Garments washing

GARMENTS WASHING

Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013)Department : Wet Processing Technology Email: [email protected] : www. Textilelab.blogspot.com (visit)

Southeast University Department Of Textile

EngineeringI/A 251,252 Tejgaon Dhaka

Bangladesh

Prepared By :

©right

Total Textile Process at a Glance

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With the change of time, human choice, demand, garment design and fashion is

changing very quickly. To meet the demand of users, garment manufacturers are

adapting new technology and processes. Garment wash is a new technology, which is

used to modify the outlook, appearance, comfort ability and fashion of the garments is

called garments washing. Garment washing is normally processed after stitching. As per

fashion trend and customer demand buyers ask for garment washing though it

increases the cost of the garment. For the washing they mention exactly what types of

washing they need for the order. For example, Tom Tailor buyer asked for washes like –

Vintage wash, Cloud wash, softener wash or Acid wash. Each wash has different types

of appearance on the fabric surfaces. Wash types mainly depends on the product

types. For denim product heavy enzyme is required where for knitted Tee light softener

wash may be okay.

Introduction

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In line with ever changing human behaviors and longing to be unique in outlook,

mankind dress themselves in fashionable as well as comfortable garments. To be

or get unique in outlook garment washing is very convenient way. This is a wing of

garment wet processing technology.

This is the textile technology by which a unique appearance along the seam, size,

comfort ability & fashion etc. properties are changed of a solid or multi colored or

printed garment.

Fabric of the garment may be dyed with reactive dye, direct dye, sulpher dye, acid

dye, basic dye, pigment and even metal complex dye and printed with pigment,

direct dye, reactive dye etc.

Garment Washing

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Types of Garment Washing:

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1. Wet process/Chemical process Normal wash/ garment wash/rinse wash Pigment wash Caustic wash Enzyme wash Stone wash Stone enzyme wash Tinting (Tie) & Over Dyeing(Dip Dyeing) Super white wash Bleach wash Acid wash Silicon wash Soft wash

2. Dry process/Mechanical process Sand blasting Hands scraping Over all wrinkles Permanent wrinkle Broken and tagging Grinding and destroy PP spray and PP sponging etc.

Types of Garment Washing:

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These are the main objects for garments washing

1.To develop softness in garment: Size materials in fabric are removed by

washing & there is also advantage to add softener. Drape ability also increased.

2.To introduce unique appearance: washing that introduces fading effects along

with the seam on the garments by washing out dyes or pigments in the

garments.

3.To create new fashion: Washing process of garments bring different out looks

(faded, color tinted, old look etc.) of garment that is used for creating new

fashion.

4.Special type of finishes are also possible such as wrinkle, wrinkle free, flame

retardant, water proof breathable, soil retardant finish etc.

5.To satisfy the customer: As shrinkage occurs so customer can wear it just

after purchasing/buying.

Objects of Garments Washing

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Garments from store house ↓

Count ↓

Quality check ↓

Batch ↓

Washing ↓

Hydro extractor ↓

Drying ↓

Quality check ↓

Packing ↓

Delivery

Flow Chart of Washing:

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Common procedure of garments washing:

1. Garments can be inverted to minimize unwanted abrasion streaks (especially useful when preset creases are present).

2. Load machine with garments.3. Desize with alpha amylase enzyme and detergent.4. Drain.5. Rinse.6. Fill machine with water and heat to 60◦C. The liquor ratio can range from 10:1 to 20:1. A

number of synthetic detergents can be used. Also, alkaline products such as soda ash or caustic soda can be added in amounts ranging from 0.5 to 2.0 grams/liter. Some chemical suppliers offer special products that accelerate the wash down process, dependent upon the particular dyestuff used.

7. Wash/tumble action for 20-60 minutes, depending upon desired effect.8. Drain and rinse.9. Apply softener.10. Tumble dry.11. Invert garments, if previously turned.12. Press, if required.

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1. Starch or size materials, which are applied during fabric production especially

in case of woven fabric are removed by wash as a result the garment become soft

and hence the drape ability and comfort ability increased significantly.

2. Softness could be increased by addition of softeners by doing soft finish or

applying the softener.

3. Dirt’s, impurities, germs etc. obviously will be added in the garment during its

manufacturing are removed due to washing because a variety of chemicals are

used such as detergent, bleaching agents etc.

4. Due to washing, maximum shrinkage occurs; hence there is the zero

possibility of further shrinkage. As a result there is no size or fitting problem in

washed garments.

Advantages of Garments Washing

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1. Faded effect and a variety of stylish effects produced by different washing

techniques. Nowadays these faded and stylish effects are accepted as a new

fashion for fashion world.

2. Similar out look and effect could be produced by different washing techniques or

by different process. As a result there is a great scope of implementation of

brilliances of technicians. Every machine of a garment washing factory can be

used for multipurpose for this reason total project cost is comparatively lower

where as washing add a handsome value to the garments.

Advantages of Garments Washing

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Garments Size Change:

This change takes place due to shrinkage properties of the fabric. The amount of

shrinkage properties of fabric determines the amount of size changing of the

garments.

Size materials and finishing's partly removed:

Different types of washing are done with different types of chemicals and process,

which are responsible for the removal of size materials and finishing's from the

fabric.

Color is partly removed:

Unfixed dyes may remain on the garment after dyeing. This un-fixed dye will be

subsequently removed due to washing. Thus color is partly removed.

Unavailable Changes/Limitation of Garments washing

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There Are Different Types of Garments washing in our country• Normal wash/Garment wash/Rinse wash /Soft

wash,• Pigment wash,• Silicon wash,• Bleach wash,• Caustic wash,• Acid wash,• Enzyme wash,• Stone wash,• Enzyme wash with stone,• Supper white wash,• Wash & over dyeing,• Wash & Tinting,• Over all wrinkles,• Permanent wrinkle/Resin Finish.• etc.

Types of Garment washing

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Some Washing Chemical List

1. Desizing Agent : DesizingHts, D-Peast

2. Anti Back Stain Agent : Antistain – Lp-30

3. Fastness Improvers For Dyeing : Albafix®

4. Levelling Agents For Dyeing : Albatex®

5. Fastness Improvers For Dyeing : Albafix®

6. Enzyme : G Enzyme S89, G Enzyme – Sl,

InnozymeNpe S89

7. Salt : G/Salt.

8. Alkali : Naso4

9. Ph Control : Using Buffer & Acid

10. Bleaching Agent : Sodium Hypochlorite Naocl; 15% Cl2 Available

11. Calcium Hypochlorite.

12. Neutralizing Agent : Hydro Peroxide, Bisulphate OrThiosulphate.

13. Softener : Innosoft 1070

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• Enzyme

• Detergent

• Acetic Acid

• Antistatic

• Bleaching powder

• Sodium hyposulfite

• Caustic Soda

• Soda Ash

• Sodium Bicarbonate

• Potassium permanganate

• Cationic / nonionic Flax softener

Washing Chemicals:

• Micro Emulsion Silicon

• Salt (sodium chloride)

• Buffer

• Hydrogen peroxide

• Stabilizer

• Fixing agent

• Catanizer

• Optical Brightener

• Resin

• Sodium Metabisulphite

• Desizing agent

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BASIC MACHINERIES OF A WASHING PLANT

• Garments washing m/c for sample,

• Garments washing m/c for bulk,

• Hydro extractor,

• Tumble Dryer: i) Gas dryer, ii) Steam dryer.

• Boiler

• Compressor

MACHINES USED IN WASHING PLANT

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Different kinds of washing & Garments dyeing price list

Please see below the our price list (Wash Type)

• Normal Garments wash per dozon = 0.6$

• Trumble/Normal fabric wash per kg = 10 taka

• Stone wash per dozon = 1.5$

• Stone Enzyme wash per dozon = 2.0$

• Acid wash per dozon = 5.0$

• Sand wash per dozon = 4.0$

• Enzyme wash per dozon = 1.0$

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• Garments made from indigo, vat, reactive, direct etc dyed fabric can be bleach washed.

• It is a decolorization process by oxidation action.

• Color can be removed uniformly from the garment and removal of color done as per requirement. In general there are three categories such as light bleach (where maximum color is removed), medium bleach and bleach.

• All types of garment can be washed. Such as: woven knit garments.

• In case of woven fabric a pretreatment (Desizing) process is required.

• Dust, dirt, oil spot, impurities etc. are removed that may come from during process i.e. cutting, stitching and the back process.

• Significant fading effect can be achieved. But we can achieve more wash effect by increasing processing time and decreasing the liquor ratio.

• To improve the color fastness & rubbing fastness.

• To increase the hairiness on garments this increases its old-look appearance.

• Maximum weight losses occur in case of light bleach.

Bleach Wash

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Process :

This washing process follows the following steps.

• Step 01 or Desizing

• Step 02 or Bleaching

• Step 03 (Neutralization of Chlorine)

• Step 04 or Neutralization

• Step 05 or Softening

• Step 06 or Drying

Bleach Wash

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Suppose a lot size 100kg of twill trouser.Step 01 or Desizing:

1. Load the garment in washing m/c 100kg garment2. Add water at 1:5 liquor ratio 500lt 3. Start m/c running Speed 15/12 rpm4. Add amylase enzyme 1-3% 1-3kg5. Add detergent/antistain to the liquor;1% i.e. 1kg6. Supply steam to raise temp. 60 c7. Continue the process 20 min8. Drop the liquor9. Hot wash with water temp 40-50c for 5 min.

Step 02 or bleaching:1. Add water in 1:5 liquor ratio 500lt2. Start m/c running Speed 12-15 rpm3. Add soda to liquor 2% i.e. 2kg4. Add caustic to liquor 2% i.e. 2kg5. Add bleaching powder (K.C.I.) 10 gm/lt i.e. 5 gm6. Rinse thoroughly.

Bleach Wash

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Step 03 (Neutralization of Chlorine):• Add water with 1:5 liquor ratio =500Lt• Start m/c running with moderate speed =12-15 rpm• Add 35% of H2O2 0.5-1.0% = 500gm-1kg

Or Add bisulphate 1-2% =1kg-2kg• Continue the process at Room temp. =5 min• Drop the liquor & a hot wash at 40-60 c =5 min• Add water in 1: 5 Liquor ratio = 500 Lt• Start machine running = speed 12-15 rpm• Add sodium hyposulphite 3 gm/ltr = 1500gm.• Supply steam to raise temp As required (40c)• Continue the process 10-20 min• Drop the liquor,• Rinse thoroughly.

Bleach Wash

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Step 04 or Neutralization:1. Add water in 1: 5 Liquor ratio = 500 Lt2. Start machine running = speed 12-15 rpm3. Add acetic acid to the liquor 1-2ml/lt = 0.5-1Lt4. Continue the process = 5 min5. Drop the liquor

Step 05 or Softening:1. Add water in 1:5 liquor ratio = 500 Lt2. Start m/c running speed 12-15 rpm3. Add softener to the liquor 0.1 - 0.5% = 100- 500gm4. Supply steam to raise the temp. = As required 40 to 60 c5. Continue the process = 5 min6. Drop the liquor & unload the garments

Step 06 or Drying:1. Hydroextract the garments.2. Dry in the tumble dryer.

Incase of knit garments desizing step is not required but a wash for 5 minutes at room temperature is necessary.

Bleach Wash

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Stone wash is done on garments made from denim & jeans fabric. Sometimes twill fabric garments are also subjected for stone wash.

Fading effect is produced in the garments in irregular pattern. Fading effect is more pronounced across the seam line and the multiple ply position.

Stone wash mainly followed by a decolouration process.

Garments become comfortable during use.

Stone Wash

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Process :

This washing process follows the following steps:

• Step 01 or Desizing

• Step 02 or Stone Wash followed by Bleach wash

• Step 03 (Neutralization of Chlorine)

• Step 04 or Neutralization

• Step 05 or Softening

• Step 06 or Drying

Stone Wash

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Process Cycle

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Process: It follows the bellow mentioned steps.Suppose 100kg of garments in a lot size.Step 01 or Desizing

1. Load the garment in washing m/c 100kg garment2. Add water at 1:5 liquor ratio 500lt 3. Start m/c running Speed 15/12 rpm4. Add amylase enzyme 1-3% 1-3kg5. Add detergent/antistain to the liquor; 1% i.e. 1kg6. Supply steam to raise temp. 60 c7. Continue the process 20 min8. Drop the liquor9. Hot wash with water temp 40-50c for 5 min.

Step 02 (Stone Wash):1. Load the m/c with water at 1:5 liquor ratio = 500Lt water2. Add pumic stone ½ of volume of garments volume or as required

= 30kg to 50 kg 3. Start m/c running with moderate speed =12-15 rpm4. Add bleaching powder to the liquor 2-4% =2-4kg 5. Add soda ash to the liquor 6-8% = 6-8 kg6. Continue the process =20-40 min7. Drop the liquor & a hot wash at 40 to 50c = 5min

Stone Wash

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Step 03 (Neutralization of Chlorine):1. Add water with 1:5 liquor ratio = 500 Lt2. Start m/c running with moderate speed = 12-15 rpm3. Add 35% of H2O2 0.5-1.0% = 500gm-1k

Or Add bisulphate 1-2% =1kg-2kg4. Continue the process at Room temp. = 5 min5. Drop the liquor & a hot wash at 40-60 c = 5 min

Note: H2O2 Neutralization gives brighter tone then the bisulphate.

Step 04: (Neutralization)1. Add water with 1:5 liquor ratio = 500 Lt2. Start m/c running with moderate speed = 12-15 rpm3. Add acetic acid 1-2% = 1Lt-2Lt4. Continue the process at Room temp to 60c. = 5-8 min5. Drop the liquor

Stone Wash

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Step 05 or Softening:1. Add water in 1:5 liquor ratio 500 Lt2. Start m/c running speed 12-15 rpm3. Add softener to the liquor 0.1 - 0.5% 100- 500gm4. Supply steam to raise the temp As required 40 to 60 c5. Continue the process 5 min6. Drop the liquor & unload the garments

Step 06:1. Hydroextract the garments.2. Dry in the tumble dryer.

Note: Stone wash sometimes done without bleaching; actually it depends upon

the requirement

Stone Wash

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• Garments made from heavy jeans & denim fabrics course canvas, sweater & thick twill etc. are washed by acid wash technique.

• Irregular pattern fading effect is produced in the garments. But the effects more

pronounce than stone wash.

• This is very dirty process due to widely use of pumic stone.

Acid Wash

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Process:It follows the following steps. Step 01 or Desizing:

Load the garment in washing m/c 100kg garment1. Add water at 1:5 liquor ratio 500lt 2. Start m/c running Speed 15/12 rpm3. Add amylase enzyme 1-3% 1-3kg4. Add detergent/antistain to the liquor;1% i.e. 1kg5. Supply steam to raise temp. 60 c6. Continue the process 20 min7. Drop the liquor8. Hot wash with water temp 40-50c for 5 min.

Step 02:1. Unload the garments from m/c2. Hydro extract the garments3. Dry it partially by running tumble dryer for 5 to 10 mins.4. Unload the garments & keep in open air for conditioning (1/2 an hour)

Stone Wash

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Step 03:1. Take stone of same volume of the volume of garments.2. Soak the stone with the following chemical solution for 2-3 min

Water 100 Lt Potassium permanganate 1kg (1gm/Lt)Phosphoric Acid 200-300gm (0.2-0.3gm/lt)

Here the porous of stone will, pick up the solution3. Soaked stones are dried in the open air for 60-90 min

Step 04:1. Load the garments treated in step 01 & step 02 in a dry m/c. lot size should

be 20 to 30kg.2. Load treated stone in step 03 volume of the garments volume.3. Run the m/c for 5 to 7 min. Due to rotation of inner cylinder the soaked stones

will hit the garments surfaces, thus the chemicals in the stone will destroy the color of fabric where the stone will hit. Multi layer fabric area like collar, cuff, and pocket, pocket side seam etc area will brushed more than the single layer areas, hence more fading effect will be produce in those areas result new color effect in the garments.

4. Unload the garments & separate the stone from the batch.

Stone Wash

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Step 05:It is a neutralizing process. KMnO4 & H3PO4 reacts & gives Oxygen, which oxidized the color. Hence a by-product MnO2 is also produced which should be neutralized.

6KMnO + 4H3PO4 =2K3PO4+ Mn3(PO4)2+ 6H2O+ 3MnO2+2O2

This MnO2 is solubilized by sodium Metabisulfite (Na2S2O5)

Na2S2O5 + H2O = 2NaHSO3

NaHSO3+MnO2=MnSO4+NaOH

1. Load the garments to the m/c

2. Add water with 1: 5 liquor ratio 500Lt

3. Run m/c with moderate speed 12-15 rpm

4. Add Sodium meta-bisulfite 1-2 g/Lt 500gm-1kg

5. Continue the process 5-10 min

6. Drain the liquor

7. Hot wash 40-50c 5 min

Stone Wash

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Step 06 or Neutralization:1. Add water in 1: 5 Liquor ratio 500 Lt2. Start machine running speed 12-15 rpm3. Add acetic acid to the liquor 1-2ml/lt 0.5-1Lt4. Continue the process 5 min5. Drop the liquor

Step 07 or Softening:1. Add water in 1:5 liquor ratio 500 Lt2. Start m/c running speed 12-15 rpm3. Add softener to the liquor 0.1 - 0.5% 100- 500gm4. Supply steam to raise the temp As required 40 to 60 c5. Continue the process 5 min6. Drop the liquor & unload the garments


Stone Wash

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• Enzyme wash is done on garments made from denim & jeans fabric, twill fabric

garments. Sometimes knit items are also subjected for Enzyme wash

• Garments made from indigo, vat, direct etc dyed fabric can be enzyme washed.

Reactive dyed garments can be washed also but wash effect not pronounced as

mentioned earlier.

• It produces frosty/ice effect on garment and seam abrasion across the seam.

• Enzyme works chemically not mechanically for this reason it provide less

damage/wastage then stone wash.

• It improves improve the color fastness & rubbing fastness.

• Enzyme improves the anti-pilling properties and decrease the hairiness hence it

gives a very smooth surface of the garments.

Enzyme wash

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Process:It follows the bellow mentioned steps.Suppose 100kg of garments in a lot size.

Step 01 or Desizing1. Load the garment in washing m/c 100kg garment2. Add water at 1:5 liquor ratio 500lt 3. Start m/c running Speed 15/12 rpm4. Add amylase enzyme 1-3% 1-3kg5. Add detergent/antistain to the liquor;1% i.e. 1kg6. Supply steam to raise temp. 60 c7. Continue the process 20 min8. Drop the liquor9. Hot wash with water temp 40-50c for 5 min.

Enzyme wash

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Step 02 Enzyme1. Add water at 1:5 liquor ratio 500lt 2. Start m/c running Speed 15/12 rpm3. Supply steam to raise temp. As required 55-60 C4. Add acetic acid 1-3% 1-3kg5. Add anti back staining 1% i.e. 1kg6. Add Acid Enzyme As required 1-3% i.e. 100-300gm7. Continue the process depending up on the effect 30-50 min8. Drop the liquor9. Hot wash with water temp 80-90c run 1-2 min. (for killing the enzyme).10. Drain the bath11. Rinse thoroughly

Enzyme wash

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Step 03 or Softening:1. Add water in 1:5 liquor ratio = 500 Lt2. Start m/c running = speed 12-15 rpm3. Add softener to the liquor 0.1 - 0.5% = 100- 500gm4. Supply steam to raise the temp = As required 40 to 60 c5. Continue the process = 5 min6. Drop the liquor & unload the garments


Note: Enzyme wash usually followed by bleaching; and it depends upon the

requirements of lightening the garments.

Enzyme wash

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• Enzyme wash with stone is done on garments made from denim & jeans fabric, twill fabric garments. Sometimes knit items are also subjected for Enzyme wash with stone

• Garments made from indigo, vat, direct etc dyed fabric can be Enzyme washed with stone. Reactive dyed garments can be washed also but wash effect not pronounced as mentioned earlier.

• It produces more frosty/ice effect on garment and seam abrasion across the seam than the enzyme wash.

• Enzyme works chemically and stone works mechanically for this reason it provide effect more quickly then enzyme wash.

• It improves improve the color fastness & rubbing fastness.• Enzyme improves the anti-pilling properties and decrease the hairiness where as

stone mechanically increase hairiness. On the other hand this process shortens the time. For this reason enzyme and stone amount should be used very carefully.

Enzyme wash with stone

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Process:It follows the bellow mentioned steps.Suppose 100kg of garments in a lot size.

Step 01 or Desizing1. Load the garment in washing m/c 100kg garment2. Add water at 1:5 liquor ratio 500lt 3. Start m/c running Speed 15/12 rpm4. Add amylase enzyme 1-3% 1-3kg5. Add detergent/antistain to the liquor; 1% i.e. 1kg6. Supply steam to raise temp. 60 c7. Continue the process 20 min8. Drop the liquor9. Hot wash with water temp 40-50c for 5 min.


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Step 02 Enzyme with stone1. Add water at 1:5 liquor ratio 500lt 2. Start m/c running Speed 15/12 rpm3. Supply steam to raise temp. As required 55-60 C4. Add acetic acid 1-3% 1-3kg5. Add anti back staining 1% i.e. 1kg6. Add Acid Enzyme As required 1-3% i.e. 100-300gm7. Add pumic stone ½ of volume of garments volume or as required

= 30kg to 50 kg 8. Continue the process depending up on the effect 30-50 min9. Drop the liquor10. Hot wash with water (for killing the enzyme) temp 80-90c run 1-2 min. 11. Drain the bath12. Rinse thoroughly


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Step 03 or Softening:1. Add water in 1:5 liquor ratio 500 Lt2. Start m/c running speed 12-15 rpm3. Add softener to the liquor 0.1 - 0.5% 100- 500gm4. Supply steam to raise the temp As required 40 to 60 c5. Continue the process 5-15 min6. Drop the liquor & unload the garments


Note: Enzyme wash usually done with bleaching; and it depends upon the

requirements of lightening the garments.


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• Cotton garments made from grey fabric are used for super white wash.• To obtain maximum whiteness effect on garments super white wash is performed.

Process: This process follow the below steps. Suppose a lot of 100 kg garments is produced.

Step 01 or Desizing 1. Load the garment in washing m/c 100kg garment2. Add water at 1:5 liquor ratio 500lt 3. Start m/c running Speed 15/12 rpm4. Add amylase enzyme 1-3% 1-3kg5. Add detergent/antistain to the liquor;1% i.e. 1kg6. Supply steam to raise temp. 60 c7. Continue the process 20 min8. Drop the liquor9. Hot wash with water temp 40-50c for 5 min.

Super White Wash

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Step 02 :1. Add water in 1:5 liquor ratio 500 Lt water2. Start m/c running with moderate speed 12-15 rpm3. Add detergent as 2% 2 kg4. Caustic soda as 10% 10 kg5. H2O2 as 12% 12 Lt6. Stabilizer as 5% 5 Lt7. Supply temp to raise temp 95 c8. Continue the process 75 min9. Drop the liquor.

Super White Wash

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Step 03 : (Refining Wash)1. Add water in 1:5 liquor ratio 500 Lt2. Start m/c with moderate speed 12-15 rpm 3. Add detergent as 2% 2 kg4. Caustic soda as 4% 4 kg5. H2O2 as 10% 10 Lt6. Stabilizer as 4% 4 Lt7. Raise temp by steam supply 95 C8. Continue the process 75 min9. Drop the liquor 10. Hot wash 50 C for 5 min.

Super White Wash

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Step 04: Neutral Wash1. Add water in 1:5 liquor ratio 500 Lt2. Start m/c with moderate speed 12-15 rpm3. Add A. acid as 1% 1 Lt4. Continue the process at R.T to 50 C 5 min5. Drop the liquor.

Step 05: Brightening Treatment1. Add water in 1:5 liquor ratio 500 Lt water2. Add FWA/FBA as required (considering 1%)1 kg 3. Supply steam to raise the temp 80 C4. Continue the process 10 min5. Drop the liquor.

Super White Wash

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Step 05: Softening1. Add water in 1:5 liquor ratio = 500 Lt2. Start m/c running = speed 12-15 rpm3. Add softener to the liquor 0.1 - 0.5% = 100- 500gm4. Supply steam to raise the temp = As required 40 to 60

c5. Continue the process = 5-15 min6. Drop the liquor & unload the garments


Note: white garments should be soften with non-ionic softener and dried in the

steam dryer. Otherwise a reddish tone will appear.

Super White Wash

It is the easiest, shortest and cheapest process as a result it is most popular wash.

1. Size material is removed partially

2. Dust, dirt, oil spot, impurities etc. are removed that may come from during

process i.e. cutting, stitching and the back process.

3. With the addition of softener the softness of the garments can be improved

as well as drape ability

4. All types of garment can be washed. Such as: woven and knit garments.

5. No significant fading effect can be achieved. But increasing processing time

and decreasing the liquor ratio we can pronounce the wash effect.

Note: white garments should be soften with non-ionic softener and dried in the

steam dryer. Otherwise a reddish tone will appear.

Normal Wash

Process:Suppose a lot size of 100kg garments:1. Load the garment in washing m/c 100kg of garment2. Add water at 1:5 liquor ratio 500lt3. Start m/c running Speed 15/12 rpm4. Add detergent to the liquor 0.3-1% i.e. 0.30-1.0kg5. Supply steam to raise temp. 40 c to 60 c6. If back staining is occur then use anti back staining chemicals to minimize such kind of problem 1-2% i.e. 1.0-2.0kg7. Run the process 5-20 min8. Drop the liquor9. Hot wash with minimum liquor 1:3 i.e. 300lt (its temp 40-60c)10. Add water at 1:5 liquor ratio 500lt11. Add softener to the liquor 0.1 to 0.5% i.e. 100gm to 500gm12. If back staining & bleeding then use anti back staining & fixing chemical

Anti back 1-2% i.e. 1-2kg, Fixing agent 0.5-1% i.e. 0.5-1kg

13. Supply steam to raise temp As required (40c to 60c)14. Continue the process for 2-15 min15. Drop the liquor16. Unload the garment17. Hydro extracts the garment.18. Dry it in a tumble dryer.

Normal Wash

We have to follow the bellow sequences:

1. Trial a sample batch (If back-staining occur)

2. Wash another sample batch with antiback-staining chemicals. (If back-staining occur)

3. Wash another sample batch without detergent (If back-staining occur)

4. Wash another sample batch without temperature (If back-staining occur)

5. Wash another sample batch without detergent & temperature and with antiback-staining agent after fixing with fixing chemicals (If back-staining occur).

6. Stop washing and inform customer.

How to solve Back-staining Problem During Normal Wash

It is also easiest, shortest and cheapest process as a result it is most popular wash like as

normal wash.

1. Pigment dyed/Pigment printed fabric used for making garment can be pigment

washed.

2. Size material is removed partially

3. Dust, dirt, oil spot, impurities etc. are removed that may come from during process

i.e. cutting, stitching and the back process.

4. With the addition of softener the softness of the garments can be improved as

well as drape ability. But as pigments harden the printed or dyed surface softener

need more in compare with normal wash.

5. All types of garment can be washed. Such as: woven knit garments.

6. Significant fading effect can be achieved. But we can achieve more wash effect by

increasing processing time and decreasing the liquor ratio.

Note: white garments should be soften with non-ionic softener and dried in the steam

dryer. Otherwise a reddish tone will appear.

Pigment Wash

Process:

Suppose a lot size of 100kg garments (woven)

Step 01 or Desizing:

1. Load the garment in washing m/c 100kg garment

2. Add water at 1:5 liquor ratio 500lt

3. Start m/c running Speed 15/12 rpm

4. Add amylase enzyme 1-3% i.e. 1-3kg

5. Add detergent/antistain to the liquor; 1% i.e. 1kg

6. Supply steam to raise temp. 60 c

7. Continue the process 20 min

8. Drop the liquor

9. Hot wash with water temp 40-50c for 5 min.

Silicon wash

Step 021. Add water at 1:5 liquor ratio 500lt2. Start m/c running Speed 15/12 rpm3. Add Silicon to the liquor 0.1 to 0.5% i.e. 100gm to 500gm4. Add softener to the liquor 0.1 to 0.5% i.e. 100gm to 500gm5. Supply steam to raise temp As required (40c to 60c)6. Continue the process for 10-15 min7. Drop the liquor8. Unload the garment

Step 031. Hydroextract the garments.2. Dry in the tumble dryer.

Incase of knit garments desizing step is not required but a wash for 5 minutes at room temperature is necessary.

Silicon wash

• Caustic wash generally doing on Reactive dye, Sulpher dye, Direct dyed or printed

Garments.

• If printed fabric is used for making garments then about 20-30% pigment is

washed out, as a result faded color effect is produced.

• Size material is removed partially but more then normal wash & pigment wash.

• Dust, dirt, oil spot, impurities etc. are removed that may come from during

process i.e. cutting, stitching and the back process.

• All types of garment can be washed. Such as: woven knit garments.

• Significant fading effect can be achieved. But we can achieve more wash effect by

increasing processing time and decreasing the liquor ratio.

• To improve the color fastness & rubbing fastness.

• To increase the hairiness on garments this increases its oldlook appearance.

Caustic wash

Process:

The washing procedure follows the bellow mentioned steps.

Supposed a lot size 100kg garments.

1. Load the garments in the washing m/c = 100kg garments.

2. Load the m/c with water at 1:5 liquor ratio= 500Lt water

3. Start m/c running with moderate speed =12-15 rpm

4. Add caustic soda to the liquor 4% =4kg

5. Add soda ash to the liquor 2% = 2 kg

6. Add detergent to the liquor 1% = 1 kg

7. Add H2O2 to the liquor 4% = 4 Lt

8. Add stabilizer to the liquor 2% = 2 Lt

9. Supply steam to raise the temp =70 c

10. Continue the process for achieving the desire shade = 60-90 min

11. Drop the liquor

12. Hot wash 50c to remove all unaccepted material for = 5 min

13. Drain the liquor

Caustic wash

14. Neutralization:

a. Add water in 1: 5 Liquor ratio = 500 Lt

b. Start machine running = speed 12-15 rpm

c. Add acetic acid to the liquor 1-2ml/lt =0.50- 1Lt

d. Continue the process =5 min

e. Drop the liquor

15. Add water at 1:5 liquor ratio = 500Lt

16. Run m/c running with moderate speed =12-15 rpm

17. Add softener as required 0.1 to 0.5% = 10-50gm

18. Continue the process at 40-50c = 5-10 min

19. Drop the liquor

20. Unload the garments.

21. Hydroextract & dry the garments with the tumble dryer.

Caustic wash

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