Masters of Fashion Management (2021 - 23)

National Institute of Fashion Technology, Kannur

Assignment 2

FASHION MATERIAL AND PRODUCTION

MANAGEMENT FOR MERCHANDISERS

Submitted to: Mrs Mukthy

Submitted by:
Pavithra - MFM/21/255
Prerna - MFM/21/292
Arathy - MFM/21/1060
Sanjana S - MFM/21/N941
Shraddha V. - MFM/21/343
Table of Introduction

Contents
Brief History

Types of washing

1. Wet washing
2. Dry washing

Chemicals of washing

Maintenance process of
the machine

Innovations in the field

Introduction
Garment washing is an important aspect of the garment
industry, and it is mostly used on denim and other casual
items. In the first stage, the garment does not inherit the
desired qualities of the client, but after washing, it
becomes the most generally used owing to its new look,
softness, comfort, strength, and low cost, which results in
the customer's complete pleasure. The chemical or wet
washing process and the mechanical or dry washing
process both present a profitable and rosy outlook for the
garment washing process.
Scraping, spraying, whiskering, damages,
spots, rubbing, and tacking are the most
commonly used dry washing processes for
garments, whereas wet washing processes
for garments to develop new a look and
effect are normal wash or rinse wash,
pigment wash, caustic wash, silicon wash,
enzyme wash, stone wash, stone enzyme
wash, bleach wash, and acid wash. This
research demonstrates the many types of
washing procedures and the changes in
physical and chemical qualities caused by
the use of wet and dry washing processes as
a means of imparting desired effects on
clothes.
The basic goals of clothing
washing are as follows:

To remove starch that was added during fabric

manufacture.
To soften the touch, feel of the garment and
increase bulkiness
To remove dirt, blotches, and oil stains that build
on garments throughout the manufacturing
process.
Remove chemicals used in the printing and
embroidery processes
Typically, garment washing entails cleaning filthy
clothing using soap or detergent. However, industrial
garment washing is a process that is used to change the
look, appearance, comfortability, and design of ready-
made clothes produced from solid color dyed or pigment
printed fabric. We cannot provide the correct look that
customers have requested in recent years unless we have
sufficient washing knowledge. Garment cleaning is a new
fad in Bangladesh, yet it has been practiced for 50 years.
Washing now involves introducing different hues, dry
procedures, dyeing, and a variety of other processes
based on the buyer's specifications.
The History of Laundry Begins
with Early Civilizations
The garment washing techniques were originally developed for
denim garments. The evolution of the jeans market led to the
development of some unique and creative methods for the
processing of denim garments. Originally, jeans were marketed
and sold as workwear, but when jeans were appreciated by
consumers as general casual wear, they became fashionable and
new techniques were developed to enhance denim garments.
The first generation of indigo jeans was stiff and uncomfortable
when first purchased, due to the finishing techniques used for
denim fabrics. The second generation of the jean’s market
evolution produced pre-washed jeans by the manufacturer.
These jeans had a slightly faded appearance and a softer hand
that felt comfortable.
Not long after the introduction of pre-washed jeans, the
idea of using abrasive stones to accelerate the aging
process was developed, and “stone washing” was born,
creating an even more “broken-in” look. Next, chlorine
bleach was incorporated into these wash techniques ice
washing was developed, in which the porous stones are
soaked in a bleaching agent and then tumbled with dry
or slightly damp garments.
These garment washing techniques were originally
developed for denim garments, but are now being used
for a wide variety of different garment types.
The first versions of the modern washing machine appeared in the nineteenth century. The portable mechanism
was straightforward: the machines had a tub base, paddles or rods, and a handle to spin the rods. Instead of
paddles, other variants used a revolving tub/drum. Both styles aimed to stir dirt away from materials. James King,
Hamilton Smith, and William Blackstone are among those attributed to the development of the first washing
machines. Blackstone is supposed to have invented the automatic washing machine as a gift to his wife. These
machines came with a mangle, a hand-operated wringer that eliminated the need to physically twist garments to
squeeze out all the water.
Types of Washing

Wet Washing Dry Washing

Chemical Process Mechanical Process
Wet Washing
Chemical Washing Process

Wet or chemical washing process is one of the most widely used

processes, which can be done by using various types of chemical
and garments loading washing machine. Water is used as a
solvent processing medium as well as a washing and rinsing
medium. A significant amount of water is required for the series of
operations at each stage.
Flowchart of
Wet Washing Process
01
Singeing
The process by which the
protruding fibers are
removed from the fabrics by
burning / heat to increase
the smoothness of the fabric
is called singeing.
02 03 04
Desizing Scouring Souring
The process by which the The process by which the The process by which
natural impurities (oil, the alkali is removed
sizing materials (starch)
wax, fat etc) and from the scoured
are removed from the
fabric is known as added/external/impurities fabric with dilute acid
desizing. This must be (dirt, dust etc) are solution is known as
done before printing. removed from the fabric is souring.
called scouring.
05 06
Bleaching Mercerizing
The process of removing The process by which the
the natural colors cellulosic
(nitrogenous substance) materials/substance are
treated with highly conc.
from the fabric to make
NaOH to enhance various
the fabric pure and
properties such as increase
permanent white is in dye affinity, chemical
known as bleaching. reactivity, dimensional
stability, tensile strength,
luster and fabric
smoothness is known as
mercerizing.
07 08
Dyeing Printing
A process of coloring A process for producing a
fibers, yarns, or fabrics pattern on yarns, warp,
with either natural or fabric, or carpet by any of
synthetic dyes. Dyeing is a large number of
the most important printing methods. The
coloration process of color or other treating
textile. material, usually in the
form of a paste, is
deposited onto the fabric
which is then usually
treated with steam, heat,
or chemicals for fixation.
Methods of
Wet Washing Process
Normal wash or rinse wash
Pigment wash
Caustic wash
Silicon wash
Stone wash
Bleach wash
Enzyme wash
Stone enzyme wash
Acid wash
Normal Wash

Normal washing is the most common, easiest, and

most widely used washing method, with the lowest
washing cost. It is almost mandatory for all buyers.
Some unwanted materials, such as dirt, dust, and
starch, are removed without shrinkage during the
normal wash manufacturing process.
The washing effect on the surface of the garments
can be varied by varying the temperature, time, and
detergent quantity. Normal washing is also known by
other names such as detergent wash, common wash,
and rinse wash.
Pigment Wash Caustic wash

The pigment washing effect is created by pigment Caustic washing is typically performed on reactive dye,

dyed or printed garments using the pigment sulpher dye, direct dyed, or printed garments, and these

washing method. This procedure is similar to regular fabrics are used to manufacture apparel. This washing

washing. The goal is to create a fading or aged process differs slightly from the previous one. Printing

appearance on the garment as well as the seam area. on fabric is typically done after some pre-treatment

Wear the garment after purchasing it for a soft feel. such as desizing, scouring, and bleaching.

Silicon Wash Stone Wash

Silicon wash is the most common and widely used Stonewashing is the process of using stone to create

washing method. It can be used on almost any type fading and discolouration effects on the surfaces of

of fabric, including knit, denim, canvas, and twill. This garments. Heavy fabrics are washed to give them an

washing process increases the softness and elasticity aged and worn-out appearance. Changing the amount

of the hand. Silicon and softener are used together in of liquor ratio, stone size and shape, cycle time,

the silicon washing process. chemical addition, and garment load can produce a
variety of washing effects.
Machineries of
Wet Washing Processes
Gas Flame Singeing Machine
Singeing is carried out rarely on knitted fabrics
and frequently on yarns and woven fabrics.
Instead of the traditional singeing process, it is
possible to apply an enzymatic treatment (for
cotton and lyocell fabrics). The process by which
the projecting or floating or hairy fibres that
stand out on the fabric surface are burnt off,
which is called singeing.
Objects of Singeing Machine
To remove hairy fibres projecting on the
surface of the cloth and to smooth the
surface.
Optical levelness of the dyeing and clean-out
lines of a printing design.
To increase lustre in the finished fabric.
To prepare the fabric for the next process.
Working Procedure Of Gas Flame Singeing

In the gas singeing machine, both sides of the fabric

can be singed at the same time.
Normally two-burners are used for both sides singed.
In this machine, the fabrics are passed through some
guide roller over the gas burner in open width as
shown in the figure.

The length of the burner can be adjusted according to

the width of the fabric. The fabric passes over the
burner at the speed of 200-400 yard/min.
When the fabric passes over the burner, it burns the
projecting fibre from the surface of the fabric.
The brush is used for brushing both sides of the fabric.

After singeing, the fabric is immersed in the water or

desizing tank to prepare the next process.
Advantages Disadvantages

Uniform temperature ensures proper A dirty burner can produce a spot on the fabric.
singeing. The process is not suitable for synthetic fabric.
Both sides of the fabric can be singed. Due to inconsistent fabric speed, it may be burnt.
As the process is continuous, there is no
hamper in the production.
All sparks can be easily removed.
The fabric in inter-stitches of warp and
weft are singed.
Machineries of
Wet Washing Processes
Kier Boiling Machine

Kier boiling is a scouring process for cotton wool in addition to linen inwards which the fibers are treated for
removal of impurities past times boiling amongst a 1% solution of caustic soda. Its principal role is to take
away most of the natural impurities such as every bit of wax, and woods fragments in addition to crude stains.

Kier boiling physical care for of cotton wool is performed inwards a kier boiler in addition to the stuff is
scoured inwards rope shape past times alkali liquor. Kier is a large cylindrical atomic divulge 26 vessel. The kier
may last opened upward 1 every bit unopen 1 in addition to horizontal or vertical.

Kier Capacity: 200 kg – 5000 kg but industrially 2000 kg kiering is rattling popular.
Characteristics of Kier Boiler

Heating is done past times using high-

pressure level steam, generated inwards an
independent boiler instead of heating past
times straight boiler.
Improvement inwards the treatment of the
goods past times the usage of automatic
pilling device.
Improvement of the circulation of kier liquor
through the stuff past times the usage of the
powerful pump.
Use of high pressure level kier shorten the
duration of boiling off in addition to thence
saves the damage of the steam, ability etc.
Working Procedure Of Kier Boiling

Kier boiler is provided with 2 tubes. One is at the bottom in

addition to to a greater extent than or less the other is top.
There is 1 manhole for loading in addition to unloading of the
sample.
The preheater is besides provided in the middle of these 2 tubes.
The liquor is prepared into the mixing tank past times to higher
house chemicals in addition to so it brought into the preheater in
addition to heated past times the steam.
The stuff is loaded inwards the machine past times human being
hole in addition to kept inwards rope form.
Then the hot liquor is pumped in addition to sprayed past times
spader plate onto the stuff which is packed into the kier.
The temperature of the liquor is almost 100 oC in addition to
boiling for 8 hrs. the excess liquor passes slowly over the packed
cloth in addition to percolating through the faux bottom of the
kier.
Then this excess liquor is collect at the bottom of the kier in
addition to being pumped into the auxiliary heater past times a
centrifugal heart in addition to this cycle is repeated.
After scouring, the stuff is washed amongst lxxx oC H2O
otherwise impurities on the stuff would non last removed.
Advantages

Material scoured well.

Remove most of the natural color in
addition to to a greater extent than or less
other adventitious.

Disadvantages

Failure of pressure level gauge, boiler

may last brust.
Machineries of
Wet Washing Processes
J-Box Machine/Continuous Scouring Process

The scouring vessel looks like the English letter ‘J’ hence;
this process is called the J-Box process. In this process
desizing, scouring and bleaching operations can be done
at a time. This process is also known as Scouring in J-Box.

Caustic soda solution from J-Box is maintained and this

solution is placed in the fabric. The temperature here is
approximately 100 ° C. NaOH responds with and removes
the impurities in the fabric in J-Box.
Working Procedure Of Continuous Scouring Process

The scouring process in J-Box can be divided into four units. They
are:
1. Saturation.
2. Pre-heater.
3. J-Box.
4. Washing unit

Saturation: Saturation is prepared by the above recipe without

caustic soda in the saturation. Then the fabric is passed through
the guide roller and immersed in the solution. Here the
temperature is about 0-80ºC.
Pre-heater: In pre-heater, the materials are passed at a
temperature of 110-120ºC and then passed to the J-Box.
J-Box: In the J-Box solution of caustic soda is kept and the fabric is
stored in this solution. Here the temperature is about 100ºC. In J-
Box, NaOH reacts with the impurities present in the fabric and is
finally removed.
Washing unit: The water-soluble impurities or products left on the
materials are removed here. First the material are washed in hot
water and then cold water and finally dried.
Advantages

This process is continuous process, so it is

consumes less time.
This process is more economical.
Desizing, scouring, bleaching operation
can be done at a time.

Disadvantages

The result is not as good as compared to kier.

Machineries of
Wet Washing Processes
Padding Mangle

The padding mangle essentially consists of a small trough containing the liquor and a set of squeezing
bowls. "The cloth is passed in full width through the liquor in the trough and the excess solution is removed
by passing it through the squeezing bowls; thus, the mangle effects impregnation of the liquor and
squeezes out excess liquor. Huge quantities of cloth are to be dyed in light or medium shades, in a
continuous manner, padding mangles are best suited for many purposes. It produces dyeing cheaper than
those produced on Jigger or Winch machine and it can process up to 200 m of cloth per minute

Advantage: The m:l ratio used the lowest therefore, there is a saving in the consumption of water, steam
and chemicals.
Percent Expression

This term is used in relation to padding mangles only. The amount of liquor left in the cloth after
padding is measured in terms of percent expression.

For example:

A batch of cloth weighing mangle 50 kg is padded with an expression of 80%, which means that - 40
kg of the liquor (80% of 50kg) is left on the cloth (or is retained by the cloth) after padding and the
cloth will thus weigh 50 + 40 = 90 kg of the percent expression is 100% it means that 50 kg of the liquor
will be left on the cloth after padding i.e. more than what was left earlier?

Thus if more liquor is squeezed out by increasing the pressure on the squeezing bowls, it will leave a
lesser quantity of liquor on the cloth i.e. the percent expression will be lower. Usually, the percent
expression varies from 60 to 80.

The rate at which the fabric takes up the liquor should be uniform and the trough should be
replenished from time to time to maintain the liquor level constant otherwise the take-up decrease
results in a tailing effect. At the end of the padding operation, the liquor left in the padding mangle
has to be thrown out and is thus wasted.
Machineries of
Wet Washing Processes
Beam Dyeing Machine

The beam dyeing machine is suited to process a wide range of knitted and woven textiles. The fabric in
open width is rolled onto a perforated beam, then subsequently loaded into a vessel that is closed and
pressurized. The dye impregnates the fabric as the dye liquor is allowed to go on circulating through the
perforations (holes) in the beam. Usually, the beam dyeing machines are designed to hold a single beam.
The fabric is placed under controlled tension and is wound onto a perforated beam. This results in the
elimination of creases on the fabric.

The fabric is restricted to non-movement during the dyeing process. This means that there is no
mechanical application of action to the fabric, the actual dyeing process is motionless. The fabric remains
stationary in the vessel as the pressure of the pump forces the dye liquor through the fabric roll.
Features of Beam Dyeing Machine

Able to adjust water level in accordance with fabric volume.

Even dyeing and superior dyeing quality.
Optimized circulation system along with high performance pumps.

Advantages

The fabric is put under controlled tension and is wound onto a perforated
beam. This consequence is the removal of creases from the fabric. It as
well ensures total management of dimensions of the roll of fabric.

The fabric is held in an attached position during the procedure of dying.

This means that there is no application of mechanical action onto the
fabric. As revealed in the figure, there is no movement of the fabric as the
hydrostatic pressure of the pump forces the dye liquor throughout the
fabric roll.
Machineries of
Wet Washing Processes
Hank Dyeing Machine

Hank dyeing machines are mostly used for dyeing patterned wool carpets. There are mainly four types of
Hank Dyeing machines used. They are the following, single stick Hussong-Type Machines the double-stick
machine, double-stick cabinet machine, and lastly circular carrier machine. Out of this four, the first
category of Hussong-Type Machines is the most popular one.

In the Hussong type machines hanks needs to be hung on removable sticks, from the underside of the
dyeing vessel lid. The lid is then vertically lowered onto the dyeing vessel. The dyeing vessel consists of a
simple box that has a perforated false bottom. A reversible impeller, that is placed vertically in a weir
chamber at one corner of the machine is used for circulating liquor. Heat is generated by closed steam coils
located beneath the false bottom. While on the smaller machines heat is generated by live steam injection.
Features of Hank Dyeing Machine

Temperature control is done by electro-mechanical or programmable logic

controllers.
Machine capacities can range from 10 kg sample machines -1 ton
machines.
Yarn loads up to 4000 kg can be dyed by coupling together of machines.
Typical liquor ratios are 1:15 to 1:25.

Advantages

Elimination of hank reeling.

Waste is less.
Less number of labour.
More controlled dyeing with better levelness and fastness.
A lower liquor ratio causes savings in water, effluent, energy, dyes and
chemicals.
Back winding is faster.

Larger control over the process makes automation easier.

Lesser floor space.
Drying
 Textile Drying
The liquid fraction of a solution (moisture content) is removed from
the fabric during the drying process. This is done after the fabric has
been de-watered. The water disseminated in a textile material
through a chemical–physical process is usually removed by heated
air, which causes the water to evaporate. The dryer is used in the
textile finishing unit to dry knit, woven fabrics, and coloured yarn.
However, the drying method and mechanism for yarn and fabrics
change from one to the next. Textile drying machines are used to
complete the drying process. It's critical to pay attention to how heat
is directed on the fabric during the drying process.
Methods of
Drying Process
1. Heating
2. Blowing dry air on the materials
3. Centrifuging and throwing the moisture out
4. Using radio frequency (RF) waves
5. Using vacuum
6. Exposing to open sunlight and air and so on
 Drying Techniques

Mechanical and thermal drying procedures are two types of drying methods.
Mechanical techniques are commonly employed to remove water that has been
mechanically attached to the fibre. This is done to increase the efficiency of the next
phase. The term "thermal process" refers to the process of heating water and
converting it to steam. Convection, infrared radiation, direct touch, and RF can all be
used to transport heat.

16
Typical
Drying Systems
Before evaporative drying, the water content of the fibre is first lowered by centrifugal
extraction. Dry or hot moving air is used for evaporative drying.
Centrifugal extraction is used to lower the water content in hanks, followed by
evaporative drying.
After wet processing, cheeses are usually dried by centrifugal extraction followed by
radio frequency drying (RFD).
Drying cylinders are commonly used to dry yarn sheets after they have been dried. In
some circumstances, it is used in conjunction with hot air or infrared drying.
Fabric drying in rope form is accomplished by squeezing the fabric with a mangle and
then blowing hot dry air.
After initial squeezing by mangles, the fabric in open width is dried using a chain of
drying cylinders or hot air drying.
Textile Dryer
A textile dryer is a device or equipment that is used to
remove moisture from fabrics or clothes. The dryer, in a
technical sense, is equipped with a motorised centring and
tensioning system for individual conveyors.

Following points should consider during buy a dryer.

1.Heating methods: The textile fabrics may be heated by gas

burner or steam.
2.Chamber: Number of chamber.
3.Burner: Number of burner.
 Types of Dryer Machine Used in
Textile Industry

1. Textile centrifugal extractors or hydroextractors

2. Mangling
3. Cylinder dryer
4. Hot air drying system
5. Yarn package dryer
6. Radio Frequency Drying (RFD)
7. Hydroextraction by suction
8. Stenter
9. Relax dryers
Working Principle of Dryer

After de-watering then the fabric through the dryer. The main function of the textile drying machine is given
below,

To dry the fabric.

To increase the GSM by over feed system.
To control the overfeed system.
To control the vibration which increase the G.S.M.
To control the shade matching such as for white shade if need few yellowish or reddish increase
temperature and low speed. If need few red or yellow increase temperature and low speed.
 Passage Diagram of The fabric in Dryer Machine.

There are two chambers in this machine. Conveyor net and filter net are two mesh unending conveyors that run
lengthwise through the chamber. Each chamber has a burner that supplies hot air. A suction fan transports this hot
air through the ducting system. Between the filter net and the conveyor net are nozzles. Hot air is delivered to the
wet cloth as it passes through the conveyor net, allowing it to dry. There are exhaust fans that remove the moist air
and discharge it into the atmosphere via the ducting system.
 Schematic diagram of dryer with fabric path

The speed of the dryer is determined by the machine's temperature and the fabric's G.S.M. When the machine
temperature is high, the speed is high, and when the machine temperature is low, the speed is low. The machine
vibrates at 730 m/min for heavy fabric and 480 m/min for normal cloth.
The temperature of different chambers according to the shade of the fabric:

Shade Chamber-1 Chamber-2

Light 120oC 130oC

Medium 135oC 140oC

Deep 150oC 170oC

Operating
Parameters
1. Temperature: Set the temperature between 120oC
-130oC for white and 150oC -170oC for color fabric.
(GSM temperature or moisture content
temperature).
2. GSM: Set the over feed up to 10~20% or as required
to get finish G.S.M.
3. Speed: Set the speed as much as possible
(6~20m/min).
Special
Features
1. Steam dryer (two chambers ).
2. Vibration occur in heating zone.
3. Process air pressure switch present.
4. Maximum temperature increase up to 170oC .
5. Steam control switch present.
6. Two burners present.
7. Two conveyor belt is present.
 Steps in
Dry washing
1.Inspection and tagging
The item is taken to the nearest dry cleaner and the dry cleaner puts a tag on the item. This is also done again
when clothes are examined for any stains, missing buttons, tears, etc. and all the things are mentioned on the tag
that needs to be sorted.

2. Pre-spotting
Once dropped off the garments, the cleaners typically go through a pre-spotting process where there will be an
application of a chemical solvent. Then by the process of vacuum cleaning, or heating the stains on garments are
removed and it is a major step of dry cleaning.
3. The dry cleaning proces
This part of dry cleaning is less known to the people. Once clothes have been pre-spotted, they are placed into a
machine, and submerged into a non-water based solvent. The clothes are then rotated in a perforated cylinder,
having tiny holes where the solvent for cleaning is pumped out in a steady amount throughout the entire process.
From there, the bucket in the machine swiftly spins the clothes to get rid of any excess solvent and releases warm
air. Then the clothes emerge completely dry.

4. Post-spotting
Here dry cleaner will inspect the clothes for any remaining stains or residue and remove them using the same
procedure he did in the pre-spotting stage.
5. Finishing
After the clothes have gone through the complete procedure of dry cleaning, they are gone through the process of
steam ironing.
Dry Cleaning is very beneficial for garments made from fibers that don’t react well when exposed to water, like silk
sarees, woolen sweaters. It’s also good for the clothes that shouldn’t be exposed to the heat of a traditional dryer for
an extended period of time.
While the Dry Cleaning process can seem a bit complex, all in all, it’s not as complex as it seems .
 Advantages & Disadvantages
It dries sooner, especially in humid Dryers wear things out faster. Stuff can shrink, stretch, or abrade. That

conditions. stuff in the lint trap means your clothes are wearing out a little more.

The tumble action leaves the clothes and Heat from the dryer can set some stains.

especially towels softer than hanging. It's an added cost to own and maintain a dryer and for the energy to

The relatively faster and hotter dry cycle run one. In a public or shared facility, it's an added fee per load. The

can help keep laundry from smelling sour dryer itself also takes up space.

or musty. The dryer makes noise while it runs.

The dryer and the washer may have different, incompatible cycle
Laundry hung up, folded, or laid flat
times. In a shared facility, it's one more resource to compete for.
straight out of the dryer can often be worn
The heat source can be a fire hazard, especially if lint is left to collect
without ironing.
nearby.
The tumble action can shake out dust.
It's an additional action, often stooped or hunched over, to move
There's no need to carry wet laundry back
laundry in and out of a dryer.
from a laundry room or laundromat.
If you don't remove clothes promptly when the dry cycle finishes, they
will tend to set wrinkles.
Parameters Used For
Different Constructed
Fabric

COTTON
Parameters Used For Different Constructed Fabric
POLYESTER

Note: For Polyamide, the

temperature range is 110°C to
115°C. Speeds range from 16 to 18
mph, with a 5% overfeed margin.
The data varies depending on the
Gray GSM and Finished GSM, as
well as the fabric's diameter. All of
these values are appropriate for
G.S.M ranges 140–160 in order to
achieve a finished G.S.M 170–185
without Lycra Fabric.
Extra Considerations

• If fabric is more redder than the standard one, then

reduce the temperature.
• If fabric is more Yellower than the standard one,
then increase the temperature.
• If fabric is more Bluer than the standard one, then
increase the temperature.
• All this data’s are practiced in mills which may
varied factory to factory.
 Chemicals inWashing
Enzyme

The action of the enzyme during enzyme wash it hydrolysis the

cellulose. At first it attacks the having projecting fibers and hydrolyzed
them. Then it attacks the yarn portion inside fabric and party
hydrolyzed the yarn portion. As a result, color comes out from the
yarn portion and faded affect is produced.

Detergent

Chemical character is fatty alcohol polyglycol ether in an

aqueous, glycolic solution. Detergent is widely applicable in
the continuous and discontinuous pretreatment of all types
of fiber and their blends. To remove impurities, mineral oil
contamination and sizes from the garments.
Acetic Acid ( CH3-COOH)

Acetic Acid is used to neutralize the garments from alkaline condition

and to control the pH value in wash bath.

Antistain

Antistain is used to prevent the staining on weft yarn of the

denim (white yarn), white pockets of garment, levels, and
contacted fabrics of garment and increased the brightness
of fabrics; it is also acts as anti-creasing agent.

Sodium Hyposulphite
Sodium hyposulphite is used to neutralize the garments from
chlorine bleach.
 Bleaching Powder
Bleaching powder is an oxidizing agent. It is used in washing
plant for color out from the denim garments. We can achieve
deferent shade of color on garment (Dark, medium, light
shade).

Caustic Soda

Caustic created the role in bleach technique without color change the
garment and has a good cleaning power. It is work as fading affect or old
looking affect come rapidly on garments.

Sodium Bicarbonate
Sodium bicarbonate is used in washing plant in the bleach
bath with bleaching powder for denim light shade because
easily color out with in shot time. As a result, production
increase and costing is low.
Soda Ash

Soda ash creates alkaline medium for the breakdown of pigment

dye. Soda ash help to uniform bleaching action on bleach bath. It
has a cleaning power and help color fading effect of garment. It is
used also for color fixing in dye bath.

Potassium Permanganate
Potassium permanganate is used in acid wash with
pumice stone for color out from the garments. It is used
also spray chamber by nozzle for color out (whitish
affect) from the garments.
Flax Softener (Cationic, Nonionic)

Softener is used to make the garments treated textiles a surface

feel that is both sickly and soft and also provides excellent
lubricating properties. Flax softener (cationic or nonionic) diluted
with hot water then use in the machine.

Micro Emulsion Silicon

Amino Silicon is a textile finishing agent consisting
mainly of amino modified silicon. When applied on
fabrics, it gives durable softness, lubricity, elastic handle,
anti-pilling, dimensional stability, tear resistance and
fabric to be cut and sewn more easily allows and
improving wear and easy care properties.
Resin

Resin is high efficiency textile resin based on etherified dimethylol

glyoxalin monoureine urea. Resin is used for the creation of semi-
permanent creases in denim and other cellulose fabrics. It is used
also cotton and polyester fabric. Fabric retains soft handle after
washing.

Sodium Chloride
It helps to exhaust dye in to the fiber.

Buffer
Buffer is used in washing plant for pH control of enzyme bath,
softener bath, desizing bath.
Hydrogen Peroxide

Hydrogen peroxide creates the prime role in bleach wash

technique. In alkaline medium, hydrogen peroxide breaks up and
gives some perhydroxhyl ion, which discolor the coloring materials
and as a result fading affect is developed. Hydrogen peroxide is
used in scouring, bleaching bath for white or ready for dyeing of
gray fabric garments. It is used also neutralized the garment from
alkaline condition.

Stabilizer
Hydrogen peroxide is work a good condition at temperature
above 90°c, when temperature raise to 90°c then break the
hydrogen peroxide. Stabilizer is used to protect break the
hydrogen peroxide and peroxide works in bath smoothly.
Fixing Agent

Fixing agent is used for unfixed dye to fix on fabrics, when fabric color will
be proper fixing then color fastness and rubbing fastness will be
increased.

Catanizer
Catanizer is used in pigment exhaust method processing.
Pigment is color not dyestuff. Pigment colors have no affinity
to fabric when catanizer is used in fabric then increase the
affinity between pigment color and fabrics.

Optical Brightness

Two types of optical brightener are used in the washing plant, red
brightener and blue brightener. Mainly optical brightener is used for
improve the brightness of garments.
 Sodium Metabisulphite
Sodium metabisulphite: Sodium metabisulphite is used in the
washing plant to neutralize the garment from potassium
permanganate.

Desizing Agent

Desizing agent is used to remove mainly starches, cmc, waxes, fats

pectin’s, minerals and unfixed indigo dye from denim, twills, poplin and
canvas fabrics.
Maintenance
Maintenance is a process that allows us to keep active
functioning in operation based on the behavior and
usability of a certain piece. Machines, buildings, and other
facilities deteriorate over time as a result of their use and
exposure to the elements. If left uncontrolled, the
deterioration process will eventually render these service
facilities unusable and bring them to a halt. As a result,
the industry has no choice but to attend to them from
time to time to repair and recondition them to extend
their life as far as is economically and physically viable.
Cleanliness is a basic factor
in maintenance
When it comes to maintenance, cleanliness is the
first and most crucial consideration. This means
that you must keep your dryers and washing
machines, as well as the rest of your equipment,
clean at all times. There are a few aspects of each
machine to which special attention should be
given.
For example, with washing machines, it's critical
to clean the door seals every day to ensure they're
waterproof and prevent leaks, as well as the water
inlet filters on a regular basis to ensure proper
flow and avoid filling the drum taking longer.
Regular cleaning will also avoid blockage and mould
formation in machines with a manual soap drawer.
For dryers, the lint filters must be cleaned frequently, as
should all the outlet pipes and the blades of the turbines.
The latter is also true for ironers, as it ensures a better air
current and therefore gives a shorter drying cycle and
less accumulation of dampness.
It is also advisable to keep the area around any machine
clean and clear, to avoid sources of dampness and dirt
building up, as in the long term these can cause rusting
of electronic components, unprotected metal parts, and
so on.
Safety as a risk prevention factor
When it comes to maintenance, it's also important
to keep safety in mind. In this regard, the parts and
features of the machines must be checked on a
regular basis to ensure that they are in good
functioning order and that they are ready or
working to ensure the safety of the operators or
users who use them. This means that the
emergency stop and safe door opening on dryers
and washing machines must be checked at least
once a week. When it comes to ironers, daily safety
checks include inspecting the handguards.
By maintaining equipment and machinery well,
industries can consistently deliver effective outputs. In
this way, we can achieve plant safety, optimum efficiency,
time-saving in different processes, and long-term savings
in cost and commitments. Industries that carry out a
good follow-up on maintenance always attract the
customer by full utilization of machines as well as
housekeeping.
Mainly, there are two kinds of machine maintenance in
the textile industry;
Schedule/Planned/Routine Maintenance and
Breakdown/Immediate Maintenance
 Schedule/Planned/ Breakdown/Immediate
Routine Maintenance Maintenance

Scheduled Maintenance is planned Maintenance. This is the daily breakdown service of the machine,

The plan is based on the time duration and working which occurs during work. This may be of any nature –
hours of the machine. This Maintenance reduces
Major or Minor. This could be attended by a qualified
the frequency of breakdown maintenance and this
technician only. In this category minor problem occurs
is an excellent method to keep machines in healthy
often I.e. skip stitch, loose stitch, thread breakage,
condition. If machines would be in healthy
needle breakages, etc.
condition automatically the productivity increases
and this improves the quality of products also.
The benefits of preventive
maintenance for your laundry
equipment.
Keeps laundry equipment running at top
performance & extends the life of the machines.
Saves the utility and labor costs.
Identifies the problem and prevents it from
becoming serious.
Maintenance reduces the possibility of dryer
fires.
Decreases drying time – increase production
time.
Reduces costly downtime.
 Innovations
Types of Enzymes Applications
New technique’s on base of chemical use:
1. Enzyme Wash : Enzymes are proteins, found in all
Desizing
Amylase (Removing Starch) living organisms, plants, as well as animals and
microorganism. All organisms produce a wide range
Breaks and
Cellulase removes fibres of enzymes. Enzyme washing is ecologically friendly
due to the natural origins of enzymes Enzymes
Laccase Bio-Bleaching
basically catalyze specific chemical reactions and are
Catalase Anti-Peroxide known as 'bio-catalysts'. Enzymes act on living cells
Wool Treatment and can be work at atmospheric pressure and in mild
Proteases and degumming of
temp and pH.
raw silk
a) Powder form (Novozymes)
b) Liquid form i.e.SL Enzyme.
2. Spray: Potassium permanganate spray is done
on jeans to take a bright effect on sandblast area.
One important thing about potassium
permanganate spray is this is usually a sporting
process to increase the effect of sandblast.
Potassium permanganate solution is sprayed on
blasted area of jeans garment with the help of
normal spray gun. This potassium permanganate
spray appears pink on garment when fresh and
turns to muddy brown on drying.
3. Ozone Fading: In this technique of denim washing, the
garment is bleached with ozone dissolved in water in a
washing machine. However this technique can also be
carried out in a closed chamber by using ozone gas. i.
There is minimum loss of strength. ii. It is a simple
method and environmentally friendly. The ozonized water
after laundering can easily be deozonized by UV radiation.
iii. In the presence of UV light, there is an interaction
between the hydrocarbons, oxides of nitrogen and
oxygen that causes release of ozone. iv. Indigo dyestuff
tends to fade or turn yellow due to ozone reaction
Other Innovations

1. Upgradation of machinery with the

development of technology
2. High Pressure Cleaning
3. Reduce, Reuse Recycle- The waste water
management system
4. Management and Mobility Solutions
 Thank You For Attention

Arathy Padmakumar
Pavithra Sridhar
Prerna
Sanjana Santhosh
Shraddha Virmani