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135033 denim
This document provides an overview of denim manufacturing using rope dyeing. It describes the denim production process which includes ball warping, rope dyeing, long chain beaming, sizing, weaving, and finishing. Rope dyeing involves dyeing 12-36 individual ropes of yarn simultaneously. The long chain beaming process produces the rope into a beam for sizing. Weaving is typically done on air jet or rapier looms to produce the twill weave structure of denim fabric. Finishing processes such as singeing, softening, and sanforizing are then applied.
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135033 denim
- 1. Presentation on denimmanufacturing by use of rope dyeing Submitted To: Mr. Shamsuzzaman Sheikh Assistant professor Dept.of textile engineering,DUET Submitted By: Md. Tanvir ahmed sourov Id: 135033
- 2. Introduction Denim is acotton or cotton/polyester blend, durable heavy weight twill weave yarn dyed fabric. Usually the warp is colored and weft is white. It is often right-hand twill with a blue (indigo) warp and white weft for use in apparel in a variety of weights. Since it is a warp faced twill, the colored warp yarns predominate on the face and the white weft yarns on the back.
- 3. Denim quality criteria •Minimum staple length- 2.7 cm • Proportion of short fiber(<less then 12 mm long): under 40% • Micronaire value – 4 to 4.5 • Twist factor – 4.5 to 5( for warp) & 4.2 ( for weft) • Count range: warp 50-90 tex & 75-120 tex • Low yarn hairiness • Yarn strength and uniformity Types of yarn : rotor yarn , open end yarn, slub yarn, polyester and elastomer yarn.
- 4. Denim production processflow Ball warping Rope dyeing Long chain beamer (LCB) Sizing Weaving Finishing
- 5. Ball warping Ball warpingis done for denim production. 250 to 400 yarn ends are pulled from the creel.
- 6. Rope dyeing Typically 12-36individuals ropes of yarn are fed side by side simultaneously into the range.
- 7. Rope dyeing(cont.) • Dyeingprocess that is maintained as follows: • Pure Indigo- Continuous Indigo Dyeing • Bottoming- Sulphur(Bottom) & Indigo(Topping) • Topping- Indigo(Bottoming) & Sulphur (Topping) • Black Denim-Continuous Sulphur Black Dyeing creeling Pretreatment box Wash box Dyeing box Wash box Drying zone Rope storage into can
- 8. Long chain beaming(LCB) Special process for rope dyeing. Producing rope into beam like as warper beam. Ready for sizing
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- 10. sizing The purpose ofsizing is to increase the strength of yarn through chemically binding the fibers with each other. The main object of sizing warp yarns is also to encapsulate the yarn with a protective coating which reduces yarn abrasion that takes place during the weaving operation and reduces yarn hairiness preventing adjacent yarns from entangling with one another at the weaving machine creeling Size box Drying zone Leasing Head stock
- 11. Sizing (cont.) • Viscosityof the size solution • Sizing machine speed • Size add-on levels • Concentration of the size mixture • Volume of the size box (both quantity and size level)
- 12. Weaving Design used indenim : 3/1 R.H.T Or L.H.T 4/1 R.H.T Or L.H.T 4/1 Satin 5/1 R.H.T Or L.H.T 2/1 R.H.T Or L.H.T Types of fabric Normal Fabric = 6 OE * 6 OE / 66 * 35 Ring Fabric = 6, 9, 12 * 7 OE / 66 * 35 Half Cross Fabric = 6 slub * 7 OE / 66 * 35 Cross Latch Fabric = 10 slub * 10 slub / 66 * 35
- 13. Weaving( cont.) Air jetand rapier loom used for denim fabric production.
- 14. Finishing In general, beforemarketing, all the process which is applied on the fabric after weaving is called finishing. The following types of finishes are applied to the denim fabric: • Singeing • Softening • Skew control • Desizing • Mercerizing • Sanforizing • Calendering • Resin finishing
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- 16. SANFORIZING: To protectfrom residual shrinkage.
- 17. References 1. http://amber.com.bd/ 2. http://morrisontexmach.com/welcome.cfm 3.http://textilelearner.blogspot.com/ 4. http://www.denimsandjeans.com/ 5. http://articles.fibre2fashion.com/ 6. http://www.picanol.be/PICBESITE/EN/ 7. http://www.mechmar.com.my/products_as.htm 8. http://www.dresserwaukesha.com/index.cfm/go/listpro dsubline/productline/gas-compression-engine/