Overall process of Denim

1. Welcome to my presentation on
denim fabric manufacturing
Presented by
Salauddin(135041)
Presented to
Shamsuzzaman Sheikh
Assistant Professor, Department of Tex111tile
Engineering,
DUET, Gazipur 1/14/2019
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2. Content
History & Introduction of Denim Process sequence of rope dyeing
Production process flow chart Rope dyeing
Quality criteria of yarn Long Chain Beamer
Specialty of yarns Sizing
Types of warping Process flow chart of weaving
Ball warping Finishing
Denim dyeing process Thank you
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3. History & Introduction of Denim
The term “denim” has originated from the city of Nimes in France where
“ serge de Nimes” was manufactured. Denim fabric is dyed by Vat or
indigo dye. Whish is applied to cotton fabric in loosely held form in
layers. In manufacturing process of denim , It is similar to that of Grey
fabric up to the process of weaving with the only difference that in case
of denim fabric, it is dyed at the stage of sizing where as in case of grey
fabric, the decision regarding dyeing stage depends upon the finished
product. Generally, denim fabric are 3/1 warp faced twill fabric made
from a yarn dyed warp & an undyed weft yarn. Normally dyed & grey
ring or open- end yarn are used in warp &weft respectively.
Denim is a very versatile fabric, and is very popular for a variety of
shade , looking & hand feel on same fabric for different types of wash.
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4. Production Process Flow Chart
Packing
Inspection
Finishing
Weaving
Drawing -In
Sizing
Long Chain Beamer
Rope dyeing
Ball warping
Spinning 4
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5. Quality Criteria of Yarn
Minimum staple length: 2.7
Micronaire value should be 4.0-4.5
Twist factor:4.5 to 5.0, for warp yarn, 4.2 for filling yarn
Low yarn hairiness, low nenniness
Good yarn strength and uniformity.
Short fiber proportion(less than 12mm long ) should be under 40%1/14/2019
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6. Specialty of Yarns
Modern ring-spinning frames and open-end machines can be installed with devices
that can manufacture predetermined yarn effects. These effects can vary from slubs
(thick places) with different lengths, different spacing between slubs, or variations in
the yarn count
Fig: Yarn Winding Cones
Lycra yarn
This picture shows that how lycra yarn are stretched among the fiber and by force too.
That the dia reduces or decreases by the applied force that’s the specialty of lycra yarn.
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7. Types of warping used in
the Denim Industries
High speed warping (Direct warping)
Sectional warping(Indirect warping)
Ball warping(used for denimfabric)
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Ball Warping
Ball Warping is mainly used in manufacturing of denim fabric. In ball
warping 250 -500 yarn ends are pulled from on creel. Yarn pass through
reed which keeps the yarn separate and parallel to its neighboring ends.
A lease string is used at interval of every 1000-2000 yard or meter to aid
yarn separation for the re beaming operation. Then yarn are condensed
into rope form for dyeing by a trumpet.
Fig: Ball warping
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Denim Dyeing Process
Rope Dyeing
Slasher or sheet Dyeing
Loop Dyeing
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Process Sequence in Indigo Rope Dyeing of
Denim
In rope dyeing, 12-36 ball warping ropes of yarn are fed side-by-side
simultaneously into the rope dyeing range for application of the indigo
dyeing. The process sequence is as below
Pre
scouring
Hot wash Cold wash
8 dye
bath Hot wash Cold wash
Softner
applicatio
n
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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. It is
consists of twisting the yarn into a rope that is then quickly dipped into indigo bathes
Denim as the short dyeing time does not allow the indigo to fully penetrate the fibers.
Fig. : Rope dyeing and subsequent sizing, Step 1: Ball Warper, Step 2:Rope Dyeing,
Step 3: Long Chain Beamer, Step 4: Sizing 1/14/2019

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Long Chain Beamer
The basic purpose of long chain beamer is to open the rope into a sheet
form of yarn and wind onto a warper beam which in turn transferred to
the sizing machine.
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13. Object of sizing
Increase the strength of yarn
Encapsulate the yarn with
aprotective
Prevent the indigo dye from
abrasion 1/14/2019
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Flow Chart of weaving
Weavers beam
Drawing/Knotting
Denting
Shedding
Picking
Beat up
Fabric Take up
Fabric Let off 1/14/2019

15. Finishing
Singeing
Softening
Sanforizing
Callendering
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Diversification of Denim
 By using slub / fancy yarn
 By using different count
 By using lycra yarn
 By change weave
 By changing EPI, PPI& count.
 By applying different wash effect(Stone,
Enzyme, blech)
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Types of Denim Fabric
Normal fabric
Ring fabric
Half cross fabric
Cross latch fabric
 Slub denim
Poly denim
Stretch denim
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