Denim Washing Process
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July 14, 2019
Denim Washing
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
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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.
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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
1. Pattern
2. 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)
3. 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
1. Laser Machine
2. Leather hand gloves and goggles for safety.
Hand Scrapping
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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
1. Abrasive paper
2. Dummy
3. Chalk for marking and masks
Working Procedure of Hand Scrapping
1. Specify the area
2. Put the garments into dummy
3. Scrapping with emery paper
4. 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
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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
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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.
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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.
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Specifications of Front Loading Machine
Washing Capacity 30kg
Drum 900*500mm
Size(diameter*depth)
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 850*450mm
Size(diameter*depth)
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
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Type/Parameter Model : TG-25
Capacity 25kg
Speed 820rpm
Diameter of Drum (diameter 570×290mm
x depth)
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 590×3000mm
(diameter x depth)
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
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