In the clothing industry, sewing thread is seen as a minor expense in the production. But its impact on product quality, machine efficiency, seam durability, and production is far more significant than its purchase price can begin to imply. The lower the cost of thread, the lower the cost of material in the immediate future, but it can also lead to lower productivity in terms of breakage, rework, machine downtime, and rejections out of the garment.
The true challenge is then not only finding a lower-cost thread for apparel manufacturers; it is also discovering the right thread. It is determined to find an optimum combination of cost, quality, and production performance of threads. With an optimized thread selection strategy, manufacturers can manage the costs, quality, and production processes.
Table of Contents
The True Cost Of Sewing Thread
The cost of thread is just one component of its overall expense. There may be additional issues of total cost of sewing that manufacturers should address, such as the cost of thread, machine downtime, operators’ involvement in the process, production defect rates, rework, and defective garments rejected.
A little more costly, but it breaks less; it can become less costly than an inexpensive machine that stops so often for threads.
These are some of the key cost considerations:
- Thread purchase price
- Thread consumption per garment
- Thread breakage rate
- Machine downtime
- Rework/repair expense
- Garment rejection
- Operator intervention
- Maintenance requirements
This ensures that manufacturers are able to assess the impact of thread in the overall production of the product rather than just its cost per cone.
Selecting Quality According to Application
Not all garments need the same type and quality of thread. Using an expensive, high-performance thread for every application can unnecessarily increase costs.
For simple “average” garments with medium seaming needs, an average quality polyester thread will be adequate. But for items like workwear, uniforms, outdoor wear, sportswear, and protective articles, the threads may need to be stronger, more durable to tear, resist chemicals, or have treated finishes.
So it is just important for the manufacturers to classify the clothes on the basis of their performance and choose the right thread material for the specific use.
For example:
1. Basic apparel: Polyester thread is fine for basic applications.
2. Sportswear: possibly need more fatigue resistance and flexibility.
3. Workwear: Higher strength and abrasion resistance may be significant. (para-aramid thread)
4. Project Apparel: Moisture, UV, and environmental resistance could be important factors. (flame-resistant sewing thread)
This approach to application-specific specification helps avoid underspecification and overspecification.
Thread Construction and Its Effect on Performance
The type of thread used will make a big difference in sewing speed. Common types include spun, core-spun, and continuous filament threads.
Spun threads can have acceptable sewing properties and be used in a wide variety of typical clothing fineries.
Core-spun threads are made with a durable core yarn covered in a wrapper yarn, resulting in a balanced blend of strength and aesthetics.
Continuous-filament threads can provide high strength and smooth performance, making them suitable for applications where durability and low lint generation are important.
To decide: The garment, fabric, seam, speed of the machine, and desired appearance determine the correct choice.
Optimizing Thread Size
Another aspect of thread size in which manufacturers may exert control without diminishing performance is their selection of the appropriate thread and masking material. Thicker threads don’t necessarily have greater quality.
A thicker thread may use more thread and produce more bulkiness in the seam and a larger needle size and may impact the garment’s appearance. However, an overly fine thread can cause loss of threads or seams to break.
The appropriate size of the thread must be decided with regard to the following:
- Fabric thickness
- Seam strength requirements
- Stitch type
- Stitch density
- Needle size
- Machine capability
- Garment design
Optimize the size of the thread to avoid unneeded consumption and still have the desired seam performance.
Reducing Thread Breakage
Of all sewing problems, the most costly is thread breakage, as damage also affects the garment being stitched as well as the thread. They can cause the machine to stop, require operator intervention, and may cause a defective stitch.
Manufacturers can reduce breakage by:
- Using the right type of thread
- Maintaining correct machine tension
- Using suitable needles
- Checking thread paths
- Maintaining sewing machines
- Controlling sewing speed
- Using suitable thread lubrication and finishes
Minimize breakage to increase productivity and enable an operator to sew more, rather than fix the machine.
Machine Compatibility: An Importance
It is easy to sew with a thread that is bad but difficult to sew with good thread that is incompatible.
The main requirement of high-speed industrial sewing is consistent sewing thread. Excessive friction and heat can be caused by poor lubrication, damaged tension discs or worn thread guides, or incorrect needle type and size.
Before starting a new thread on mass production, manufacturers should do sewing trials. These tests can be used to determine if the thread is operating at the specified speed and tension at the machine.
Controlling Thread Consumption
High production quantity can equate to a significant cost of thread. It is important for the manufacturer to be aware of how stitch type, stitch density, seam length, and thread size affect thread consumption.
A method of decreasing brand can be to reduce the number of stitches used where it is not needed, but this needs to be done without sacrificing seam performance.
Production engineers also have the option to go into seam construction and machine settings and find ways to cut waste without impacting the quality of the material produced.
Precise consumption criteria are helpful in manufacturing planning, costing, and inventory control.
Quality Control & Supplier Evaluation
The option of reliable suppliers is also an important factor in cost and quality balancing. Generally, manufacturers should be able to consider the suppliers based on the consistent quality, which leaves aside the price.
These are some key supplier performance measures:
- Batch-to-batch consistency
- Tensile strength
- Color consistency
- Lubrication and finish
- Package quality
- Delivery reliability
- Technical support
- Traceability
Sometimes slightly expensive thread will guarantee a more level product, as well as technical support, which can help reduce costs throughout the manufacturing process.
Manufacturers should set up incoming-quality checks and develop specifications of approved threads.
Measuring the Total Cost of Quality
The easiest way to calculate threads is to compare the cost of the thread to the cost of the quality problems.
Let’s say that the low-cost thread costs ₹1 per garment, but the high break rate in production and extra rework cost ₹3 per garment. However, this seemingly saving money is actually costing the taxpayer.
Manufacturers thus need to keep an eye on several indicators, including:
- Thread breaks per 1,000 stitches
- First-pass yield
- Rework percentage
- Machine downtime
- Detect rate
- Thread consumption per garment
These metrics offer a better indication of the nature of the thread’s performance than the purchase price would.
Using Standardization to Control Costs
Adopting the same type of approved threads can help to greatly simplify cost control. An approved list of thread specifications to be used can be produced by manufacturers, rather than having to develop a large number of different issues for the same use.
Standardization can:
- Simplify inventory
- Reduce purchasing complexity
- Improve operator familiarity
- Reduce material variation
- Strengthen supplier negotiations
- Improve production consistency
The important point is to ensure that standardization is not rigid. Sometimes the special clothes will require special threads as well.
Sustainability and Cost Efficiency
Optimization of threads can also help promote sustainability. Less material waste due to efficient usage of thread and fewer defects in sewing equates to fewer materials used to rework or replace the defect.
Appropriate and durable stitching can make garments last longer and therefore reduce garment replacements. Manufacturers can additionally go the recycled or less harmful path with regards to thread, given that it performs effectively with the garment’s necessities.
The most sustainable isn’t always the least costly or the most expensive, but it is the one that is able to deliver the necessary performance in an optimum way of using its resources.
Conclusion
Any sewing thread manufacturer will need to consider thread cost, quality, and production performance and go beyond the purchase price of the thread. The choice of the machine should take into account the total sewing process, consumables, machine efficiencies, seam quality, defect occurrence, rework, and product durability.
In order to achieve this balance, the manufacturers can select proper threads based on application need, optimize thread size and stitch parameters, minimize thread breaking, maintain machines, assess suppliers, and control production data. The final word for the cheapest thread is that it is not necessarily the most economical choice.
