Improving Textile Testing Lab Efficiency: A Comprehensive Guide from Equipment Selection to Quality Control

 

The Importance of Textile Testing Labs

Textile testing is key in textile production. It helps keep product quality high. It involves checking the qualities of various textile products to ensure they meet quality standards. Textile testing labs mainly assess how well textile products perform. They use test results to predict future performance. We must consider the product’s performance in conjunction with end use. Therefore, textile testing labs perform tests with the ultimate end use in mind.

Why do you need to conduct textile lab tests?

Textile testing ensures that raw materials and finished products meet quality standards.

It is also known as a lab experiment. This test checks the textile data of fiber, yarn, fabrics, and other products.

Testing checks the nature and quality of fibers, yarns, fabrics, and materials. This helps to ensure high standards.

Testing can include various types, such as:

• • Fiber length

  • Strength

  • Fitness

  • Maturity

It also covers yarn strength, count, twist, fabric, EPI, PPI, and GSM.

Textile testing uses special techniques and procedures. These follow standards from international organizations like ISO and ASTM.

Objectives of the Textile Testing Lab

The objectives of textile testing labs are as follows.

1. Checking Raw Material

2. Production Monitoring

3. Faulty material investigation

4. Final product’s assessment

5. Product Development

6. Research Purpose

How are textile testing labs helpful?

The results of textile testing labs will help the scientists decide which route to take.

It helps to select the raw materials. The raw materials are a relative term. For example, fiber is the raw material for a spinner, and yarn is the raw material for a weaver.

Textile testing labs help control the spinning, weaving, dyeing, and finishing processes. You can control end breakage by adjusting the weight based on the length of each lap.

They control the weaving process by preventing excessive warp and weft yarn breakage. The fabric-liquid ratio, temperature, and pressure control the dyeing process.

Quality control assures the quality of the end product, such as yarn, which is the end product of spinning.

Process development boosts product quality by saving time and money.

Textile testing labs help in the continual search for new knowledge and developing new products.

Common Textile Testing Methods and Instruments

Textile testing checks product quality and tracks production processes. It uses various methods to meet specific requirements. These methods include mechanical, physical, and chemical testing. Here, we will discuss a few standard testing methods.

1. Fabric Strength Testing

Fabric strength testing shows how much force a fabric can withstand without rupturing. Fabric strength depends on ends per inch, picks per inch, and yarn count. There are two tests to check textile strength and fabric durability.

• Tensile strength testing

• Tear strength testing

Let’s have a look at these two methods.

• Tensile Strength Testing

The fabric’s tensile strength is key to how well a garment performs. The fabric or material can withstand tensile force.

The type of fibre, the method of fabric production, and the finishes used can affect the fabric’s strength. This, in turn, impacts how well it performs during use.

ChiuVention tensile testers measure grab strength. The results show a material’s tensile properties well.

                                                                                                                               Fabric Tensile Strength Tester

A fabric tensile strength tester measures the tensile strength of woven fabric. This tester can apply a load at a constant extension rate and record the load at which the specimen breaks down. Two commonly used methods are tensile and grab.

The Sampling Requirement of Tensile Testing

This procedure details the grab strength method with the ChiuVention tensile testing machine. Cut five test pieces along the length (warp) and five along the width (weft) from the sample.

The specimens measure 150 millimeters and 500 millimeters. The longer side runs parallel to the testing direction. The ChiuVention tester is set up with the correct jaw phases in both the top and bottom holders.

The back jaw face is 75 × 25 mm, and the front face is 25 × 25 mm. The gauge length, the distance between the top and bottom jaws, is set to the specified distance.

Choose the right test program from the computer menu. Then, enter the required details on the screen. The computer will set the machine up for testing.

Mount the test specimen in the upper jaw and clamp it. Then, place it in the bottom jaw and clamp it too. This keeps it straight.

The user depresses the start button to allow the machine to apply the load until the specimen breaks. The computer records this data, and you may then remove the specimen.

We mount the next specimen as before. The process keeps going until every specimen is tested. Then, the computer prints the test results.

• Tear Strength Testing

This is an important test to check how strong a fabric is when it starts to tear. It measures how well the fabric can resist further tearing once a tiny rip or cut has already begun.

This test matters for industrial fabrics, bulletproof vests, tents, jeans, and trendy clothes. It checks how well these materials resist tearing once a small rip starts.

There are two main types of tearing strength tests used in the textile industry.

• Tongue or Single Rip Tear Test

• Elmendorf Tear Test

In the tongue test, two cuts create a tongue shape in a sample. Then, a tensile testing machine pulls on the sample. This measures the force needed to keep tearing.

                                                                                                                                  Tongue or Single Rip Tear Test

Number two is the Elmendorf tear test. This standard method determines the force to propagate a tear through a fabric. A pendulum device tears the fabric, and we measure the energy absorbed in tearing it.

This guide explains how to perform the Elmendorf tearing strength test. We will follow the ISO 13937 part one method. We are using a ChiuVention Elmendorf tear tester for this test.

                                                                                                                         Elmendorf Tearing Strength Tester

How to Perform Elmendorf Tearing Strength Test

Let’s prepare our fabric samples. We need five specimens cut along the length, or warp direction, and five along the width, or weft direction.

To do this, we place the tear template on the fabric and mark the size of each piece as 100 × 75 mm. Then, we cut out a small piece 15 mm × 12 mm from the top center of each sample. We will do the same for both warp and weft specimens.

Next, we condition the specimens. This means we keep them in a controlled room at 20° C and 65% relative humidity for a specific time. This ensures our tests are accurate. Now, we’re ready to test.

We place the tear-strength tester on a sturdy table and set it to zero. We also check the weights to ensure their calibration is accurate.

We select the right weight for our samples to get results within 15% to 85% of the full scale. Next, we put the first specimen in the tester’s clamps. We ensure the long edge rests against the bottom step of the static clamps.

                                                                                                         To get results within 15% to 85% of the full scale.

And what about other details of the Fabric Elmendorf Tearing Test?

Next, we use a knife to cut a 20 mm slit in the bottom edge of the sample. The cut should be clean, and the fabric should stay in place. We release the pendulum to tear the fabric. Once we finish, we catch the pendulum on its return swing to avoid disturbing the pointer.

We then read the result from the scale or digital display. It’s essential to check that the tear happened in the central area of the specimen. If it didn’t, we discard that result and repeat this process for all the remaining samples.

Finally, we calculate the mean strength in the warp and weft directions. If any specimens didn’t tear, we report their strength as more than the pendulum’s greatest capacity.

That’s how we test the tearing strength of fabrics.

                                                                                                                    Tearing Strength Test of Fabric

The Elmendorf Tearing Tester with IoT

This ensures that fabrics for high-performance and industrial uses are strong and dependable. An easy-to-use tearing strength tester offers reliable results. It features automation efficiency and built-in IoT technology.

This tester connects to the SmarTex lab app with minimal effort. It sets parameters, monitors tests, and sends important alerts to your smartphone.

The innovative balance pendulum plate design guarantees top testing accuracy. It aligns the center of gravity. This ensures reliable Elmendorf tier strength tests every time.

This tearing strength tester detects attached weights without manual intervention. It adjusts to the right force range, ensuring optimal testing results.

2. Color Fastness Testing

Various tests check how well a fabric holds its color. Common colorfastness (CF) testing methods are below.

• CF to Washing

• CF to Rubbing

• CF to Light

• CF to perspiration

• CF for dry cleaning

Here, we will discuss the color fastness of rubbing.

• Colorfastness to Rubbing

We will use a ChiuVention crock meter for assessing the rubbing fastness of fabric. The rubbing test has two techniques.

• Dry Rubbing

• Wet Rubbing

 

•                                                                                                                 Crock meter

To test fabric rubbing fastness, cut two pieces at least 14 × 5 cm for dry rubbing. Then, cut two more pieces for wet rubbing.

The technician cuts one sample of each pair along the warp direction. Then, Colby finishes getting a sheet of 14 × 5 centimeters from the yarn and fiber.

The clamps fix the test specimen onto the chronometer in the case of printed fabric. Fix the sample so that the test rubs against all colors of the design.

In the dry rubbing test, you attach a piece of white cotton cloth to the end of the crock meter’s finger. The cloth is usually provided by the manufacturer.

Someone rubs the test sample back and forth ten times. We do this on a straight track that is ten centimeters long on the dry specimen. We measure the color transferred from dry rubbing by comparing it to the grayscale. This helps us check for staining.

In the wet rubbing test, we repeat the previous test. This time, a fabric rubs against a white fabric that is wet with water. They squeeze the white fabric to keep its water mass.

3. Abrasion Resistance Testing

Fabrics wear out due to abrasion on clothes. This often happens at elbows, knees, collars, and cuffs. The way the manufacturer makes and finishes the fabric impacts the garment’s durability.

The Martindale abrasion test checks how well fabrics resist wear. It helps ensure that garments can handle normal use over time.

The Martindale abrasion tester measures how well textile materials resist abrasion.

A standard reference fabric, often woven from wool, rubs against the test material. Many directions cause this rubbing, which we call Lissajous movement.

The test ends when a set number of threads break on plain fabrics. It also ends if the look of pile fabrics changes a lot.

Someone cuts a piece of fabric from the main sample. Then, a cutting die produces four round test specimens. The technicians mount these specimens in the top holders of the Martindale tester.

The Main Process of Abrasion and Resistance Testing

First, place the specimen in the holder. Then, put a circular piece of foam on top. Finally, screw in the metal insert using the tester’s jig. Someone places a new wool abrasive fabric on the abrading table with a piece of felt beneath it.

The operator places the tension weight on the abrader and fixes the retaining frame. Someone prepares all four or six holders and the braiding tables as described.

The abradant receives the tension weight.

The holders move to the operating position. Then, we apply the right loading weight. I reset the counters. Then, I set the preset counter to the needed revolutions and turned on the machine.

When the machine stops, the top holders come off. The test specimens stay in the holder. The ChiuVention tester lets you connect to your smartphone with the Smart-Tex Lab app.

                                                Martindale Abrasion Testing Results

Researchers use a low-power microscope to check whether they have reached the endpoint.

If not, we replace the testers’ holders, and the machine runs for a further number of revolutions. Once the specimens reach their endpoint, someone takes them from the holder. Then, we mount them onto a test card for the report.

How to Choose the Right Textile Testing Instruments?

                                                                                                   How to Choose the Right Textile Testing Instruments?

Choosing the right textile testing instrument requires research and a roadmap. It requires the answer to these questions.

• What do you want to test?

• What type of test do you require for your material testing?

• How much of a budget do you have to choose the right instrument?

1. Test Identification

Textile testing covers many areas. You need to know what type you want. For instance, think about physical, chemical, or mechanical testing.

Physical testing includes tensile, tear, and abrasion testing. Chemical testing has a wide range of colorfastness tests of dyeing and printing.

2. Required Testing Standard

Different international standards like ASTM, ISO, and BS exist for the same test. Make sure you know which international standard you need. Check if your chosen instruments meet the standard’s guidelines and rules.

3. Select Manual or Automatic.

Manual instruments work best for fewer tests and cost less than automatic ones. Automatic instruments are great for many tests. They offer better precision, but they are more expensive than manual instruments.

4. Availability of Spare Parts and Maintenance

Lab instruments are sensitive. Make sure their spare parts are easy to find. Also, check the maintenance costs.

5. Cost & ROI

The lab manager needs to know the total cost. This includes shipping fees, installation charges, and equipment prices.

How Laboratory Information Management Systems (LIMS) enhance laboratory testing efficiency？

1. Automating workflows to reduce manual intervention.

• Automated Sample Tracking: LIMS creates unique electronic labels for each sample. It tracks location and status in real time, like received, processed, or stored. This system eliminates manual recording errors.

• The system assigns testing tasks to staff without manual intervention. It also sends deadline alerts through email or the app. This cuts down on communication overhead.

• Direct Instrument Integration: Links to lab equipment like HPLC and mass spectrometers. This captures raw data without any intermediary. It cuts out manual transcription and lowers error rates by more than 90%.

Case Study: A pharmaceutical lab cut sample turnaround time from 72 hours to 24 hours. They did this by using LIMS, which led to a 300% increase in efficiency.

2. Centralized Data Management to End Information Silos

• Unified Database: Keeps all test data, reports, and SOPs in one spot. You can search with keywords, so you won’t have to rummage through files.

• Version Control & Audit Trails: It tracks data changes without manual input. This helps meet regulations like FDA 21 CFR Part 11 and cuts audit prep time by 70%.

• Cross-Department Collaboration: Helps R&D, QA, and production teams share data. This cuts down on redundant testing. For example, a chemical company saved more than ¥2 million each year.

3. Intelligent Workflow Optimization

• Dynamic Priority Change: This feature alters testing sequences without manual input. It considers sample urgency and instrument workload. As a result, it boosts resource use by 40%.

• Anomaly Alerts: These warn you about out-of-spec results or equipment failures. They suggest actions such as recalibration or replacing reagents.

• Template-Driven Reporting: Generates industry-compliant reports in minutes instead of hours, slashing human effort.

An environmental lab cut report errors from 15% to less than 1% by using LIMS templates.

4. Strengthening Compliance and Quality Control

• Electronic Signatures & Access Controls: Restrict data approval to authorized personnel, preventing tampering.

• Real-Time Compliance Checks: This checks methods against standards like ISO 17025 and GLP. It blocks any operations that don’t comply.

• Automated QC Charts: Create control charts like Levey-Jennings with minimal effort. This helps to spot instrument drift or batch problems on time.

5. Resource and Cost Optimization

• Smart Inventory Alerts: Automatically places orders for supplies when their levels decrease. This helps avoid workflow disruptions.

• Equipment Use Analytics: Tracks how often instruments are in use and when they are idle. This helps with better scheduling. For example, one lab cut idle time from 30% to 8%.

• Cost Allocation: Calculates per-project costs (reagents, labor, equipment) to support pricing decisions.

6. Remote and Mobile Capabilities

• Mobile Access: Check progress or approve reports on your phone or tablet. This lets you respond to emergencies from anywhere.

• Cloud Deployment: Syncs data across labs worldwide. This cuts project delivery times by 50% for global CROs.

Summary: How LIMS Acts as an Efficiency “Booster”

• Short-Term Benefits: Reduces repetitive tasks, minimizes errors, and accelerates response times.

• Long-Term Value: Builds data assets, optimizes resource allocation, and drives digital transformation.

Action Tip: When choosing a LIMS, focus on three things:

• Flexibility: Look for customizable workflows.

• Integration: Ensure it works with your current devices and ERP systems.

• Vendor Expertise: Check their experience in fields like pharma, environmental, or food testing.

By the Numbers: Labs with LIMS see 40–60% more efficiency, 80% fewer errors, and 50% lower compliance costs.

Quality Management Systems in Textile Testing Labs

                                                                                                                  Quality Management Systems in Textile Testing Labs

The quality management system includes documented activities. These activities help the organization meet customer needs and improve over time. It has two components: quality control and quality assurance.

Importance of QMS

QMS in textile labs is a system of steps that checks product quality. It ensures that the results meet customer needs. This system boosts product quality and customer satisfaction. It does this by following ISO 9001 rules.

Optimizing Lab Workflows with Innovative Technology

Laboratory optimization applies technology to perform laboratory tasks with minimal human involvement. This approach enhances efficiency and accuracy and is pivotal in modern textile labs. We can divide lab optimization into several key areas.

• Instrument automation

• Sample handling

• Plate handling and management workflow automation

• Data management automation

• Robotics and lab automation

• Quality control and monitoring automation

• Safety and containment automation

• Sample Transport and Logistics

Adapting innovative technology enhances workflow efficiency, reducing testing time and costs. It also avoids human error, providing more accurate and precise results.

For instance, ZARA uses an AI-driven QMS. This system boosts production and cuts down on waste. The laboratory information management system (LIMS) makes data management easier. It also helps to track faults.

Near-infrared spectroscopy (NIR) performs a rapid analysis of materials. This saves time and helps make fast decisions, boosting production.

Interpreting textile testing results and generating reports.

Interpreting textile results relies on a complete analysis of the fabric. This includes physical, chemical, and mechanical tests. Someone should provide a detailed and comprehensive report of textile testing results.

If the customer wants shrinkage under 3% but our fabric shrinks 5%, our sample fails their test. We will analyze and test the fabric to meet customer needs.

The textile report must include details about the sample.

This list includes:

• Party name

• Sample name

• Quantity

• Test standard

• Testing method

• Results

A thorough report impresses customers. It boosts their trust in the organization.

Development and Challenges of Smart Textile Testing Technologies

Google Jacquard by Levi’s features a smart coding system. It uses smart textile technology, which is the next generation of wearables.

The Ridge and small wearables, which have limited interfaces, are evolving. They are now becoming a large, flexible smart loading system. This new system connects the physical and digital worlds through smart textiles. It offers an unlimited interface, enhancing usability and functionality.

Conclusion

Textile testing labs focus on assessing the performance of textile products. They use test results to predict future performance.

Testing checks and confirms the type and quality of fiber, yarn, fabric, or other materials. It helps ensure high standards.

Laboratory optimization uses technology like QMS, LIMS, and NIR. This helps do lab tasks with less human effort. This approach enhances efficiency and accuracy and is pivotal in modern textile labs.

FAQs

What is the purpose of textile testing labs?

The main goal of textile testing labs is to check how textile products perform. They also use test results to predict future performance.

Why do you need to Conduct Textile Lab Tests?       

Textile testing checks the quality and fit of raw materials and finished products.

What are the objectives of textile testing labs?

Textile testing labs aim to:

• Check raw materials.

• Check production

• Investigate faulty materials.

• Assess the final product.

• Develop new products.

• Conduct research

How are Textile Testing Labs Helpful?        

Textile testing labs help control the spinning, weaving, dyeing, and finishing processes. You can control end breakage by adjusting the weight based on the length of each lap.

How can we improve the efficiency of the textile testing lab?

Tech tools like QMS, LIMS, and NIR boost textile lab efficiency. They let labs do tasks with less human help. This approach enhances efficiency and accuracy and is pivotal in modern textile labs.