Jute

How a Jute Bag or Carpet Cloth Is Made In a Jute Mill?

The production sequence of Jute Mills is slightly different from the sequence of traditional Textile Mills. The difference is due to the variance of finished goods quality and buyers requirement. Textile mills produce compatibly finer yarn and smooth fabric where the Jute mills produces coarser yarn and rough fabric which only used in making packaging Bag or the backing cloths of Carpet.

Though the main purpose of the Jute mills and a Textile mill is same but still lots of difference have found and bellow I will particularly brief you how a cloth is made from raw materials in a Jute Mill.

Raw Material Selection:

The one and only raw materials of Jute Mills is Jute. There are several Jute buying and selling Agency in a Jute producing country and Jute mill collect Raw Jute from this agency. After bringing the raw jute into the mill; a selection process is applied on the raw jute go-down to separate different quality of jute in different grade. The higher quality of jute which is Toss b or C is used for higher quality of fabric in addition to mixed up with other grades of jute. The lower quality of jute which is Toss0-X or SMR and Mesta D is used for lower quality and coarser packaging Bag. This is the way how the jute bales are separated and then prepared for making particular types of quality of a fabric.

Preparing a particular Batch (Batching):

There are several types of fabrics are prepared in Jute Mills like- hessian, Sacking and Carpet backing Cloth (CBC). In order to make hessian fabric or Bag; it needs hessian Warp and Hessian Weft yarn. Successively, sacking bag needs to have sacking warp and Sacking Weft. The high quality yarn is needed to make CBC. So, three batches are prepared for the three types of fabric. Therefore, different grades of Jute are mixed up to make a particular Batch. After selection of Jute, it needs to be treated by Oil and Emulsifier to make the fiber soften and flexible. As we see the Jute fibers are usually brittle and weak in strength. Jutes are kept in a row for a definite time for maturity which is called piling. After the maturity of jute; it is sent to the Breaker Card Machine for making a jute fiber roll which is called breaker roll. Sometimes Spreader Machine is used before the feeding of roll in Breaker Card machine.

Carding & Drawing:

Jutes are carded in the Breaker Card and Finisher Card for straightening the fiber and removing the dust. At the finisher card the particular batch system is maintained. Finisher Card matching provides the jute in a Roll Format which is then set to the Drawing Machine. At best three Drawing Frame machine are settled one after one row to make the Jute Finisher Card roll to more straightened, larger and individualized. At the Finisher Drawing or 3^rd Drawing machine, slivers are delivered as Crimp from so that it can be run on Spinning Frame without any problem.

Spinning:

Spinning is a very important stage to make a Jute Fabric. Yarn is one of the vital parts of a fabric and by applying proper twist and Draft in spinning frame the jute yarn are produced. By changing DCP and TCP you can change the weight and finer yarn as much as you want. There are two types of yarn are generally used in the Jute Mills named 1. Slip Draft 2. Apron Draft. The twisted or spun yarn then sent to the Winding Section.

Winding:

The yarn Bobbin that has been found from Spinning is then put on Winding Machine to make a Cop or Spool Winding Package for making it in a usable form in next process. Cop is used in Shuttle at Loom which provides the weft yarn and Spool is used in Beam which provides the warp yarn while fabrics are made on Loom.

Beaming & Sizing:

To provide Warp yarn in Loom, the yarn should be formed in Beam which is done in Beaming section. As spool is used in beam and in Loom a beam have to face lots of friction by Shuttle and Reed; the Beam should be sized with various enzymes and other related materials like starch, seeds powder etc in order  to give strength on Warp yarn which is called sizing. After sizing; beam is sent to the Loom section.

Weaving:

Weaving is done by interlacing the Warp and Weft yarn. Weft yarn is come from Winding section as a Cop from and Warp yarn is from beam. Loom is used to interlace the Warp and Weft yarn. A motion which is called Shedding, Picking and Beating is used here to make a Jute Fabric. After weaving the cloth is sent to the Finishing Section.

Finishing:

Finishing is the utmost and last stage of making a fabric where the quality and faults of fabric care checked. Later the cloth are formed in roll from or in other forms cut form. In the Hessian and Sacking section the cloth is calendared and then cut for making the Jute Bags.

Process Flow Chart of Jute Fabric Manufacturing With Emulsion

Emulsion Components of Jute:

Mineral Oil : 20%
Water : 79.5%
Emulsifier : 0.5%
Total       =      100%

Process Flow Chart of  Jute Fabric Production:

In the process of Jute Fabric; firstly the Jute Yarn is taken. There are two types of Jute Yarn is to be taken which are –
1. Warp yarn and
2. Weft Yarn.

Warp Yarn ——————-Weft Yarn

Spool Winding ————Cop Winding

Beaming or Dressing

Weaving

Finishing ———————Jute Bag Making

Damping

Calendaring

Lapping ——Bale Presss——- Hessian Cloth

Cutting

Sewing

Bundling

Branding

Bale Press ——— Sacking Bag in Bale Form.