A Distinctive Digest of Garment Washing & Dyeing INDUSTRIAL GARMENT WASHING & DYEING Garment washing is very important part of a garment industry. In this process a garment is provided with a lucrative and glassy outlook. Chemicals used here are very costly and may harmful if used more than essential. Cost can be lessen if the proper use of chemical is known. As there is no such book on Industrial Garment Washing and Dyeing I believe this book will help very much. ASM TOWHEED 3/23/2011 2 GARMENT WASHING The technology which is used to modify the appearance, outlook comfortable and fashion of the garments is called garment washing. PURPOSE OF WASHING Purpose of washing/Best wash look is the best touch of a garment - This may be explained in the following way:-  Washing process of garment is done to create wash look appearance. After washing the garments create a new looks which seems the new touch of fashion.  By the washing technique, faded/old look, color or tinted affect is created in the garments which also seem the best touch of garments.  Washing technique creates new fashion such as tagging, grinding, destroy, Blasting, whickering, permanent wrinkle, deep dye, tie dye, P. P spray, hand crapping, P.P spoonzing etc. This also seems the best touch of garments.  The main and important function of washing is to reduce size materials as a result the garment become size free and become soft hand feel.  When these soft garments are touched then it seems to best touch of garments.  To attraction the customers/Buyer by different types of Fashionable washing and market developments.  Due to washing, shrinkage occurs in the garments. There is no possibility of further shrinkage of the wash garments.  Any dirt, spot or germ if added in the garments during manufacturing is also removed due to washing. A Distinctive Digest of Garment Washing & Dyeing 3 TYPECS OF WASHING Wet and Dry processes are mentioned below:  Normal wash/Garments wash/Rinse wash  Pigment wash  Caustic wash  Enzyme wash (Boi wash &Boi polishing)  Stone wash  Bleach wash (Ice wash& snow wash)  Stone Enzyme wash  Acid wash  Silicon wash  Sand Blasting & Hands scraping.  P. P Spray  Over all wrinkle  Permanent wrinkle  Tinting & Over dyeing  Grinding & Destroy  Broken & Tagging.  P.P Sponging  Dip Dyeing  Tie & Dye etc. TYPE OF WHAT MACHINE USED IN WASHING PLANT  Sample washing Machine (Horizontal / Vertical Type)  Washing Machine (Side loading)  Washing Machine (Front loading)  Hydro extractor Machine A Distinctive Digest of Garment Washing & Dyeing 4  Dryer Machine (Steam)  Dryer Machine (Gas)  Chemical Mixture Machine  Industrial Oven (Gas/Electric)  Boiler  Submersible Pump  Grinding Machine  Tagging Machine  Steam chamber for crinkle  E.T.P (Effluent Treatment Plant)  Generator  Sand Blasting Gun  Sand Blasting chamber  Spray gun and dummy  Screw compressor SEQUENCE OF PROCESS OF ANY GARMENT WASHING 1. Lot size 2. L:R – Liquor ratio 3. Temperature 4. Chemicals 5. Time NORMAL WASH / GARMENTS WASH Normal wash is required for the following reasons: 1. To remove dust, dirt, oil spot, impurities from the garments 2. To remove starch presents on the garment fabrics 3. For soft feeling to wear the garments after purchasing 4. To achieve buyer washing standard A Distinctive Digest of Garment Washing & Dyeing 5 WASHING PROCESS OF NORMAL / GARMENT WASH The Normal/Garment washing process of batch of 70 kg Twill/Canvas Garments are described below: First Step :  Lot size: 70 kg Twill/Canvas Garment.  Add water at L: R = 1: 8-10 560 - 700 Liter.  Machine Running.  Add detergent at 0.5 gm / liter 280-350 gm.  Temperature Sometime cold & sometime 40°c to 60°c.  Time 5 to 10 minutes.  Drop the liquor.  Cold wash Second Step :  Add water at L: R = 1: 6 420 liter.  Washing machine running  Add Flax softener at 0.6 gm / liter 252 gm.  Add Acetic Acid at 0.5 gm / liter 210 gm.  Time 5 to 10 minutes.  Drop the liquor.  Unload the Garments on trolley. Third Step: Hydro extractor machine.  Hydro-extraction the garments to remove excess water from the washed Garments. Fourth Step: Steam Dryer/Gas Dryer.  Load on steam dryer - 50 kg  Temperature - 60°c - 70°c  Time - 40 - 50 min for dry.  Time - 10 - 15 min for cold dry.  Load on gas dryer - 50 kg, A Distinctive Digest of Garment Washing & Dyeing 6  Running the machine  Temperature: - 70°c - 90°c.  Time: - 30 - 35 min for dry.  Time: - 10 - 15 min for cold dry. Fifth Step: After drying it will be quality checking and good quality Garments will be delivery to Garments factory. NOTE: - Flax softener (cationic or nonionic) diluted with hot water then use in the machine. SILICON WASH Silicon washes generally doing on all type of fabrics i.e. Twill, Denim, Canvas, Knit, Corduroy. Silicon wash is required for the following reasons:- It gives durable softness, elastic handle, It helps to anti-pilling affects, dimensional stability, and tear resistance. It helps to fabrics to be cut and sewn more easily allows and improving wears and easy care properties. SILICON WASH PROCESS The silicon washing process of batch of 60 kg Twill/Canvas/Poplin/Corduroy/Trouser is described below:- First Step: - Desizing  Lot weight (Approx 125 Pecs) 60 kg.  Add water at L: R = 1: 10 600 Liter  Machine Running.  Add Desizing agent at 0.6 gm / liter 360 gm.  Add Detergent at 0.5 gm / liter 300 gm.  Temperature 40 50°c. A Distinctive Digest of Garment Washing & Dyeing 7  Time 10 20 min.  Drop the liquor.  Rinse one time 3 minutes. Second Step:-  Add water at L: R = 1: 8 480 Liter.  Add Acetic Acid at 0.6 gm / liter 288 gm.  Cationic Softener at 1 gm / liter 480 gm.  Silicon (ME) at 0.5 gm / liter 240 gm.  Temperature 40°c  Time 15 to 20 min.  Drain the bath.  Then unload the garments on trolley. Third Step: - Hydro-extractor Machine After unloading garments from the washing machine then they are sent to hydro-extractor machine to remove excess water from the washed garments. Fourth Step: - Drying Machine  Load 60 kg garments to gas/steam dryer.  Temperature set - 75°c to 85°c.  Run about 35 to 45 min.  After run 10 to 15 minutes for cold dryer. Fifth Step:- After drying garment go to quality section for quality checking and then delivery. PIGMENT WASH Pigment wash generally doing on pigment dyed or printed Garments by pigment washing technique. Pigment wash is required for the following reasons:  To fading affect/old looking affect on Garment and also seam abrasion.  For soft feeling to wear the garment after purchasing. A Distinctive Digest of Garment Washing & Dyeing 8  To achieve the buyer washing standard.  To increase the color fastness & rubbing. WASHING PROCESS OF PIGMENT WASH The pigment washing process of batch of 80 kg Twill/canvas Garments are described below:- First Step :-  Lot size: - 80 kg Twill/Canvas Garment.  Add water at L: R = 1: 8 640 Liter  Machine Running.  Add Caustic soda (NAOH) at 0.8 gm / liter 512 gm.  Add Soda Ash (Na2Co3) at 1.50 gm / liter 950 gm.  Add Detergent at 0.8 gm / liter 512 gm.  Temperature 50°c to 60°c.  Time (Depend upon the shade) 20 to 60 min.  Drop the liquor.  Wash 1 time by hot wash for 5 min at the temperature 50°c.  Wash 1 time by cold water for 5 min Second Step:-  Add water at L:R = 1:6 480 liter.  Washing machine running  Add Acetic Acid (for pH 4.5 - 5.0) at 0.5 gm / liter 210 gm.  Add Flax softener at 0.6 gm / liter 288 gm.  For more slippery hand feel use silicon - at 0.6 gm / liter 288gm.  Time 10 to 20 min.  Drop the liquor  Unload the Garments on trolley Third Step: - Hydro extractor machine. A Distinctive Digest of Garment Washing & Dyeing 9  Hydro-extraction the garments to remove excess water from the Garments. Time required about 2 - 4 minutes Fourth Step :  Steam Dryer / Gas Dryer.  Load on steam dryer - 50 kg  Running the machine  Temperature - 60°c - 70°c  Time - 40 - 50 min for dry.  Time - 10 - 15 min for cold dry. Or  Load on gas dryer - 50 kg,  Running the machine  Temperature: - 70°c - 90°c for dry.  Time: - 30 - 35 min for dry.  Time: - 10 - 15 min for cold dry. Fifth Step :  After drying garments go to quality section and check the garment, good quality garment will be delivery and Deep shade again rewash, other quality Garment rectify then delivery. CHEMICAL USED IN PIGMENT WASHING AND THEIR FUNCTION  CAUSTIC SODA (NaOH) :-  Caustic created the role in bleach technique without color change the garments.  Caustic has a cleaning power which is more powerful then soda Ash.  Fading affect/old looking affect come rapidly on garments SODA ASH (Na2Co3) : A Distinctive Digest of Garment Washing & Dyeing 10  Soda ash created alkaline medium for the breakdown of pigment dye.  It has also a cleaning power.  It has also help color fading affect of garments. Detergent: Here detergent is used to remove impurities from the Garment fabric surfaces and temperature helps detergent to enhance its action. Detergent removes the impurities from the garments fabric surface. During coming these impurities, some pigment will be washed out from the pigment dyed or printed area of the garments. As a result fading affect will be developed. Acidic Acid (CH3COOH) : Acidic Acid is used to neutralize the garment from alkaline condition and to control the pH value in wash bath. Flax Softener (Cationic, anionic): Softener is used to make the garments treated textiles is surface feel that is bath sickly and soft and also provides excellent lubricating properties CAUSTIC WASH: Caustic wash generally doing on Reactive dye, Sulpher dye, Direct dyed or printed Garments Caustic wash is required for the following reasons:  To fading/old looking affect on Garment and seam abrasion affection seam area.  To remove the size materials, starch from the garments.  To increase the color fastness & rubbing fastness.  For soft feeling to wear the garments.  To increase the hairiness on garments. A Distinctive Digest of Garment Washing & Dyeing [...]... Time 10 to 15 min  Drain the bath  Then unload the garments on trolley A Distinctive Digest of Garment Washing & Dyeing 17 Fourth Step: Hydro-extractor Machine  After unloading garments from the washing machine then they are sent to hydroextractor machine to remove excess water from the washed garments Fifth Step: Drying Machine  Load 60 kg garments to gas dryer  Temperature set - 75°c to 85°c... 10 to 15 min  Drain the bath  Then unload the garments on trolley A Distinctive Digest of Garment Washing & Dyeing 19 Sixth Step: Hydro-extractor Machine  After unloading garments from the washing machine then they are sent to hydroextractor machine to remove excess water from the washed garments Seventh Step: - Drying Machine  Load 60 kg garments to gas dryer  Temperature set - 75°c to 85°c... 10 to 20 min  Drain the bath  Then unload the garments on trolley Fourth Step :- Hydro-extractor Machine  After unloading garments from the washing machine then they are sent to hydroextractor machine to remove excess water from the washed garments Fifth Step : Drying Machine A Distinctive Digest of Garment Washing & Dyeing 23  Load 60 kg garments to gas/steam dryer  Temperature set - 75°c... the garments to trolley Seventh Step :- Hydro-extractor Machine  Hydro-extraction the garment to remove excess water from the washed garments Eighth Step : Drying Machine :  Load 40 kg garments  Set temperature 75°c to 85°c  Time 35 to 40 min  Time 10 minutes in cold dry Ninth Step : Delivery  After quality checking garment will be delivery BLEACH WASH A Distinctive Digest of Garment Washing. .. low grinding  Bad smell due to poor neutralization A Distinctive Digest of Garment Washing & Dyeing 30  Poor hand feel  To high hairiness  Poor brightness  High or low affect / abrasion on garments  Spot on garments  Out of range / level of pH value of garments APPROX RATE FOR DIFFERENT TYPECS OF WASHING  NORMAL WASH / GARMENT WASH – Kids / Boy's item - us$ 0.70 - $ 1.25 / DOZ – Adult item -... Digest of Garment Washing & Dyeing 36  Rinse one for 3 minutes (cold) Second Step: - Hot wash  Add water at L: R = 1: 10 600 liter  Temperature 60°c  Time 5 min  Drop the liquor Here hot wash is used to remove the adhering materials from the garment surface  Unload the garments from the washing m/c in the trolley  Load the pre treated garments in the dryer m/c  Dry the garment completely... pre-treated garment 30 – 40 kg per batch load in the dry washing machine  Load the per-treated stones (about 50 kg) in washing machine  Start machine running for each batch 7 to 10 min  Stop machine running  Unload the treated garment separately Pumic stones with P.P solution hit on garment surface as a result fading will be developed Then load the stones treated garment in another washing machine... Every bag contain 22 kg to 25 kg and price 400/= to 425/=/ bag THE ACT OF PUMIC STONES DURING GARMENT WASHING  During different garments washing like stone wash, Acid wash, Stone Enzyme wash etc Pumic stones are used to create irregular fading affect on garments  The pumic stones act a brushing action on the garment fabric surfaces  The areas where more brushing action take place, there more fading... min  Drop the liquor  Unload the garments to trolley Sixth Step :- Hydro-extractor Machine  Hydro-extraction the garment to remove excess water from the washed garments Seventh Step :- Drying Machine  Load 40 kg garments  Set temperature 75°c to 85°c  Time 35 to 40 min  Time 10 minutes in cold dry  Eighth Step :- Delivery : After quality checking garment will be delivery STONE ENZYME... then run 10 min in cold dryer Eighth Step: After dryer garment go to quality section for quality checking and good one delivery Hydro-extractor Machine  After unloading garments from the washing machine then they are sent to hydroextractor machine to remove excess water from the washed garments ENZYME WASHES PROCESS LIGHT SHADE: The enzyme washing process of batch of 60 kgs denim men's long pant . Distinctive Digest of Garment Washing & Dyeing INDUSTRIAL GARMENT WASHING & DYEING Garment washing is very important part of a garment industry. In this process a garment is provided. garments is called garment washing. PURPOSE OF WASHING Purpose of washing/ Best wash look is the best touch of a garment - This may be explained in the following way:-  Washing process of garment. the wash garments.  Any dirt, spot or germ if added in the garments during manufacturing is also removed due to washing. A Distinctive Digest of Garment Washing & Dyeing 3 TYPECS OF WASHING Wet