The document provides an overview of denim manufacturing, beginning with an introduction to denim fabrics and their widespread popularity. It then defines denim and jeans, discusses the history of denim, describes the global denim market and common types of denim fabrics. The document also outlines the key raw materials used, including cotton fibers and yarns, and explains important processes like dyeing, sizing, warping and weaving involved in denim production.
Hairiness is characterized by the quantity of freely moving fibre ends or fibre loops projecting from a yarn or textile fabric (woven, knitted or non woven fabrics).
In term of measurement Hairiness corresponds to the total length of the protruding fibres in unit length of one centimeter.
Hairiness is characterized by the quantity of freely moving fibre ends or fibre loops projecting from a yarn or textile fabric (woven, knitted or non woven fabrics).
In term of measurement Hairiness corresponds to the total length of the protruding fibres in unit length of one centimeter.
Knowing the basics of raw material, yarn production process and the other factors influencing quality will put the sourcing manager at the same eye level as a spinner /supplier when negotiating quality issues.
As a consequence this puts the sourcing manager in the position to pay the right price for the corresponding quality level.
This kind of know-how supports a retailer enormously in his efforts to establish a reliable supply chain which is based on mutual understanding.
Weave is the method or process of interlacing two yarn or similar material so that they cross each other at right angle to produce woven fabric . Traditionally, denim fabric are 3/1 warp-faced twill fabric made from a yarn dyed warp and an undyed weft yarn and the warp yarn is indigo dyed ,however this twill weave fabric is also available in textures, such as cross hatch and jacquard etc. The textures selected during the design development process for upcoming seasons are chosen with the wash treatment in mind, such as enzyme, acid etc and look & performance requirement of finish product.
THIS COVERS HONEY COMB, BRIGHTON HONEY COMB, HUCK A BACK, DISTORTED THREAD EFFECT AND OTHER WEAVES.. IT IS VERY MUCH USEFUL TO TEXTILE DIPLOMA AND DEGREE STUDENTS
Terry fabric is a knitted fabric with ring yarn or terry covering at one or both sides. It belongs to one of the fancy knitted fabrics. Terry fabric is characterized by soft touch, thick texture, excellent water absorption and heat retention. Terry fabric can be divided into single-sided and double-sided terry loop fabrics. The terry can form pattern effect on the knitting surface distributed according to some certain rules. Terry fabric after shearing or other process can be turned into fleece fabric or velvet fabric.
This presentation is my graduation internship presentation at BSL (LNJ group) Bhilwara (Rajasthan).
In this presentation I describe BSL company profile, Process significance, all steps which use for fibre to fabric in textile.
You can find the diffences between mechanical and electronical dobby mechanisms in principle in this presentation.
Also , you can reach the details of dobby mechanisms type like as of single , double and negative dobby systems.
Fancy yarns are special products of spinning, twisting, wrapping, texturing and knitting, etc. The demand for yarns with structural and/or optical effects is due to the special aesthetic and high decorative appeal to the woven, knitted materials, and other textiles as well. Textile materials that are produced using yarns with effects find applications in normal and high fashion clothing.
Knowing the basics of raw material, yarn production process and the other factors influencing quality will put the sourcing manager at the same eye level as a spinner /supplier when negotiating quality issues.
As a consequence this puts the sourcing manager in the position to pay the right price for the corresponding quality level.
This kind of know-how supports a retailer enormously in his efforts to establish a reliable supply chain which is based on mutual understanding.
Weave is the method or process of interlacing two yarn or similar material so that they cross each other at right angle to produce woven fabric . Traditionally, denim fabric are 3/1 warp-faced twill fabric made from a yarn dyed warp and an undyed weft yarn and the warp yarn is indigo dyed ,however this twill weave fabric is also available in textures, such as cross hatch and jacquard etc. The textures selected during the design development process for upcoming seasons are chosen with the wash treatment in mind, such as enzyme, acid etc and look & performance requirement of finish product.
THIS COVERS HONEY COMB, BRIGHTON HONEY COMB, HUCK A BACK, DISTORTED THREAD EFFECT AND OTHER WEAVES.. IT IS VERY MUCH USEFUL TO TEXTILE DIPLOMA AND DEGREE STUDENTS
Terry fabric is a knitted fabric with ring yarn or terry covering at one or both sides. It belongs to one of the fancy knitted fabrics. Terry fabric is characterized by soft touch, thick texture, excellent water absorption and heat retention. Terry fabric can be divided into single-sided and double-sided terry loop fabrics. The terry can form pattern effect on the knitting surface distributed according to some certain rules. Terry fabric after shearing or other process can be turned into fleece fabric or velvet fabric.
This presentation is my graduation internship presentation at BSL (LNJ group) Bhilwara (Rajasthan).
In this presentation I describe BSL company profile, Process significance, all steps which use for fibre to fabric in textile.
You can find the diffences between mechanical and electronical dobby mechanisms in principle in this presentation.
Also , you can reach the details of dobby mechanisms type like as of single , double and negative dobby systems.
Fancy yarns are special products of spinning, twisting, wrapping, texturing and knitting, etc. The demand for yarns with structural and/or optical effects is due to the special aesthetic and high decorative appeal to the woven, knitted materials, and other textiles as well. Textile materials that are produced using yarns with effects find applications in normal and high fashion clothing.
Denim is a sturdy cotton warp-faced textile in which the weft passes under two or more warp threads. This twill weaving produces a diagonal ribbing that distinguishes it from cotton duck.
Denim is available in a range of colors, but the most common denim is indigo denim in which the warp thread is dyed while the weft thread is left white. As a result of the warp-faced twill weaving, one side of the textile is dominated by the blue warp threads and the other side is dominated by the white weft threads. Jeans fabricated from this cloth are thus predominantly white on the inside.
Bahauddin Zakariya University College of Textile Engineering.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
1. WELCOME TO
MY
PRESENTATION
ON DENIM MANUFACTURING
Presented to
Shamsuzzaman sheikh
Assistant professor,
Department of T.E,
DUET,Gazipur
Presented by
Soriful islam
S.ID :135057
2. INTRODUCTION
Since the first pair of jeans appeared in America about one and
half century ago, denim wear has gained popularity all over the
world. As a result, jeans wear is one of the most prominent
apparel items in the world apparel market.
Denim fabrics are used as jeans trousers both for men and
ladies. It is extensively used in the world as casual garments,
Shirts, jackets, children wears are also made of denim fabrics.
Its versatility, finds applications in furniture upholstery, bed
covers, curtains, etc. Denim now-a-days is a very
demandable product. To make a denim fabric the required yarn
for the definite construction should be dyed then make a
weavers beam to go to weaving to make fabric.
3. DEFINATION OF DENIM & JEANS
According to Textile terms and definition published by
Textile Institute “ Denim is traditionally a 3/1 warp faced twill fabric made
from yarn dyed warp and undyed weft yarn and Jeans is a 2/1 warp faced
twill fabric used chiefly for overalls or casual wear.”
According to Encyclopedia of Textile Finishing edited by
Prof. Dr. Hans-Karl Rouerre published by Springer “Denim is a firm 2/1 or
3/1 cotton twill-weave fabric with dyed blue warp and raw white weft. The
warp is sometimes dyed during sizing.”
4. HISTORY OF DENIM
Denim at its most basic is a simple cotton fabric – but it has created one of the
most enduring and beloved fashion items in recent history.
The first use of denim as a cotton material dates as far back as the 17th century
when it appeared in upholstery, work pants and awnings, ship’s sails and
cowboy jeans – the fabric of hardworking, honest labour. The origin of its
name is widely believed to be an Anglicism of the French for ‘ serge de Nimes’
– the serge fabric, made in Mines, France.
5. WORLD DENIM MARKET
The world denim market is likely to frow continuously for the next few years.
However, supply is growing at a faster pace.
World Jeans Market- 51.6 $ Billion in 2007.
Expected to become 56.2 $ Billion by 2014.
The gross production of denim fabric is approximately 3,000 million metres
per year.
Over 50 percent of denim production is based in Asia with Bangladesh, China,
Pakistan, India and Turkey.
70 Percent of world jeans consumption is in EU, USA and China.
6. TYPE OF DENIM
Demand for fashion variants of classic denim will continue to grow. The most
popular variants are:
Stone-washed and double stone-washed denims
Chambrays
Fancy multi-colour denims
Denim with metal-effect yarns
Elastic denins
Printed denims
Jacquard-patterned denims
Denims with fancy yarns
7. TYPES OF DENIM – CONT.
The following denim fabrics with their specific commercial name are widely
produced in the denim industry of Bangladesh.
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
10. Fiber
Most of the denims are produced with 100% cotton and cotton-based blends with Lycra®, Polyester, Tencel®,
Bamboo, Jute, Nylon, and Linen etc. An ideal cotton mix for denim should have the following quality
parameters.
2.5% span length > 25mm
Strength (g/tex) >18
Micronaire > 4.5 to 5.0
Maturity Coefficient >0.75
Uniformity Ratio> 49%
Trash> 4.9%
i. 80% waste, which consists of
(i) Dropping-1,
(ii) Dropping-2,
(iii) Flat strip,
(iv) Comber noil.
ii. 20% Fresh Cotton.
11. Denim yarn
The spinning capacity usually determined by in the dye range.For 10 million capacity unit producing 12
ozs average fabric weight with a standard with of 150cms require denim yarn of 16 to 17 ton per day .
Thus spinning of denim yarn is really scale business because of heavy yarn and fabric.
Common yarn size for denim
Warp yarn for bottom weight jeans
Warp yarn for bottom weight jeans typically range in size from Ne 4.0 to 12.5/1.
Finer yarns are used lighter weight chambray shirting fabrics,vests,dresses and skirts.
These yarns may range in count from Ne 12.5 to 30.0
12. Spun yarn characteristics by spinning system
Ring spun Open-end(rotor)
1. Strongest yarn 1. More even
2. Finest yarn 2. Higher strength uniformity
3. Softest yarn 3. Higher production rate
4. “Z” and “S” twist 4. Fewer processes
5. Lowest productivity 5. Lower cost
6. Most unevent 6. Fewer imperfections
7. Most expensive 7. Harsher hand(feel)
8. More hairy 8. Not as strong
9. More torque 9. Limited counts-coarser
10. Widest range of yarn counts 10. “Z” twist only
13. Specialty yarns
Structured denim yarns
Slub thick place with different lengths.
Different spacing between slub.
Variations in the yarn count.
Elastic denim yarns
The drafted cotton fibers twists around the spandex core
to produce an elastic ring type yarn.
16. Introduction
Denim dyeing may be achieved in different forms like rope form
sheet form or perforated beam wound form.
Each process required separate preparation process specially the
warping process.
Moreover, sheet dyeing or slasher dyeing can be executed in
different types dyeing machine e.g. continuous combined sheet
dyeing-sizing machine, loop dyeing machine.
17. Warping
Warping is the process of transferring multiple yarns
from individual yarn packages on to a single packages
assembly .
Types of warping in used
1. Beam warping
2. Ball warping (the yarns are brought together and
condensed into a rope before being wound onto a
relatively short cylindrical barrel that has no end
flanges)
18. Warping (cont.)
In ball warping, 250 to 400 yarn ends are pulled from the creel
At interval of every 1000 to 2000 yards (or meters), a lease string is
placed across the sheet of warp yarns to aid yarn separation for the
re-beaming operation,
which will occur later
The yarns go through a funnel- shaped device called a trumpet
which collapse and condense the sheet of yarn into rope form
19. Dyeing and sizing in denim manufacturing
process
Dyeing in denim manufacturing is the most crucial in the
production sequence .
There are three general types of dyeing
1. Rope dyeing range
2. Open warp/ slasher dyeing range
3. Loop dyeing range
21. FLOWCHART OF DYEING & SIZING:
Warper’s Beam
Pretreatment (Scouring) bath
Dryer- wash bath (1, 2, 3)
Color box - 1
Dryer - 1
Color box- 2
Dryer - 2 (Air oxidation is done here)
Color box - 3
Steam box
Color box - 4
Yarn pass between a set of guide roller for oxidation
Color box - 5
22.
Oxidation
Color box - 6
Guide Roller
Color box - 7
Oxidation
Color box - 8
Oxidation
Wash box (1, 2, 3)
Dryer
Sizing box
Dryer
Accumulator
Leasing
Winding
Weaver’s beam
•Type- Sliding creel
•Arrangement- Two creels are placed parallel to each others.
•Creel capacity-16 warp beams can be placed in each creel.
•Electronic motor is available to slide the creel as well as mount the beams.
Beam creel section:
23. Slasher dyeing vs rope dyeing
criteria Slasher dyeing Rope dyeing
First introduced 1970’s 1915
Required space Less More
mercerising Easy Difficult
Manpower Less More
Broken and repairing Not possible Possible
flexibility Flexible Less flexible
Extra end Extra end No
Different color mixing Not possible Possible
Count mixing Ne 1-30 Ne 1-16
Production capacity Approx. 9 to 11 mill.mt.of
normal capacity
12 ropes=9 to 11.5 mill. Mt.
Cost Less than rope dyeing More than slasher
Yarn quality Higher average
24. FUNCTION OF THE CHEMICALS USED IN SCOURING:
1. Alkali: It converts the oil into water soluble fatty acid & soap.
02. Wetting agent: A soluble or dispersible material that reduces the surface
tension between the material & liquid. Detergency effect helps to clean the
material.
03. Sequestering agent: It reacts with metallic ions & thus makes the metallic
compounds to become a part of complex anion.
DYEING:
Dyeing is consists of 2 dyes. The indigo blue & Sulphur black is used in the
dyeing process of denim. Sometimes brown color is used instead of indigo
blue in the factory according to the requirement of buyer.
25. DYEING RECIPE
For leuco preparation here is a ratio which is followed:
Indigo : 100 g/l
Caustic Soda : 73 g/l
Reducing agent : 93 g/l
Dispersing agent : 0.5 g/l
Sequestering agent : 0.5 g/l
Wetting agent : 0.3 g/l
For leuco preparation here is a ratio which is followed:
Indigo : 100 g/l
Caustic Soda : 73 g/l
Reducing agent : 93 g/l
Dispersing agent : 0.5 g/l
Sequestering agent : 0.5 g/l
Wetting agent : 0.3 g/l
26. Dyeing Process
Dyeing process that is maintained as follows:
Pure Indigo- Continuous Indigo Dyeing
Bottoming- Sulphur(Bottom) & Indigo(Topping)
Topping- Indigo(Bottoming) & Sulphur (Topping)
Black Denim-Continuous Sulphur Black Dyeing
Color Denim.
27. Sizing
Sizing is the process in which the threads of a warp are treated with a sizing assistant
in order to increase the wear resistance.
Requirements of sizing
1.Adequate friction resistance and yarn strength
2.Uniform warp yarn tension.
3.Crossing-free yarn passage.
4.Warp splitting/no. of threads.
28. Fig: Beam creel
Capacity of cooking tank: 1000
Ltr
Cooking Temperature: 85º
Cooking time: 25-50 mins
Pick up: 5-10%
Cylinder temperature: 110-130ºc
Squeezing Pressure: By top
roller
Delivery squeeze pressure:
Lowest: 12-17 kN
Highest: 15-20 KN
Stretch: 0.7-1%
Refractro reading: 7-11%
Viscosity: 12-30 sec
Sizing Temperature: 85-90ºc
Sizing BATH:
No of dry cylinders used in this bath = 12
Sizing parameter:
30. The Starch & Softener are used in the sizing bath are given below:
Starch: Emsland E-55 (Modified starch)
Emsland E-14
Softener: Mutton Tallow
Fin Fix
Trefin Wax
Starch:
These are products from grains & tubers. These are mixture of
carbohydrate, oil, nitrogenous substances & mineral matter.
Carbohydrate is a polymer consisting of 25% amylase and 75%
amylopectin. Structurally it is a highly branched glucose polymer.
Starches are cheap & easily available & have proved to valuable
adhesives over a many years especially for cellulosic yarns. This is
manufactured mainly from maize, wheat, rice etc. When starch is
boiled with water, the starch granules swell & break up forming a
smooth & homogenous gelatinous mass.
31. EMSIZE E-14:
Application: Emsize is a starch sizing
agent for spun yarns
Characteristics:
Kind of product: High modified
polymer
Appearance: Off white granules
Moisture content: 9-14%
pH value (5% conc): 9.5-11.5
Viscosity:
Preparation of the solution:
The required quantity of product is added to cold water. Under stirring the slurry should be heated
up till 95ºc and kept for at least 20 minutes at this temperature. Preparation in an autoclave has to be
heated up to 110ºc and kept for at least 10 mins at this temperature.
Both the starch has the following common properties:
excellent sizing effect
transparent flexible film
high adhesion power
compatible with other sizing agents
washed out quickly without enzymes
good biological degradability
32.
33. Introduction
Traditional denim fabric are woven by interlacement of indigo dyed
warp and grey weft.
A variety of denim fabric are made with weave design such as
2/1 twill weave ,broken twill , zig-zag twill, reveres twill,etc.
It also manufactured with fancy design in order to meet the latest
fashion.
Denim fabric normally made of weight range of 3.5 to 16.5 oz per
square yards through 21 oz per square yards has recently developed in
japan
34. The typical reed and picks of some commonly produced fabric is given below;
Construction Finish
EPI
Loom
State
EPI
Finish
PPI
Loom
State
PPI
Finished
Cover Factor
warp
Cover
factor
Weft
Cover
factor
9Rs+9R*7Rs+7R/
72*48
72 68 48 44/45 26.59 24 18.14
8Rs+9R*8Rs(MC)/68
*50
68 63 50 50 26.04 23.33 17.68
8Rs*10Rs+10R/76*5
4
76 71 54 50 27.56 26.87 17.08
9Rs+9OE*12Rs+10+
70D/
78*54
78 64 54 48/49 27.16 26 16.28
8Rs+10R*8Rs+7OE/
72*50
72 71 50 47/48 26 24 17.68
9OEs+9OE*10
OE/75*43
75 68 43 37/39 26.47 25 13.6
10Rs+10OE*6OE+70
D/
76*50
76 71 50 44/45 26.93 24.03 20.41
8Rs+7R+10R*9R/72
*48
72 66 48 41/44 26.69 24.94 16
35. We know,
Cover factor, Kc =( K1 + K2 – K1*K2/28 )
Where, warp Cover factor, K1 = EPI/√ count
And weft Cover factor, K2 = PPI/√ count
Denim fabrics are highly sensitive to the fault incidence. Therefore
maximum care is necessary at all levels to avoid fabric faults.
Normally the loom stoppages are regarded as a serious matter in
accumulating fault level. Loom stoppages in turn depend on a large
extent on the yarn quality. A recommendation based on research
study has suggested the following yarn breakage norms in the
warping and sizing department;
44. Description of the processes:
Brushing:
The purpose of this process is to remove the lint, fluffs and
loose impurities. This is achieved by subjecting the fabric to kind
of roller beating action.
Singeing:
The objective of this process is to burn out the protruding fibres
from the surface of the fabric. Only blue side singed and it is done
twice.
Softening:
The aim of this process is to modify the feel of denim fabric and to
facilitate the movement of the threads during skewing and shrinkage
process. This is just a softening process where the fabric is passed
continuously through a solution containing 5gm/Htre softener.
Sometimes softener is used as foam form. Use of foam reduces the
quantity of heat required to dry the fabric.
45. CORRECTION OF SKEWING:
The 3/1 twill weave is in the classical denim fabric is inherently
unstable weave and has a tendency to twist anticlockwise
considering blue side as face side to stable configuration when it is
put in water. Due to this unstable condition the weft yarns lies with
warp yarn at an angle different from 90°. This is regarded as skewing
and if it is not corrected then there will be deformation and leg
twisting in the jeans made out of it. Therefore skewing is corrected
in this section where the fabric is basically passed either over a roller
or through two sets of rollers. The basic idea of correction the skewing
is that warp yarns deliberately pulled at one end so that the weft yarn
can lie with warp at 90° .In the former case the fabric is pulled by a
pair of squeeze rollers and the correction roller is either pushed up
or down. In the later case two sets of rollers are set at the two
extreme ends, the rollers are capable of pulling fabric at different
speeds. What ever is the method of correcting the skew ness, in all
cases attempt is made to compact the fabric sufficiently so that the
tendency of skewing is eliminated.
46. Machine that are used in Tube line are given below:
J - Box
Brushing Unit
Singing / Burning
Washing / Softing
Skew Roller
Dry Cylinder
Shrinkage by rubber belt with 33º pressure
Calendering / Palmer
Folding
Softening Agent
Softener (Persaftier ISD)
Wetting Agent ( Lionil )
Acetic acid