Impact of production methods on waste minimization in v-bed flat knitting:a case study

Sustainable development in the textile industry is challenging due to growing demand and urgent environmental impact. Waste minimization at every production stage is a promising way toward sustainability. Knitting is the most flexible textile technology for zero-waste production. This study aims to investigate the impact of production methods on production efficiency and waste minimization using the V-bed flat knitting machine and the men`s cardigan as an example. The comparative analysis of yarn consumption and production time for different production methods (part cut and fully fashioned) was used. Research results of men`s cardigan manufacturing by four distinct methods derived from part-cut and fully fashioned methods highlight their significant effect on yarn consumption, duration of production cycle, and cardigan performance. The fully fashioned method minimizes yarn consumption by 16.5%, with 3.9% waste compared to the part-cut method. The advanced fully fashioned method using a front knitted part with integrated cardigan pockets decreases yarn consumption by 2.6% more and incurs only 3.0% waste. This method produces the highest cardigan performance compared to the other methods due to its linking stitching and integrated knitted pockets. Within the part-cut method, using the part-shaped panel instead of the rectangular panel for sleeves leads to a 9.7 % decrease in yarn consumption and a 2.6% reduction in waste. It also leads to better product performance because of minimizing the overlocking seams. These findings underscore the importance of selecting appropriate production methods to enhance efficiency and reduce waste in knitwear manufacturing. Embracing waste reduction measures, mainly through natural yarn, holds promise for environmentally friendly garment production. This research emphasizes the need for ongoing exploration of eco-conscious manufacturing processes to promote sustainable knitwear production.