All Possible information about Denim, Finishes , Dyeing of denim, Flow chat of Denim Production, Spinning , advantages, differences, n many more

1. BY:
HASSAN QURESHI
&
SUNDUS SAGHIR

3.  WORD DENIM IS ORGINATED FROM THE CITY
SERGE THE NIMES (FRANCE).
 IT’S FIRST USE BY COTTON PLANTATION WORKER
IN 18th CENTURY.
 MADE FROM COTTON YARN 3/1
 TO MAKE JACKET OTHER KIND OF CLOTHING &
EVEN UPHOLSTRY.
 SUITABLE FOR LONG TIME WEARING.

4. Flow Chart of Denim Production
Spinning
Warping
Rope Dyeing/Slasher Dyeing
.
Long Chain Beaming
Sizing
Weaving
Finishing
Inspection
Packing
Dispatch

5. SPINNING
 Initial Process Of Spinning Consist Of Opening And
Blending Of Fiber
 Carding Is Done
 So That The Bale Convert Into Sliver
 Yarn Is Spun Through Open End & Ring Spinning
 Drawing & Roving Also Carried On

7. WARPING
 Warping is the process of transferring multiple yarns.
 Yarns are collected in a sheet .
 Where the yarns lie parallel to each other and in the same
plane onto a beam
 There are two types of warping
 BALL WARPING
 BEAM WARPING

8. DYEING
THERE ARE TWO METHOD OF DYEING
DINEM YARNS.
ROPE DYEING.
SLASHER DYEING.

9. ROPE DYEING
 Only Warp Yarn Is Dyed.
 Mainly Dyed Indigo.
 Filling Yarn is Un Processed (grey yarn).
 Yarn Are dyed In Rope Like Form.
 Kept Separated To Not To Be Tangled.

10. First Fed Into Scouring Bath.
To Remove Natural Impurities.
Sulphur Bottom Is Required.
Rinsed Several Times To Remove Unfixed Dyes.

11. SLASHER DYEING
 For Certain Manufacturer Rope Dyeing Is Not Possible or
Desirable.
 Sheet Of Yarn Is Dyed.
 Can't Be Dip Multiple Time.
 Only Light & Medium Shade Can Be Obtain
 Work Well With Light Weight Denim
 Requires Less Floor Space For Machines Low Machinery Cost.
 Can Produce Wide Varity Of Colors Other Than Indigo.

12. ADVANTAGES OF SLASHER DYEING
 THE TECNOLOGY IS LESS CAPITAL INTENSIVE.
 THE TECCNOLOGY IS PROVEN ON.
 THE COST OF PRODUCTION IS LOWER.
 THE PROCESS TIME IS LOWER.
 THE SHEET DYEING MACHINES ARE VERY EASY TO
OPERATE.

13. LONG CHAIN BEAMING
THE DRAWN WEAVERS BEAM ARE FIXED ON
WEAVING MACHINES.
WARP THREADS ARE DIRECTLY KNOTTED TO
THE THREADS OF FINNISHED BEAMS
TIS OPRATION IS NECESSARY BECAUSE OF
LONG LENGTH OF FABRIC

14. SIZING
 Main Purpose Of Sizing Is To Reduce Abrasion That Take Place
During Weaving.
 Sizes Keep Indigo Dye From Rubbing Off During Weaving.
 Native Starches Or Slightly Modified Starches Is Used.
 Most Warp Yarns For Weaving Denim Have 7-14% Sizes Add On.
 In Many Denim Style, The size Is Left On The Fabric.

15. WEAVING
 Denim fabrics are woven by interlacement of indigo dyed warp and grey
weft.
 Generally denim is a 3/1 RHT warp faced fabrics.
 A variety of denim fabric are made with different weave designs, such as
2/1 twill weave, broken twill, zigzag twill, 1/1 chambray twill etc.
 Today, denim fabrics are also manufactured with fancy design.
 Denim fabrics normally made of weight range of 6.5 to 15.5 oz per sq. yd.

17. FINISHING
 After weaving fabric is send to the finishing section for adding
some properties.
 Finishes are applied on finished fabric.
 Washes/processed jeans can go through many process to achieves
realistic fading effect.
 Denim washes are different types of washing :
 DENIM BLEACH:
 In this process bleaching agent such as Sodium Hydro chlorite or
KMnO4 is added during washing with or without stones addition.
 STONE WASH
 In this process, freshly dyed jeans are loaded into large washing
machine
 Tumbled with pumice to achieve a soft hand & desirable look.

18.  SAND BLASTING
 This techniques is based on blasting on abrasive material(mostly sand) in
granular powder.
 Purely mechanical & water free process.
Other washes are :
 Rinse Wash
 Cellulose Wash
 Acid Wash
 Enzyme wash
 Salt water denim
 Hand Sanding & Hand Brushing
 Over dyed
 Ozone fading
 Etc.

19. INSPECTION
 Inspection and Measurement Machines have been designed to
prevent problems.
 Cost increases that may arise in sewing departments of apparel
industries due to production faults in the fabric.
FEATURES
 Automatic Stop Sensor - for Next Roll Joining This will allow for
continuous fabric inspection, from one piece of roll to next.
 Automatic Linear Cut (Fabric Roll End Cutter).

20. PACKING & Dispatch
Rolls and sets so formed and packed as per buyers’ requirements
are then sent for final dispatches.