Garments washing - Total Textile Process at a Glance

Garment wash is a new technology, which is used to modify the outlook, appearance, comfort ability and fashion of the garments is called garments washing.. Each wash has different types

GARMENTS WASHING

Prepared By : Mazadul Hasan sheshir ID: 2010000400008

13 th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com

Blog : www Textilelab.blogspot.com (visit)

Southeast University

Department Of Textile

Engineering I/A 251,252 Tejgaon Dhaka Prepared By :

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Total Textile Process at a Glance

With the change of time, human choice, demand, garment design and fashion is changing very quickly To meet the demand of users, garment manufacturers are adapting new technology and processes Garment wash is a new technology, which is used to modify the outlook, appearance, comfort ability and fashion of the garments is called garments washing Garment washing is normally processed after stitching As per fashion trend and customer demand buyers ask for garment washing though it increases the cost of the garment For the washing they mention exactly what types of washing they need for the order For example, Tom Tailor buyer asked for washes like – Vintage wash, Cloud wash, softener wash or Acid wash Each wash has different types

of appearance on the fabric surfaces Wash types mainly depends on the product types For denim product heavy enzyme is required where for knitted Tee light softener wash may be okay

Introduction

In line with ever changing human behaviors and longing to be unique in outlook, mankind dress themselves in fashionable as well as comfortable garments To be

or get unique in outlook garment washing is very convenient way This is a wing of garment wet processing technology

This is the textile technology by which a unique appearance along the seam, size, comfort ability & fashion etc properties are changed of a solid or multi colored or printed garment

Fabric of the garment may be dyed with reactive dye, direct dye, sulpher dye, acid dye, basic dye, pigment and even metal complex dye and printed with pigment, direct dye, reactive dye etc

Garment Washing

Types of Garment Washing:

1 Wet process/Chemical process

 Normal wash/ garment wash/rinse wash

 Pigment wash

 Caustic wash

 Enzyme wash

 Stone wash

 Stone enzyme wash

 Tinting (Tie) & Over Dyeing(Dip Dyeing)

 Super white wash

 Broken and tagging

Types of Garment Washing:

These are the main objects for garments washing

1.To develop softness in garment: Size materials in fabric are removed by washing & there is also advantage to add softener Drape ability also increased.2.To introduce unique appearance: washing that introduces fading effects along with the seam on the garments by washing out dyes or pigments in the garments

3.To create new fashion: Washing process of garments bring different out looks (faded, color tinted, old look etc.) of garment that is used for creating new fashion

4.Special type of finishes are also possible such as wrinkle, wrinkle free, flame retardant, water proof breathable, soil retardant finish etc

5.To satisfy the customer: As shrinkage occurs so customer can wear it just after purchasing/buying

Objects of Garments Washing

Garments from store house

↓ Count

↓ Quality check

↓ Batch

↓ Washing

↓ Hydro extractor

↓ Drying

↓ Quality check

↓ Packing

↓

Flow Chart of Washing:

Common procedure of garments washing:

1 Garments can be inverted to minimize unwanted abrasion streaks (especially useful when preset creases are present)

2 Load machine with garments

3 Desize with alpha amylase enzyme and detergent

4 Drain

5 Rinse

6 Fill machine with water and heat to 60◦C The liquor ratio can range from 10:1 to 20:1 A number of synthetic detergents can be used Also, alkaline products such as soda ash or caustic soda can be added in amounts ranging from 0.5 to 2.0 grams/liter Some

chemical suppliers offer special products that accelerate the wash down process,

dependent upon the particular dyestuff used

7 Wash/tumble action for 20-60 minutes, depending upon desired effect

8 Drain and rinse

9 Apply softener

10 Tumble dry

11 Invert garments, if previously turned

12 Press, if required

1 Starch or size materials, which are applied during fabric production especially in case of woven fabric are removed by wash as a result the garment become soft and hence the drape ability and comfort ability increased significantly.

2 Softness could be increased by addition of softeners by doing soft finish or applying the softener

3 Dirt’s, impurities, germs etc obviously will be added in the garment during its manufacturing are removed due to washing because a variety of chemicals are used such as detergent, bleaching agents etc

4 Due to washing, maximum shrinkage occurs; hence there is the zero possibility

of further shrinkage As a result there is no size or fitting problem in washed

Advantages of Garments Washing

1 Faded effect and a variety of stylish effects produced by different washing techniques Nowadays these faded and stylish effects are accepted as a new fashion for fashion world

2 Similar out look and effect could be produced by different washing techniques or

by different process As a result there is a great scope of implementation of brilliances of technicians Every machine of a garment washing factory can be used for multipurpose for this reason total project cost is comparatively lower where as washing add a handsome value to the garments

Advantages of Garments Washing

Garments Size Change:

This change takes place due to shrinkage properties of the fabric The amount of shrinkage properties of fabric determines the amount of size changing of the garments

Size materials and finishing's partly removed:

Different types of washing are done with different types of chemicals and process, which are responsible for the removal of size materials and finishing's from the fabric

Color is partly removed:

Unfixed dyes may remain on the garment after dyeing This un-fixed dye will be

Unavailable Changes/Limitation of Garments washing

There Are Different Types of Garments washing in our country

• Normal wash/Garment wash/Rinse wash /Soft wash,

• Enzyme wash with stone,

• Supper white wash,

• Wash & over dyeing,

• Wash & Tinting,

• Over all wrinkles,

• Permanent wrinkle/Resin Finish.

Types of Garment washing

Some Washing Chemical List

1 Desizing Agent : DesizingHts, D-Peast

2 Anti Back Stain Agent : Antistain – Lp-30

3 Fastness Improvers For Dyeing : Albafix®

4 Levelling Agents For Dyeing : Albatex®

5 Fastness Improvers For Dyeing : Albafix®

6 Enzyme : G Enzyme S89, G Enzyme – Sl,

InnozymeNpe S89

7 Salt : G/Salt

8 Alkali : Naso4

9 Ph Control : Using Buffer & Acid

10 Bleaching Agent : Sodium Hypochlorite Naocl; 15% Cl2 Available

11 Calcium Hypochlorite

12 Neutralizing Agent : Hydro Peroxide, Bisulphate OrThiosulphate

13 Softener : Innosoft 1070

• Micro Emulsion Silicon

• Salt (sodium chloride)

BASIC MACHINERIES OF A WASHING PLANT

• Garments washing m/c for sample,

• Garments washing m/c for bulk,

MACHINES USED IN WASHING PLANT

MACHINES USED IN WASHING PLANT

MACHINES USED IN WASHING PLANT

Different kinds of washing & Garments dyeing price list

Please see below the our price list (Wash Type)

• Normal Garments wash per dozon = 0.6$

• Trumble/Normal fabric wash per kg = 10 taka

• Stone wash per dozon = 1.5$

• Stone Enzyme wash per dozon = 2.0$

• Acid wash per dozon = 5.0$

• Sand wash per dozon = 4.0$

• Enzyme wash per dozon = 1.0$

• Garments made from indigo, vat, reactive, direct etc dyed fabric can be bleach

washed.

• It is a decolorization process by oxidation action.

• Color can be removed uniformly from the garment and removal of color done as per

requirement In general there are three categories such as light bleach (where maximum color is removed), medium bleach and bleach.

• All types of garment can be washed Such as: woven knit garments.

• In case of woven fabric a pretreatment (Desizing) process is required.

• Dust, dirt, oil spot, impurities etc are removed that may come from during process

i.e cutting, stitching and the back process.

• Significant fading effect can be achieved But we can achieve more wash effect by

increasing processing time and decreasing the liquor ratio.

• To improve the color fastness & rubbing fastness.

• To increase the hairiness on garments this increases its old-look appearance.

• Maximum weight losses occur in case of light bleach.

Bleach Wash

Suppose a lot size 100kg of twill trouser.

Step 01 or Desizing:

1 Load the garment in washing m/c 100kg garment

2 Add water at 1:5 liquor ratio 500lt

3 Start m/c running Speed 15/12 rpm

4 Add amylase enzyme 1-3% 1-3kg

5 Add detergent/antistain to the liquor;1% i.e 1kg

6 Supply steam to raise temp 60 c

7 Continue the process 20 min

8 Drop the liquor

9 Hot wash with water temp 40-50c for 5 min

Step 02 or bleaching:

1 Add water in 1:5 liquor ratio 500lt

2 Start m/c running Speed 12-15 rpm

3 Add soda to liquor 2% i.e 2kg

4 Add caustic to liquor 2% i.e 2kg

5 Add bleaching powder (K.C.I.) 10 gm/lt i.e 5 gm

6 Rinse thoroughly

Bleach Wash

Step 03 (Neutralization of Chlorine):

• Add water with 1:5 liquor ratio =500Lt

• Start m/c running with moderate speed =12-15 rpm

• Add 35% of H2O2 0.5-1.0% = 500gm-1kg

Or Add bisulphate 1-2% =1kg-2kg

• Continue the process at Room temp. =5 min

• Drop the liquor & a hot wash at 40-60 c =5 min

• Add water in 1: 5 Liquor ratio = 500 Lt

• Start machine running = speed 12-15 rpm

• Add sodium hyposulphite 3 gm/ltr = 1500gm.

• Supply steam to raise temp As required (40c)

• Continue the process 10-20 min

• Drop the liquor,

• Rinse thoroughly.

Bleach Wash

Step 04 or Neutralization:

1 Add water in 1: 5 Liquor ratio = 500 Lt

2 Start machine running = speed 12-15 rpm

3 Add acetic acid to the liquor 1-2ml/lt = 0.5-1Lt

4 Continue the process = 5 min

5 Drop the liquor

Step 05 or Softening:

1 Add water in 1:5 liquor ratio = 500 Lt

2 Start m/c running speed 12-15 rpm

3 Add softener to the liquor 0.1 - 0.5% = 100- 500gm

4 Supply steam to raise the temp = As required 40 to 60 c

5 Continue the process = 5 min

6 Drop the liquor & unload the garments

Step 06 or Drying:

1 Hydroextract the garments

2 Dry in the tumble dryer

Incase of knit garments desizing step is not required but a wash for 5 minutes at

Bleach Wash

 Stone wash is done on garments made from denim & jeans fabric Sometimes twill fabric garments are also subjected for stone wash.

 Fading effect is produced in the garments in irregular pattern Fading effect is more pronounced across the seam line and the multiple ply position.

 Stone wash mainly followed by a decolouration process.

 Garments become comfortable during use.

Stone Wash

Process :

This washing process follows the following steps:

• Step 01 or Desizing

• Step 02 or Stone Wash followed by Bleach wash

• Step 03 ( Neutralization of Chlorine )

• Step 04 or Neutralization

• Step 05 or Softening

• Step 06 or Drying

Stone Wash

Process Cycle

Process: It follows the bellow mentioned steps.

Suppose 100kg of garments in a lot size.

Step 01 or Desizing

1 Load the garment in washing m/c 100kg garment

2 Add water at 1:5 liquor ratio 500lt

3 Start m/c running Speed 15/12 rpm

4 Add amylase enzyme 1-3% 1-3kg

5 Add detergent/antistain to the liquor; 1% i.e 1kg

6 Supply steam to raise temp 60 c

7 Continue the process 20 min

8 Drop the liquor

9 Hot wash with water temp 40-50c for 5 min

Step 02 (Stone Wash):

1 Load the m/c with water at 1:5 liquor ratio = 500Lt water

2 Add pumic stone ½ of volume of garments volume or as required

= 30kg to 50 kg

3 Start m/c running with moderate speed =12-15 rpm

4 Add bleaching powder to the liquor 2-4% =2-4kg

5 Add soda ash to the liquor 6-8% = 6-8 kg

6 Continue the process =20-40 min

Stone Wash

Step 03 (Neutralization of Chlorine):

1 Add water with 1:5 liquor ratio = 500 Lt

2 Start m/c running with moderate speed = 12-15 rpm

3 Add 35% of H2O2 0.5-1.0% = 500gm-1k

Or Add bisulphate 1-2% =1kg-2kg

4 Continue the process at Room temp = 5 min

5 Drop the liquor & a hot wash at 40-60 c = 5 min

Note: H2O2 Neutralization gives brighter tone then the bisulphate.

Step 04: (Neutralization)

1 Add water with 1:5 liquor ratio = 500 Lt

2 Start m/c running with moderate speed = 12-15 rpm

3 Add acetic acid 1-2% = 1Lt-2Lt

4 Continue the process at Room temp to 60c = 5-8 min

Stone Wash

Step 05 or Softening:

1 Add water in 1:5 liquor ratio 500 Lt

2 Start m/c running speed 12-15 rpm

3 Add softener to the liquor 0.1 - 0.5% 100- 500gm

4 Supply steam to raise the temp As required 40 to 60 c

5 Continue the process 5 min

6 Drop the liquor & unload the garments

Step 06:

1 Hydroextract the garments

2 Dry in the tumble dryer

Note: Stone wash sometimes done without bleaching; actually it depends upon the requirement

Stone Wash

• Garments made from heavy jeans & denim fabrics course canvas, sweater & thick

twill etc are washed by acid wash technique

• Irregular pattern fading effect is produced in the garments But the effects more

pronounce than stone wash.

• This is very dirty process due to widely use of pumic stone.

Acid Wash

It follows the following steps.

Step 01 or Desizing:

Load the garment in washing m/c 100kg garment

1 Add water at 1:5 liquor ratio 500lt

2 Start m/c running Speed 15/12 rpm

3 Add amylase enzyme 1-3% 1-3kg

4 Add detergent/antistain to the liquor;1% i.e 1kg

5 Supply steam to raise temp 60 c

6 Continue the process 20 min

7 Drop the liquor

8 Hot wash with water temp 40-50c for 5 min

Step 02:

1 Unload the garments from m/c

2 Hydro extract the garments

3 Dry it partially by running tumble dryer for 5 to 10 mins

Stone Wash

Step 03:

1 Take stone of same volume of the volume of garments

2 Soak the stone with the following chemical solution for 2-3 min

Potassium permanganate 1kg (1gm/Lt)Phosphoric Acid 200-300gm (0.2-0.3gm/lt)Here the porous of stone will, pick up the solution

3 Soaked stones are dried in the open air for 60-90 min

Step 04:

1 Load the garments treated in step 01 & step 02 in a dry m/c lot size should

be 20 to 30kg

2 Load treated stone in step 03 volume of the garments volume

3 Run the m/c for 5 to 7 min Due to rotation of inner cylinder the soaked stones will hit the garments surfaces, thus the chemicals in the stone will destroy the color of fabric where the stone will hit Multi layer fabric area like collar, cuff, and pocket, pocket side seam etc area will brushed more than the single layer areas, hence more fading effect will be produce in those areas result new color effect in the garments

4 Unload the garments & separate the stone from the batch

Stone Wash