MANUFACTURING PROCESS

OF DENIM FABRIC

BY:HASSAN QURESHI

& SUNDUS SAGHIR

INTRODUCTION 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.

Flow Chart of Denim Production

Spinning

Warping

Rope Dyeing/Slasher Dyeing.

Long Chain Beaming

Sizing

Weaving

Finishing

Inspection

Packing

Dispatch

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

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

DYEING

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

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.

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

Dyes.

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.

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.

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

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.

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.

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.

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.

 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).

PACKING & Dispatch

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