Now You Know Overview of Denim Fabric Production with Flow Chart
Thursday, 17 May 2018
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Overview of Denim Fabric Production with Flow Chart
Md. Nure Alam
Teaching Assistant at Dept. of Textile Engineering
Daffodil International University
Dhaka, Bangladesh
Email: nure23-4238@diu.edu.bd
Teaching Assistant at Dept. of Textile Engineering
Daffodil International University
Dhaka, Bangladesh
Email: nure23-4238@diu.edu.bd
Introduction:
The wide consumption of denim by fashion globally has created a new opportunity for Bangladesh. The industry in Bangladesh presently has 30 denim producing factories with total investment of over USD 1 Billion. The monthly productions of denim stands at 30 million yards per month while the demand of nearly 60 million yards. To fulfill the balance demand, imported 30 to 35 million yards per month from countries like China, India & Pakistan which average value is USD 75 million. In this article I will give production of denim fabric with process flowchart.
Fig: Denim fabric production |
Denim fabric production section:
Yarn store section.
↓
Warping section.
↓
Weavers beam preparation section( Scouring, Dyeing, sizing section)
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Weaving section.
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Finishing section (Singing, Mercerization).
↓
Fabric store.
Warping section:
Cone from winding.
↓
Creeling.
↓
Control system
↓
Reed
↓
Measuring device
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Winding on beam .
Yarn store section.
↓
Warping section.
↓
Weavers beam preparation section( Scouring, Dyeing, sizing section)
↓
Weaving section.
↓
Finishing section (Singing, Mercerization).
↓
Fabric store.
Warping section:
Cone from winding.
↓
Creeling.
↓
Control system
↓
Reed
↓
Measuring device
↓
Winding on beam .
Weavers beam preparation by continuous method:
1. Warp beam creeling.
2. Scouring
3. Dyeing: Slasher dyeing is done for warp yarn. There have two ways for dyeing such as (bottoming and tapping.)
***Bottoming Process:
Sulphur Dyeing.
↓
Washing.
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Indigo dyeing.
↓
Washing.
↓
Oxidation.
↓
Washing.
*** Topping process:
Indigo dyeing.
↓
Washing
↓
Sulphur Dyeing.
↓
Washing.
↓
Oxidation .
↓
Washing.
Sulphur Dyeing.
↓
Washing.
↓
Indigo dyeing.
↓
Washing.
↓
Oxidation.
↓
Washing.
*** Topping process:
Indigo dyeing.
↓
Washing
↓
Sulphur Dyeing.
↓
Washing.
↓
Oxidation .
↓
Washing.
4. Sizing.
5. Weavers beam.
Weaving section:
1. Air jet loom used for producing fabric.
2. Example of Loom card.
- Weave design: 3/1 R.H.T
- EPI & PPI: 65 & 42.
- Total ends: 4440.
- Beam length: 2000m.
- Fabric construction:
- Total air jet loom: 66
- Singing and desizing process.
- Mercerization process.
***Offline quality control:
- Yarn breakage.
- Pump pressure.
- Warp beam creeling.
- Temperature.
- Shade%.
- Dyeing solution feeding.
- Strength test.
- Check shade%.
- Fastness properties test.
- Oil spot.
- Impurities in yarn.
***Offline quality control:
- Thread breakage.
- Auto selvedge cutting.
- Tension maintain.
- GSM of fabric.
- EPI and PPI.
- Fabric shade%.
- Oil spot.
- Strength test etc.
***Matrohm machine:
- Testing the indigo in the sample g/l.
- To determine redox in dyed sample.
- To measure pH
Finally with the help of this topic we learned about the denim fabric production process. We also learned about different process and function of different equipment that is used for the denim fabric production.
Resource on Denim- You can also like:
- What is Denim | Different Types of Denim
- Process Flow Chart of Denim Manufacturing
- Denim Manufacturing Process from Fiber to Finishing
- Overview of Denim Fabric- Types and Manufacturing Process of Denim
- Knitted Denim Manufacturing and Limitation of Woven Denim
- Application of Recycled Denim
- Innovation in Spinning Technologies for Denim Wear
- Denim Washing | Types of Denim Washing | Process of Denim Washing
- Different Types of Dry Process for Denim Wash
- Denim Wet Processing: Importance of Blanket Wash
- Bleach Wash of Woven Denims: Analysis of before and after Wash Properties
- Performance Analysis of Denim Garments by Bleach Wash
- Latest Dry Washing Techniques in Denim Garments
- Different Types of Denim Fabric Used in Apparel Manufacturing
- Different Types of Jeans for Men's and Women's
- Denim Garment Finishing Treatments: Types and Process
- Enzyme Wash Process of Denim Mens Long Pant in Medium Shade
- Acid Wash Procedure on Denim Jeans
- Stone Wash on Denim Garments