Today in the sewing business, the efficiency of sewing machines plays a significant role in manufacturing productivity, product quality, the cost of operating the machine, and the timeliness of product delivery. However, alongside the maintenance of the machine and the skill of the operator, machine technology is a big factor in sewing efficiency.
The proper sewing thread will help decrease thread breakage and lower machine stoppages, provide more consistent stitching, and enable machines to run more quickly. However, by using the wrong thread, you can cause tension issues, stitch misses, faulty stitching of the seams, needles to start to heat up, and idle time.
So choosing the appropriate recycled sewing thread is an essential aspect of optimizing the sewing process.
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Understanding the Relationship Between Thread and Machine Performance
Throughout the process, there is pressure on the thread and rubbing. When the thread does not fit into the machine or work application, these contacts can be varied.
Common consequences include:
- Frequent thread breakage
- Uneven stitch formation
- Excessive lint generation
- Needle heating
- Thread tension variation
- Machine stoppages
- Increased rework
A well-designed thread can then run easily throughout the machine and provide uniform performance for the whole production run.
Select Thread Based on the Application
There is not one universal thread that is right for all articles. Factors like the materials and end-use of the individual should be considered when choosing the type of thread.
Fine threads are needed for the seams of lighter garments, whereas heavy garments like denim, workwear, and upholstery will need stronger threads that can provide higher loads.
Manufacturers should consider:
- Fabric type and thickness
- Seam construction
- Stitch type
- Required seam strength
- Sewing machine type
- Machine operating speed
- Garment end use
- Washing & finishing specifications
The fact that the thread is matched to the application helps to prevent any issues with the machine and will boost productivity.
Use High-Performance Thread Construction
The effect on sewing efficiency is profound when considering the different types of thread. A range of constructions is available, including spun as well as continuous-filament, core-sprung, and other specialized constructions, which give varying combinations of strength (meta-aramid sewing thread), elongation, surface, and abrasion resistance.
Manufacturers can be aided with threads capable of giving consistent run performance and minimum breakage for their high-speed sewing.
Threads with a strong core and fiber covering, such as core-spun material, can offer a helpful equilibrium of strength and sewing capacity. Continuous filament threads can have a relatively smooth surface and be of high strength.
The key is to choose construction for the machine and application that does not necessarily mean the strongest that is available.
Pay Attention to Thread Finish and Lubrication
Another key efficiency attribute of the machine lies with thread finish. The sewing thread has to pass through the sewing machine over and over again during sewing and also against the needle. Too much friction can lead to higher tension and heat.
Modifying the length of the basic thread per inch or adding various finishes and lubrication to the thread can help to ensure that it slides through the machine more smoothly.
A well-rounded finishing can help in achieving:
- Reduced friction
- Better thread movement
- Lower risk of breakage
- More consistent tension
- Improved high-speed sewing performance
But too much or the wrong lubricant can cause residue or compression of the next steps in the garment process. This finish, then, should be suitable for the machine, fabric, and finishing processes.
Optimize Thread Tension
A poor tension in the machine can lead to a poor performance even with the quality of the thread being used.
Tightly wound threads put undue strain on the thread and may cause damage or puckering at the seams. Loose or poorly formed stitches may result from lack of tension.
Sewing trials should be used to set up the correct tension on the machine, and this should be checked throughout the actual production.
Tension adjustment should not be restricted to setup time only but should be viewed as a process control exercise in the factories.
Match Needle and Thread Correctly
There are occasions when thread is evaluated without considering the needles. This means that the needle eye must be located to allow for smooth passage of the thread and without too much friction or damage.
An incorrectly sized needle can:
- Damage the thread
- Increase friction
- Produce oversized fabric holes
- Caused skipped stitches
- Increase needle heating
- Reduce seam quality
To sew efficiently, the following factors must be taken into account: the size of the needle, the size of the threads, the thickness of the fabric, and the stitch density.
Select Threads for High-Speed Machines
Industrial sewing machine manufacturers are now producing equipment that can be used at high speeds. At higher speeds thread movement is more difficult, and heat generation may occur.
If the high production speed is required, the manufacturers should make sure that their threads have:
- Consistent dimensions
- High abrasion resistance
- Controlled elongation
- Stable lubrication
- Reliable knot strength
- Low tendency to break
- Consistent winding
If a machine or machines does not stop automatically when the thread runs too fast, it can lead to machine stoppage and adversely affect the output per machine hour.
Reduce Downtime Through Better Thread Quality
One of the easiest but most costly threads to break in sewing. This involves the operator stopping the machine, discarding the broken thread, feeding the threads into the machine, and returning to the production process for every break.
Additionally, repeated breaks can cause:
- Lower operator productivity
- Increased machine idle time
- More defective garments
- Higher labor costs
- Production delays
Standard quality thread will take a long way towards reducing these interruptions. The quality of threads should, therefore, be checked during incoming inspection and production.
Consider Automated Sewing Operations
In particular in repetitive and high-volume production, automation is transforming the garment manufacturing industry. Less room is available for an operator to manually fix it at each sewing cycle; this means highly consistent thread behavior is imperative with automated sewing systems.
In an automated environment, characteristics like uniformity, winding quality, friction, and strength of thread become paramount.
A standard thread allows performance of a machine that is more predictable and enables manufacturers to benefit from automated processes more.
Monitor Thread Performance as a Production KPI
Production parameters can be monitored for thread instead of waiting for some significant quality issues to arise in the factory to improve efficiency.
Useful measurements include:
- Thread breaks per machine or production shift
- Machine stoppage time
- Defects caused by stitching
- Rework percentage
- Needle changes
- Production speed
- First-pass yield
These measurements can be used to see if a specific thread, machine setting, needle, or combination of fabric and thread is causing a problem in the production process.
Sustainability and Cost Efficiency
The other indirect sustainability aspects of thread selection are also an issue. Common thread breakages create material waste and machine downtime. Labels that come out wrong might need extra materials to repair and fix them or may simply be scrapped.
An efficient running, durable thread, in this way, can help to reduce the waste, as well as increase the production efficiency.
Important: Manufacturers should consider not only the thread purchase price but also the total cost of use of the thread. Sometimes a moderately higher cost thread can be more economical because it helps cut back on thread breakage, rework, man-hours, and downtime.
Conclusion
Efficiency of sewing machines is not merely about buying faster machines or operating at a higher speed. Technique is one of the key aspects of the sewing system.
The appropriate thread material, structure, surface and quality characteristics, tensile and lubrication characteristics, and size can enhance thread movement, lessen thread breakage, stabilize stitch formation, and facilitate fast threaded production.
The manufacturer should consider thread in conjunction with the fabric, needle, machine, stitch type, and production conditions. Efficient combinations can be further determined by regular testing and monitoring.
In fact, the right thread isn’t just a consumable; it’s one of the facets of the sewing process. Appropriate investments in appropriate garment application of thread would allow the garment manufacturer to have superior productivity, fewer defects, less downtime, and better garment quality consistency.
