Denim Washing Process

Washing is a process that is done in denim garments for increasing its value. It also makes the garment comfortable for the users. Denim without a wash is not always user-friendly. Washing increases the outlook of denim garments added extra value to the customer. A better-washed product ensures a higher standard of denim. The purpose of washing varies and the outlook of denim also varies because of different washing methods.

Flow Chart of Denim Washing

Types of Denim Washing Process

There is two widely used process of washing denim. One is a dry process and the other is a wet process.

Dry Process	Wet Process
1. Whiskering	1. Desizing
2. Brushing	2. Enzyme
3. Tacking	3. Acid Wash
4. 3DCrinkle	4. Bleaching
5. P.P Spray	5. Neutralization
6. Grinding	6. Rinse Wash
7. Tie	7. Tint
8. Twist	8. Over Dyeing
9. Damage	9. Cleaning
10. Laser	10. Softening

Dry Process

This process is done in the unwashed condition. Basically, denim garments are treated here but nowadays twill garments are also treated.

Whisker

Whisker is the most common dry process for denim garments. This is done by making a pattern and put the garments then remove the color from the pattern area. After wash, we can see the pattern mark. It is one kind of design on the garments.

Manual Whisker

This whisker is done in a manual way with the help of a pattern. On denim garments, we have done it by abrasive paper.

Material Needed for Manual whisker

Pattern
Abrasive paper
For work, a worker is used different types of abrasive paper. Like as –
I) P-320 (for very rough surface)
II) P-400 (for very rough surface)
III) P-600(for less rough surface)
IV) P-800 (for medium surface)
Marking Chalk

The Procedure of Manual whisker

Put the whisker pattern into the garments
Then rub the pattern area according to standard intensity by abrasive paper
Quality check

Laser Whisker

This whisker is done by a laser machine. Here, garments specific areas are burned by imposing laser with high intensity. After wash, the burned indigo color will be removed and the whisker effect will be visible.

The Procedure of Laser Whisker

Making the design by Photoshop/illustrator
Put the garments on the machine surface
Set the intensity of the burn
Burn the garments
Quality check

Required Equipment’s for Laser Whisker

Laser Machine
Leather hand gloves and goggles for safety.

Hand Scrapping

This process is used to remove/fade the color from a specific area of the garments with an abrasive paper. The faded effect is nicely visible after wash.

Required Tools for Hand Scrapping

Abrasive paper
Dummy
Chalk for marking and masks

Working Procedure of Hand Scrapping

Specify the area
Put the garments into dummy
Scrapping with emery paper
Quality checking

P.P Spray

Potassium Permanganate is sprayed on the garments at a specific area. Garments are placed on a dummy first and then pp spraying is done with the help of a gun by air pressure. After that garments are dried and finally neutralize it to get the desired effect.

Materials Needed for P.P Spray

Spray gun.
PP solution
Air pressure
Mask

The procedure of P.P Spray

Placement on dummy
Spraying
Drying
Neutralization
Quality check

Tagging

Tagging or tacking is the process that is done at the unwashed condition of garments. After wash, we will get its effect. The maximum time we will do it at edge area by folding the garments. Sometimes this process damages the garments by creating a hole.

Materials Needed for Tagging

Tag gun
Tag pin
Chalk
Hand Gloves

Procedure of Tagging

Marking the garments
Fold the garments as per standard
Then tag the garments
Quality check

Destroy

This process is done by a pen grinding machine which destroys only the warp yarns of the fabrics or garments. The destroy look on the garments is best viewed after washing.

Necessary Tools to Destroy

Pen grinding machine
Marking Chalk
Pattern board
Hand gloves
Masks

Working Procedure of Destroy

Marking the area
Destruct the garments by pen grinder
Check the quality

Grinding

This process is done at the edges area of garments. If the garments require two-time wash in that case grinding is done after the first wash to avoid the damages of garments.

Materials Needed for Grinding

Grinding machine
Hand gloves for safety.

Procedure of Grinding

Run the machine
Touching the edge of garments according to standard.
Quality Check.

Crinkle

This process is done by crinkle machine or by manual clipping of a specific area and the effect is more visible at the front and back knee area.

2D Crinkle

This process is done by crinkle machine or by manual clipping of a specific area and the effect is more visible at the front and back knee area. In this process, the two-dimensional effect is produced.

Material Needed for Crinkle

Crinkle machine
Resin
Clip
White fabric

Process flow of 2D Crinkle

Applying Resin
Garment Placement on machine
Squeeze the garments
Keep it up to retention time (Curing)
Quality Check.

3D Crinkle

This effect is found by the special treatments of garments. By this system, the 3-dimensional effect is produced. The final is more visible after washing the garments.

Tools used in 3D Crinkle

3D crinkle machine
Resin
White fabric

The procedure of 3D Crinkle

Apply resin
Placement into dummy
Make 3D crinkle as per standard
Pre-cure the garments at 90 degrees C
Taken out the garments from the machine
Put into curing oven for full cure
Quality check

Wet Process

This type of process is done at the wet conditions. There are so many stages in the wet process.

Normal Wash

This wash is the combination of rinse wash and softener wash.

The purposes of Normal Wash

To remove dust, oil spot, and other impurities.
To make the garments soft.

Problems of Normal Wash

Sometimes pocket staining may occur.
Colorfastness may be failing.
Tone change if wash time is increased.

Enzyme Wash

In this wash, the enzyme is used to create the desired effect. They work basically on the surface of the fabric. The enzyme may be neutral or acidic according to the requirement of shade. The main benefits of using enzymes are that it is biodegradable and hence eco-friendly.

Purpose of Enzyme wash

To remove size and starch materials.
To make the garments softer.
To improve fastness and anti-pilling properties.

Stone Enzyme Wash

Stone and Enzyme are used together for washing. Heavy abrasion occurs in this wash. Typically done for Denim garments.

Problems of Stone Enzyme Wash

Sometimes metal may be found after using stone.
Hem and seam area can be damaged.

Bleach Wash

In bleach wash, a strong oxidative bleaching agent is added during the washing, with or without pumice stones.

Acid Wash

Acid washing or ice washing is usually done by dry tumbling the garments with pumice stones presoaked in an acid solution.

Problems of Acid Wash

Wide variation in effect.
PP spot may come.
Garments can be damaged due to vigorous action.

Specifications of Front Loading Machine

Washing Capacity	30kg
Drum Size(diameter*depth)	900*500mm
Drum Volume	315L
Washing Speed	37rpm
High Extractor Speed	750rpm
Extractor G Value	285
Motor Power	4kW
Inverter Power	5.5kW

Specifications of Top Loading Machine

Washing Capacity	25kg
Drum Size(diameter*depth)	850*450mm
Drum Volume	290L
Washing Speed	34rpm
High Extractor Speed	680rpm
Extractor G Value	255
Motor Power	3.5kW
Inverter Power	2.5kW
Electric Heating Power	20kW
Steam Consumption Ratio	0.7kg/kg

Specifications of Hydro Extractor Machine

Type/Parameter	Model : TG-25
Capacity	25kg
Speed	820rpm
Diameter of Drum (diameter x depth)	570×290mm
Motor Power	1.1kW
Rated Voltage	380V/50HZ/3 P; 220V/60HZ/3 P; 400V/50HZ/3 P; 415V/50HZ/3 P
Width	950mm
Depth	900mm
Height	650mm
Weight	350kg

Another Specifications of Hydro Extractor Machine

Type/Parameter	Model : RA-29
Capacity	30kg
Speed	850rpm
The diameter of Drum (diameter x depth)	590×3000mm
Motor Power	1.3kW
Rated Voltage	380V/50HZ/3 P; 220V/60HZ/3 P; 400V/50HZ/3 P; 415V/50HZ/3 P
Width	990mm
Depth	950mm
Height	600mm
Weight	350kg

Related Article You May Love to Read