GARMENT WASHING

The technology which is used to modify the appearance, out look

comfort ability of the garments is called garment washing.

Requirements of garments washing

It should be removed size materials from the garments . Hence feels soft during use.
It should be removed any dust, dirt, spot, impurities or germ which is present or
added in garments during manufacturing.
It should be shrinkage occurred i.e. no possibility of further shrinkage of wash
garments due to washing.
It should be produced similar or different outlook in the garments by different
washing techniques.
It should be created faded affect in the garments.
It should be possible to wearing directly the garments after purchasing from the
shop.
Should be used new/ modern/ latest machines.
It should also be produced fading affect in the specific area of the garment as per
specific design.
It should be comparatively more profitable than others.

Effects of garments washing

1. Change the appearance of the garments.
2. Change in size.
3. Change in color.
4. Change out look of the garments.
5. Change in comfort.
6. Change in design.

TYPES OF WET AND DRY PROCESS

Normal wash / Garments wash/ Rinse wash.
Pigment wash.
Caustic wash.
Silicon wash.
Stone wash.

Enzyme wash.
Stone Enzyme wash.
Acid wash.
Bleach wash.
Tinting & over dyeing.
Sand Blasting.
Hands scraping.
over all wrinkles.
Permanent wrinkle.
Grinding & Destroy.
Broken & Tagging.
P P Spray & P P Sponging etc.
NORMAL WASH / GARMENTS WASH
Normal wash is required for the following reasons:To remove dust, dirt, oil spot, impurities from the garments.
To remove size materials from the garments.
To remove starch presents on the garment fabrics.
For soft feeling to wear the garments after purchasing.
To achieve buyer washing standard.

WASHING PROCESS OF NORMAL / GARMENT WASH

The Normal/Garment washing process of batch of 70 kg Twill/Canvas Garments
are described below:First Step :Lot size: -....................... 70 kg Twill/Canvas Garment.
Add water @ L: R = 1: 8-10 ............560 -- 700 Litre.
Machine Running.
Add detergent @ 0.5 gm / litre ............ 280-350 gm.
Temperature..... Sometime cold & sometime 40c to 60c.
Time .............................. 5 to 10 mts.
Drop the liquor.
Cold wash.
Second Step :Add water @ L : R = 1: 6 ......... 420 litre.

Washing machine running

Add Flax softner @ 0.6 gm / litre .......... 252 gm.
Add Acetic Acid @ 0.5 gm / litre........... 210 gm.
Time................................... 5 to 10 mts.
Drop the liquor.
Unload the Garments on trolley.
Third Step :Hydro extractor machine.
Hydrocxtraction the garment to remove excess water from the Garment.
Fourth Step :Steam Dryer / Gas Dryer.
Load on steam dryer - 50 kg
Temperature - 60c - 70c
Time - 40 - 50 mts for dry.
Time - 10 - 15 mts for cold dry.
or
Load on gas dryer - 50 kg,
Running the machine
Temperature: - 70c - 85c.
Time: - 30 - 35 mts for dry.
Time: - 10 - 15 mts for cold dry.
Fifth Step:After drying it will be quality checking and good quality Garments will be
delivery to Garments factory.
NOTE: - Flax softner (cationic or nonionic) diluted with hot water then use in the
Machine.

PIGMENT WASH
Pigment wash generally doing on pigment dyed or printed Garments by pigment
washing technique.
Pigment wash is required for the following reasons:- To fading affect/old looking
affect on Garment and also seam area. For soft feeling to wear the garment after
purchasing.To achieve the buyer washing standard.To increase the colourfastness
& rubbing fastness.

WASHING PROCESS OF PIGMENT WASH

The pigment washing process of batch of 80 kg Twill/canvas Garments are
described below:-

First Step :
Lot size: - ...................... 80 kg Twill/Canvas Garment.
Add water @ L: R = 1: 8.............. 640 Litre
Machine Running.
Add Caustic soda (NAOH)..... @ 0.8 gm / liter ............ 512 gm.
Add Soda Ash (Na2Co3) ........@ 1.50 gm / litre........... 960 gm.
Add Detergent ........................ @ 0.8 gm / litre ............ 512 gm.
Temperature........... 50c to 60c.
Time (Depend upon the shade) ....... 20 to 60 mts.
Drop the liquor.
Wash 1 time by hot wash for 5 mts at the temperature 50c.
Wash 1 time by cold water for 5 mts
Second Step :
Add water @ L : R = 1: 6 ......... 480 litre.
Washing machine running
Add Acetic Acid (for pH 4.5 - 5.5) @ 0.5 gm / litre ............. 240 gm.
Add Flax softner ...
. @ 0.6 gm / liter........... 288 gm.
For more slippery hand feel use silicon - @ 0.4 gm / litre.....192gm.
Time................................... 15 to 25 mts.
Drop the liquor.
Unload the Garments on trolley.
Third Step :Hydro extractor machine.
Hydrocxtraction the garment to remove excess water from the Garment. Time
required about 2 - 4 minutes.
Fourth Step :- Steam Dryer / Gas Dryer.
Load on steam dryer - 50 kg
Running the machine
Temperature - 60c - 70c
Time - 40 - 50 mts for dry.
Time - 10 - 15 mts for cold dry.
or
Load on gas dryer - 50 kg,
Running the machine
Temperature: - 70c - 85c for dry.
Time: - 30 - 35 mts for dry.
Time: - 10 - 15 mts for cold dry.

Fifth Step :
After drying garments go to quality section and check the garment, good quality
garment will be delivery and Deep shade again rewash, other quality Garment
rectify then delivery.

CHEMICAL USED IN PIGMENT WASHING AND THEIR FUNCTION

CAUSTIC SODA (NaoH) :
1. Caustic created the role in bleach technique without colour change the garments.
Caustic has a cleaning power which is more powerful then soda Ash. fading
affect/old looking affect come rapidly on garments.
SODA ASH (Na2Co3) :Soda ash created alkaline medium for the breakdown of pigment dye. It has also a
cleaning power. It has also help color fading affect of garments.
Detergent:Here detergent is used to remove impurities from the Garment fabric surfaces
and temperature helps detergent to enhance its action. Detergent removes the
impurities from the garments fabric surface. During coming these impurities,some
pigment will be washed out from the pigment dyed or printed area of the garments.
As a result fading affect will be developed.
Acidic Acid (CH3COOH) :Acidic Acid is used to neutralize the garment from alkaline condition and to
control the pH value in wash bath.
Flax Softner (Cationic, nonionic) :Softener is used to make the garments treated textiles is surface feel that is bath
sickly and soft and also provides excellent lubricating properties.

CAUSTIC WASH
Caustic wash generally doing on Reactive dye, Sulpher dye, Direct dyed or
printed Garments. Caustic wash is required for the following reasons:To fadding/old looking affect on Garment and seam abrasion affection seam area.
To remove the size materials, starch from the garments.
To increase the colour fastness & rubbing fastness.
For soft feeling to wear the garments.
To increase the hairiness on garments.
To achieve the buyer reference sample.
WASHING PROCESS OF CAUSTIC WASH
The caustic washing processes of batch of 80 kg twill/canvas garments are
described below:First Step :Lot size: - ...................... 80 kg.
Add water @ L : R = 1 : 8.............. 640 Litre
Machine Running.
Add Caustic soda (NAOH)..... @ 1.60 gm / litre........ 1024 gm.
Add Detergent ........................ @ 0.8 gm / litre ............ 512 gm.
Temperature........... 50c to 60c.
Time (Depend upon the shade) ....... 20 to 60 mts.
Drop the liquor.
Wash cold water for 3 mts.
Second Step :- Neutral Wash
Add water @ L : R = 1: 5 ...................... 400 litre.
Add Acetic Acid @ 1 gm / litr e ............. 400 gm.
Time .......................................................... 5 mts.
Here acetic acid is used to neutralize the garments from alkaline medium.
Third Step :Add water @ L : R = 1 : 6 .............. 480 Litre
Machine Running.
Add Acetic Acid @ 0.5 gm / litre ............ 240 gm.
Add Flax softner @ 0.6 gm / litre........... 288 gm.
If mor e soft use silicon @ 0.4 gm / litre ... 192 gm.
Time................................ 10 to 20 mts.
Drop the liquor.
Unload the garments on trolley.

Fourth Step :Hydro extractor machine.Hydro extraction the garment to remove excess water
from the Garment. Timerequired about 2 - 4 minutes.
Fifth Step :Steam Dryer / Gas Dryer.
Load on steam dryer - 50 kg
Running the machine
Temperature - 60c - 70c
Time - 40 - 50 mts for dry.
Time - 10 - 15 mts for cold dry.
or
Load on gas dryer - 50 kg,
Running the machine
Temperature: - 70c - 85c for dry.
Time: - 30 - 35 mts for dry.
Time: - 10 - 15 mts for cold dry.
Sixth Step :After drying garments go to quality section and check the garment, good quality
garment will be delivery and Deep shade again rewash, other quality Garment
rectify then delivery.

CHEMICAL USED IN CAUSTIC WASH AND THEIR FUNCTION

CAUSTIC SODA (NaoH) :
Caustic created the role in bleach technique with color change the garments.
Caustic has powerful cleaning power.
Fadding affect/old looking affect come rapidly on garments.
DETERGENT :
Here detergent is used to remove impurities from the garments fabric surfaces and
temperature helps detergent to enhance its action. During coming these impurities,

some color will be washed out from the colored fabric garments. As a result fading
affect will be developed.
Washing equipment

washer

Tumble Drying processCuring Ov

ENZYME WASH
Enzymes are bio chemical substances that behave as catalysts toward specific
reactions. What makes very interesting the enzymes under a chemical point of
view is their high specificity or in other words, their ability to attack selectively a
given substrate.
Among the two traditional enzymes used in the treatments ofdenim garments
(amylase to hydrolyze starches and cellulose to degrade in different way's cotton's
cellulose) there is another enzyme that can be employed to attack selectively the
molecule that constitutes the blue indigo color resulting ineffective on other kind of
dyes.
The action of enzyme during enzyme wash, it hydrolysis the cellulose, at first it
attacks the having projecting fiber and hydrolyzed them. Them it attacks the yarn
portion inside fabric and partly hydrolyzed the yarn portion and fadded affect is
produced.
Mainly two types of enzyme used in Bangladesh. One is Acid Enzyme (liquid)
and another is Neutral Enzyme. Neutral Enzyme is twotypes - a) Powder form b)
Liquid form i.e, SL Enzyme.

ACID ENZYME
Acid enzyme colour is slightly brown.
pH range is 4.5 to 5.5
Temperature - 40c - 55c.
Time required 25 mts to 50 mts.
Enzyme affects come within short time.
Staining/Bleeding occurs more in garments.
Production high.

NEUTRAL ENZYME
Enzyme is slightly white powder form.
pH range is 6 to 7.
Temperature - 40c - 60c.
Time required 40 to 70 mts.
Enzyme affects come slowly.
Less staining/bleeding on garments.
With pumic stone comes good affect/abrasion on garments.

In dark shade enzyme affect comes good.

SL ENZYME
SL enzyme is liquid form.
pH range is 6 to 7.
Time required 45 to 80 mts.
Enzyme affects come slowly.
Less staining/bleeding on garments.
With pumic stone come better affect.
In dark shade enzyme affect comes good.

ENZYME WASH
Enzyme wash is required for the following reasons:To remove the size materials from the garments.
To remove the starch presents on the garments fabrics.
To achieve the high low abrasion (stone affect) on garment and seam abrasion in
sewing area.
Enzyme attack as chemically not mechanically for this reason low
damage/wastage then stone wash.
For soft feeling to wear the garment.
To achieve the buyer reference sample.
To increase the colour fastness & rubbing fastness.
Especially develop the "Bio-Polishing" affect of cotton/denim.
Enzyme improves the anti-pilling properties.
Enzyme attacks more the surface of the fabrics and gives a very smooth surface.

ENZYME WASH PROCESS

The enzyme washing process of batch of 60 kgs denim men's long pants Trouser)
are described below:-

First Step :- DESIZING

Lot weight (80 pes) ............ 60 kg denim long pant.
Add water @ L : R = 1 : 9 .............. 540 Litre
Machine Running.
Temperature.......................... 60c.

Add Desizing agent @ 0.6 gm / litre ............ 324 gm.

Add Detergent @ 0.8 gm / litre.................... 432 gm.
Time...............................10-- 20 mts.
Drop the liquor.
Wash 1 time by cold water.

Second Step :- ENZYME

Add water @ L : R = 1 : 8 .............. 450 Litre
Temperature.......................... 45c.
Add Acetic Acid @ 0.6 gm / litre ................... 270 gm.
Add Anti back staining @ 0.6 gm / litre........ 270 gm.
Add Acid Enzyme @ 2.00 gm / litre ................ 900 gm.
Time .............. (Depend upon the shade )...40-- 60 mts.
Increase temperature to 90c and run 1 minute (enzyme killing).
Drain the bath.
Rinse Twice, each 3 minutes.
Third Step :- SOFTENING
Add water @ L : R = 1 : 8 ..................... 450 Litre.
Add Acetic Acid @ 0.6 gm / litre ............ 270 gm.
Cationic Softner @ 1 gm / litre.............. 450 gm.
Temperature................................... Cold.
Time ................................................ 15 to 20 mts.
Drain the bath.
Then unload the garments on trolley.

FourhtStep :-Hydroextractor Machine

After unloading garments from the washing machine then they are sent to
hydroextractor machine to remove excess water from the washed garments.

Fifth Step :- Drying Machine

Load 60 kg garments to gas dryer.
Temperature set - 75c to 85c.
Run about 40 mts.
After then run 10 mts in cold dryer.

Sixth Step :After dryer, garment goes to quality section for quality checking and good one
delivery.

ENZYME WASH PROCESS(TWILL/CANVAS/POPLIN)

The enzyme washing process of batch of 60 kg Twill/Canvas/Poplin/Cord ray)
trouser is described below:-

First Step :- DESIZING

Lot weight (Approx 125 pes) ............ 60 kg.
Add water @ L : R = 1 : 10 .............. 600 Litre
Machine Running.
Add Desizing agent @ 0.6 gm / litre ............ 360 gm.
Add Detergent @ 0.5 gm / litre.................... 300 gm.
Temperature.................................... 50c.
Time........................................10--- 20 mts.
Drop the liquor.
Rinse one time 3 minutes.

Second Step :- ENZYME

Add water @ L : R = 1 : 8 .............. 480 Litre
Temperature.......................... 45c.
Add Acetic Acid @ 0.5 gm / litre ............ 240 gm.
Add Acid Enzyme @ 1.2 gm / litre ............ 576 gm.
Add Antistain @ 0.50 gm / litre ................ 240 gm.
Time.. (Depend upon the standard)........ 30 to 60 mts.
Increase temperature to 90c and run 1 minute.
Drain the bath.
Rinse Twice, each 3 minutes.

Third Step :- Softing

Add water @ L : R = 1 : 8 .............. 480 Litres.
Add Acetic Acid @ 0.6 gm / litre .......... 288 gm.
Cationic Softner @ 1 gm / litre.............. 480 gm.
Silicon (ME) @ 0.5 gm / litre................. 240 gm.
Temperature.......................... 40c..
Time................................ 15 to 20 mts.
Drain the bath.
Then unload the garments on trolley.

Fourth Step :-Hydroextractor Machine

After unloading garments from the washing machine then they are sent to
hydroextractor machine to remove excess water from the washed garments.

Fifth Step :- Drying Machine

Load 60 kg garments to gas/steam dryer.
Temperature set - 75c to 85c.
Run about 35 to 45 mts.
After run 10 to 15 minutes for cold dryer.

Sixth Step :After dryer garment go to quality section for quality checking and then delivery.

INTRODUCTION OF PUMIC STONE

Pumice Stone :The pumice stone are the perforated stones, produced from volcanic explosion.
At first these stones are soft but becomes cold, it becomes the stones with rough
surface,
Pumice stones float on water.
Pumice stones come from Indonesia and Turkey.
Indonesia stone color is slightly brown and Turkey stone is white color.
Pumice stones are available in 3 size i.e. small 2-3 cm, medium 3-5 cm and large
size 5-7 cm.
Two to Three times can be used are pumice stone.
Every bag contain 22 kg to 25 kg and price 400/= to 425/=/ bag (varies).

THE ACT OF PUMIC STONES DURING GARMENT

WASHING
During different garments washing like stone wash, Acid wash, Stone Enzyme
wash etc. Pumic stones are used to create irregular fading affect on garments.
The pumic stones act a brushing action on the garment fabric surfaces.
The areas where more brushing action take place, there more fading or discolor
affect will be developed and the areas where less brushing action takes place, there
less discolor affect will be developed.
The multi layer fabric areas like Collar, Cuff, Pocket, Placket, Side seams etc.
areas will be brushed more than the single layer areas.

As a result irregular fadding is developed in the garments by the action of pumic

stones.

STONE WASH
A process of stone wash of 60 kg batch of Denim Long Pant as mentioned below:-

First Step :- PRE-TREATMENT / DESIZING

Batch size....................... 60 kg Denim Long Pant.
Add water @ L : R = 1 : 9 .............. 540 litres.
Start the machine.
Temperature.................... 60c
Add Desizing agent @ 0.6 gm / litre................. 324 gm.
Add Detergent / Antistain @ 1 gm / litre ......... 540 gm.
Time................................ 15 to 25 mts.
Drop the liquor.

Second Step :- HOT WASH

Add water @ L: R = 1: 9.............. 540 litres.
Temperature.................... 60c.
Time................................ 5 mts.

Third Step :- BLEACHING

Add water @ L: R = 1: 8.............. 480 litres.
Machine running.
Add bleaching powder (k.c.i) @ 10 gm/litre ...... 4800 Gms.
Add soda ash @ 5 gm/litre .................................. 2400 Gms.
Pumic stone @ vol of garments.
Temperature............................. 60c.
Time (Depend upon the shade) .......... 12 to 15 mts.
Drop the liquor.
Rinse twice, each 3 minutes.

Fourth Step :- NEUTRAL WASH

Add water @ L : R = 1 : 9 .............. 540 litres.
Add sodium hyposulphite @ 3 gm/litre ...... 1620 Gms.
Temperature............................. 40c.
Time (Depend upon the shade) .......... 10 to 12 mts.
Drop the liquor.
Rinse one.

Fifth Step :- SOFT WASH

Add water @ L: R = 1: 8.............. 480 litres.
Add Acetic Acid @ 0.6 gm/litre ..................... 288 Gms.
Cationic softner @ 1 gm/litre ........................ 480 Gms.
Time................................ 5 mts.
Drop the liquor.
Unload the garments to trolley.

Sixth Step :-Hydroextractor Machine

Hydroextraction the garment to remove excess water from the washed garments.

Seventh Step :- Drying Machine

Load 40 kg garments
Set temperature ................ 75c to 85c.
Time ......................... 35 to 40 mts.
Time ..................... 10 minutes in cold dry.

Eighth Step :-Delivery

After quality checking garment will be delivery.

STONE ENZYME WASH

Now in our Bangladesh maximum Denim garment is washing STONEENZYME
WASH. It is most popular wash for Buyer. A process of stoneenzyme wash of 60
kg batch of Denim Long Pant as mentioned below:-

First Step :-PRE-TREATMENT / DESIZING

Batch size....................... 60 kg Denim Long Pant.
Add water @ L: R = 1 : 9 ............................ 540 litres.
Start the machine.
Temperature.................... 60c
Add Desizing agent @ 0.6 gm / litre................. 324 gm.
Add Detergent / Antistain @ 1 gm / litre ......... 540 gm.
Time................................ 15 to 25 mts.
Drop the liquor.

Second Step :-HOT WASH

Add water @ L: R = 1: 9.............. 540 litres.

Temperature.................................... 60c.
Time................................................. 5 mts.

Third Step :Add water @ L : R = 1 : 8 .............. 480 litres.

Add pumic stone @ vol of garments.
Add Enzyme @ 1.50 gm/litre ..................... 720 Gms.
Add Acetic Acid @ 0.6 gm/litre .................. 288 Gms.
Add Antistain @ 0.8 gm/litre ..................... 384 Gms.
Temperature......................................... 40c to 50c
Time (Depend upon the shade) .......... 60 to 70 mts.
Then temperature raise to 90c for 1 minute.
Drop the liquor.
Rinse Twice, each 3 minutes.
Then pumic stone out from washing machine

Fourth Step :-BLEACHING

Add water @ L: R = 1: 8.............. 480 litres.
Machine running.
Add bleaching powder (k.c.i) @ 10 gm/litre ....4800 gms.
Add soda ash @ 5 gm/litre................................ 2400 gms.
Temperature........................................................... 60c.
Time (Depend upon the shade) ..................... 12 to 15 mts.
Drop the liquor.
Rinse twice, each 3 minutes.

Fifth Step :- NEUTRAL WASH

Add water @ L: R = 1: 9 ............................ 540 litres.
Add sodium hyposulphite @ 3 gm/litre ....... 1620 Gms.
Temperature..................................................... 40c.
Time ............................................................. 10 to 12 mts.
Drop the liquor.
Rinse one.

Sixth Step :- SOFT WASH

Add water @ L : R = 1 : 8 .............. ..............480 litre.
Add Acetic Acid @ 0.6 gm/litre ..................... 288 Gms.
Cationic softner @ 1 gm/litre ........................ 480 Gms.
Time................................ 5 mts.

Drop the liquor.

Unload the garments to trolley.

Seventh Step :-Hydroextractor Machine

Hydroextraction the garment to remove excess water from the washed garments.

Eighth Step :-Drying Machine

Load 40 kg garments
Set temperature ................ 75c to 85c.
Time ......................... 35 to 40 mts.
Time ..................... 10 minutes in cold dry.

Ninth Step :-Delivery

After quality checking garment will be delivery.

BLEACH WASH
A process of bleach wash of 60 kg batch of Denim Long Pant as mentioned
below:-

First Step :- PRE-TREATMENT / DESIZING

Batch size....................... 60 kg Denim Long Pant.
Add water @ L: R = 1: 9.............. 540 litres.
Start the machine.
Temperature.................... 60c
Add Desizing agent @ 0.6 gm / litre ............ 324 gm.
Add Detergent / Antistain @ 1 gm / litre..... 540 gm.
Time................................ 15 to 25 mts.
Drop the liquor.

Second Step :-HOT WASH

Add water @ L: R = 1: 9.............. 540 litres.
Temperature....................................... 60c.
Time................................................... 5 mts.

Third Step :- BLEACHING

Add water @ L: R = 1: 8.............. 480 litres.
Machine running.
Add bleaching powder (k.c.i) @ 10 gm/litre..4800 Gms.
Add soda ash @ 5 gm/litre ............................... 2400 Gms.
Temperature............................................................ 60c.
Time (Depend upon the shade).................... 12 to 15 mts.
Drop the liquor.
Rinse twice, each 3 minutes.

Fourth Step :- NEUTRAL WASH

Add water @ L: R = 1: 9.......................... 540 litres.
Add sodium hyposulphite @ 3 gm/litre ....... 1620 Gms.
Temperature ......................................................... 40c.
Time (Depend upon the shade).............. 10 to 12 mts.
Drop the liquor.
Rinse one.

Fifth Step :- SOFT WASH

Add water @ L: R = 1: 8.............. 480 litres.
Add Acetic Acid @ 0.6 gm/litre ..................... 288 Gms.
Cationic softner @ 1 gm/litre ........................ 480 Gms.
Time................................ 5 mts.
Drop the liquor.
Unload the garments to trolley.

Sixth Step :-Hydroextractor Machine

Hydroextraction the garment to remove excess water from the washed garments.

Seventh Step :- Drying Machine :Load 40 kg garments

Set temperature ................ 75c to 85c.
Time ......................... 35 to 40 mts.
Time ..................... 10 minutes in cold dry.

Eighth Step :- Delivery

After quality checking garment will be delivery.

DIFFERENT TYPES OF WASHING FAULTS

Colour shade variation.
Crease Marks.
After wash hole.
Very dark & very light.

 Bleach Spot.
Bottom hem & course edge destroy.
Running shading.
Over blasting / low Blasting.
Over grinding / low grinding.
Bad smell due to poor neutralization.
Poor hand feel.
To high hairiness.
Poor brightness.
High or low affect / abrasion on garments.
Spot on garments.
Out of range / level of pH value of garments.

Super White wash

Super white wash is done on the garments made from cotton grey fabrics. Due to
this type of wash, the garments becomes extremely white.
Objects:
1. To make white the garments.
2. To achieve the buyer washing standard.
3. For soft feeling to wear the garments.
4. To remove size materials from the garments, etc.
The process of super white wash of batch of 60kg cotton grey fabrics is described
below:
First step: Desizing
- Batch size: 60 kg cotton grey fabrics
- Water @ L:R: 1:8
- Machine running
- Temperature up to 90C
- Add detergent@2%(OWF)
- Cold caustic soda@8% (OWF)
- Add Soda ash @ 5% (OWF)
- Hydrogen per oxide @ 12% (OWF)

- Stabilizer @ 5% (OWF)
- Time: 70minutes
- Drop the liquor
Second step: Bleaching
1. Add detergent @1% (OWF)
2. Add Caustic soda @ 3-4% (OWF)
3. Hydrogen per oxide @ 6-8% (OWF)
4. Stabilizer @ 2% (OWF)
5. Time: 45-60 minutes
6. Temperature: 90C

Third step: Hot Wash

1. Temperature: 50C- 80C
2. Time: 5-10 minutes
3. Drop the liquor
Fourth step: Neutralization:
1. Add Acetic acid @ 1%
2. Time: 5-10 minutes
3. Cold wash

Fifth Step: Brightening

1. Add optical brightener agent @ 0.5-0.6%
2. Time: 5-10 minutes

Sixth step:
1. Add softener @ 0.5-1%
2. Time: 5-10 minutes

Seventh step: Hydroextractor

Eight step: Drying machine
1. Load 60kg garments to gas dryer
2. Machine running
3. Temperature: 75C- 85C
4. Time: 40 minutes in hot dryer
5. After then run 10 minutes in cold dryer.

Ninth step: Deliver

Tinting &Over dyeing

Tinting and over dyeing process is done after washingbut before softening.
Normally after acid wash, stone wash with bleach or enzyme, stone wash, sand
blasting, etc, process tinting and over dyeing is done. The fadedarea is normally
over dyed with orange (bright color),yellow or similar hue and stone. Normally
denimgarments are of blue color. When orange or yellow coloris placed is placed
on the faded area, the garments looklike dirty but actually the garment is clean and
new.Another color is again reused in the faded portion, this iscalled over dyeing.

Precautions to be taken in over dyeing and tinting

1. During fabric sewing low and high thread tension required. Otherwise irregular
dyeing effect happen but low tension more preferable.
2. Selection of interlining before garments dyeing.
The main recipe of tinting and over dyeing is given bellow:
1. L:R: 1:7
2. Dye: 0.01-0.05 % (Direct/Reactive)
3. Leveling agent: .05%
4. salt: 15-20 g/l
5. Soda ash: 10-15 g/l
6. Temp: 50C- 70C
7. Time: 1-2 hrs
The process of enzyme bleach wash with tinting is described below:
Step 1: Desizing: Batch size: 60pcs
1. Water is added
2. Garments are loaded
3. Machine started
4. 500 gm Soda ash added
5. 500 gm Caustic soda added
6. 200 gm Bio. D added
7. Steam temp: 60C
8. Process time: 25 minutes
9. Drop liquor
10. Two time wash

Step 2: Enzyme wash:

1. Water added 400 liters
2. Machine running
3. 200 ml liquid, 400 gm powder type enzyme added
4. 150 ml Acetic acid added
5. 200 gm Anti Back staining agent added
6. 10 kg Pumice stone added
7. Temp: 50C
8. Process time: 60 minutes
9. Drop liquor

Step 4: Neutral wash

1. Water is added: 400 liters
2. Machine running
3. 500 gm Hypo sulphide added
4. Steam temp: 45C
5. Process time: 10 minutes
6. Drop liquor

Step 5: Tinting
1. Water is added (400 liters)
2. Machine running
3. .02% Direct Brown GTL and .01% Direct Black V-200 added
4. 4kg salt is added
5. Steam temp: 70C
6. Process time: 20 minutes
7. Check shade
8. Drop the liquor

Step 6: Drying

WHAT TYPE OF MACHINE USED IN WASHING

PLANT
Sample washing Machine (Horizontal / Vertical Type)
Washing Machine (Side loading)
Washing Machine (Front loading)
Hydro extractor Machine
Dryer Machine (Steam)
Dryer Machine (Gas)

 Chemical Mixture Machine

Industrial Oven (Gas/Electric)
Boiler
Submersible Pump
Grinding Machine
Tagging Machine
Steam chamber for crinkle
E.T.P (Effluent Treatment Plant)
Generator
Sand Blasting Gun
Sand Blasting chamber
Spray gun and dummy
Screw compressor
Laser draw

WHAT TYPES OF CHEMICAL USE IN WASHING PLANT

Enzyme
Detergent
Acetic Acid
Antistain
Bleaching powder
Sodium hyposulfite
Caustic Soda
Soda Ash
Sodium Bicarbonate
Potassium permanganate
Cationic / nonionic Flax softener
Micro Emulsion Silicon

Salt (sodium chloride)

Buffer
Hydrogen peroxide
Stabilizer
Fixing agent
Catanizer
Optical Brightener
Resin
Sodium Metabisulphite
Desizing agent

WHAT IS THE FUNCTION OF CHEMICALS IN

TEXTILES
ENZYME : The action of 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 (CH3COOH) : 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 contached
fabrics of garment and increased the brightness of fabrics; it is also acts
as anticreasing agent.

BLEACHING POWDER : Bleaching powder is an oxidizing agent. It

is used in washing plant for colour out from the denim garments. We can
achieve deferent shade of colour on garment i.e. Dark, Medium, Light
shade.
SODIUM HYPOSULPHITE : Sodium hyposulphite is used to
neutralize the garments from chlorine bleach.
CAUSTIC SODA : Caustic created the role in bleach technique with
outcolour change the garment and has a good cleaning power. It is work
as fadding affect/old looking affect come rapidly on garments.
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 colourfaddingaffect of garment. It is
used also for colour fixing in dye bath.
SODIUM BICARBONATE: Sodium bicarbonate is used in washing
plant in the bleach bath with bleaching powder for Denim Light shade
because easily colour out within shot time. As a result production
increase and costing is low.
POTASSIUM PERMANGANATE : Potassium permanganate is used
in Acid wash with Punic stone for colour out from the garments. It is
used also spray chamber by nozzle for colour out (whitish affect) from
the garments.
FLAX SOFTENER (Cationic, non ionic) : Softener is used to make
the garments treated textiles a surface feel that is both sickly and soft
and also provides excellent lubricating properties.
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, antipilling,
dimensional stability, tear resistance and fabric to be cut and sewn more
easily allows and improving wear and easy care properties.
SODIUM CHLORIDE (SALT) : 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 discolour the colouring

materials and as a result fadding affect is developed. Hydrogen peroxide
is used in scouring, bleaching bath for white/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 90c, when temperature raise to 90c 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 colour will be proper fixing then colour fastness &
rubbing fastness will be increased.
CATANIZER :Catanizer is used in pigment exhaust method processing.
Pigment is colour not dyestuff. Pigment colours have no affinity to
fabric when catanizer is used in fabric then increase the affinity between
pigment colour& fabrics.
OPTICAL BRIGHTNESS : Two types of optical brightener are used in
the
washing plant a) Red brightener. b) Blue brightener. Mainly optical
brightener is used for improve the brightness of garments.
RESIN : Resin is high efficiency textile resin based on etherified
dimethylol glyoxalin monoureine urea. Resin is used for the creation of
semi-permanent creases indenim and other cellulose fabrics. It is used
also cotton and polyester fabric. Fabric retains soft handle
after washing.
SODIUM METABISULPHITE : Sodium metabisulphite is used in the
washing plant to neutralized the garment from potassium permanganate.
DESIZING AGENT : Desizing agent is used to remove mainly
starches, cmc, waxes, fats pectins, minerals & unfixed indigo dye from
denim, twills, poplin & canvas fabrics etc.

SILICON WASH
Silicon washes generally doing on all type of fabrics i.e. Twill, Denim,
Canvas, Knit, Corduroy. Silicon wash is required for the following
reasons: It gives durable softness, elastic handle,
It helps to antipilling affects, dimensional stability, tea resistance.
It helps to fabrics to be cut and sewn more easily allows and improving
wears and easy care properties.
The silicon washing process of batch of 60 kg
Twill/Canvas/Poplin/Corduroy/Trouser is described
below:-

First Step: - Desizing

Lotweight (Approx 125 pes) ............ 60 kg.
Add water @ L: R = 1: 10.............. 600 Litre
Machine Running.
Add Desizing agent @ 0.6 gm / litre ............ 360 gm.
Add Detergent @ 0.5 gm / litre.................... 300 gm.
Temperature.......................... 50c.
Time...............................10- 20 mts.
Drop the liquor.
Rinse one time 3 minutes.

Second Step :Add water @ L : R = 1 : 8 .............. 480 Litres.

Add Acetic Acid @ 0.6 gm / litre ............ 288 gm.
Cationic Softner @ 1 gm / litre.............. 480 gm.
Silicon (ME) @ 0.5 gm / litre ................ 240 gm.
Temperature.......................... 40c..
Time................................ 15 to 20 mts.
Drain the bath.

Third Step: - Hydroextractor Machine

After unloading garments from the washing machine then they are sent
to hydroextractor machine to remove excess water from the washed
garments.

Fourth Step: - Drying Machine

Load 60 kg garments to gas/steam dryer.
Temperature set - 75c to 85c.
Run about 35 to 45 mts.
After run 10 to 15 minutes for cold dryer.

Fifth Step :After dryer garment go to quality section for quality checking and then
delivery.

Ultimate affect of Acid wash

During Acid wash, pumic stones are used. By the action ofpumic stones,
irregular faddeng affect is developed on theheavy garments like denims,
thick canvas/twill, and sweater. Thepumic stones act a brushing action
on the garment fabricsurface. The area where more brushing action takes
place theremore dicolour or fadding affect is developed and the
areawhere less brushing action takes place less brushing actionand takes
place less fading affect will be developed. Themulti-layer fabric areas
likecollar, calf, pocket, placket, sideseam etc area will be brushed more
than the single layer areas.As a result irregular fadding affect will be
developed on thegarments fabric surface. Thus in this way fadding affect
may bedeveloped on the garment by acid wash technique.

ACID WASH PROCESS

A processor Acid wash of 60 kg batch of Denim Trouser as mentioned
below:First Step: - Pretreatment/Desizing.
Add water @ L : R = 1 : 10 .............. 600 litres.
Start Machine.
Add desizingagent @ 1 gm/litre .................600 Gms.

Add detergent @ 1 gm/litre ........................ 600 Gms.

Temperature............................. 60c.
Time........................... 20 mts.
Drop the liquor.
Rinse one for 3 minutes (cold).

Second Step :- Hot wash

Add water @ L: R = 1: 10.............. 600 litres.
Temperature............................. 60c.
Time........................... 5 mts.
Drop the liquor.
Here hot wash is used to remove the adhering materials from the
garment surface.
Unload the garments from the washing m/c in the trolley.
Load the pre treated garments in the dryer m/c.
Dry the garment completely & unload the garments.
The pumic stones used for acid wash need to pre-treat in the following
chemical solution:Water ..................... 100 L
Potassium per manganate.............. 1000 Gms.
Phosphoric Acid............................... 250 Gms.
Stire the solution in a stainless steel tub with dry pumic stone.
Soak the stones with the chemical solution ......... 10
15 minutes.
The stones will pick up the solution. Then the soaked stones are dried in
the open air
for.............. 2 to 3 hrs.
Then pre-treated garment 30

40 kg per batch load in the dry washing machine.

Load the per-treated stones (about 50 kg) in washing machine.
Start machine running for each batch ........................ 7 to 10 mts.
Stop machine running.
Unload the treated garment separately. Pumic stones with P.P. solution
hit on garment surface as a result fadding will be developed.
Then load the stones treated garment in another washing machine.

Third Step :- Wash for cleaning

Batch wt................................ 70 kg.
Add water @ L: R = 1: 8.............. 560 litres.
Add detergent @ 1 gm/litre .............560 Gms.
Temperature............................. 40c - 50c.
Time ..................................10 mts.
Drop the liquor.
Here detergent is used to remove the breaking stone dust and chemicals
from the garmentsurface.

Fourth Step :-Whitening/Neutralization.

Add water @ L: R = 1: 8.............. 560 litres.
Machine running.
Add Metabisulphite @ 5 gm/litre..... 2800 Gms.
Cold temperature.
Time 5 mts.
Drop the liquor.

Fifth Step : Add water @ L: R = 1: 7.............. 490 litres.

Machine running.
Add Acetic acid @ 0.6 gm/litre ..................... 294 Gms.
Add Softner @ 1 gm/litre ........................ 490 Gms.
Then unload the garments.

Sixth Step :-Hydro extractor machine.

Hydro extractor machine to remove excess water from the garments.

Seventh Step :-Dryer machine.

After hydro extraction the garments are sent to drying m/c for complete
drying.

Eighth Step :-Quality & Delivery.

Nano finish:
Nano process of applying resin and fluro-carbons. It is also a permanent chemical
process. Following are the nano finish advantages:
1.Water, oil and alcohol repellency but air permeability.
2. The crease resistance feature keep clothing neat.
3. Dye fastness can be improved and wet increases.
4. It also helps to improve resilience, handle and drapping properties of the fabric.

Recipe:
Wetting agent: 0.5-1 % on the wt of the goods.
Resin: 4-6 % owf
Softener: 2-3 % owf (non ionic)
Fluoro carbon: 4-6 %

Wrinkle free:
This process is one kind of resin finishing process. In this process of applying
resins on the textile material that they cross linked with the amorphous block the
free (-OH) that prevent the hydrogen bond formation and thus improve the wrinkle
free finishing.
Mainly it is applied on twill fabrics, single jersey, and Denim fabric.

Some advantages:
Improve resistance and recovery to creasing by wrinkle free process.
Good water repellency and moderately soil repellency and remove of soil by
washing can be achieved by wrinkle free process.
Resin improves resilience, handle and draping properties of fabric.
Improve wet and dye fastness.

Recipe:
Wetting agent: 0.5 % on the weight of the fabric.
resin: 6-10 %
,,
Softener: 3-5 %
,,
Then make 60-80 liter liquor put in the machine tank.

Special chemicals for garments dyeing:

Use of special chemicals and dyesbecome essential for garments dyeing. Because
the use of special chemicals and dyes facilities additional advantages as well as
saves accessories from risk of damage present in the garments. For example, zipper
used in the garment may be protected from corrosion during garments dyeing by
the use of special chemicals.
Pretreatments of garments made from cotton greyfabrics prior to dyeing are very
important because good pretreatment means half dyeing is completed. Normally
pretreatment means Desizing; bacterial alpha amylase base Desizing agent
provides better performance asbecause stability of enzyme activity is not affected
by the variation of temperature and ph. normally at 70c, ph 6- 7.5, 60 mins
processing is enough for satisfactory Desizing. Use of high temperature reduces
processing time. Use of nonionic wetting agent in the bath improves Desizing
effect. Water hardness helps in stability of Desizing agents. Biolase, Bactosol, etc
are the example of some of such Desizing agents.After Desizing of garments made
from cotton grey fabric
needs scouring and bleaching treatments to removenatural impurities present in
the cotton fibers such as fats, waxes, pectins, pectose, ash, mineral organic
compounds and coloring substances. During scouring and bleaching those
impurities are removed from the cotton fibre. If those removed impurities forms
insoluble compounds and suspended in the liquor, may redeposit on the garments
fabric surface resulting color spot in the garment fabric after dyeing. To avoid such
problemspecial chemicals like Sandopan LFW or sirrix A.K. liquidmay be used.
Metal compound containing copper, iron, etc can destroythe bleaching
performance. Presence of aluminum may be damaged by the action of the alkali.
To avoid the problems of metals, during chemical treatment, Sandoclear 8160 or
Sandopan SF liquid may be used. During bleaching of cotton/nylon blended fabric,
nylonfibre may be damaged by the action of peroxidebleaching agent. If Lanalbin
PA powder is used during peroxide bleaching then the nylon fibers will be
unaffected by the bleaching agent. During hydrogen peroxide bleaching, stabilizer
AWN of sandoze can be used which is better as stabilizer for hydrogen
peroxide;moreover it has some detergency power and softness handle property.
To avoid the problem of crease marks formation duringwet treatment, imacol
brand as lubricant may be used in the chemical bath. Cotton fibres in garments
form may be cataionised bysanden 8425 liquid @ 3% before garments dyeing to
develop new color effect in the garments. During garments dyeing, some areas of
the garments like collar, cuff, pocket and seam areas may be irregularly dyed due
to interruption of dye penetration in those areas. To avoid the risk of irregular

dyeing, leveling agent may be used in the bath. Drimagen E2R of clariant company
if used in the dye bath, such types of problem can be avoided.