Overall process of Denim

1. WELCOME TO THE PRESENTATION ON
PRODUCTION OF DENIM FABRIC BY THE USE
OF ROPE DYEING.
Submitted to
Mr. Shamsuzzaman Sheikh
Assistant professor
Dept. of Textile Engineering,
DUET
Submitted by
Md. Samsuzzaman
STD. ID.: 135029
4th Year, 2nd Semester
Dept: TE
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2. DENIM
• Denim is the oldest, most widely used, most fashionable and most versatile fabric of the world. At
present denim is mainly used for producing garments particularly trousers for the young people.
• Denim is a rugged, sturdy, twill weave woven 100% cotton fabric.
• Warp thread is dyed indigo where as weft thread is left undyed.
• Different type of twill weave use in denim fabric like as
2
1
rht,
3
1
rht,
2
1
lht,
3
1
lht etc.
Denims are produced from 4 oz. To 16 oz./ Sq. Yds in weight.
• Now a days different type of fabric structure also use in denim production to increase variety,
processability etc.
• Use spandex as core or other stretch yarn in weft direction to increase stretching property.
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3. TYPES OF DENIM
Many types of denim are produce -
The most popular denim variants are given below
• Stone washed and double stone washed denim
• Chambrays
• Fancy multicolour denim
• Denim with metal effect yarns
• Elastic denim
• Printed denim
• Jacquard patterened denims
• Denims with fancy yarns.
• Some specific commercial name are widely produced in the denim industry
of bangladesh
• Basic or regular denim :
3
1
• Ring denim :
2
1
there are 7, 9, 12 count of yarn are
used.
• Slub denim : only warp slub and weft slub
• Cross hatch denim
• Stretch denim : weft yarn elastomer
• Poly denim : polyester used in weft.
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4. DENIM FABRIC IDENTIFICATION
Fabric identification:
• Normal fabric =
6 OE × 6 OE
66 × 35
• Ring fabric =
6,9,12 × 7 OE
66 × 35
• Half cross fabric =
6 slub × 7 OE
66 × 35
• Cross latch fabric =
10 slub × 10 slub
66 × 35
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5. DENIM PRODUCTION FLOW CHART
Ball warping
Rope dyeing
Long Chain Beamer
Sizing
Drawing-in
Weaving
Finishing
Inspection
Packing
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6. BALL WARPING
• The main object of ball warping is
to prepare log for the rope dyeing
machine. Here magazine type of
creels is used for the creeling of
yarns in the form of cheese. The
no. Of ends taken one as per
requirement of further processes
that is for preparing the weavers
beam.
Figure: Ball warping machine
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7. ROPE DYEING
• The indigo rope dyeing technology for denim production is considered a superior
dyeing technology, where better uniformity of dyeing is achieved than other
indigo dyeing technologies like slasher dyeing. Indigo rope dyeing was started in
USA.
• Today rope dyeing accounts for a large percentage of warp yarn dyed for denim
production.
• The system offers highest production.
• More even dyed warp sheet.
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8. ROPE DYEING PROCESS FLOW
Ball/logs
Creel
Draw nip
Scouring
Washing -1
Washing-2
Dye box-1
Dye box-2
Dye box-3
Dye box-4
Dye box-5
Dye box-6
Figure:Rope dyeing process
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9. ROPE DYEING PROCESS FLOW (CONT.)
Dye box-7
Dye box-8
Washing-1
Washing-2
Washing-3
Softening
Drying
Coiler
Can
Figure:Rope dyeing process
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10. COLOURS PROCESSED IN PLANT
• Pure 100% indigo dyed
• Pure 100% black
• Bottom black top indigo (bottoming)
• Bottom indigo top black (topping)
And many others
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11. LONG CHAIN BEAMING
• The dyed ropes in the cans coming from the rope dyeing machines are converted
into pre beams. The no. Of ends (around 360-520, which is depends on
requirement and creel capacity) in a rope is the same as set in ball warping
machine.
• Lcb process flow:
Can
Accumulator
Tension stand
Tension controller
Reed
Counting roller
Beam
Figure: Long chain beaming machine 1/14/2019 11

12. SIZING
• The purpose of sizing is to increase the strength of yarn through
chemically binding the fibers with each other.
• The main object of sizing warp yarns is also to encapsulate the yarn
with a protective coating which reduces yarn abrasion that takes
place during the weaving operation and reduces yarn hairiness
preventing adjacent yarns from entangling with one another at the
weaving machine.
• Also this size protective coating also prevents the indigo dye from
rubbing of during the weaving
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13. SIZING (CONT.)
• PROCESS FLOW
Creeling
Size box
Drying
Head stock
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14. WEAVING
• Drawing-in and warp tying
• Drawing-in → warp tying →
loom
• Denim fabrics are woven by
interlacing two sets of yarns
perpendicular to one another in
fabric form. Yarns in the machine
direction are called warp yarns or
warp ends, and these are
interlaced with filling yarns or
picks.
Figure: Toyota loom produce denim fabric (Airjet)
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15. DENIM FABRIC FINISHING:
The following types of finishes are applied to the denim fabric:
• Singeing
• Softening
• Skew control
• Desizing
• Mercerizing
• Sanforizing
• Calendering
• Resin finishing
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16. USES OF DENIM FABRIC
• Jeans trousers both for men and ladies.
• It is extensively used in the world as casual
garments,
• Shirts,
• Jackets,
• Children wears
• And many others
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17. THANK YOU FOR
YOUR KIND
ATTENTION
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