efficient
 Takes a lot of time
 Can’t be used for bulk
production
Semi automated Cutting

 Band Knife
 Round Knife
 Notcher cutting
 Die cutting
Fully automatic machines
 Laser Cutting Machine
 Computerized Cutting Machine
 Water Jet Cutting Machine
 Rib Cutting Machine
 Air jet Cutting Machine
 Ultrasonic Cutting Machine
 Plasma Torch Cutting Machine
Working
Pattern that are developed or digitized in a CAD system.

These are connected to the automatic cutter.

Lines, notches, drill holes, and other marks are detected owing to the cutter software.

The laying machine is part of the cutting table

Operation is carried out by only 1 person

All cutter machines include a labeling system that mark pattern pieces with words or
codes used by the company and its quality management system. The cutting bridge
outfits the equipment for labeling and ultrasonic sealing, an inkjet printer, and other
optional tools.
Laser Cutting Machine:

 The fabric is cut by a ray of light in a very fine spot

by using a laser.
 The cutting head is controlled by a computer.

Spreading automation
1. Feeding unit
2. Conveyer belt
3. Table extension
4. Winding unit
Use of automation
 Less waste due to Nesting Software
The software analyses the parts (shapes) to be produced at a particular time
and arranges them in a way for the best optimization.

 Conveyor System for the fully automated laser processing directly from
the roll.
 Edge control mechanism.
 Camera recognition for the laser cutting of printed fabrics
 Winding unit for the rolling up of already existing textiles.
 Unique variety of table sizes – suitable for many formats
 The material feed is at optimum tension.
 Stretch free feeding mechanism.
 No material distortion.
 Sensors are used to verify that fabric is positioned correctly.
 Contactless cutting.
 High accuracy and precision.
 Label different parts with printing module
 Mark sewing matches.
 Sealing of cut edges to prevent fraying
Computer controlled knife cutting
machine.
 This cutting machine provides
the most accurate possible
cutting at high speed
 It is suitable for large scale
production.
 Marker is not necessary to put
over the fabric lays during
cutting.
 Highly accurate and fast.
Working
 When fabric cutting command is given through computer.
 The cutting knife starts lay cutting from a reference point starting in the
computer memory of the marker.
 Notch point is made by the same cutting knife. Drill mark is also
produced by a separate drill situated in the cutting head.
 Speed of cutting depends on lay height.
 As the cutting proceeds, the vacuum pressure may drop into the lay. To
avoid the reduced vacuum pressure problem, another polythene sheet
roll may be used to cover the cut portion of the lay.
 Computerized straight knife cutting machine does not require any use
of marker.
Water Jet Cutting Machine:
 A very fine water-jet is passed through a
nozzle at a very high speed to cut the
fabric lay.
 The pressure of water is 60,000 pounds
per square inch.
 The high pressure jet acts as a solid tool
when it encounters the material to be
cut, tearing the fibers on impact.
Water Jet Cutting
Innovative Step

 Loading and unloading during cutting process - increased system

duty
 Easier accessibility of the pieces produced by moving the material
support
 Increasing efficiency by minimising downtime
 Easy handling
 Automatic table shift after cutting process possible
 New material is located on the top shuttle table - thereby no
material remaining is falling on the new material
Thank you
References
 http://fashion2apparel.blogspot.com/2016/12/types-fabric-cutting-
machines.html
 http://www.assignmentpoint.com/science/textile/fabric-spreading-
and-cutting-section-of-garments-industry.html
 https://www.esabna.com/us/en/education/blog/waterjet-cutting-
process-basics.cfm
 https://textilelearner.blogspot.com/2013/03/different-types-of-
fabric-cutting.html
 https://www.eurolaser.com/laser-systems/software/optimum/
 https://www.onlineclothingstudy.com/2018/01/automatic-fabric-
spreading-machine-in.html