Industrial Garment Washing

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.. 

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INDUSTRIAL GARMENT WASHING & DYEING

Garment washing is very important part of a garment industry In this process a garment is provided with a lucrative and glassy outlook Chemicals used here are very costly and may harmful if used more than essential Cost can be lessen if the proper use of chemical is known As there

is no such book on Industrial Garment Washing and Dyeing I believe this book will help very much.

ASM TOWHEED3/23/2011

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 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

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TYPECS OF WASHING

Wet and Dry processes are mentioned below:

 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

 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

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 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

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

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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,

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 Running the machine

 Temperature: - 70°c - 90°c

 Time: - 30 - 35 min for dry

 Time: - 10 - 15 min for cold dry

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

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 Time 10 20 min.

 Drop the liquor

 Rinse one time 3 minutes

Second

Step:- Add water at L: R = 1: 8 480 Liter

 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

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

 For soft feeling to wear the garment after purchasing

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 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

 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

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

 Drop the liquor

 Unload the Garments on trolley

Third Step: - Hydro extractor machine

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 Hydro-extraction the garments to remove excess water from the Garments Time required about 2 - 4 minutes

Fourth Step :

 Steam Dryer / Gas Dryer

Or

 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) :

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 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:

 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

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 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

 Drop the liquor

 Wash cold water for 3 min

Second Step :

Neutral Wash

 Add Acetic Acid at 1 gm / liter 400 gm

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

 Drop the liquor

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 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

or

 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:

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 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.

 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

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 Temperature - 40°c - 55°c.

 Time required 25 min to 50 min

 Enzyme affects come within short time

 Staining/Bleeding occurs more in garments

 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

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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

DesizingEnzyme(Acid)BleachingNeutralization1Neutralization2Caustic washSoftener & PH ControlHydro-extractorDryerQualityDelivery to finishing

ENZYME WASH PROCESS (DARK SHADE)

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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

 Time 10- 15 min

 Drop the liquor

 Wash 1 time by cold water

Second Step: ENZYME

 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

 Drain the bath

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Fourth Step: Hydro-extractor Machine

 After unloading garments from the washing machine then they are sent to extractor machine to remove excess water from the washed garments

hydro-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

 Time 15- 20 min

 Drop the liquor

Second Step: - ENZYME

 Add water at L: R = 1 : 8 480 Liter

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 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

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

 Add soda ash at 2 gm / liter 840 gm

 Drop the liquor

Fourth Step : Neutral

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

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

 Add detergent at 0.5 gm / liter 300 gm

 Drop the liquor

Fifth Step : SOFTENING

 Drain the bath

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Sixth Step: Hydro-extractor Machine

hydro-Seventh Step: - Drying Machine

 Load 60 kg garments to gas dryer

hydro-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

 Time 15- 25 min

 Drop the liquor

Second Step : ENZYME

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 Temperature 45°c.

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

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

 Drain the bath

Third Step : Bleaching

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

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

 Drop the liquor

Fourth Step : Neutral -1

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

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

 Add detergent at 0.5 gm / liter 300 gm

 Drop the liquor

Fifth Step: Neutral-2

 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

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 Time 10 min.

 Drop the liquor

Sixth Step: SOFTENING

 Drain the bath

Seventh Step: - Hydro-extractor Machine

hydro-Eighth Step: Drying Machine

 Load 60 kg garments to Steam dryer

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

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 Machine Running.

 Temperature 50-60°c

 Time 10- 20 min

 Drop the liquor

 Rinse one time 3 minutes

Second Step: ENZYME

 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

 Drain the bath

Fourth Step :- Hydro-extractor Machine

hydro-Fifth Step : Drying Machine

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 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

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 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

 Start the machine

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

 Drop the liquor

Second Step :- HOT WASH

 Time 5 min

Third Step :- BLEACHING

 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

 Drop the liquor

 Rinse twice, each 3 minutes

Fourth Step :- NEUTRAL WASH

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 Add water at L: R = 1: 9 540 liter.

 Add sodium hyposulphite at 3 gm/liter 1620 gms

 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 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

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 Batch size 60 kg Denim Long Pant.

 Drop the liquor

Second Step : HOT WASH

 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

 Then temperature raise to 90°c for 1 minute

 Drop the liquor

 Then pumic stone out from washing machine

Fourth Step : BLEACHING

 Machine running

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

 Drop the liquor

Fifth Step :- NEUTRAL WASH

 Drop the liquor

 Rinse one

Sixth Step :- SOFT WASH

 Time 5 min

 Drop the liquor

Seventh Step :- Hydro-extractor Machine

 Hydro-extraction the garment to remove excess water from the washed garmentsEighth Step : Drying Machine :

Ninth Step : Delivery

 After quality checking garment will be delivery

BLEACH WASH

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

:-First Step :- PRE-TREATMENT / DESIZING

 Batch size 60 kg Denim Long Pant

 Drop the liquor

Second Step : HOT WASH

 Time 5 min

Third Step : BLEACHING

 Machine running

 Drop the liquor

Fourth Step : NEUTRAL WASH

 Time ……… 10 to 12 min

 Drop the liquor

 Rinse one

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Fifth Step : SOFT WASH

 Time 5 min

 Drop the liquor

Sixth Step : Hydro-extractor Machine

 Hydro-extraction the garment to remove excess water from the washed garments.Seventh Step : Drying Machine :-

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

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