industrial garment washing

INDUSTRIAL GARMENT WASHING & DYEING

GARMENT WASHING

The technology which is used to modify the appearance, outlook comfortable and 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, faded/old look, color or tinted affect is created in the garments

which also seem the best touch of garments.

Washing technique creates new fashion such as tagging, grinding, destroy, Blasting,

whickering, permanent wrinkle, deep dye, tie dye, P. P spray, hand crapping, P.P spoonzing

etc. This 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 the wash garments.

Any dirt, spot or germ if added in the garments during manufacturing is also removed due to

washing.

TYPECS OF WASHING

Wet and Dry processes are mentioned below:

A Distinctive Digest of Garment Washing & Dyeing

Normal wash/Garments wash/Rinse wash

Pigment wash

Caustic wash

Enzyme wash (Boi wash &Boi polishing)

Stone wash

Bleach wash (Ice wash& snow wash)

Stone Enzyme wash

Acid wash

Silicon wash

Sand Blasting & Hands scraping.

P. P Spray

Over all wrinkle

Permanent wrinkle

Tinting & Over dyeing

Grinding & Destroy

Broken & Tagging.

P.P Sponging

Dip Dyeing

Tie & Dye etc.

TYPE OF WHAT MACHINE USED IN WASHING PLANT

Sample washing Machine (Horizontal / Vertical Type)

Washing Machine (Side loading)

Washing Machine (Front loading)

Hydro extractor Machine

Dryer Machine (Steam)

Dryer Machine (Gas)

Chemical Mixture Machine

Industrial Oven (Gas/Electric)

Boiler

Submersible Pump


Grinding Machine

Tagging Machine

Steam chamber for crinkle

E.T.P (Effluent Treatment Plant)

Generator

Sand Blasting Gun

Sand Blasting chamber

Spray gun and dummy

Screw compressor

SEQUENCE OF PROCESS OF ANY GARMENT WASHING

1. Lot size

2. L:R – Liquor ratio

3. Temperature

4. Chemicals

5. Time

NORMAL WASH / GARMENTS WASH

Normal wash is required for the following reasons:

1. To remove dust, dirt, oil spot, impurities from the garments

2. To remove starch presents on the garment fabrics

3. For soft feeling to wear the garments after purchasing

4. 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 at L: R = 1: 8-10.............. 560 - 700 Liter.


Machine Running.

Add detergent at 0.5 gm / liter ............ 280-350 gm.

Temperature........... Sometime cold & sometime 40°c to 60°c.

Time .............................. 5 to 10 minutes.

Drop the liquor.

Cold wash

Second Step :

Add water at L: R = 1: 6 ......... 420 liter.

Washing machine running

Add Flax softener at 0.6 gm / liter.... 252 gm.

Add Acetic Acid at 0.5 gm / liter ...... 210 gm.

Time................................... 5 to 10 minutes.

Drop the liquor.

Unload the Garments on trolley.

Third Step: Hydro extractor machine.

Hydro-extraction the garments to remove excess water from the washed Garments.

Fourth Step: Steam Dryer/Gas Dryer.

Load on steam dryer - 50 kg

Temperature - 60°c - 70°c

Time - 40 - 50 min for dry.

Time - 10 - 15 min for cold dry.

Load on gas dryer - 50 kg,

Running the machine

Temperature: - 70°c - 90°c.

Time: - 30 - 35 min for dry.

Time: - 10 - 15 min for cold dry.

Fifth Step:

After drying it will be quality checking and good quality Garments will be delivery to Garments

factory.

NOTE: - Flax softener (cationic or nonionic) diluted with hot water then use in the machine.

SILICON WASH


Silicon washes generally doing 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, and tear resistance.

It helps to fabrics to be cut and sewn more easily allows and improving wears and easy care

properties.

SILICON WASH PROCESS

The silicon washing process of batch of 60 kg Twill/Canvas/Poplin/Corduroy/Trouser is described

below:-

First Step: - Desizing

Lot weight (Approx 125 Pecs) ............ 60 kg.

Add water at L: R = 1: 10.............. 600 Liter

Machine Running.

Add Desizing agent at 0.6 gm / liter ............ 360 gm.

Add Detergent at 0.5 gm / liter.................... 300 gm.

Temperature.......................... 40--50°c.

Time ................................10-- 20 min.

Drop the liquor.

Rinse one time 3 minutes.

Second Step:-

Add water at L: R = 1: 8.............. 480 Liter.

Add Acetic Acid at 0.6 gm / liter ............ 288 gm.

Cationic Softener at 1 gm / liter.............. 480 gm.

Silicon (ME) at 0.5 gm / liter ................ 240 gm.

Temperature.......................... 40°c

Time................................ 15 to 20 min.

Drain the bath.

Then unload the garments on trolley.

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 min.

After run 10 to 15 minutes for cold dryer.

Fifth Step:-

After drying garment go to quality section for quality checking and then delivery.

PIGMENT WASH

Pigment wash generally doing on pigment dyed or printed Garments by pigment washing technique.

Pigment wash is required for the following reasons:

To fading affect/old looking affect on Garment and also seam abrasion.

For soft feeling to wear the garment after purchasing.

To achieve the buyer washing standard.

To increase the color fastness & rubbing.

WASHING PROCESS OF PIGMENT WASH

The pigment washing process of batch of 80 kg Twill/canvas Garments are described below:-

First Step :-

Lot size: - ...................... 80 kg Twill/Canvas Garment.


Machine Running.

Add Caustic soda (NAOH)..... at 0.8 gm / liter ....... 512 gm.

Add Soda Ash (Na2Co3) ........at 1.50 gm / liter..... 950 gm.

Add Detergent ........................ at 0.8 gm / liter.... 512 gm.

Temperature........... 50°c to 60°c.

Time (Depend upon the shade) ....... 20 to 60 min.

Drop the liquor.


Wash 1 time by hot wash for 5 min at the temperature 50°c.

Wash 1 time by cold water for 5 min

Second Step:-

Add water at L:R = 1:6 ......... 480 liter.

Washing machine running

Add Acetic Acid (for pH 4.5 - 5.0) at 0.5 gm / liter ............. 210 gm.

Add Flax softener at 0.6 gm / liter.............. 288 gm.

For more slippery hand feel use silicon - at 0.6 gm / liter.....288gm.

Time................................... 10 to 20 min.

Drop the liquor

Unload the Garments on trolley

Third Step: - Hydro extractor machine.

Hydro-extraction the garments to remove excess water from the Garments. Time

required about 2 - 4 minutes

Fourth Step :

Steam Dryer / Gas Dryer.


Running the machine




Or


Running the machine

Temperature: - 70°c - 90°c for dry.



Fifth Step :

After drying garments go to quality section and check the garment, good quality

garment will be delivery and Deep shade again rewash, other quality Garment

rectify then delivery.


CHEMICAL USED IN PIGMENT WASHING AND THEIR FUNCTION

CAUSTIC SODA (NaOH) :-

Caustic created the role in bleach technique without color change the garments.

Caustic has a cleaning power which is more powerful then soda Ash.

Fading affect/old looking affect come rapidly on garments

SODA ASH (Na2Co3) :

Soda ash created alkaline medium for the breakdown of pigment dye.

It has also a cleaning power.

It has also help color fading affect of garments.

Detergent:

Here detergent is used to remove impurities from the Garment fabric surfaces and temperature

helps detergent to enhance its action. Detergent removes the impurities from the garments fabric

surface. During coming these impurities, some pigment will be washed out from the pigment dyed

or printed area of the garments. As a result fading affect will be developed.

Acidic Acid (CH3COOH) :

Acidic Acid is used to neutralize the garment from alkaline condition and to control the pH value in

wash bath.

Flax Softener (Cationic, anionic):

Softener is used to make the garments treated textiles is surface feel that is bath sickly and soft and

also provides excellent lubricating properties

CAUSTIC WASH:

Caustic wash generally doing on Reactive dye, Sulpher dye, Direct dyed or printed Garments

Caustic wash is required for the following reasons:A Distinctive Digest of Garment Washing & Dyeing

To fading/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.

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 processes of batch of 80 kg twill/canvas garments are described below:--

First Step :

Lot size: - ...................... 80 kg.


Machine Running.

Add Caustic soda (NAOH) at 1.60 gm / liter …. 1024 gm.

Add Detergent.............. at 0.8 gm / liter ......... 432 gm.

Temperature........... 50°c to 60°c.


Drop the liquor.

Wash cold water for 3 min.

Second Step :

Neutral Wash


Add Acetic Acid at 1 gm / liter ............. 400 gm.

Time................................... 5 min.

Here acetic acid is used to neutralize the garments from alkaline medium.

Third Step:


Machine Running.


Add Flax softener at 0.6 gm / liter........... 288 gm.

If more soft use silicon at 0.6 gm / liter ... 288 gm.


Time................................ 10 to 20 min.

Drop the liquor.

Unload the garments on trolley

Fourth Step: Hydro- extractor machine.

Hydro-extraction the garments to remove excess water from the Garments. Time

required about 2 - 4 minutes.

Fifth Step : Steam Dryer/Gas Dryer


Running the machine




or


Running the machine

Temperature: - 70°c - 85°c for dry.



Sixth Step :

After drying garments go to quality section and check the garment, good quality

garment will be delivery and Deep shade again rewash, other quality Garment

rectify then delivery.

CHEMICAL USED IN CAUSTIC WASH AND THEIR FUNCTION

CAUSTIC SODA (NaoH):

Caustic created the role in bleach technique with color change the garments.

Caustic has powerful cleaning power.

Fading affect/old looking affect come rapidly on garments.

DETERGENT:


Here detergent is used to remove impurities from the garments fabric surfaces and

temperature helps detergent to enhance its action. During these impurities, some

color will be washed out from the colored fabric garments. As a result fading affect

will be developed.

ENZYME WASH

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 cellulose to degrade in different way's 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.

The action of enzyme during enzyme wash, it hydrolysis 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 affect is

produced.

Mainly two types of enzyme used in Bangladesh. One is Acid Enzyme (liquid) and

another is Neutral Enzyme

Neutral Enzyme is two types - a) Powder form b) Liquid form i.e., SL Enzyme.

ACID ENZYME

Acid enzyme color is slightly brown.

pH range is 4.5 to 5.5

Temperature - 40°c - 55°c.

Time required 25 min to 50 min.

Enzyme affects come within short time.

Staining/Bleeding occurs more in garments.


Production high

NEUTRAL ENZYME

POWDER ENZYME

Enzyme is slightly white powder form.

pH range is 6 to 7.

Temperature - 40°c - 60°c.

Time required 40 to 70 min.

Enzyme affects come slowly.

Less staining/bleeding on garments.

With pumic stone comes good affect/abrasion on garments.

In dark shade enzyme affect comes good

SL ENZYME

SL enzyme is liquid form.

pH range is 6 to 7.

Temperature range 40°c - 60°c.

Time required 45 to 80 min.

Enzyme affects come slowly.

Less staining/bleeding on garments.

With pumic stone come better affect.

In dark shade enzyme affect comes good

ENZYME WASH

Enzyme wash is required for the following reasons :

To remove the size materials from the garments.

To remove the starch presents on the garments fabrics.

To achieve the high low abrasion (stone affect) on garment and seam abrasion in

sewing area.


Enzyme attack as chemically not mechanically for this reason low damage/wastage

then stone wash.

For soft feeling to wear the garment.

To achieve the buyer reference sample.

To increase the color fastness & rubbing fastness.

Especially develop the "Bio-Polishing" affect of cotton/denim.

Enzyme improves the anti-pilling properties.

Enzyme attacks more the surface of the fabrics and gives a very smooth surface.

DIFFERENCES AMOUNG DARK SHADE MEDIUM SHADE & LIGH SHADE:

Dark Shade Medium Shade Light Shade

Desizing

Enzyme(Neutral)

Caustic wash

Softener & PH Control

Hydro-extractor

Dryer

Quality

Delivery to finishing

Desizing

Enzyme(Acid)

Bleaching

Neutralization

Caustic wash


Hydro-extractor

Dryer

Quality


Desizing

Enzyme(Acid)

Bleaching

Neutralization1

Neutralization2

Caustic wash


Hydro-extractor

Dryer

Quality


ENZYME WASH PROCESS (DARK SHADE)

The enzyme washing process of batch of 60 kg denim men's long pant (Trouser) are described

below :

First Step : DESIZING

Lot weight (80 Pecs) ............ 60 kg denim long pant.


Machine Running


Temperature.......................... 60°c.

Add Desizing agent at 0.6 gm / liter........ 324 gm.

Add Detergent at 0.8 gm / liter ............... 432 gm.

Time ................................10- 15 min.

Drop the liquor

Wash 1 time by cold water

Second Step: ENZYME


Temperature................................ 45°c.

Add Acetic Acid at 0.3 gm / liter..... 135 CC.

Add Anti Back staining at 0.6 gm / liter ... 270 gm.

Add Neutral Enzyme at 2.00 gm / liter ... 900 gm.

Time... (Depend upon the shade)….40- 80 min.

Increase temperature to 90°c and run 1 minute (enzyme killing).

Drain the bath.

Rinse Twice, each 3 minutes

Third Step: - SOFTENING




Temperature.......................... Cold.

Time................................ 10 to 15 min.

Drain the bath


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 dryer.


Run about 40 min.

After then run 10 min in cold dryer.


Sixth Step:

After dryer garment go to quality section for quality checking and good one delivery

ENZYME WASH PROCESS (MEDIUM SHADE)

The enzyme washing process of batch of 60 kegs denim men's long pant (Trouser) is described

below:

First Step: DESIZING



Machine Running.

Temperature.......................... 60°c.



Time ................................15- 20 min.

Drop the liquor.


Second Step: - ENZYME

Add water at L: R = 1 : 8 ........... 480 Liter

Temperature .............................. 45°c.

Add Acetic Acid at 0.6 gm / liter ... 270 gm.

Add Anti Back staining at 0.6 gm / liter .... 270 gm.

Add Acid Enzyme at 2.00 gm / liter ... 900 gm.

Time... (Depend upon the shade)……..30- 60 min.


Drain the bath.


Third Step : Bleaching-

Add water at L : R = 1 : 7 .......... 420 Liter

Temperature............................. 60°c.

Add chlorine bleach (k.c.i) at 10 gm / liter …… 4200 gm.

Add soda ash at 2 gm / liter........ 840 gm.


Time (Depend upon the shade)........ 12 to 15 min.

Drop the liquor.


Fourth Step : Neutral

Add water at L : R = 1 : 10 ....... 600 Liter

Temperature............................. 50°c.

Add sodium hypo sulphite at 2 gm / liter ............ 1200 gm.

Add detergent at 0.5 gm / liter ... 300 gm.

Time.................................... 10 to 15 min.

Drop the liquor.


Fifth Step : SOFTENING


Add Acetic Acid at 0.6 gm / liter... 270 gm.

Cationic Softener at 1 gm / liter.... 450 gm.


Time................................ 10 to 15 min.

Drain the bath.

Then unload the garments on trolley

Sixth Step: Hydro-extractor Machine


extractor machine to remove excess water from the washed garments.

Seventh Step: - Drying Machine

Load 60 kg garments to gas dryer.


Run about 40 min.


Eighth Step:-

After dryer garment go to quality section for quality checking and good one delivery.

Hydro-extractor Machine




ENZYME WASHES PROCESS LIGHT SHADE:

The enzyme washing process of batch of 60 kgs denim men's long pant (Trouser) are described

below:

First Step: - DESIZING



Machine Running.

Temperature.......................... 60°c.



Time ................................15- 25 min.

Drop the liquor.


Second Step : ENZYME


Temperature.......................... 45°c.


Add Anti Back staining at 0.6 gm / liter. 270 gm.

Add Acid Enzyme at 2.00 gm / liter ....... 900 gm.

Time ... (Depend upon the shade).......35- 60 min.


Drain the bath.


Third Step : Bleaching


Temperature.......................... 50°c to 60°c.

Add chlorine bleach (k.c.i) at 20 gm / liter. 8400 gm.

Add sodium bi carbonate at 4 gm / liter..... 1680 gm.

Time (Depend upon the shade)........ 12 to 20 min.

Drop the liquor.


Rinse Twice, each 3 minutes.

Fourth Step : Neutral -1

Add water at L : R = 1: 10…………600 Liter

Temperature................................... 50°c.

Add sodium hypo sulphite at 2 gm / liter.... 1200 gm.

Add detergent at 0.5 gm / liter ............ 300 gm.

Time................................ 10 to 15 min.

Drop the liquor.


Fifth Step: Neutral-2


Temperature.......................... 60°c.

Add hydrogen peroxide at 4 gm / liter.....1920 gm.

Add caustic soda at 1 gm / liter ............ 480 gm.

Add detergent at 1 gm / liter ............ 480 gm.

Time................................ 10 min.

Drop the liquor.


Sixth Step: SOFTENING





Time................................ 10 to 15 min.

Drain the bath.


Seventh Step: - Hydro-extractor Machine



Eighth Step: Drying Machine

Load 60 kg garments to Steam dryer.



Run about 40 min.


Ninth Step:

After dryer garment go to quality section for quality checking and good one delivery.

ENZYME WASH PROCESS

(TWILL/CANVAS/POPLIN)

The enzyme washing process of batch of 60 kg Twill/Canvas/Poplin/Corduroy) trouser are described

below :

First Step: - DESIZING

Lot weight (Approx 125 Pecs) ............ 60 kg.

Add water at L : R = 1 : 10 .............. 600 Liter

Machine Running.

Add Desizing agent at 0.6 gm / liter........ 360 gm.

Add Detergent at 0.5 gm / liter ............... 300 gm.

Temperature.......................... 50-60°c.

Time ........................................10- 20 min.

Drop the liquor.

Rinse one time 3 minutes

Second Step: ENZYME


Temperature.......................... 45°c.

Add Acetic Acid at 0.5 gm / liter.............. 240 gm.

Add Acid Enzyme at 1.2 gm / liter ............ 600 gm.

Add Antistain at 0.50 gm / liter ...........,,.. 240 gm.

Time (Depend upon the standard).... 30 to 60 min.

Increase temperature to 90°c and run 1 minute.

Drain the bath.


Third Step :- SOFTENING





Silicon (ME) at 0.5 gm / liter ................ 240 gm.

Temperature.......................... 40°c.

Time................................ 10 to 20 min.

Drain the bath.


Fourth Step :- Hydro-extractor Machine



Fifth Step : Drying Machine

Load 60 kg garments to gas/steam dryer.


Run about 35 to 45 min.

After run 10 to 15 minutes for cold dryer.

Sixth Step :

After dryer garment go to quality section for quality checking and then delivery.

INTRODUCTION OF PUMIC STONE

Pumic Stone:-

The pumic stone are the perforated stones, produced from volcanic explosion.

At first these stones are soft but becomes cold, it becomes the stones with rough surface,

Pumic stones float on water.

Pumic stones come from Indonesia and Turkey.

Indonesia stone color is slightly brown and Turkey stone is white color.

Pumic stones are available in 3 size i.e. small 2-3 cm, medium 3-5 cm and large size 5-7 cm.

Two to Three times can be used are pumic stone.

Every bag contain 22 kg to 25 kg and price 400/= to 425/=/ bag

THE ACT OF PUMIC STONES DURING GARMENT WASHING


During different garments washing like stone wash, Acid wash, Stone Enzyme wash etc.

Pumic stones are used to create irregular fading affect 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 affect will

be developed and the areas where less brushing action takes place, there less discolor affect

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 WASH

A process of stone wash of 60 kg batch of Denim Long Pant as mentioned below:

First Step : PRE-TREATMENT/DESIZING

Batch size....................... 60 kg Denim Long Pant.

Add water at L: R = 1: 9 ..................... 540 liter.

Start the machine.

Temperature ................................. 60°c

Add Desizing agent at 0.6 gm / liter ......... 324 gm.

Add Detergent / Antistain at 1 gm / liter. 540 gm.

Time................................ 15 to 25 min.

Drop the liquor

Second Step :- HOT WASH

Add water at L: R = 1: 9.............. 540 liter.

Temperature.................... 60°c.

Time................................ 5 min.

Third Step :- BLEACHING

Add water at L: R = 1: 8.................... 480 liter.

Machine running.

Add bleaching powder (k.c.i) at 10 gm/liter ..................... 4800 gms.

Add soda ash at 5 gm/liter................. 2400 gms.

Pumic stone at ½ vol of garments.


Temperature ....................................... 60°c.

Time (Depend upon the shade) .......... 12 to 15 min.

Drop the liquor.

Rinse twice, each 3 minutes

Fourth Step :- NEUTRAL WASH


Add sodium hyposulphite at 3 gm/liter .......... 1620 gms.

Temperature............................. 40°c.


Drop the liquor.

Rinse one.

Fifth Step :- SOFT WASH


Add Acetic Acid at 0.6 gm/liter ..................... 288 gms.

Cationic softener at 1 gm/liter ........................ 480 gms.

Time................................ 5 min.

Drop the liquor.

Unload the garments to trolley

Sixth Step :- Hydro-extractor Machine

Hydro-extraction the garment 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 min.

Time ..................... 10 minutes in cold dry.

Eighth Step :- Delivery :-

After quality checking garment will be delivery.

STONE ENZYME WASH


Now in our Bangladesh maximum Denim garment is washing STONE ENZYME WASH. It is most

popular wash for Buyer. A process of stone enzyme wash of 60 kg batch of Denim Long Pant as

mentioned below:

First Step :- PRE-TREATMENT / DESIZING



Start the machine.

Temperature.................... 60°c

Add Desizing agent at 0.6 gm / liter .......... 324 gm.

Add Detergent / Antistain at 1 gm / liter ... 540 gm.

Time................................ 15 to 25 min.

Drop the liquor

Second Step : HOT WASH


Temperature.................... 60°c.

Time................................ 5 min.

Third Step :


Add pumic stone at ½ vol of garments.

Add Enzyme at 1.50 gm/liter ..................... 720 gms.


Add Antistain at 0.8 gm/liter ..................... 384 gms.

Temperature............................. 40°c to 50°c..


Then temperature raise to 90°c for 1 minute.

Drop the liquor.


Then pumic stone out from washing machine

Fourth Step : BLEACHING


Machine running.



Add soda ash at 5 gm/liter................. 2400 gms.

Temperature ....................................... 60°c.

Time (Depend upon the shade) ...... 12 to 15 min.

Drop the liquor.


Fifth Step :- NEUTRAL WASH

Add water at L: R = 1: 9..... 540 liter.

Add sodium hyposulphite at 3 gm/liter ..................... 1620 gms.

Temperature ......................... 40°c.

Time ............................... 10 to 12 min.

Drop the liquor.

Rinse one

Sixth Step :- SOFT WASH

Add water at L: R = 1: 8 .......... 480 liter.

Add Acetic Acid at 0.6 gm/liter... 288 gms.

Cationic softener at 1 gm/liter.... 480 gms.

Time................................ 5 min.

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 min.

Time.......................... 10 minutes in cold dry.

Ninth Step : Delivery

After quality checking garment will be delivery

BLEACH WASH

A process of bleach wash of 60 kg batch of Denim Long Pant as mentioned below :-


First Step :- PRE-TREATMENT / DESIZING



Start the machine.

Temperature.................... 60°c


Add Detergent / Antistain at 1 gm / liter.... 540 gm.

Time................................ 15 to 25 min.

Drop the liquor

Second Step : HOT WASH

Add water at L: R = 1: 9... 540 liter.

Temperature ..................... 60°c.

Time ................................. 5 min.

Third Step : BLEACHING


Machine running.


Add soda ash at 5 gm/liter ............... 2400 gms.

Temperature............................. 60°c.


Drop the liquor.


Fourth Step : NEUTRAL WASH


Add sodium hyposulphite at 3 gm/liter ......... 1620 gms.

Temperature.................................................. 40°c.

Time …………………………………................ 10 to 12 min.

Drop the liquor.

Rinse one.

Fifth Step : SOFT WASH




Cationic softener at 1 gm/liter ........................ 480 gms.

Time................................ 5 min.

Drop the liquor.

Unload the garments to trolley

Sixth Step : Hydro-extractor Machine

Hydro-extraction the garment 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 min.


Eighth Step : Delivery

After quality checking garment will be delivery

DIFFERENT TYPECS OF WASHING FAULTS

Color shade variation.

Crease Marks.

After wash hole.

Very dark & very light.

Bleach Spot.

Bottom hem & course edge destroy.

Running shading.

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 affect / abrasion on garments.

Spot on garments.

Out of range / level of pH value of garments.


APPROX. RATE FOR DIFFERENT TYPECS OF WASHING

NORMAL WASH / GARMENT WASH

– Kids / Boy's item - us$ 0.70 - $ 1.25 / DOZ

– Adult item - us$ 1.00 - $ 1.50 / DOZ

PIGMENT WASH / CAUSTIC WASH


– Adult item - us$ 1.25 - $ 2.00 / DOZ

SILICON WASH


– Adult item - us$ 1.50 - $ 2.00 / DOZ

ENZYME WASH (TWILL/CANVAS/POPLIN/CORDREY/T.SHIRT)


– Adult item - us$ 2.25 - $ 2.75 / DOZ

ENZYME WASH (DENIM )


– Adult item - us$ 3.50 - $ 5.00 / DOZ

STONE ENZYME WASH (TWILL/CANVAS/POPLIN/CORDREY)


– Adult item - us$ 2.50 - $ 3.00 / DOZ

STONE ENZYME WASH (DENIM)


– Adult item - us$ 4.00 - $ 6.00 / DOZ

ACID WASH

– Boy's item (Woven/Knit) - us$ 5.00 - $ 5.50 / DOZ

– Adult item " - us$ 6.00 - $ 7.00 / DOZ

– Sweeter item - us$ 7.00 - $ 8.00 / DOZ

STONE ENZYME + SAND BLASTING

– Boy's item (Twill/Canvas etc.) - us$ 5.00 - $ 6.00 / DOZ

– Boy's item (Denim) - us$ 5.50 - $ 6.50 / DOZ

– Adult item (Twill/Canvas etc.) - us$ 6.00 - $ 7.00 / DOZ


– Adult item (Denim) - us$ 7.00 - $ 8.00 / DOZ

STONE ENZYME + SAND BLASTING + TINTING

– Boy's item (Twill/Canvas/Denim etc.) - us$ 7.00 - $ 9.00 / DOZ

– Adult item (Twill/Canvas/Denim etc.) - us$ 8.50 - $ 10.00 / DOZ

STONE ENZYME + SAND BLASTING + GRINDDING

– Boy's item - us$ 7.00 - $ 9.00 / DOZ

– Adult item - us$ 8.00 - $ 10.00 / DOZ

STONE ENZYME + SAND BLASTING + TAGGING + GRINDING

– Boy's item - us$ 8.00 - $ 10.00 / DOZ

– Adult item - us$ 9.00 - $ 12.00 / DOZ

STONE ENZYME + SAND BLASTING + WHICKERING

– Boy's item - us$ 7.00 - $ 9.00 / DOZ

– Adult item - us$ 8.00 - $ 10.00 / DOZ

STONE ENZYME + WHICKERING + PERMANENT CRINKLE

– Boy's item - us$ 10.00 - $ 12.00 / DOZ

– Adult item - us$ 12.00 - $ 13.00 / DOZ

STONE ENZYME + TAGGING + GRINDING

– Boy's item - us$ 7.00 - $ 8.00 / DOZ

– Adult item - us$ 8.00 - $ 9.00 / DOZ

WHAT TYPECS OF CHEMICAL USE IN WASHING PLANT

Enzyme

Acetic Acid

Detergent

Antistain

Bleaching powder

Sodium hyposulfite

Caustic Soda

Soda Ash

Sodium Bicarbonate

Potassium permanganate


Cationic / nonionic Flax softener

Micro Emulsion Silicon

Salt (sodium chloride)

Buffer

Hydrogen peroxide

Stabilizer

Fixing agent

Catanizer

Optical Brightner

Resin

Sodium Metabisulphite

Desizing agent

WHAT IS THE FUNCTION OF CHEMICALS IN TEXTILES

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 party hydrolyzed the yarn portion. As a result color comes out from the

yarn portion and faded affect is produced.

DETERGENT: Chemical character is fatty alcohol polyglycol ether in an aqueous, glycolic

solution. Detergent is widely applicable in the continuous and discontinuous pretreatment

of all tyPecs of fiber and their blends. To remove impurities, mineral oil contamination and

sizes from the garments scouring of goods for dyeing and printing fully white and colored

articles.

ACETIC ACID (CH3COOH) : Acetic Acid is used to neutralize the garments from alkaline

condition and to control the pH value in wash bath.

ANTISTAIN: Antistain is used to prevent the staining on weft yarn of the denim (white yarn),

white pockets of garment, 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 deferent shade of color on garment i.e.

Dark, Medium, Light shade.


SODIUM HYPOSULPHITE: Sodium hyposulphite is used to neutralize the garments from

chlorine bleach.

CAUSTIC SODA: Caustic created the role in bleach technique without color change the

garment and has a good cleaning power. It is work as fading affect/old looking affect come

rapidly on garments.

SODA ASH: Soda ash creates alkaline medium for the breakdown of pigment dye. Soda ash

help to uniform bleaching action on bleach bath. It has a cleaning power and help color

fading affect of garment. It is used also for color fixing in dye bath.

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 increase 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 sickly 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, antipilling, dimensional stability, tear resistance and fabric to be cut and sewn more

easily allows and improving wear and easy care properties.

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,

desizing 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 fading affect is developed. Hydrogen peroxide

is used in scouring, bleaching bath for white/ready for dyeing of gray fabric garments. It is

used also neutralized the garment from alkaline condition.

STABILIZER: Hydrogen peroxide is work 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.


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 color has 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 glyoxal

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 metabisulphite is used in the washing plant to neutralize

the garment from potassium permanganate.

DESIZING AGENT : Desizing agent is used to remove mainly starches, cmc, waxes, fats

pectin’s, minerals & unfixed indigo dye from denim, twills, poplin & canvas fabrics etc.

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

a brushing action on the garment fabric surface. The area where more brushing action takes place

there more discolor or fading affect is developed and the area where less brushing action takes place

less brushing action and takes place less fading affect will be developed. The multi-layer fabric areas

like – collar, calf, pocket, placket, and 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 garment by acid wash technique.

ACID WASH PROCESS


A processor Acid wash of 60 kg batch of Denim Trouser as mentioned below:-

First Step: - Pretreatment/Desizing.

Add water at L: R = 1: 10 ............ 600 liter.

Start Machine.

Add desizing agent at 1 gm/liter ... 600 gms.

Add detergent at 1 gm/liter........... 600 gms.

Temperature............................. 60°c.

Time........................... 20 min.

Drop the liquor.

Rinse one for 3 minutes (cold).

Second Step: - Hot wash


Temperature............................. 60°c.

Time.......................................... 5 min.

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.

The pumic stones used for acid wash need to pre-treat in the following chemical solution:-

Water ..................... 100 liter.

Potassium per manganate.............. 1000 gms.

Phosphoric Acid....................... 250 gms.

Stir 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 min.

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.

Third Step: - Wash for cleaning

Batch wt ....................................... 70 kg.


Add detergent at 1 gm/liter .......... 560 gms.

Temperature ................................. 40°c - 50°c.

Time .............................................10 min.

Drop the liquor.

Here detergent is used to remove the breaking stone dust and chemicals from the garment

surface.

Fourth Step: - Whitening/Neutralization.


Machine running.

Add Metabisulphite at 5 gm/liter ......... 2800 gms.

Cold temperature.

Time 5 min.

Drop the liquor.

Fifth Step:-


Machine running.

Add Acetic acid at 0.6 gm/liter..... 294 gms.

Add Softener at 1 gm/liter.............. 490 gms.

Then unload the garments.

Sixth Step: - Hydro extractor machine.

Hydro-extractor is used machine 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.


Precaution

Maintain the stock solution properly constant when comes socking the stone.

No water licks 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,

it’s 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 Pecs.

Every cut Pecs 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.

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 & poley etc.

Tinting & over dyeing:

This type of process is done after different types of washing before softening.

Normally after Acid wash, Stone wash, Stone enzyme wash, Sand Blasting, Enzyme wash etc.

tinting & over dyeing is done.

Tinting & over dyeing is done with Direct dyes or Reactive dyes.


Due to tinting and over dyeing, the white/base area colored with required dye yellow,

Brown, Orange etc.

As a result, new color effect is produced in the garments.

If direct dye is used then color fixing treatment should be done at the end of dying process.

In case over dyeing/Tinting with reactive dyes, color fastness is good hence no after

treatment is required to fix the reactive dyes.

Tinting by Direct Dye:

First Step: - After different wet processing i.e. Acid wash, Stone wash, Enzyme wash, Stone enzyme

wash, Bleach wash take 60 kg garment for Tinting & over dyeing.

Water at L: R = 1: 7.............. 420 Liter

Run the Machine.

Temperature................. 50 - 80°c

Dir. Brown GTL - at 0.04%........... 24 Gms.

Dir. Orange ZTL - at 0.01%........... 6 Gms.

Add Salt at 20 gm / liter ............ 8.40 kg.

Add Leveling agent at 0.5% /........ 210 gm.

Time................................ 10 to 30 mts.

Rinse by cold water 3 minutes.

Second Step: - FIXING

Batch size .............................. 60 kg.

Water at L: R = 1: 7.............. 420 Liter

Run the Machine.

Temperature................. 50°c

Add fixing agent at 0.8 %(owf) ... 480 gm.

Time............................................ 10 mts.

Third Step: - Softening.

Batch size.................... 60 kg.

water at L : R = 1 : 7 ............................ 420 Liter

Add Acetic Acid at 0.6 gm/liter ............ 250 gm.

Add Cationic softener at 1 gm/liter ...... 420 gm.


Time................................ 10 mts.

Drop the liquor.


Fourth Step: - Hydro extractor machine.

Hydro extractor machine is used to remove excess water from the garments.

Fifth Step: - Dryer machine.


Sixth Step: - Quality & Delivery.


delivery.

Tinting by Reactive dye:

First Step: - After different wet processing i.e. Acid wash, Stone wash, Enzyme wash, Stone enzyme

wash, Bleach wash take 60 kg garment for Tinting & over dyeing.

Water at L: R = 1: 7.... 420 Liter

Run the Machine.

Temperature................. 60°c

Reactive Red –

Reactive Yellow - Brown ......... 100 gm.

Reactive Black -

Leveling agent - at 0.5 gm / liter.......240 gm.

Salt - at 20 gm / liter........... 8.40 kg.

Soda ash at 10 gm / liter ............ 4.20 kg.

Time................................ 20 to 30 mts.

Drop the liquor.

Second Step: - Fixing.

Batch size.................... 60 kg.

Water at L: R = 1 : 8 .............. 480 Liter

Run the Machine.

Temperature.................................. 50°c

Add fixing agent at1 gm / liter..... 480 gm.

Time............................................. 10 mts.


Drop the liquor.


Batch size.................... 60 kg.

Water at L: R = 1: 7.............. 420 Liter

Add Acetic Acid at 0.6 gm/liter ............ 250 gm.

Add Cationic softener at 1 gm/liter ...... 420 gm.

Time................................ 10 mts.

Drop the liquor.

Then unload the garments on trolley



Fifth Step: - Dryer machine.




delivery.

SAND BLASTING:

Sand blasting is recently a popular dry process & fashion.

Sand blasting is a mechanical process of creating fadding affect/old looking affect on heavy

garments like denim, canvas, twill, sometimes corduroy by the action of aluminum oxide

which looks like sand. For this reason this process termed as “Sand blasting”.

Sand blasting is generally doing which area that long time used/wear the garment fadding

effect occurs. By sand blasting at new position old/fadding affect on garment comes before

use/wear.

Sand blasting is performed with combine the wash like, Normal/Rinse wash, Enzyme wash,

Stone enzyme wash, Bleach wash, Stone wash and tinting/dyeing etc.

A process of Sand Blasting on Denim/Canvas/Twill/Corduroy garments is

described bellow:-


Aluminum oxide (Al2O3) is used for Sand Blasting which is looks like sand.

These aluminum oxides are very fine & very hard/sharp.

These aluminum oxides through by gun with dry air to perform sand blasting action.

The gun has a switch to start and stop the flow of aluminum oxides.

The garments to be Sand Blasting are placed on the bed of a closed chamber.

The garments are instantly faded by the frictional affect of aluminum oxide.

Sand Blasting is a hazardous process.

Sand Blasting area is isolated from other production area.

The handling of sand blasting gun is a risky process.

The flow of aluminum oxide on fabric surface is done at 10_20° angles.

The blowing angle is very important.

Higher the blowing angle higher the fading affect & higher the risk of fabric damage.

The operators should have protective standard musk, helmet, gloves, ear plug and uniform.

Production/hour/gun varies from 25_50 pcs garments depend on the area, extent of fading.

After mechanical fading, chemical treatments are required for the buyer’s requirement.

P.P SPRAY & P.P SPONGING:

P.P spray & P.P sponging is doing in Denim, Twill, Poplin, Corduroy generally middle of wash

i.e. after enzyme wash, stone enzyme wash.

If need some particular area more white then we are doing p.p spray & p.p. sponging.

If we want more white effect in some particular area of garments by Blasting then it high risk

of damage. So we select p.p. spray & p.p. sponging which is chemically action.

After p.p. spray & p.p. sponging need to neutralize the garment Sodium metabisulphite, then

whitish effect come on respective area of garments.

Standard stock solution is 0.4% i.e. 100 Liter water 400 grams potassium permanganate.

P.P. spray is done by nozzle and has a switch to start & stop.

For spray on garments need dry air which is supplied from screw compressor and p.p. stock

solution tank.

P.P. spray on garment need one chamber, different types of dummy and exhaust fan.

P.P. sponging is done manually.


By foam/fabric pcs wet in p.p. stock solution and rubbing particular area of garment by hand

as a result fadding affects on garments.

P.P. spray & P.P. sponging operator must be used Hand gloves, Helmet, Mask, Ear plug &

Uniform for their safety.

WHISKERING:

A process of whickering denim/Canvas/Twill/Corduroy garment is deserved below:-

By rubber pattern & sand blasting gun. i.e. rubber pattern set on garment and sand through

over the pattern by nozzle.

By manually created whisker by sand paper on garment.

Make a pattern just like pacific whisker and put it inside the garment, then rubbing front side

of garment over pattern,

By p.p. spray and p.p. sponging on garments.

Mentioned all process is done on garments fadding effect occurs in garments.

TAGGING:

Tagging is doing on garment for fashion and value added fashion wear.

Tagging is doing by Tagging machine.

Tagging is doing also by needle & thread & manually.

After wash upper portion of garment shows crease marks and inside of tagging occurs Dark

shade.

GRINDING:

Grinding is doing on garment for mainly old/used look appearance & fashion.

Grinding is doing on hem, pocket edge, west belt, pocket opening, and pocket pluf of

garments.

Grinding is done by grinding machine, sand paper by manually.

DESTROY:


Destroy is newly fashion on garments.

Destroy is doing by manually.

Different types of machine used for destroy the garments – Grinding machine, Emery cloth,

Hacksaw blade, Knife etc.

When destroy is done one garment, it seems to be long time used effect.

PERMANENT WRINKLE PROCESS:

Generally permanent wrinkle is doing on garments after all types of wet process wash in dry

position.

Permanent wrinkle is done on the garments made from all types of fabrics like, Denim, Twill,

Canvas, Poplin, Corduroy, Knit & Polyester etc.

For permanent wrinkle we are use resin which is spray on garments particular/specific area

by nozzle.

Resin is diluted with water which is recommended by chemical supplier, generally 20% resin

& 80% water.

After resin spray on respective area, then fold by buyer demand and clip attached upon the

folding area.

Now hangers the garment in to the hanger trolley, Trolley capacity approx. 80-100 pcs

garments.

Then trolley with resin treatment garments put inside the Industrial oven.

Set temperature 140°c to 160°c, Time 20-40 minutes (if folding layer is less, Less time

required, if folding Layer is more, more time is required).

Start the machine.

When setting time is over, machines are automatically off.

After heating time over garments with hanger will stay 10 minutes for cold in oven.

Now open the door and trolley with garment out from oven.

Open the clip from garment and go to quality section for quality checking & delivery.

OVERALL WRINKLE PROCESS:


Generally overall wrinkle is doing on garments after all types of wet process & dry process.

Overall wrinkle is done on the garment made from all types of fabrics like, Denim, Twill,

Canvas, Poplin, Corduroy, Knit, Polyester, Viscose & Nylon etc.

Now tie the whole garment in tight position by thread.

For overall wrinkle, we are used resin in washing machine with water and run tied garments

for 5 to 10 minutes at 50°c temperature.

Then unload the garments from washing machine to trolley for hydro extractor to remove

the excess water.

Open the tie or cut the thread.

Now hanger the garments into the hanger trolley. Trolley capacity appreciates 80-100 pcs

garments.

Then trolley with resin treatment garments put inside the Industrial oven.

Set temperature 140°c to 160°c, Time 50-70 minutes.

Start the machine.

When setting time is over, machines are automatically off.

After heating time over garments with hanger will stay 10 minutes for cold in oven.

Now open the door and trolley with garments out from oven and go to quality section,

checking & delivery.

INTRODUCTION OF GARMENT DYEING

Garments Dyeing:-


The process of dyeing garments after manufacturing from grey fabric is called garment

dyeing.

Colored garments are not used for garments dyeing but the garments which are

manufactured from grey fabric is used to dye only in solid color form.

Checks, Stripes or multi-colored fabrics are not used for garments dyeing.

In Bangladesh cotton garments manufactured from grey fabric is used to dye in solid color

form.

READY FOR DYEING FABRICS:

First Step:-

Batch size.................... 60 kg cotton shirt (grey).

Water at L: R = 1: 8.............. 480 Liter.

Running the machine.

Temperature .................. 90°c.

Detergent at 2% ............ 1.2 kg.

Caustic at 8% ................ 4.8 kg.

Soda Ash at 5% ............ 3.00 kg.

Hydrogen Peroxide (H2o2) at 12%... 7.20 kg.

Stabilizer at 5% ............ 3.00 kg.

Time............................. 60 to 80mts.

Drop the liquor

Second Step: - HOT WASH.

Batch size ...................... 60 kg.

Water at L: R = 1: 10.... 600 Liter.


Temperature ................... 50°c.

Time................................ 5 mts.

Drop the liquor.

Third Step: - NEUTRAL.

Batch size....................... 60 kg.

Water at L: R = 1: 7......... 420 Liter.


Machine Running.

Acetic Acidat 1 %(owf) ..... 600 gm.

Time................................ 5 mts.

Drop the liquor & Ready for dyeing.

SUPER WHITE WASH:

Normally done on the garments made from cotton grey fabric.

The garments after wash become extremely white.

Washing is carried out in steps:---

WASHING PROCESS:-

First Step:-

Batch size.................... 60 kg cotton shirt (grey).

Water at L: R = 1: 8.............. 480 Liter.


Temperature...................................... 90°c.

Detergent at 2% (owf)........................ 1.20 kg.

Caustic Soda at 8% (owf).................... 4.80 kg.

Soda Ash at 5% (owf).......................... 3.00 kg.

Hydrogen Peroxide (H2o2) at 12% (owf)...7.20 kg.

Stabilizer at 5% (owf)........... 3.00 kg.

Time................................ 70 -80 mts.

Drop the liquor.

Second Step:-

Batch size......................... 60 kg.

Water at L: R = 1: 8........ 480 Liter.


Temperature ...................... 90°c.

Detergent at 2%................. 1.20 kg.

Caustic at 4% ..................... 2.40 kg.

Hydrogen Peroxide (H2O2) at 10%... 6.00 kg.


Stabilizer at 2%................. 1.20 kg.

Time................................... 40 ---- 70 mts.

Drop the liquor.

Third Step: - HOT WASH.

Batch size.......................... 60 kg.

Water at L: R = 1: 8 .......... 480 Liter.


Temperature ...................... 50°c.

Time................................... 5 mts.

Drop the liquor.

Fourth Step: - NEUTRAL.

Batch size....................... 60 kg.

Water at L: R = 1: 8..... 480 Liter.

Acetic Acidat 1%........... 600 gm.

Time................................ 5 mts.

Drop the liquor.

Fifth Step:-

Batch size .............................. 60 kg.

Water at L: R = 1: 7.............. 420 Liter.

Machine Start.

Optical Brightener 0.5%........ 300 gm.

Time ....................................... 5 mts.

Drop the liquor.

Sixth Step: - Softening

Batch size ........................................ 60 kg.

Water at L: R = 1: 7 .................. 420 Liter.

Non-ionic Softener at 0.4% ............ 240 gm.

Micro Emulsion silicon at 0.4%..... 240 gm

Time ........................................ 5 to 10 mts.

Drop the liquor.

Then unload the garment on trolley.

Seventh Step: - Hydro extractor machine.



Eighth Step: - Drying machine.

Load 50 kg garments to steam dryer.

Temperature set ................ 70°c.

Run about................. 40-45 mts.

After run 10 to 15 mts. for cold dry.

Ninth Step: - Quality & Delivery.


delivery.

DIRECT DYEING:

First Step: - Dyeing

Batch size.................... 60 kg ready for dyeing garments.

Water at L: R = 1: 8.............. 480 Liter.

Machine Running.

Temperature ...................... 50°-80°c.

SCARLET. BNL... at 1.00%........ 600 gm.

Dyes/CBA Orange TGL ... at 0.3% ............. 180 gm.

Salt........ at 20 gm/liter..... 9.60 kg (Light color)

40 gm/liter ... 19.20 kg (deep color)

Add Leveling agent at 0.5% ............ 300 gm.

Time................................ 30-50 mts.

3 minutes cold water wash.

Second Step: - FIXING.

Batch size................................ 60 kg.

Water at L: R = 1: 7.............. 420 Liter.


Temperature ............................ 50°c.

Add Fixing agent at 0.8% ....... 480 gm.

Time................................... 10-15 mts.


Drop the liquor.


Batch size.................... 60 kg.

Water at L: R = 1: 7.............. 420 Liter.

Add Acetic Acid at 0.6 gm/liter................. 250 gm.

Add cationic softener at 1 gm/liter........... 420 gm.

Time................................ 10 mts.

Drop the liquor.

Then unload the garments trolley.



Fifth Step: - Drying machine.



Run about.............. 40-45 mts.




delivery.

REACTIVE DYE PROCESS:

First Step: - Dyeing

Batch size .................. 60 kg ready for dyeing garments.

Water at L: R = 1: 8.............. 480 Liter.

Machine Running.

Red – 3BS.................... 0.1%.............. 60 gm.

Blue - /F2RL.............. 0.01% ............... 6 gm.

Leveling agent at 0.5 gm/liter ............ 240 gm.

Salt ......... at 40 gm/liter ............ 19.20 kg (deep shade)

at 20 gm/liter .......... 9.60 kg (Light shade)

Soda ash...at 20 gm/liter ............ 9.60 kg (deep colour)


at 10 gm/liter .......... 4.80 kg (Light colour)

Temperature ...................... 60°c.

Time .................................. 40-60 mts.

Drop the liquor.

Second Step: - FIXING.

Batch size................................ 60 kg.

Water at L: R = 1: 8.............. 480 Liter.

Machine running.

Add Fixing agent at 1 gm/liter.. 480 gm.

Temperature ...................... 50°c.

Time................................ 15 to 20 mts.

Drop the liquor.


Batch size................................ 60 kg.

Water at L: R = 1: 7.............. 420 Liter.

Add Acetic Acid at 0.6 gm/liter ....... 250 gm.

Add cationic softener at 1 gm/liter... 420 gm.

Time................................ 10 mts.

Drop the liquor.







Run about.............. 40-45 mts.




delivery.

PIGMENT DYEING PROCESS AT EXHAUST:


First Step: - Cationizing.

Batch size.................... 60 kg ready for dyeing garments.

Water at L: R = 1: 8.............. 480 Liter.

Machine running.

Add Cationizing (Acramin prefix K)at 4%...... 2.40 kg.

Machine run at room temperature for .......... 10 mts.

After 10 mts run, temperature raise to 60°c.

Now run.......................... 20 mts.

Drop the liquor.

Second Step: - HOT WASH.

Batch size....................... 60 kg.

Water at L: R = 1: 8..... 480 Liter.


Temperature ...................... 60°c.

Time ................................. 5 mts.

Drop the liquor.

Third Step: - Dyeing

Batch size.................... 60 kg.

Water at L: R = 1: 7.......................... 420 Liter.

Add..... Pigment Red at 3%................ 1800 gm.

Pigment Black at 0.1%............. 60 gm.

Add Acetic Acid at 1cc/liter.................... 420 cc.

Temperature ..................................... 80°c-85°c

Time ................................................. 30 -40 mts

Drop the liquor.

Fourth Step: - FIXING.

Batch size................................ 60 kg.

Water at L: R = 1: 8.............. 480 Liter.

Add Binder at 5% ......................3.00 kg.

Temperature ........................ 30°c - 40.

Time ................................10 - 20 mts.


Fifth Step: - Softening.

Batch size................................... 60 kg.

Water at L: R = 1: 7................. 420 Liter.

Add Acetic Acid at 0.6 gm/liter ... 250 gm.

Add cationic softener at 1 gm/liter.......... 420 gm.

Time................................ 10 mts.

Drop the liquor.


Sixth Step: - Hydro extractor machine.


Seventh Step: - Drying machine.



Run about.............. 40-45 mts.


Eighth Step: - Quality & Delivery.


delivery.

SULPHER DYEING:

First Step: - Cationization.

Batch size ...60 kg garments ready for dyeing.

Water at L : R = 1 : 8 .............. 480 Liter.

Machine running.

Add Cationization (Indosol E-50 liter) at 4%..... 2.40 kg.

Temperature ................... 60°c.

Time....................... 30-40 mts.

Drop the liquor.

Second Step:- Dyeing

Batch size................................ 60 kg.

Water at L: R = 1: 7.............. 420 Liter


Optical Yellow - 2.50%.......... 1500 gm.

Optical Orange - 0.4%........... 240 gm.

Add Salt at 20 gm/liter ............ 8.40 kg.

Temperature....................... 90°c

Time................................ 60 to 70 mts.

Drop the liquor.

Rinse overflow until clear water.


Batch size ............................ 60 kg.

Water at L: R = 1: 7 .......... 420 Liter.

Add Acetic Acid at 0.6 gm/liter ....... 250 gm.

Add cationic softener at 1 gm/liter.. 420 gm.

Time................................ 10 mts.

Drop the liquor.







Run about.............. 40-45 mts.


Sixth Step :- Quality & Delivery.


delivery.

DIRECT COST/CHEMICAL COST:

We can consider stone enzyme wash 60 kg/80 pcs of denim men’s long pant. Now in our Bangladesh

maximum Denim garment is washing STONE ENZYME WASH. It is most popular wash for Buyer. A

process of stone enzyme wash of 60 kg batch of Denim Long Pant as mentioned below:-

First Step: - PRE-TREATMENT / DESIZING




Start the machine.

Temperature.................... 60°c

Add Desizing agent at 0.6 gm / liter ....324 gm - (150.00/kg)......48.60 Tk.

Add Detergent / Antistain at 1 gm /liter- 540 gm – (160.00/kg)..86.40Tk.

Time................................ 15 to 25 mts.

Drop the liquor.

Second Step: - HOT WASH


Temperature ..................................... 60°c.

Time.................................................. 5 mts.

Third Step:-

Water at L: R = 1: 8.............. 480 liter.

Add pumic stone at ½ vol of garments-(420.00/Bag)... 210.00 Tk.

Add Enzyme at 1.50 gm/liter. 720 Gms – (400.00/kg. 288.00 Tk.

Add Acetic Acid at 0.6 gm/liter...288 gms – (110.00/k... 31.68 Tk.

Add Antistain at 0.8 gm/liter... 384 gms – (160.00/kg. 61.44 Tk.

Temperature............................. 40°c to 50°c...

Time (Depend upon the shade) .......... 60 to 70 mts.

Then temperature rise to 90°c for 1 minute.

Drop the liquor.


Then pumic stone out from washing machine

Fourth Step: - BLEACHING


Machine running.

Add bleaching powder (k.c.i) at 10gm/liter..4800gms-(36.00/kg)..172.80 Tk.

Add soda ash at 5 gm/liter ........2400 gms-(24.00/kg)............... 57.60 Tk.

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 sodium hyposulphite at 3 gm/liter..1620 gms-(25.00/kg).. 40.50 Tk.

Temperature............................. 40°c.

Time ...................... 10 to 12 mts.

Drop the liquor.

Rinse one.

Sixth Step: - SOFT WASH

Add water at L: R = 1: 8........... 480 liter.

Add Acetic Acid at 0.6 gm/liter ....288 gms-(110.00/kg).......... 31.68 Tk.

Cationic softener at 1 gm/liter ........480 gms-(300.00/kg)........ 144.00 Tk..

Time................................ 5 mts.

Drop the liquor.

Unload the garments to trolley.

Seventh Step: - Hydro-extractor Machine

Hydro-extraction is used 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.


Ninth Step: - Delivery

After quality checking garment will be delivery.

Total chemical cost for 80 pcs -- 1172.70 Tk

Add 10% for Rewash ------------ 1289.97 Tk

Chemical cost / pcs --------------- 16.12 Tk

Chemical cost/Doz (16.12×12)----193.44 Tk


Chemical cost / Doz – US$ - 2.976

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ASM TOWHEED

072-001-045

+8801717226072

ABU RAIHAN

072-046-025

+8801717716158

MD. RIZWAN RAZU

072-039-045

+880717010100

072 Batch

BIFT.


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