RAW MATERIAL/ BLOW ROOM
The process starts with cotton before yarn is even in the picture. Various cotton varieties from around the world and Turkey are available, these varieties are blended according to a special blend recipe in an attempt to acquire raw material that meets specific properties. The aim to use quality cotton and process it to yield high quality yarn.
Once blended cotton arrives at factory, there are certain tests that needs to be performed in order to determine whether the product is really, what we expected it to be?, these tests are done to execute an input control before the process begins.
Once the tests are completed cotton can enter the process where the cleaning and blending has been done, for this the bales has been stacked in blow room unit and certain procedures are performed to thoroughly remove stems dirt and dust that occurs naturally in the cotton plant. We focus in achieving sustainable homogeneous quality and optimum performance in our production.
By the time the mixing fluffing phase is finished. The cotton is completely free of foreign matter like dirt and dust and is ready to be spun into yarn, which begins at the combing machines. combing machines create cotton sliver before additional cleaning to remove the nets cotton as well as the remaining dirt and dust.
Subsequently, in the drawing frame process the slivers from different combing machines are joined to form a homogeneous mix and eliminate irregularities. After the drawing process, an interim step is achieved in which the roving machine thin out the strip so it can be fed into the spinning machine.
eventually, this raw material reaches the ring spinning machine, which is the final stage of spinning the production of yarn by giving twist and draw/ draft. Afterward, forming of yarn into bobbins has been accomplished , for use in subsequent process.
The Indigo unit where we give denim its legendary color , yarn in processed in the form of ball 12/ 24 7 36 ropes at Rope Dyeing Machine. At first pretreatment is done for dyeing the yarn in different colors ranging from very light to very dark shades. various dyes substance groups on the bottom and topping can also be done. It is the crucial aspect of indigo for darkness and lightness of the color, and this is made possible by increasing or decreasing the number of vats/ dye boxes.
once the dyeing process is complete, the semi finished product in rope form is redeemed before being transferred to the sizing beam.
Below link mention complete process for sustainable dyeing.
https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html
warp yarn is prepared in Re-beaming processes before arriving in for sizing, this is where yarn is prepared for the subsequent stage. Which is weaving, unwound warp yarn arrives here on unwinding beams to be coated with chemicals prepared at optimum process conditions. special chemicals are used to increase the resistance of warp yarn against mechanical strain in the weaving stage. In the next stage warp yarn is wound on the weaving beam and stored for subsequent process in weaving.
It is a process in which warp and weft yarn are interlaced at right angles to form a fabric. The weaving process depends on three basic motions. First is shedding this is the stage where warp yarn is grouped in preparation for the weft insertion process. Second comes weft insertion, this stage involves inserting weft inside the shed. The third motion is Beat up and this is when the weft that has been inserted into the shed is compressed.
The finishing unit is where we improve the properties hand feel and appearance of the fabric product by means of physical and chemical processes. Our job consists of three main processes Pre-finishing, Coloring and Finishing.
Pre- finishing involves brushing and singeing. Coloring involves dyeing and coating. The finishing phase is where the fabric is given its final properties, this is what defines the fabrics hand feel properties.
At the quality control department we perform our work with three main control mechanisms are developed. Physical tests, Visual inspection and Shade assessment. Test are done based on the specifications desired by the customer. This link offers the same in depth:
https://bindaprocess.blogspot.com/2022/02/denim-fabric-stucture-application.html
For maximum yeild and great results, engineering automation in current line may be made, below link specify the same in detail:
https://bindaprocess.blogspot.com/2022/02/denim-rope-dyeing-automation-2022.html
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