Scarves are great promotional products for sports teams, music festivals, or outdoor corporate events. They can be fully customized and offer a large area for branding. Also they are very useful as they will keep your customers warm during winter months and outdoor events or while enjoying a football game on a cold weekend.
The Knitted Scarf production process combines both automated machine work and manual labour.
Production can be broken into six different steps that span from creating the design, to manufacturing and packaging. Here is what our customer learned from his visit.
Step One: is creating the design of the scarf, selecting the patterns, the logos and wording. Each side of the scarf can have different design but need to use the same colors. How will the knitting machine know what pattern to create? The design of the scarf is created on a computer and is saved in a certain file type which is then converted into a knitting program.
Step Two: is to choose the quality and type of textile to use. Once the textile is chosen whether it be acryclic, cotton or satin, the fabric needs to be dyed in order to match the color that your client requested. This is a very important step, it is crucial to make sure that all pantone colors are according to the client’s demand.
Step Three: is the knitting process. Once all the fabric has been dyed correctly the fabric is brought to the knitting machines. The machine begins running the fabric through the machine (see picture on the left of machine with scarf being produced). The knitting program is loaded on to the electronic knitting machine, which can store the data of the design. These knitting machines are controlled electronically and one employee can supervise several machines at the same time in order to make sure there are no problems or glitches.
For knitted football scarves the machine can handle a total of five colors at the same time on an automated kitting machine.
The machine will keep knitting scarves repeatedly until there is no more thread. Manual labor comes into work at this moment, in order to reload fabric into the machine and also to cut all of the knitted scarves individually. The machine does not separate each scarf during the knitting process, once it finishes one scarf’s design it immediately begins a new one which is still attached to the previous one.
Depending on the stitch density your scarf requires different machines are used. The knitting machines vary between 8 to 16 knitting needles per inch (many more needles per inch are possible), this is referred to as a 8 to 16 gauge machines. The higher the gauge the higher number of stitches are knitted per inch.Once the scarves are separated by cutting them loose individually they are moved to the next process.
Step Four: is the ironing process. In order for the scarves to be nice and flat they are ironed on a steam board. Since the scarves are not closed at both ends, a board is slipped inside the scarf. Each scarf is then ironed thoroughly.
Step Five: of the scarf production process is the sewing of the tassels. The tassels are created with a different knitting machine (see pictures below). The tassels can be made in any color even if it is a different color then the ones on the scarf. Since they are manufactured independently there are no color issues. Factory workers will then sow the tassels on each end of the scarf in order to complete the manufacturing process. A standard size for tassels is between 4cm and 6cm long. After the tassel is sewn on the scarf production process is complete.
Step Six: is the packaging. Before shipping the goods to your client you need to package each scarf individually in the packaging required by your client and to then prepare the cartons for shipping. How about putting a paper insert if giving these away as an on-pack or cardboard header on the polybag for retailers.
When placing orders for scarves please prepare ample time in order to make several production samples before placing the order. Don’t forget to schedule quality control inspection throughout the production of the goods in order to guarantee the quality of the scarves.
Interested in knowing about some other production processes? Check out the links below: