Value Addition in Denim through its washing effects at Shahi Exports Pvt.

Ltd

Presented By:
Kumari Priyanka Roll No- 13

Introduction
Denim washing is know as one of the
finishing treatment that has vast usage because of creating special appearance and updating clothes There is different methods of denim washing.

DENIM WASHING
Aesthetic finish Dry denim-Not washed after dyeing Washed denim-Natural distressing of dry denim
is attempted to replicate

WHEN IT STARTED?
The concept of washing the Denim jeans was
started by Jack Spencer for the brand Lee. Stone-wash was first started by Francois Girbaud. The concept of sandblasting was started in 1988 by a number of branded companies in Italy.

Types of washes

Mechanical washes

Chemical washes

Stone wash

Whiskering

Sand blasting

Enzyme wash

Bleach wash

Acid wash

spray

On the base of chemical use

TYPES OF DENIM WASHES

1. Chemical washes - Denim bleaching - Enzyme wash - Acid wash 2. Mechanical washes - Stone wash - Microsanding
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CHEMICAL WASHES DENIM BLEACH

Strong oxidative bleaching agent such as
sodium hypochlorite or potassium permanganate. Bleaching methods Bleaching effect

Process cycle:

Limitations:
Process is difficult to control Problem of yellowing Required antichlor treatment Causes corrosion Harmful to human health Source of environmental pollution
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ENZYME WASH
Application of organic enzymes Easy to stop the action of enzymes Environment friendly wash

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Limitations:
Garment load size of the machine is limited. Post treatment required.
More advantages than disadvantages: Soft handle More reproducible results Increased luster Less corrosive Less damage to seams Less wear & tear of machinery Applicable to cotton and its blends
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ACID WASH
Pumice stones presoaked in
a solution of sodium hypochlorite or potassium permanganate. Non-uniform contrast.

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Process cycle

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 Results depends on:-Fabric -Chemical used(conc.) -Stone(quantity) -Machine used

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Limitations
Yellowing; residual manganese
Remedy: Using ethelene-diamine-tetra-acetic acid as chelating agent.

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MECHANICAL WASHES STONE WASH

Tumbled with pumice stones Variations in composition, hardness, size, shape
and porosity make these stones multifunctional.

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Selection of stone
According to the end product & effect required. Large, hard stones last longer and may be suited for
heavy weight fabrics only. Smaller, softer stones would be used for light weight fabrics and more delicate items. Stone wt. /fabric wt. = 0.5 to 3 /1

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Limitations
Outcome of a load of jeans is never uniform. Damage to wash machineries and garment due
to stone to machine abrasion. Increase in labor to remove stone particles from finished garments. Water pollution during disposal of used liquor.

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MICROSANDING
There are 3 ways for this technique: Sandblasting Machine sanding Hand sanding or hand brushing

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Used in various ways:

- Flat surfaces (tables, ironing boards) - On the dummy (inflatable dummies, sometimes standing, sometimes flat, sometimes 'seated') - Various templates can be used to create a 3D effect

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SAND BLASTING
This technique is based
on blasting an abrasive material (mostly sand) in granular, powdered or other form through a nozzle. It is purely mechanical process. It is a water free process. Variety of distressed or abraded looks possible.
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process

product look

MACHINE SANDING
In this fabric treatment process, a
series of cylindrical rolls in a horizontal arrangement, either wrapped with an abrasive paper or chemically coated with an abrasive.

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HAND SANDING OR HAND BRUSHING

Use of sandpaper to
abrade surface. Variety of looks and designs can be created.

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WHISKERING
Also known as Cat's
Whiskers. Crease lines around the crotch. Knee whiskers. Honeycombs. Industrially done using different techniques.

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Materials & Methodology

This is the general processing cycle which
I analyses in the company for all the four samples
Load garment & Stone Desize Rinse

Soften

Rinse

Stone Wash

Tumble Dry

Unload

Extract
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Following Wash are Applied in the Samples:

Dark Stone Wash Mid Stone Wash Super Stone Wash Ice Wash

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Result & Discussion

Swatch No Type Shade Result

Sample 1

Dark Stone

Dark

Good

Sample 2

Mid Stone

Medium

Good

Sample 3

Super Stone

Light

Good

Sample 4

Ice Wash

Whitish Blue

Good

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Swatch No

Type

Test Done

Result

Sample 1

Dark Stone

1. Shrinkage 2. Shading..
1. Shrinkage 2. Shading.. 1. Shrinkage 2. Shading..

Good

Sample 2

Mid Stone

Good

Sample 3

Super Stone

Good

Sample 4

Ice Wash

1. Shrinkage 2. Shading..

Good

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Conclusion
Denim is unique in its singular connection
with one color. The warp yarn is traditionally dyed with the blue pigment obtained from indigo dye. The durability of indigo as a color and its darkness of tone made it a good choice, when frequent washing was not possible. The different tones are made in the garment by using different type of stone wash like Dark stone, Mid stone, Light stone, Ice wash.
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Thank You!!

Percentage of Benefits Achieved Typical Results from Lean Conversions

0
Lead Time Reduction

25

50

75

100

Productivity Increase
WIP Reduction Quality Improvement Space Utilization