Dry process of garments washing with different chemicals & equipments

All about Garments Washing part-2

Maruf Mahfuz

E-mail: maruf.txt@gmail.com

Cell 01738676060

Department of Textile Engineering

World University of Bangladesh

A typical process sequence for garment wet processing is: desize, rinse, abrasion, rinse, bleach, bleach neutralization, rinse, laccase enzyme, rinse, tint/softener, extraction (high speed), dry. We have several products to facilitate this process including:

Chemicals for garments Washing:

• Abrasion
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• Anti-Ozonates
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• Anti-Redeposition Aids
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• Buffers
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• Coated Finishes
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• Desize
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• Durable Press Agents
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• Enzymes
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• Fixing Agents for Dyes/Tints
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• Flourocarbon Finishes
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• Lubricants
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• Machine Cleaners
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• Optical Brighteners
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• Softeners – Polyethelyne
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• Softeners – Silicone
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• Tints
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• Wetting Agents
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• Wrinkle Free 

Machineries & equipments for industrial garments:

Washing Machine: 

The Garment washing machine has a large volume, front-loading packet cylinder & simplificated compact structure. Machine is suitable for all types of washing processes, such us Enzyme, Stone, Rinsing, Softener, bleaching and other washing treatments on garments of different materials (cotton, linen, viscose, tensel treatment etc).

 

Figure: Washing Machine

The inner drum has numerous holes, so washing and rinsing operations can be done in a limited time. The machine has a fixed rotation speed and the electric system allows the semiautomatic control of the washing processes. Upon request the machine can be equipped with a fully automatic control, unloading system, pneumatic door lock, as well as with variable rotation speed.
Available in 100, 150, 200, 300, 450 & 600 Kg.


The materials used in the manufacturing of the Horizontal Industrial top loading Washing Machine are of optimum quality that ensures easy operation & maintenance and consumption of less electricity. Calibrated level indicator to control water level. Moreover, Machine is also available in varied sizes and dimensions. Available in 50, 100, 150, 200, 300, 450 & 600 Kg.

Hydro Extractor

 

Figure: Hydroextractor (Centrifugal)

Direct drive. High speed. Self balancing. Auto DC injected brake. Auto times. Suitable for centrifuge of garments after washing/dyeing. Inner basket and outer drum stainless steel. Vibration free and noiseless due to self balancing suspensions.High speed ensures shorter extraction, less energy consumption.Available in 30, 60, 120 kg.

Spray booth

 

Brushing mannequins

 

Blasting sand:

Figure: sand for blasting

Grinding machine

Besides these there needs Ironing table , Hot press, Tag gun  & Minor sewing facility

Features

Foot operated pneumatic grinding tools placed on a perforated, easy to handle and level table. This machine is pneumatic because lesser power is required. Suction device can be added if necessary for compliance. Productivity is high as the operator's hands will be free and the machine is operated by leg. Robust, powder-coated, steel structure. System can be fitted on wheels for portability. This machine can cause abrasions, breakages, tears, and so on This machine is used as the perfect tool value addition.

Dry process or physical pretreatment relevant to industrial garments washing:

1. Hand scraping/ Hand sand:

Hand sand is step which is generally being done in rigid form of garments to get distress look. Locations can be front thigh & back seat or its can be overall / global application as per Standard. Emery paper is being used to scrape the garments in particular placement & design. Emery paper comes in different number generally start from 40 till 600 and above , higher the number finer the emery paper, lower the coarseness of the paper. In garment industry from 220 , 320 & 400 number papers are most popular & widely used. 

Purpose of doing this process is make used worn out look to the garments.
The most important factor is to select right number of paper according to the fabric strength & intensity need. Feathering / merging white sanded part to dark blue area in such way that it should look natural & not artificial.
Scraping can be done on inflated rubber balloons for better effect ( horizontal or vertical its up to operators convenience ) , even it can done plain wooden board of garment size & hand pressure should be uniform in order to get better results.

 

Figure: Emery papar for Hand sanding

Hand sanding must be started from intense part & feathering out on less intense part gradually. One garment must by done by one operator only to have balance intensity on both the legs.

2. Sand blasting:

Aluminum oxide is made from bauxite. Mixture of bauxite is electrically fused at high temperature in an arc furnace and Americos Aluminum oxide is thus produced. Americos Aluminum oxide has brown color, high hardness and great toughness. The abrasive tools made of aluminum oxide are suitable for sand blasting for Denim, Grinding carbon steel, normal alloy steel, malleable cast iron and hard bronze.

 

  Figure: Sand blasting effect on denim fabric


It is ideal for sand blasting to Denim fabric because of less iron content. Due to very less iron content, damage to fabric is very less compared to any ordinary aluminum oxide. It can work at very high pressure, which is a major requirement for high production

Physical and Chemical Properties of Sand:

 

Application:

It can be used for 2 to 3 times depending on working pressure.
This process is isolated now a days due to health hazards & buyers do not like the results of sandblast because its covers the characteristics of fabric. This process is being done by using different kind of sand blown to garments with air pressure to rub out the color.Sand blasting is recently a popular wash.Sand blasting is a mechanical process of creating fading affect / old looking affect on heavy garments like denim, canvas, twill, sometimes corduroy by the action of aluminum oxide (AI2O3) which looks like sand. For this reason this process termed as sand blasting. Sand blasting is generally doing which area that long time used / wears the garment fading affect occurs. By sand blasting at new position old / fading affect on garment comes before use / wear. Sand blasting is performed with combine the wash like Normal / Rinse wash, Enzyme wash, Stone Enzyme wash, Bleach wash, Stone wash.

Two types of sand blasting:

1.Brown Sand.
2.White Sand.

A process of Sand blasting on denim, canvas, twill, corduroy garments is deserved below:

· Aluminum oxide is used for Sand blasting which is looks like Sand.

· These aluminum oxide one very fine & very hard / sharp.

· This aluminum oxide through by gun with dry air to perform Sand blasting action.

· The gun has a switch to start and stop the flow of aluminum oxides.

· The garments to be sand blasting are placed on the bed of a closed chamber.

· Sand blasting is a hazardous process:

· Sand blasting area is isolated from other production area.

· The handling of Sand blasting gun is a risky Process.

· The flow of Aluminum oxide on fabric surface is done at 10 – 20o angles.

· The blowing angle is very important.

· Higher the blowing angle higher the fading affect & higher the risk of fabric damage.

· Aluminum oxide (Al2O3) is used for Sand blasting, which is looks like sand.

· The operators should have protective standard musk, helmet, gloves, ear hag and uniform.

· Production hour gun varies from 25 – 50 garments depend on the area extent of fading.

· After mechanical fading chemical treatments are required for the buyer’s requirement.

Advantages of sand blasting process:

- It is purely mechanical process, not using any chemicals.
- It is a water free process, therefore no drying required.
- Variety of distressed or abraded looks possible.
- Any number of designs could be created by special techniques.



To be continued……