Overall process of Denim

1. Welcome to the presentation on
Denim
Presented
by
Md. Shablu
Khan
Student ID-
135028
Presented
toMr. Shamsuzzaman Sheikh
Assistant Professor
Department of TE, DUET
Mr. Abu Yousuf Mohammad Anwarul
Azim
Lecturer
Department of TE, DUET 1

2. PRESENTATION OUTLINE
What is denim
Denim step
Ball warping
Rope dyeing
Long chain beaming
Sizing
Finishing treatment
Diversification of denim
2

3. Denim is a kind of fabric that
comprises dyed warp and undyed
weft.
Weights ranges from 6 oz/y𝑑2 to 14
oz/y𝑑2
produced in twill satin rib stripe
structure
yarn count ranges from 6-10 English.
What is denim ?
3

4. DENIM STEP
Yarn
package
Ball
warping
Rope
dyeing
Long
chain
beaming
Sizing Weaving
4

5. BALL WARPING
Multiple yarns from several creels are collected to ball in rope form
Prepared
ball
Ball warping
machine 5

6. ROPE DYEING
Dyeing is performed in rope form by continuous process
The process is followed by pretreatment-dyeing-washing-softening
sequence
Dyeing process is maintained as-
Pure indigo
Pure black
Bottoming
Topping
Color denim
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7. ROPE DYEING(CONT…)
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8. LONG CHAIN BEAMING
Dyed yarn is wound on pre-beam as sheet form from rope form to
size the yarn
8

9. SIZING
A process to provide coating for higher strength and slippery
character to withstand during weaving.
Size bathFeed zone
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10. Drying zone Take up zone
Leasing zone
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11. DENIM WEAVING
Weaving of denim fabric is not much different from weaving all other
fabric except the idea about the warp and weft way shrinkage
percent. It is well known that fabric shrinks after relaxation and also
after any wet process treatment.
The fabric shrinkage percent in the length direction varies from I2%-
15% while in the width direction the shrinkage percent lies around
4.5% to 5.5 %. The higher shrinkage in the warp direction is mainly
due to greater warp tension during weaving and also due to the
coarser weft yams than that of the warp yarns.
For the production of heavy denims, leno selvedges are advisable and
for lighter denims tucked selvedges are preferable.
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12. Industry practice of denim fabric
design
1/1 chambray
2/1 left hand twill
2/1 right hand twill
3/1 left hand twill
3/1 right hand twill
Satin
Rib
Airjet loom
12

13. FINISHING TREATMENT
Singeing
Softening
Sunforizing
Skew bow process
Calendaring
Mercerizing
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14. DIVERSIFICATION OF DENIM
Different fancy yarn-slub yarn, thick thin yarns lycra yarn are used in
the diversification of denim.
Diversification is also done by the change of EPI, PPI and count.
Denim is no longer a cotton product. Denims come with either
polyamide, lycra, polypropylene or with polyester and special bonding
with a 100% nylon net for a more active look.
Plain based denim…..
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