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
6.
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.
16.
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.