Denim Production Process

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.

SPINNING

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.

Processing

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

SIZING

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.

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.

FINISHING 

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.

QC 

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
 

Textile Sustainable Denim Dyeing

 

Advanced Denim for more Sustainable
Denim Colors and Effects 

Almost 2 billion pairs of jeans are manufactured every year, no item of clothing is more popular then the  starting material is cotton. which passes through numerous processing steps from the cotton field to the finished thread in the textile factory.

The raw cotton is fluffed up cleaned and the single fibers are pressed into loose strands before being spun into yarn.

Since the gold digger era the yarn for jeans has been dyed blue with indigo. With advanced denim ,  now a days a more eco-friendly era of traditional dyeing, in which indigo requires the use of long production lines. Some stretching to more than half a mile in length.

These machines consume enormous amounts of water and energy. Moreover when the color is changed most batches create large amounts of cotton waste, because of the metre dispose off, all the fibres still inside the machine.

After spinning up to 4500 cotton threads of simultaneously pre wedded, decreased with chemicals and cleaned in several preparation lines, now the actual dyeing process begins with an average of 10 % immersed in the first indigo dyeing box.

Indigo in its natural agglomerate state is not soluble in water and in this state cannot penetrate into the fiber material. The molecules have to be separated to make them water-soluble. This is done by reduction of the double bonded oxygen in this reduction process.

The strong reducing agent sodium hydrosulfide causes the indigo to take up negative charges. The molecules repel each other making the indigo soluble in water.

In this process indigo loses its the resulting finely dispersed indigo molecules can L settle on the top layer of the cotton fiber the yarn fibers are then exposed to atmospheric oxygen which removes the negative charges from the indigo molecule causing the oxidant groups to return to the original form in other words they are oxidized the indigo.

molecules turn blue again the dye is no longer water-soluble and adheres to the fiber for intensive and uniform dyeing the cotton has to pass through 6 to 15 consecutive dyeing that's because the fiber absorbs the indigo only very slowly this process not only consumes vast amounts of energy but also an above all .

Large quantities of water in  the next step removes the chemicals previously added for cleaning and reduction as well as the unbound indigo in several washing boxes.

This produces large volumes of coloured waste water contaminated with sulfides which adversely impact the aquatic ecosystem. 

The yarn fibers are now dried and during the sizing process ,same coated with a film of starch to protect them during the stressful weaving process that follows the conventional production process.

According to National Geographic magazine an estimated water consumption of 11,000 litres for each pair of the groundbreaking technology of advanced denim the new pad sizing ups process provides savings of up to 92% water 30% energy and 87% cotton waste during dyeing and sizing and generates absolutely no waste water.

Central to the new process is the more eco-friendly,  concentrated liquid sulfur dyes with a high affinity for cotton just a single dyeing bugs and one sugar base reducing agent are needed to obtain a medium color intensity for the next step is a combined sizing and oxidation box in which the dye is fixed and the protective starch layer is applied all the other working steps are eliminated.

In chemical terms dyeing with sulfur dyes closely resembles the traditional indigo process but sulfur dyes not only have the oxygen groups but also sulfur containing functional groups known as tiles in the first step as with indigo the dye molecule is reduced causing it to dissolve in the water and change color in the oxidation process. That follows the dye is fixed to the fiber by a strong ionic bonds and the final color develops the sulfur groups can cross link with each other and can also bond very strongly to the fiber via the fixing agent this improves the strong color fastness and high abrasion.

Link may be utilized:

https://bindaprocess.blogspot.com/2022/02/denim-rope-dyeing-automation-2022.html

https://bindaprocess.blogspot.com/2022/02/denim-fabric-stucture-application.html

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html

Textile Rope Dyeing Automation/ Troubleshooting

 

TEXTILE ROPE DYEING AUTOMATION / TROUBLESHOOTING

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How to retrofit the current Rope Dyeing  processing line to increase the maximum yield with minimum rejection and maximum efficiency?

This report aims to provide the details of introducing a dosing pump and the hydro feeder in the current 3 in 1 circulation line for getting efficient and uniform (without variation) dyed product, it is observed that the current line lacks the proper feeding system which is disturbing the consistency of shade at some place, in this report three types of designed are given for making an efficient dyeing line to resolve this problem. 

INTRODUCTION

The purpose of the report is to recommend the installation of dosing pump and hydro feeder for minimizing the variations. Because the current line has no such components and for fulfilling their requirements the mobile pumps are used as alternatives  which are not functioning efficiently.

 

PROBLEMS ASSOCIATED WITH CURRENT DESIGN 

•       The mobile pumps didn’t have the proper stirring system which restricts the chemical to mix properly as a result of which the denser chemical settled down at the bottom.

•       They also don’t have the leveling system which increases the chances of making incorrect level.

•       The denser chemicals which settled down are sometime accumulate with in the pipe and as a result of which the pump get choked.

•       Mobile pumps not fulfill the basic requirement of more than 7 liters and also not worked properly at limited feeding of > 1.

•       Whereas for the continual feeding of dye, topping pump is used whose head is at a far distance from the box, which generates the heat for maintaining such a high pressure and might be get stop in the future long production runs. 

RECOMMENDATIONS

The above issues could be resolved by making some alteration in the current line, and for this three type of design are given below that could solve this problem.

 

 DESIGN 1

DESIGN 2

 

 

DESIGN 3

CONCLUSION

By selecting one of the three  above designs the system could be perform better then present, the sedimentation will not occur because of the introduction of  hydro feeding system which is directly attached with the main circulation line of the box. Besides this the installation of dosing pump in the 3 in 1 tank allows the continual flow of dye at constant rate without making any of the high heat loses, because of the low head distance and this pump will also be used for high feeding . Moreover, the topping pump could be used for the caustic feeding to completely eliminate the mobile pump from the line.

This may also be viewed:

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html

https://bindaprocess.blogspot.com/2022/02/denim-fabric-stucture-application.html

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html?m=1