DENIM DRY WASHING PROCESS

I made this slide in very simple way to know the different dry washing processes on denim garments

1. WELCOME TO OUR PRESENTATION ON

2. PRESENTED BY MD RAKIB HASAN(20) RAKIB ULLAH EMON(21) MD GOLAM RABBY(19) Special thanks to our honorable teacher ASST.PROF ALI AZAM ROKON Pabna textile engineering college

3. DENIM DRY WASHING PROCESS The washing processes where the garments are kept dry/not needed to wet to develop the washing effect . Some dry processes: Whiskering Laser Whiskering Hand Scrapping Wrinkles and 3D wrinkles Tagging or Picking PP Spray etc.

4. whiskering Whiskering It is the process of creating crease line around the crotch.It is also knows as cat’s whisker. Whiskering is the first dry process and one of the most important process in denim dry washing process. Also used for ‘Knee whisker’(whiskers on the side of knees) Honeycomb(crease mark on the back of the knee) Whiskering is done on the basis of different design and pattern.

5. Techniques used in whiskering Industrially done by these following techniques, Laser Sand blasting Machine sanding Hand sanding Abrasive rods

6. Whiskering Appearance on denim pant

7. Laser whiskering Laser whiskering It is another popular dry process in denim processing, and transfer of different images/effect to denim garments is possible by using laser beams. This process is done after the washing process. Different intensity of light is used to get the desired design. Laser is produced by the combination of CO 2 and DC current.The   indigo dyestuff  is burned and is removed during the washing process.The intensity and duration of exposure determines the final effect on the fabric. The laser intensity must be chosen correctly not to damage the garments . 

8. SPECIAL FEATURE OF LASER WHISKERING Features It is a computer controlled process for denim fading; This technique enables patterns to be created such as lines and/or dots, images, text or even pictures; It is water free fading of denim Being an automatic system, chances of human error are non considerable Also called spray painting in denims; This technique has relatively high cost

9. PROCESS OF LASER WHISKERING The process is given below : First, the whiskering design is made by photoshop or illustrator Design is transferred to laser machine The intensity of laser light is selected Laser light is imposed on the denim garments to get the design After the wash the burned indigo is removed and the whisker is visible Operating flow path of Easy mark supervisor software is given below : Open —> Import image —> Open file for insert diagram —> Image Size —> Selection —> Tools —> Pointer Online —> Pointer Online off —> Print. Configure —> Advance Configure —> Enable Automatic Selection —> Ok. Configure —> Massage Table —> Add (front right, back right, front back right) —> After Adding OK —> Print . Laser whiskering is done by this processes.

10. LASER WHISKERING EFFECT ON DENIM PANT

11. HAND SCRAPPING Hand ScraPping / Sanding :  This dry process is applied after whiskering to remove the color or fade specific area of the garments and it become very important now a days. Equipment used, Abrasive paper , Air dummy ( horizontal ) , Gum tape And hand is used . This process is more used as sand blasting process is banned due to hazadous to health.

12. ABRASIVE PAPER:THE MAIN ELEMENT OF HAND SCRAPPING PROCESS SAND COATED ABRASIVE PAPER

13. PROCESS OF HAND scraping Hand scraping process is given below : First the garments is mounted on the air dummy and fitted into two M.S. Pipe. Both end of each pipe covered with rubber tube and tightened by suitable clamping. After inserting the garments then the dummy is filled with compressed air as per required pressure. While scraping with hand , pressure should be uniform. Then sent to washing to get the desired effect .

14. Hand Scrapping

15. 3D WRINKLES 3D Wrinkle: It is one of the important finishing treatment on denim garment which is applied after wet process. Bringing 3D CREASE effect permanently on denim garments by treating with or without resins are called 3D crinkle. This process is done manually or semi autometically using resins like low formaldihyde type resins which make crosslinks between cellulosic bonds and when the fabric deforms or folds or losses its normal orientation , those chemicals prevents the transformation to normal position and that causes wrinkles or creases. Various supporting auxilliaries are used for better penetration of resins and softeners used for softness.

16. Techniques useD for 3D wrinkles Techniques  for 3D Crinkle finish : By 3D crinkle machine By heat setting machine By spray and chemical application cabinet with conveyer By 3D wire crinkle machine By 3D bendable leg or air dummy By using clip By garment crushing machine By tying garments with air But most commonly 3D wrinkles machine is used for industrial purpose.

17. 3D WRINKLES PROCESS BY 3D WRINKLE MACHINE 3D crinkle machine : The machine consist of 6 heads and changeable leg distance . Both legs can work simultanously. It requires no chemicals for crinkle effect on denim.

18. 3D wrinkles effect on denim pant

19. Precautions Precautions for 3D Wrinkle effect when resin is applied : If more resin is applied in a specific area , the garment may tear. If resin applied more than one time , garment may tear. If oven time is more , tear can occur. If exposure time is more, tear may occur. For more resins , garments can be so hard. Unwanted spots can appear. If more resin applied in pocket area ,then pocket may damage.

20. TAGGING TAGGING OR TAG PINNING Tagging or more commonly tag pinning is a very popular in fashion style in denim garment now a days. In this process the effect is created by swift tag machines with the help of plastic or nylon tag pins in rigid form of garment to get contrast . Features Tagging is done at unwashed condition of garments. It is done by tag gun or plastic staple machine which binds or fold the edge of the garments. Manually by niddle and thread. After wash the effect is visible. Sometimes it creates hole on the edge.

21. Machine used Usually tag pin machines are used to attach tag pins to garment. The procedure is very simple and proceeds as; garment is folded on required area and tacked through folds. Number of folds can be two to four or five in regular in tacking. These tag guns are not especially designed for heavy folds like we do in tacking so durability of the gun is a consistent problem. Also broken needles of tag gun are issue for both operator and consumer. Automated tacking machines are used more successfully in some units. These machines are bit expensive but are far more efficient and secure than tag guns.

22. Tag gun

23. mechanism Process mechanism of tagging This process is done by tagging small plastic tag pins to hold small gathers of fabric around pockets, hips, seams and bottom hems to get strong contrast due to less exposure of the folded parts to mechanical rubbing and chemicals. Figure shows the tag pins on the waistband and on the pocket of the jeans. After washing, the tags are snipped and colour contrasts and 3D effects are obtained in these areas. Variations are provided by using different lengths of tag pins. Using thick tags leaves large holes on the fabric surface after the washing processes, on the other hand, finer tags may break off during washing and the contrast appearance may not be achieved.

24. Tagging effect/application on denim Area of Application This effect can be designed any where on the garment in different styles. Most favorite areas for tacking are on waistband, bottom hems, back pocket and front pocket corners etc. On front or back sides of garment, tacking can also designed horizontal of vertical patterns on full length panel

25. PP SPRAY PP SPRAY This is the procedure of applying potassium permanganate as spray on the washed areas of garments to give it a certain after effect after further processing. Features Done on special areas of garments. Used to create special effects after mechanical abrasion. It is often done on denim, twill, poplin, corduroy fabrics. It is done after the first wash. Liquid potassium permanganate used.

26. Process mechanis m Potassium permanganate spray is done on jeans to take a bright effect on sand blast area. One important thing about potassium permanganate spray is, this is usually a sporting process to increase the effect of sand blast. Potassium permanganate solution is sprayed on blasted area of jeans garment with the help of normal spray gun and air flled rubber dummy. Potassium permanganate spray concentrations ranges form .25 gm per liter to 15.00 grams per liter depending to required results and fabric.The garment is hanged in open to dry after potassium permanganate spray and when the potassium permanganate turns its colors completely then it is considered to ready for next process. It is always followed by neutralization process. Sodium meta bisulphate is most commonly used neutralizer.

27. PRECAUTION PRECAUTION SHOULD BE FOLLOWED BY OPERATOR: It is very important to equip the operator with gloves, gas mask and gaggles. Long time breathing in potassium permanganate spray may cause health complications so proper preventive measures are to be taken for this department.

28. EFFECT OF P.P SPRAY ON GARMENTS

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