Waste in processing: how to avoid it?

Waste in textile processing is responsible for important losses, such as time, raw materials, impacts on quality and even its image in the market. This is a stage that involves fundamental processes for your products and that interfere with other production stages.

The exhaustion procedures, continuous and semi-continuous, have a primary influence on the results of the company’s parts and expenses. Therefore, it is necessary to invest in measures that avoid and control this waste, especially when it comes to modernizing and updating your machinery.

If you still doubt the need to avoid waste in processing, check out some of the most frequent situations that companies are not always able to analyze and correct.

Sewing errors at the exit of the looms that facilitate waste during processing

When the rolls leave the looms, they are joined together by seams. It is through this process that the batches that will be sent to the dyeing machines are formed. At this stage, the main error that generates waste in processing is sewing waste.

This happens when more line is used than necessary, which usually occurs due to a lack of monitoring in the phase.

To eliminate and minimize these raw material losses, it is necessary to control the sewing procedure in your production. The best option is for this to be done using automatic preparation machines.

Using this equipment, you can monitor the entire process, including the amount of line and raw material used, eliminating excess.

In addition to the output of the looms, it is also important to control other sewing processes, such as those that take place in openers, branches and dryers.

Failure in machine operations and the consequences of waste in processing

The machines and equipment in your industry represent an essential part of your production. However, just as they are essential for reducing costs and optimizing the production process, they can be responsible for waste in processing.

In this case, the amount of machinery used is not the only relevant factor, the machinery must meet the demand and pace of your industry. The main danger of using old or low-quality machines is operational failures that can cause electrical breakdowns, excessive consumption of energy and raw materials, in addition to not having the necessary efficiency for the product to have good quality.

Furthermore, they can affect the safety of operators, including many of them, being old, and may no longer meet NR12 guidelines.

It is also worth highlighting the importance of always applying training when a change or equipment is implemented, as a lack of understanding about machinery is a factor that can contribute to operational failures.

Have you read these?

• Quality standardization: essential methodologies
• How to modernize quality control in manufacturing?
• What is quality control? How does it work in the textile industry?

Loss control to reduce waste in processing

To monitor and avoid waste in processing, it is necessary to maintain a constant assessment of the percentage of losses. In some processes, it will be very difficult to reach zero losses. However, the more optimized and modern your production is, the less waste there will be.

To achieve this, it is important to work with loss rates that must be established according to frequent calculations. This way, it is possible to control these losses and set goals to minimize them.

To reduce waste in processing, it is essential to optimize your production processes. The most important thing is that your production line has modern and updated machines, as this eliminates several problems and you will have an easier time controlling losses that are harming the industry.

As you can see, investing in modern machinery is a matter of necessity and not just strategy. They provide solutions that bring benefits such as:

• Optimization of production and operator work;
• Elimination of operational failures;
• Increased security;
• Avoids production stoppages;
• Reduction of material waste;
• Adaptation to industry 4.0.

An example is the EHR 221 iConcept Eco Hydro Sprinkler Station. This equipment is used for the application of chemical products and/or for the recovery of residual moisture.

This Delta equipment ensures that the application is carried out at high speed, as it is equipped with modern electronic controls. This means that the exact amount is applied according to the desired weight and composition.

If you want to know more, check out our article “Moisture control of textile articles with the Hydro Sprinkler Station”.