garments washing
TRANSCRIPT
Presentation Topics Is
“GARMENTS WASHING”
GARMENTS WASHINGDefinition: The technology which is used to modify the appearance, out
look comfort ability & fashion of the garments is called garment washing.
Purpose of washing: Purpose of Washing/Best wash look is the best touch of a
garment - This may be explained in the following way:
• Washing process of garment is done to create wash look appearance. After washing the garments create a new looks which seems the new touch of fashion.
• By the washing technique, fadded/old look, colour or tinted
affect is created in the garment which also seems the best touch of garments.
CONTINUED….• Washing technique create new fashion such as tagging, grinding,
destroy, Blasting, whiskering, permanent wrinkle, deep dye, tie dye, p.p spray, hand crapping, p.p spoonzing etc. Which is also seems the best touch of garments.
• The main and important function of washing is to reduce size materials as a result the garment become size free and become soft hand feel.
• When these soft garments are touched then it seems to best touch of garments.
• To attraction the customers/Buyer by different types of Fashionable washing and market developments.
• Due to washing, shrinkage occurs in the garments. There is no possibility of further shrinkage of wash garments.
• Any dirt, spot or germ if added in the garments during manufacturing is also removed due to washing.
REQUIREMENTS OF GARMENTS WASHING
• It should be removed size materials from the garments . Hence feels soft during use.
• It should be removed any dust, dirt, spot, impurities or germ which is
present or added in garments during manufacturing. • It should be shrinkage occurred i.e. no possibility of further shrinkage
of wash garments due to washing. • It should be attracted the customers or buyer by using different types
of fashionable washing and market developments. • It should be produced similar or different outlook in the garments by
different washing techniques. • It should be created wash look appearance in the garments. After
washing the garments create a new looks which seems the new touch of fashion.
CONTINUED….• It should be created color or tinted affect in the
garments which also seems the best touch of the garments.
• It should be created faded affect in the garments. • It should be possible to wearing directly the garments
after purchasing from the shop.
• Should be used new/ modern/ latest machines.
• It should also be produced fading affect in the specific area of the garment as per specific design.
• It should be comparatively more profitable than others.
EFFECTS OF GARMENTS WASHING
• Change the appearance of the garments.
• Change in size. • Change in color.
• Change out look of the garments.
• Change in comfort.
• Change in design.
• Change in fashion, etc.
TYPES OF WASHING PROCESS
TYPES OF CHEMICAL USE IN WASHING PLANT
FUNCTION OF CHEMICALS IN WASHING• ENZYME : The action of enzyme during enzyme wash it hydrolysis the
cellulose. At first it attacks the having projecting fibers and hydrolyzed them. Then it attacks the yarn portion inside fabric and partly hydrolyzed the yarn portion. As a result color comes out from the yarn portion and fadded affect is produced.
• DETERGENT : Chemical character is fatty alcohol poly glycol either in an
aqueous, glycolic solution. Detergent is widely applicable in the continuous and discontinuous pretreatment of all types of fiber and their blends. To remove impurities, mineral oil contamination and sizes from the garments.
• ACETIC ACID (CH3COOH) : Acetic Acid is used to neutralize the garments from
alkaline condition and to control the pH value in wash bath.
CONTINUED……..• ANTISTAIN : Anti stain is used to prevent the staining on weft yarn of the denim
(white yarn), white pockets of garments, levels, and contacted fabrics of garment and increased the brightness of fabrics; it is also acts as anti creasing agent.
• BLEACHING POWDER : Bleaching powder is an oxidizing agent. It is used in washing
plant for color out from the denim garments. We can achieve different shade of color on garment i.e. Dark, Medium, Light shade.
• SODIUM HYPOSULPHITE : Sodium hypo sulphite is used to neutralize the garments from
chlorine bleach.
• CAUSTIC SODA : Caustic created the role in bleach technique with out color change
the garment and has a good cleaning power. It is work as fadding affect/old looking affect come rapidly on garments.
CONTINUED……..• SODIUM BICARBONATE Sodium bicarbonate is used in washing plant in the bleach bath with bleaching
powder for Denim Light shade because easily color out with in short time. As a result production increases and costing is low.
• POTASSIUM PERMANGANATE : Potassium permanganate is used in Acid wash with Punic stone for color out
from the garments. It is used also spray chamber by nozzle for color out (whitish affect) from the garments.
• FLAX SOFTENER (Cationic, non ionic) : Softener is used to make the garments treated textiles a surface feel that is both
silky and soft and also provides excellent lubricating properties.
• MICRO EMULSION SILICON : Amino Silicon is a textile finishing agent consisting mainly of amino modified
silicon. When applied on fabrics, it gives durable softness, lubricity, elastic handle, anti pilling, dimensional stability, tear resistance and fabric to be cut and sewn more easily allows and improving wear and easy care properties.
CONTINUED…….• SODIUM CHLORIDE (SALT) : It helps to exhaust dye in to the fiber. • BUFFER : Buffer is used in washing plant for pH control of enzyme bath, softener bath, de
sizing bath.
• HYDROGEN PEROXIDE : Hydrogen peroxide creates the prime role in bleach wash technique. In alkaline
medium, hydrogen peroxide breaks up and gives some perhydroxhyl ion, which discolor the coloring materials and as a result fadding affect is developed. Hydrogen peroxide is used in scouring, bleaching bath for white/ready for dyeing of gray fabric garments. It is used also to neutralize the garment from alkaline condition.
• STABILIZER : Hydrogen peroxide works in a good condition at temperature above 90°c, when
temperature raise to 90°c then break the Hydrogen peroxide. Stabilizer is used to protect break the hydrogen peroxide and peroxide works in bath smoothly.
CONTINUED…….• FIXING AGENT : Fixing agent is used for unfixed dye to fix on fabrics, when fabric color will be proper
fixing then color fastness & rubbing fastness will be increased.
• CATANIZER : Catanizer is used in pigment exhaust method processing. Pigment is color not
dyestuff. Pigment colors have no affinity to fabric when catanizer is used in fabric then increase the affinity between pigment color & fabrics.
• OPTICAL BRIGHTNESS : Two types of optical brightener are used in the washing plant – a) Red brightener. b) Blue
brightener. Mainly optical brightener is used for improve the brightness of garments.
• RESIN : Resin is high efficiency textile resin based on etherified dimethylol glyoxalin monoureine
urea. Resin is used for the creation of semi-permanent creases in denim and other cellulose fabrics. It is used also cotton and polyester fabric. Fabric retains soft handle after washing.
• SODIUM METABISULPHITE : Sodium meta bi sulphite is used in the washing plant to neutralized the garment from
potassium permanganate.
• DESIZING AGENT : Desizing agent is used to remove mainly starches, waxes, fats pectin’s, minerals &
unfixed indigo dye from denim, twills, poplin & canvas fabrics etc.
TYPES OF MACHINE USED IN WASHING PLANT
FABRIC INSPECTION 4-point system
The 4-point system, also called the American Apparel Manufacturers Association (AAMA) point-grading system for determining fabric quality, is widely used by producers of apparel fabrics and by the department of defense in United States and is endorsed by the AAMA as well as ASQC (American Society for Quality Control).
The system in which the penalty point of a defect is maximum 4 is called 4-point system of quality control.
FABRIC INSPECTION Basic Principle: Defect point values should be counted in
100 yd fabric. If defect point values are 40 or less then it indicates first quality fabric. The grading range is given below:
Point Grade≤ 40 A
Above 40-60 BAbove 60-80 C
Above 80 Rejected
FABRIC INSPECTION Procedure:
Should select 10% fabric randomly from the fabric received quantity.
The defects are located, marked and recorded on a frame. Fabric defect point values are taken based on the following:
Length of Defect Point AllocatedUp to 3 inch 1Over 3 inch-Up to 6 inch 2Over 6 inch-Up to 9 inch 3Over 9 inch 4≤1 inch (Holes) 2Over 1 inch 4
FABRIC INSPECTION Calculation:
Point/ 100 yd2 = {(Total point scored in a roll x 3600)/ (Total yds inspected x Fabric width in inch)}
Exercise-1. A fabric roll of 120 yd long and 48 inch wide contains the following defects:
2 defects up to 3 inch 5 defects over 3 inch but up to 6 inch 1 defect over 6 inch but up to 9 inch 1 defect over 9 inch
Find out the grade of fabric based on 4-point system.
NORMAL WASH / GARMENTS WASH Normal wash is required for the following reasons:- To remove dust, dirt, oil spot, impurities
from the garments. To remove size materials from the
garments. To remove starch presents on the garment
fabrics. For soft feeling to wear the garments after
purchasing. To achieve buyer washing standard.
WASHING PROCESS OF NORMAL / GARMENT WASH The Normal/Garment washing process of batch of
70 kg Twill/Canvas Garments are described below:-
First Step :- Lot size: -..............70 kg Twill/Canvas Garment. Add water @ L: R = 1: 8-10......560 -- 700 Litre. Machine Running. Add detergent @ 0.5 gm / Litre ....280-350 gm. Temperature.....Sometime cold & sometime 40°c
to 60°c. Time ..................5 to 10 minutes. Drop the liquor. Cold wash.
CONTINUED……Second Step :- Add water @ L : R = 1: 6 ......... 420 litre. Washing machine running Add Flax softner @ 0.6 gm / litre........ 252 gm. Add Acetic Acid @ 0.5 gm / litre.........210 gm. Time............................5 to 10 mts. Drop the liquor. Unload the Garments on trolley.
CONTINUED….Third Step: Hydro extraction (700-900rpm): Hydro-extractor is used to remove excess water from
the Garments.
Fourth Step: Steam Dryer / Gas Dryer. Load on steam dryer - 50 kg Temperature - 60°c - 70°c Time - 40 - 50 mts for dry. Time - 10 - 15 mts for cold dry. or Load on gas dryer - 50 kg, Running the machine Temperature: - 70°c - 85°c. Time: - 30 - 35 mts for dry. Time: - 10 - 15 mts for cold dry.
CONTINUED…..Fifth Step: After drying, quality is checked and
good quality Garments will be delivered to Garments factory.
NOTE: - Flax softner (cationic or nonionic) diluted with hot water then use in the machine.
PIGMENT WASH Pigment wash is generally done on pigment
dyed or printed Garments. The garments are subjects to pigment wash. Pigment wash is required for the following reasons:
Fading effect/old looking effect on garments and also seam areas
For soft feeling to wear the garment after purchasing
For achieving the buyer’s washing standard For increasing the color fastness & rubbing
fastness performance
PROCESS OF PIGMENT WASHING The pigment washing process of a batch size 80 kg Twill/canvas Garments is described below:-
First Step: Lot size: - .......... 80 kg Twill/Canvas Garment. Add water @ L: R = 1: 8.............. 640 Litre Machine Running. Add Caustic soda (NAOH)..... @ 0.8 gm / liter ............ 512 gm. Add Soda Ash (Na2Co3) ........@ 1.50 gm / litre........... 960 gm. Add Detergent ........................ @ 0.8 gm / litre ............ 512 gm. Temperature........... 50°c to 60°c. Time (Depend upon the shade) ....... 20 to 60 mts. Drop the liquor. Wash 1 time by hot wash for 5 mts at the temperature 50°c. Wash 1 time by cold water for 5 mts
During this time of action of detergent and frictional effect on the garments removes a portion of pigment from the garments surface. As a result fading effect is produced on the garments.
CONTINUED……Second Step: Add water @ L : R = 1: 6 ......... 480 litre. Washing machine running Add Acetic Acid (for pH 4.5 - 5.5) @ 0.5 gm / litre ............. 240
gm. Add Flax softner ... . @ 0.6 gm / liter........... 288
gm. For more slippery hand feel use silicon - @ 0.4 gm /
litre.....192gm. Time................................... 15 to 25 mts. Drop the liquor. Unload the Garments on trolley.
Third Step: Hydro- extraction
Hydro-extraction is used to remove excess water from the Garments. Time required is about 2 - 4 minutes.
CONTINUED…….Fourth Step: Steam Dryer / Gas Dryer Load on steam dryer - 50 kg Running the machine Temperature - 60°c - 70°c Time - 40 - 50 mts for dry. Time - 10 - 15 mts for cold dry. or Load on gas dryer - 50 kg, Running the machine Temperature: - 70°c - 85°c for dry. Time: - 30 - 35 mts for dry. Time: - 10 - 15 mts for cold dry.Fifth Step: After drying, garments send to quality section and check the
garments and good quality garments will be delivered and Deep shade again rewashed, other quality Garments are rectified then delivered.
CAUSTIC WASH Caustic wash is generally done on Reactive
dyed, Sulphur dyed, Direct dyed or printed Garments. Caustic wash is required for the following reasons:
To fade/old looking affect on Garment and seam abrasion affection seam area.
To remove the size materials, starch from the garments.
To increase the color fastness & rubbing fastness rating
For soft feeling to wear the garments. To increase the hairiness on garments. To achieve the buyer reference sample.
WASHING PROCESS OF CAUSTIC WASH The caustic washing process of a batch size 80 kg
twill/canvas garments is described below:First Step: Lot size: - ...................... 80 kg. Add water @ L : R = 1 : 8.............. 640 Litre Machine Running. Add Caustic soda (NAOH)..... @ 1.60 gm / litre........
1024 gm. Add Detergent ........................ @ 0.8 gm / litre ............
512 gm. Temperature........... 50°c to 60°c. Time (Depend upon the shade) ....... 20 to 60 mts. Drop the liquor. Wash cold water for 3 mts.
CONTINUED……..Second Step: Neutral Wash
Add water @ L : R = 1: 5 ...................... 400 litre. Add Acetic Acid @ 1 gm / litre ............. 400 gm. Time .......................................................... 5 mts. Here acetic acid is used to neutralize the garments from
alkaline medium.
Third Step: Add water @ L : R = 1 : 6 .............. 480 Litre Machine Running. Add Acetic Acid @ 0.5 gm / litre ............ 240 gm. Add Flax softner @ 0.6 gm / litre........... 288 gm. If more soft use silicon @ 0.4 gm / litre ... 192 gm. Time................................ 10 to 20 mts. Drop the liquor. Unload the garments on trolley.
CONTINUED……Fourth Step: Hydro-extractor machine Hydrocxtraction is done to remove excess water from the Garment.
Time required about 2 - 4 minutes.Fifth Step : Steam Dryer / Gas Dryer Load on steam dryer - 50 kg Running the machine Temperature - 60°c - 70°c Time - 40 - 50 mts for dry. Time - 10 - 15 mts for cold dry. or Load on gas dryer - 50 kg, Running the machine Temperature: - 70°c - 85°c for dry. Time: - 30 - 35 mts for dry. Time: - 10 - 15 mts for cold dry.Sixth Step : After drying garments go to quality section and check the garments,
good quality garment will be delivered and Deep shade again rewash, other quality Garments are rectified then delivered.
ENZYMES Enzymes are bio-chemical substances that
behave as catalysts toward specific reactions. What makes very interesting the enzymes under a chemical point of view is their high specificity or in other words, their ability to attack selectively a given substrate.
Among the two traditional enzymes used in the treatments of denim garments (amylase to hydrolyze starches and cellulase to degrade cotton's cellulose) there is another enzyme that can be employed to attack selectively the molecule that constitutes the blue indigo color resulting ineffective on other kind of dyes.
CONTINUED…….. The action of enzyme during enzyme
wash is to hydrolyse the cellulose, at first it attacks the having projecting fiber and hydrolyzed them. Then it attacks the yarn portion inside fabric and partly hydrolyzed the yarn portion and faded effect is produced.
Mainly two types of enzyme are used in Bangladesh. One is Acid Enzyme (liquid) and another is Neutral Enzyme. Neutral Enzyme is two types a) Powder form b) Liquid form ie, SL Enzyme.
CONTINUED…..FEATURES OF ACID ENZYME: Acid enzyme colour is slightly brown pH range is 4.5 to 5.5 working Temperature is 40°c to 55°c Time required is 25 min to 50 min Enzyme effect comes within short time Staining/Bleeding occurs more in garments Production is high
CONTINUED……FEATURES OF NEUTRAL ENZYME: POWDER ENZYME
Enzyme is slightly white powder formpH range is 6 to 7Working Temperature is 40°c to 60°cTime required is 40 to 70 minEnzyme effects come slowly.Less staining/bleeding on garmentsWith pumic stone, it produces good
effect/abrasion on garmentsIn dark shade, effect of enzyme is good
CONTINUED…..SL ENZYME:
SL enzyme is liquid form pH range is 6 to 7. Working Temperature range is 40°c to 60°c Time required is 45 to 80 min Enzyme effect comes slowly Less staining/bleeding on garments With pumic stone, it produces good effect In dark shade, effect of enzyme is good
ENZYMES IN THE TEXTILES INDUSTRY
Enzymes: Textile Enzymes called "Aurum" Enzymes (Greek for "in the cell" formerly also called ferments)
are biologically the most important group of proteins. Enzymes are found in all living organisms - in microbes, plants
and animals and of course also in human bodies; however, enzyme molecules are not living things themselves.
They are biocatalysts which enable metabolic processes in the cells.
Enzymes decrease the so-called activation energy for chemical reactions - the minimum energy required to enable a reaction to take place at all.
They may speed up reactions by a factor of several millions. Generally, enzyme designates a compound being transformed in
the reaction that is catalyzed, e.g., xylanase, cellulase, pectinase.
CONTINUED…… Enzymes are highly specific and will only react with a
small number, sometimes only one, substance - ("substrate specificity").
A living organism therefore needs up to 10,000 different enzymes to function smoothly.
More than 5000 have been scientifically described. Enzymes operate at mild conditions (temperature, pH,
pressure) and without the need of harsh chemicals, and because of their specificity without generating harmful side-products.
As natural proteins, enzymes are fully biodegradable. Enzymes are coded by genes within living cells and
they consist of chains of 20 different amino acids.
CONTINUED……. For the biological activity, the amino acid chain
folds to form a complex, three-dimensional molecular structure-
Figure: The Structure of Enzymes
CONTINUED………What are enzymes? Efficient biological catalysts Produced by all living organisms Proteins with three-dimensional structureWhy use enzymes?Because they- Target specific substrates Accelerate reactions Work under mild conditions Replace harsh chemicals Are easy to use and safe Are biodegradable
CONTINUED…….How are enzymes produced? Enzymes are produced by fermentation of
microorganisms The raw materials are renewable resources such
as potato starch, soya bean meal, salt and sugars Waste products can be used as fertilizer
PRE-TREATMENT WITH ENZYMESAMYLASE
can efficiently remove the starch without damaging cotton fabrics and cotton blends in pre-treatment of textiles.
CATALASE for their low energy and water consumption requirements are increasingly used in pre-treatment processes for bleach, clean up to hydrolyse residual peroxide before dyeing.
PECTINASES
are used for scouring of woven and knitted cotton. Enzyme removes efficiently pectin and other impurities from cotton fibres making it easier to process. Replacing the traditional alkaline scouring with pectinase treatment provides adequate wetting properties needed for subsequent wet-processes, such as dyeing and bleaching.
Aurum AO CONCConcentrated bacterial amylase for desizing in batch as well as continuous processes.
Aurum AP CONCFungal catalase enzyme for bleach clean-up in pre-treatment processes. Guarantees successful dyeing after bleaching.
Aurum KC SUPER
Fungal Pectinase, which together with Advasize meet industries high technical requirements in desizing and scouring. These are elementary process phases to ensure even and good dyeing of fabrics and textiles. Moreover, this new enzyme technology reduces the consumption of water and energy cutting down process costs.
DENIM STONE-WASHING AND BIO-POLISHING
Specially CELLULASES are used for denim wash in order to match special requirements of this widely used fabric and its processes.
Cellulase enzymes offer cost-effectiveness and value for denim finishing.
Cellulases usually contain different cellulase activities in unique combinations, which make these enzymes powerful in creating a rich variety of effects on denim meeting the ever-changing needs of fashion.
CONTINUED………
Aurum LWFungal cellulase preparation, which can be used both for de-pilling of fabrics and for stone washing of denim jeans in acid pH.
Aurum LEFungal cellulase enzyme, which is ideal for bio-finishing providing excellent performance in modern short cycle processes. Can be easily used for denim wash as well.
Aurum NPFungal cellulase enzyme, which is ideal for high contrast denim wash at neutral pH and wide temperature area. Neutral Cellulases leave no anti back staining on garments.
Aurum WPAcidic cellulase powder for efficient and cost effective denim wash. It provides good abrasion and high contrast.
USE OF DIFFERENT ENZYMESPRETREATMENT:
Aurum Conc
Low foaming Non Ionic Wetting Agent
Aurum MA Mercerizing Agent
Aurum SPLWash off agent for fabric and yarn
Aurum Stain
Stain extracting agent for polyester and their blends
Aurum LFLow foam scouring agent in all machines
CONTINUED……DYEING:
Aurum DFTLeveling and stripping agent for Disperse Dyes
Aurum DF Cationic Dye fixing agent
Aurum FFNon formaldehyde Dye fixing agent
Aurum Stain extracting agent for polyester and their blends
Aurum LFSynthetic thickener aqueous pigment System
CONTINUED……..GARMENT WASHING:
Aurum PC
· Anti back staining agent or Pocket clear for enzyme washing· Bio-polishing and stone washing Enzymes· Desizer Enzyme· Hydrogen Peroxide killer Enzyme· Scouring Enzyme
CONTINUED……PRINTING:
Aurum PF Fixing agent
Aurum FFP Non formaldehyde fixing agent
Aurum Binder
FEATURES OF ENZYME WASH Enzyme wash is done on the garments made
from heavy fabrics like jeans and denims.Features : To remove the size materials from the garments To remove the starch presents on the garments
fabric To achieve the high- low abrasion (stone effect)
on garment and seam abrasion in sewing area Enzyme attacks as chemically not mechanically
for this reason low damage/wastage then stone wash
CONTINUED….. For soft feeling to wear the garments To achieve the buyer’s reference sample To increase the colour fastness & rubbing
fastness performance Especially develop the "Bio-Polishing" effect
of cotton/denim Enzyme improves the anti-pilling properties
of garments Enzyme attacks more on the surface of the
fabrics and gives a very smooth surface.
ENZYME WASHING PROCESS(DARK SHADE)
The enzyme washing process of a batch size 60 kgs denim men's long pants (Trouser) is described below:
First Step: DESIZING Lot weight (80 pcs) ............ 60 kg denim long pant. Add water @ L : R = 1 : 9 .............. 540 Litre Machine Running. Temperature.......................... 60°c. Add Desizing agent @ 0.6 gm / litre ............ 324 gm. Add Detergent @ 0.8 gm / litre.................... 432 gm. Time...............................10-- 20 mts. Drop the liquor. Wash 1 time by cold water.
CONTINUED…….Second Step: Bio-Abrasion (mechanical and chemical
action)
Add water @ L : R = 1 : 8 .............. 450 Litre Temperature.......................... 45°c. Add Acetic Acid @ 0.6 gm / litre ................... 270 gm. Add Anti back staining @ 0.6 gm / litre........ 270 gm. Add Acid Enzyme @ 2.00 gm / litre ................ 900 gm Pumic stone --------@ 20 to 100 % Time .............. (Depend upon the shade )...40-- 60 min Increase temperature to 90°c and run 1 minute
(enzyme killing). Drain the bath. Rinse Twice, each 3 minutes.
CONTINUED…….Third Step :- SOFTENING
Add water @ L : R = 1 : 8 ..................... 450 Litre.
Add Acetic Acid @ 0.6 gm / litre ............ 270 gm.
Cationic Softner @ 1 gm / litre.............. 450 gm. Temperature................................... Cold. Time ................................................ 15 to 20
mts. Drain the bath. Then unload the garments on trolley.
CONTINUED……..Fourth Step: Hydro extraction (700-900rpm) Hydro-extractor is used to remove excess water from
the Garments.
Fifth Step :- Drying Machine Load 60 kg garments to gas dryer. Temperature set - 75°c to 85°c. Run about 40 mts. After then run 10 mts in cold dryer.
Sixth Step :- After drying, garment goes to quality section for
quality checking and good one is delivered.
ENZYME WASHING PROCESS(MEDIUM SHADE) The enzyme washing process of abatch size 60 kgs
denim men's long pant (Trouser) is described below:-First Step :- DESIZING Lot weight (80 pes) ............ 60 kg denim long pant. Add water @ L: R = 1: 9.............. 540 Litre Machine Running. Temperature.......................... 60°c. Add Desizing agent @ 0.6 gm / litre ............ 324 gm. Add Detergent @ 0.8 gm / litre.................... 432 gm. Time................................ 20 mts. Drop the liquor. Wash 1 time by cold water.
CONTINUED……Second Step :- ENZYME Treatment Add water @ L: R = 1: 8.............. 450 Litre Temperature.......................... 45°c. Add Acetic Acid @ 0.6 gm / litre ................ 270 gm. Add Anti Back staining @ 0.6 gm / litre .... 270 gm. Add Acid Enzyme @ 2.00 gm / litre ............ 900
gm. Time....(Depend upon the shade)...........40--- 60
mts. Increase temperature to 90°c and run 1 minute
(enzyme killing). Drain the bath. Rinse Twice, each 3 minutes.
CONTINUED……Third Step :-BLEACHING Add water @ L : R = 1 : 7 .............. 420 Litre Temperature......................................50--
60°c. Add chlorine bleach (k.c.i) @ 10 gm /
litre ...... 4200 gm. Add soda ash @ 2 gm /
litre ................................. 840 gm. Time (Depend upon the shade)....................
12 to 15 mts. Drop the liquor. Rinse Twice, each 3 minutes.
CONTINUED……Fourth Step :-NEUTRALIZATION Add water @ L : R = 1 : 10 .............. 600 Litre Temperature........................................40-- 50°c. Add sodium hypo sulphite @ 2 gm / litre ... 1200 gm. Add detergent @ 0.5 gm / litre ...................... 300 gm. Time................................ 10 to 15 mts. Drop the liquor. Rinse Twice, each 3 minutes.Fifth Step :- SOFTENING Add water @ L: R = 1 : 8 .............. 450 Litres. Add Acetic Acid @ 0.6 gm / litre ............ 270 gm. Cationic Softner @ 1 gm / litre.............. 450 gm. Temperature.......................... Cold. Time................................ 15 to 20 mts. Drain the bath. Then unload the garments on trolley.
CONTINUED…….Sixth Step :- Hydro extraction After unloading garments from the washing machine
then they are sent to hydro extractor machine to remove excess water from the washed garments.
Seven Step :- Drying Machine Load 60 kg garments to gas dryer. Temperature set - 75°c to 85°c. Run about 40 mts. After then run 10 mts in cold dryer.
Eighth Step : Delivery After drying, garments are sent to quality section for
quality checking and good one is delivered.
ENZYME WASHING PROCESS (Light shade)
The enzyme washing process of a batch size 60 kgs denim men's long pants (Trouser) is described below:-
First Step :- DESIZING Lot weight (80 pes) ............ 60 kg denim long pant. Add water @ L: R = 1: 9.............. 540 Litre Machine Running. Temperature.......................... 60°c. Add Desizing agent @ 0.6 gm / litre ............ 324 gm. Add Detergent @ 0.8 gm / litre.................... 432 gm. Time...............................15- 25 mts. Drop the liquor. Wash 1 time by cold water.
CONTINUED……..Second Step :- ENZYME treatment Add water @ L : R = 1 : 8 .............. 450 Litre Temperature.......................... 45°c. Add Acetic Acid @ 0.6 gm / litre.............. 270 gm. Add Anti back staining @ 0.6 gm / litre ... 270 gm. Add Acid Enzyme @ 2.00 gm / litre .......... 900 gm. Time....... (Depend upon the shade)......40--- 60
mts. Increase temperature to 90°c and run 1 minute
(enzyme killing). Drain the bath. Rinse Twice, each 3 minutes.
CONTINUED…….Third Step :-BLEACHING Add water @ L : R = 1 : 7 .............. 420 Litre Temperature.......................... 50°c to 60°c. Add chlorine bleach @ 20 gm / litre .........
8400 gm. Add sodium bi carbonate @ 4 gm /
litre ............ 1680 gm. Time (Depend upon the
shade)............................. 12 to 20 mts. Drop the liquor. Rinse Twice, each 3 minutes.
CONTINUED……..Fourth Step : NEUTRALIZATION Add water @ L : R = 1 : 10 ........................... 600 Liter Temperature.................................................... 50°c. Add sodium hypo sulphite @ 2 gm / litre.....1200 gm. Add detergent @ 0.5 gm / litre ...................... 300 gm. Time................................ 10 to 15 mts. Drop the liquor. Rinse Twice, each 3 minutes.Fifth Step :-BLEACHING AGAIN Add water @ L: R = 1: 8........................... 480 Liter Temperature.......................... 60°c. Add hydrogen peroxide @ 4 gm / litre.... 1920 gm. Add caustic soda @ 1 gm / litre................. 480 gm. Add detergent @ 1 gm / litre ..................... 480 gm. Time................................ 10 mts. Drop the liquor. Rinse Twice, each 3 minutes.
CONTINUED……Sixth Step :- SOFTENING Add water @ L : R = 1 : 8 .............. 450
Litres. Add Acetic Acid @ 0.6 gm / litre ............
270 gm. Cationic Softner @ 1 gm / litre..............
450 gm. Temperature.......................... Cold. Time................................ 15 to 20 mts. Drain the bath. Then unload the garments on trolley.
CONTINUED……..
Seventh Step :- Hydro extractor Machine After unloading garments from the washing machine
they are sent to hydro extractor machine to remove excess water from the washed garments.
Eighth Step :- Drying Load 60 kg garments to gas dryer. Temperature set - 75°c to 85°c. Run about 40 mts. After then run 10 mts in cold dryer.
Ninth Step :- Delivery After drying garments go to quality section for
quality checking and good one is delivered.
ENZYME WASHING PROCESS(TWILL/CANVAS/POPLIN)
The enzyme washing process of batch size 60 kg Twill/Canvas/Poplin/Cord ray) trouser is described below:-
First Step :- DESIZING Lot weight (Approx 125 pcs) ............ 60 kg. Add water @ L : R = 1 : 10 .............. 600 Litre Machine Running. Add Desizing agent @ 0.6 gm / litre ............ 360 gm. Add Detergent @ 0.5 gm / litre.................... 300 gm. Temperature.................................... 50°c. Time........................................10--- 20 mts. Drop the liquor. Rinse one time 3 minutes.
CONTINUED……
Second Step : ENZYME Teatment Add water @ L : R = 1 : 8 .............. 480 Litre Temperature.......................... 45°c. Add Acetic Acid @ 0.5 gm / litre ............ 240 gm. Add Acid Enzyme @ 1.2 gm / litre ............ 576
gm. Add Antistain @ 0.50 gm / litre ................ 240
gm. Time.. (Depend upon the standard)........ 30 to
60 mts. Increase temperature to 90°c and run 1 minute. Drain the bath. Rinse Twice, each 3 minutes.
CONTINUED……Third Step: Softening Add water @ L : R = 1 : 8 .............. 480 Litres. Add Acetic Acid @ 0.6 gm / litre .......... 288 gm. Cationic Softner @ 1 gm / litre.............. 480 gm. Silicon (ME) @ 0.5 gm / litre................. 240 gm. Temperature.......................... 40°c.. Time................................ 15 to 20 mts. Drain the bath. Then unload the garments on trolley.
CONTINUED….Fourth Step : Hydro extractor Machine After unloading garments from the washing machine then
they are sent to hydro extractor machine to remove excess water from the washed garments.
Fifth Step :- Drying Machine Load 60 kg garments to gas/steam dryer. Temperature set - 75°c to 85°c. Run about 35 to 45 mts. After run 10 to 15 minutes for cold dryer.
Sixth Step : After drying, garments go to quality section for quality
checking and then delivered.
STONE WASHPumic Stone: The pumic stones are the perforated stones,
produced from volcanic explosion At first these stones are softened but
becomes cold, then it becomes the stone with rough surface
Pumic stones float on water. Pumic stones come from Indonesia and
Turkey.
IMAGE OF STONE
CONTINUED………….. Indonesia’s stone color is slightly brown and
Turkey’s stone is white in color. Pumic stones are available in 3 size i.e.
small 2-3 cm, medium 3-5 cm and large size 5-7 cm.
pumic stone is Two to Three times of garments can be used in washing.
Every bag contains 22 kg to 25 kg and price 400/= to 425/=/ bag.
FUNCTION OF PUMIC STONES During different garments washing like stone wash,
Acid wash, Stone Enzyme wash etc. Pumic stones are used to create irregular fading effect on garments.
The pumic stones act a brushing action on the garment fabric surfaces.
The areas where more brushing action take place, there more fading or discolor effect will be developed and the areas where less brushing action take place, there less discolor effect will be developed.
The multi layer fabric areas like – Collar, Cuff, Pocket, Placket, Side seams etc. areas will be brushed more than the single layer areas.
As a result irregular fading is developed in the garments by the action of pumic stones.
STONE WASHING PROCESS A process of stone wash of 60 kg batch size of
Denim Long Pant as mentioned below:First Step: PRE-TREATMENT / DESIZING Batch size....................... 60 kg Denim Long Pant Add water @ L : R = 1 : 9 .............. 540 litres. Start the machine. Temperature.................... 60°c Add Desizing agent @ 0.6 gm / litre.................
324 gm. Add Detergent / Antistain @ 1 gm / litre ......... 540
gm. Time................................ 15 to 25 mts. Drop the liquor.
CONTINUED……Second Step: HOT WASH Add water @ L: R = 1: 9.............. 540 litres. Temperature.................... 60°c. Time................................ 5 mts.Third Step: BLEACHING Add water @ L: R = 1: 8.............. 480 litres. Machine running. Add bleaching powder (k.c.i) @ 10 gm/litre ...... 4800 Gms. Add soda ash @ 5 gm/litre .................................. 2400
Gms. Pumic stone @ ½ vol of garments. Temperature............................. 60°c. Time (Depend upon the shade) .......... 12 to 15 mts. Drop the liquor. Rinse twice, each 3 minutes.
CONTINUED…………Fourth Step: NEUTRAL WASH Add water @ L : R = 1 : 9 .............. 540 litres. Add sodium hyposulphite @ 3 gm/litre ...... 1620 Gms. Temperature............................. 40°c. Time (Depend upon the shade) .......... 10 to 12 mts. Drop the liquor. Rinse one.Fifth Step: SOFT WASH Add water @ L: R = 1: 8.............. 480 litres. Add Acetic Acid @ 0.6 gm/litre ..................... 288 Gms. Cationic softner @ 1 gm/litre ........................ 480 Gms. Time................................ 5 mts. Drop the liquor. Unload the garments to trolley.
CONTINUED………Sixth Step: Hydro extractor Machine
Hydro extraction the garments to remove excess water from the washed garments.
Seventh Step: Drying Machine
Load 40 kg garments Set temperature ................ 75°c to 85°c. Time ......................... 35 to 40 mts. Time ..................... 10 minutes in cold dry.
Eighth Step: Delivery After quality checking garments will be delivered.
STONE ENZYME WASH Now in our Bangladesh, maximum Denim garment is
washing by STONE ENZYME process. It is most popular wash for Buyers. A process of stone enzyme wash of 60 kg batch of Denim Long Pant is mentioned below:
First Step: PRE-TREATMENT / DESIZING Batch size....................... 60 kg Denim Long Pant. Add water @ L: R = 1 : 9 ............................ 540 litres. Start the machine. Temperature.................... 60°c Add Desizing agent @ 0.6 gm / litre................. 324 gm. Add Detergent / Antistain @ 1 gm / litre ......... 540 gm. Time................................ 15 to 25 mts. Drop the liquor.
CONTINUED…….Second Step: HOT WASH Add water @ L: R = 1: 9.............. 540 litres. Temperature.................................... 60°c. Time................................................. 5 mts.
Third Step: Enzyme and stone treatment Add water @ L : R = 1 : 8 .............. 480 litres. Add pumic stone @ ½ vol of garments. Add Enzyme @ 1.50 gm/litre ..................... 720 Gms. Add Acetic Acid @ 0.6 gm/litre .................. 288 Gms. Add Antistain @ 0.8 gm/litre ..................... 384 Gms. Temperature......................................... 40°c to 50°c Time (Depend upon the shade) .......... 60 to 70 mts. Then temperature raise to 90°c for 1 minute. Drop the liquor. Rinse Twice, each 3 minutes. Then pumic stone out from washing machine
CONTINUED…….Fourth Step: BLEACHING Add water @ L: R = 1: 8.............. 480 litres. Machine running. Add bleaching powder (k.c.i) @ 10 gm/litre ....4800 gms. Add soda ash @ 5 gm/litre................................ 2400 gms. Temperature........................................................... 60°c. Time (Depend upon the shade) ..................... 12 to 15 mts. Drop the liquor. Rinse twice, each 3 minutes.Fifth Step: NEUTRAL WASH Add water @ L: R = 1: 9 ............................ 540 litres. Add sodium hyposulphite @ 3 gm/litre ....... 1620 Gms. Temperature..................................................... 40°c. Time ............................................................. 10 to 12 mts. Drop the liquor. Rinse one.
CONTINUED…….Sixth Step: SOFT WASH Add water @ L : R = 1 : 8 .............. ..............480 litre. Add Acetic Acid @ 0.6 gm/litre ..................... 288 Gms. Cationic softener @ 1 gm/litre ........................ 480 Gms. Time................................ 5 mts. Drop the liquor. Unload the garments to trolley.Seventh Step: Hydro extractor Machine
Hydro extraction the garment to remove excess water from the washed garments.
Eighth Step: Drying Machine :- Load 40 kg garments Set temperature ................ 75°c to 85°c. Time ......................... 35 to 40 mts. Time ..................... 10 minutes in cold dry.
Ninth Step: Delivery After quality checking garments will be delivered.
BLEACH WASH A process of bleach wash of 60 kg batch of Denim
Long Pant is mentioned below:First Step: PRE-TREATMENT / DESIZING Batch size....................... 60 kg Denim Long Pant. Add water @ L: R = 1: 9.............. 540 litres. Start the machine. Temperature.................... 60°c Add Desizing agent @ 0.6 gm / litre ............ 324 gm. Add Detergent / Antistain @ 1 gm / litre..... 540 gm. Time................................ 15 to 25 mts. Drop the liquor.Second Step: HOT WASH Add water @ L: R = 1: 9.............. 540 litres. Temperature....................................... 60°c. Time................................................... 5 mts.
CONTINUED……..Third Step: BLEACHING Add water @ L: R = 1: 8.............. 480 litres. Machine running. Add bleaching powder (k.c.i) @ 10 gm/litre.. 4800 Gms. Add soda ash @ 5 gm/litre ............................... 2400 Gms. Temperature............................................................ 60°c. Time (Depend upon the shade).................... 12 to 15 mts. Drop the liquor. Rinse twice, each 3 minutes.Fourth Step: NEUTRAL WASH Add water @ L: R = 1: 9.......................... 540 litres. Add sodium hyposulphite @ 3 gm/litre ....... 1620 Gms. Temperature ......................................................... 40°c. Time (Depend upon the shade).............. 10 to 12 mts. Drop the liquor. Rinse one.
CONTINUED……..Fifth Step: SOFT WASH Add water @ L: R = 1: 8.............. 480 litres. Add Acetic Acid @ 0.6 gm/litre ..................... 288 Gms. Cationic softener @ 1 gm/litre ........................ 480 Gms. Time................................ 5 mts. Drop the liquor. Unload the garments to trolley.Sixth Step: Hydro extractor Machine
Hydro extraction is done to remove excess water from the washed garments.
Seventh Step: Drying Machine Load 40 kg garments Set temperature ................ 75°c to 85°c. Time ......................... 35 to 40 mts. Time ..................... 10 minutes in cold dry.
Eighth Step: Delivery After quality checking garments will be delivered.
SUPER WHITE WASH
Super white wash is done on the garments made from cotton grey fabrics. Due to this type of wash , the garments become extremely white.
Objects:1.To make white the garments.2.To achieve the buyer washing standard.3.For soft feeling to wear the garments.4.To remove size materials from the garments, etc.
SUPER WHITE WASH PROCESS The process of super white wash of batch of 60kg cotton
grey fabrics is described below:First step: Desizing-Batch size: 60 kg cotton grey fabrics-Water @ L:R: 1:8-Machine running-Temperature up to 90°C-Add detergent@2%(OWF)-Cold caustic soda@8% (OWF)-Add Soda ash @ 5% (OWF)-Hydrogen per oxide @ 12% (OWF)-Stabilizer @ 5% (OWF)-Time: 70minutes-Drop the liquor
CONTINUED…….Second step: Bleaching Add detergent @1% (OWF) Add Caustic soda @ 3-4% (OWF) Hydrogen per oxide @ 6-8% (OWF) Stabilizer @ 2% (OWF) Time: 45-60 minutes Temperature: 90°CThird step: Hot Wash Temperature: 50°C-80°C Time: 5-10 minutes Drop the liquor
CONTINUED…..Fourth step: Neutralization Add Acetic acid @ 1% Time: 5-10 minutes Cold washFifth Step: Brightening Add optical brightener agent @ 0.5-0.6% Time: 5-10 minutesSixth step: Add softener @ 0.5-1% Time: 5-10 minutesSeventh step: Hydro extractor
CONTINUED……Eight step: Drying machine1.Load 60kg garments to gas dryer2.Machine running3.Temperature: 75°C-85°C4.Time: 40 minutes in hot dryer5.After then run 10 minutes in cold dryer.Ninth step: Delivery
ACID WASH It is normally done on the garments from heavy fabrics like
denim, course canvas, sweater & thick twill etc.Ultimate affect of Acid wash: During Acid wash, pumic stones are used. By the action of
pumic stones, irregular fading affect is developed on the heavy garments like denims, thick canvas/twill, and sweater. The pumic stones act as a brushing action on the garment fabric surface. The area where more brushing action takes place there more discolour or fadding affect is developed and the area where less brushing action takes place less brushing action and takes place less fadding affect will be developed. The multi-layer fabric areas like – collar, calf, pocket, placket, side seam etc area will be brushed more than the single layer areas. As a result irregular fading affect will be developed on the garments fabric surface. Thus in this way fading affect may be developed on the garments by acid wash technique.
ACID WASHING PROCESS A process of Acid wash of 60 kg batch of Denim
Trouser is mentioned below:First Step: Pretreatment/Desizing. Add water @ L : R = 1 : 10 .............. 600 litres. Start Machine. Add desizing agent @ 1 gm/litre .................600
Gms. Add detergent @ 1 gm/litre ........................ 600
Gms. Temperature............................. 60°c. Time........................... 20 mts. Drop the liquor. Rinse one for 3 minutes (cold).
CONTINUED……Second Step: Hot wash Add water @ L: R = 1: 10.............. 600 litres. Temperature............................. 60°c. Time........................... 5 mts. Drop the liquor.
Here hot wash is used to remove the adhering materials from the garment surface.
Unload the garments from the washing m/c in the trolley.
Load the pre treated garments in the dryer m/c. Dry the garment completely & unload the garments.
CONTINUED……. The pumic stones used for acid wash need to pre-treat in the following
chemical solution:- Water ..................... 100 L Potassium per manganate.............. 1000 Gms. Phosphoric Acid............................... 250 Gms. Stire the solution in a stainless steel tub with dry pumic stone. Soak the stones with the chemical solution ......... 10 – 15 minutes. The stones will pick up the solution. Then the soaked stones are dried in
the open air for.............. 2 to 3 hrs. Then pre-treated garment 30 – 40 kg per batch load in the dry washing
machine.
Load the per-treated stones (about 50 kg) in washing machine. Start machine running for each batch ........................ 7 to 10 mts. Stop machine running. Unload the treated garment separately. Pumic stones with P.P. solution hit
on garment surface as a result fading will be developed. Then load the stones treated garment in another washing machine
CONTINUED………Third Step: Wash for cleaning Batch wt................................ 70 kg. Add water @ L: R = 1: 8.............. 560 litres. Add detergent @ 1 gm/litre .............560 Gms. Temperature............................. 40°c - 50°c. Time ..................................10 mts. Drop the liquor. Here detergent is used to remove the breaking stone dust
and chemicals from the garment surface. Fourth Step: Whitening/Neutralization. Add water @ L: R = 1: 8.............. 560 litres. Machine running. Add Metabisulphite @ 5 gm/litre..... 2800 Gms. Cold temperature. Time 5 mts. Drop the liquor.
CONTINUED……..Fifth Step: Add water @ L: R = 1: 7.............. 490 litres. Machine running. Add Acetic acid @ 0.6 gm/litre ..................... 294 Gms. Add Softener @ 1 gm/litre ........................ 490 Gms. Then unload the garments.Sixth Step: Hydro-extractor machine. Hydro extractor machine is used to remove excess
water from the garments.Seventh Step: Dryer machine. After hydro extraction the garments are sent to drying
m/c for complete drying.Eighth Step: Quality & Delivery. After drying the garments go to quality checking &
rectify washing fault and then good one delivery.
CONTINUED………Precaution: Maintain the stock solution properly constant when
comes socking the stone. No water licks age in to the machine when treated
pumic stone & garments in to the machine. Not excess load the garments in the Acid wash
processing. Add some new stone after finishing on batch to
maintain the volume for 2nd batch. It is a matter of experience.
COLOR SHADE VARIATION & SOLUTION When fabrics come in to garment factory against
any order from abroad / local fabric dyeing factory, its found different color shade roll in the same color i.e. slide light, slide dark, slide tone different for this reason garment factory to control shade variation works as follows :-
8"×8" size fabric cut from every roll. Marking roll number by permanent marking pen at
back side of cut pieces. Every cut pieces joint each other and make a
blanket. Then it washes into standard approval shade. Garment factory now segregate same color tone
in one bundle and shade grading A.B.C.D.
CONTINUED……. First A shade roll cutting by pattern then B.C.D
shade separately. After garment making shade level attached on
body. Then go to washing plant for standard washing. Washing plant shade level wise washing in
respective wash. After wash it any big shade variation found then
again rewash to match with buyer approval standard.
Final quality checking garment go to finishing section for thread cutting, button attached, iron & poly etc.
SILICON WASH Silicon washes are generally done on all type of
fabrics i.e. Twill, Denim, Canvas, Knit, Corduroy.
Silicon wash is required for the following reasons: It gives durable softness, elastic handle, It helps to anti pilling affects, dimensional stability,
tear resistance. It helps to fabrics to be cut and sewn more easily
allows and improving wears and easy care properties.
WASHING PROCEDURE The silicon washing process of batch of 60 kg
Twill/Canvas/Poplin/Corduroy/Trouser is described below:
First Step: De-sizing Lot weight (Approx 125 pes) ............ 60 kg. Add water @ L: R = 1: 10.............. 600 Litre Machine Running. Add Desizing agent @ 0.6 gm / litre ............ 360 gm. Add Detergent @ 0.5 gm / litre.................... 300 gm. Temperature.......................... 50°c. Time...............................10- 20 mts. Drop the liquor. Rinse one time 3 minutes.
CONTINUED……….Second Step: Silicon Wash Add water @ L : R = 1 : 8 .............. 480 Litres. Add Acetic Acid @ 0.6 gm / litre ............ 288
gm. Cationic Softener @ 1 gm / litre.............. 480
gm. Silicon (ME) @ 0.5 gm / litre ................ 240
gm. Temperature.......................... 40°c.. Time................................ 15 to 20 mts. Drain the bath. Then unload the garments on trolley.
CONTINUED…….Third Step: Hydro extractor Machine After unloading garments from the washing machine
then they are sent to hydro extractor machine to remove excess water from the washed garments.
Fourth Step: Drying Machine Load 60 kg garments to gas/steam dryer. Temperature set - 75°c to 85°c. Run about 35 to 45 mts. After run 10 to 15 minutes for cold dryer.
Fifth Step: After drying, garments go to quality section for
quality checking and then delivered.
DIFFERENT TYPES OF WASHING FAULTS Color shade variation. Crease marks. After wash hole. Very dark and very light. Bleach spot. Bottom hem and course edge destroy. Running shade. Over blasting/low blasting. Over grinding/low grinding. Bad smell due to poor neutralization. Poor hand feel. To high hairiness. Poor brightness. High or low effect/abrasion on garments. Spot on garments. Out of range/ level of ph value of garments.