Overview of Denim Fabric Production with Flow Chart

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



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.

Denim fabric production
Fig: Denim fabric production
Denim fabric production section:

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.

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:
            7.2RS * 6OE
            65 * 42 Finishing section:
  1. Singing and desizing process.
  2. Mercerization process.
Quality control in yarn dyeing section:

***Offline quality control:
  • Yarn breakage.
  • Pump pressure.
  • Warp beam creeling.
***Online quality control:
  • Temperature.
  • Shade%.
  • Dyeing solution feeding.
***Product control:
  • Strength test.
  • Check shade%.
  • Fastness properties test.
  • Oil spot.
  • Impurities in yarn.
Quality control in weaving:

***Offline quality control:
  • Thread breakage.
***Online quality control:
  • Auto selvedge cutting.
  • Tension maintain.
***Product control:
  • GSM of fabric.
  • EPI and PPI.
  • Fabric shade%.
  • Oil spot.
  • Strength test etc.
Instrument used for sample testing:

***Matrohm machine:
  • Testing the indigo in the sample g/l.
  • To determine redox in dyed sample.
  • To measure pH
Conclusion:
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:
  1. What is Denim | Different Types of Denim
  2. Process Flow Chart of Denim Manufacturing
  3. Denim Manufacturing Process from Fiber to Finishing
  4. Overview of Denim Fabric- Types and Manufacturing Process of Denim
  5. Knitted Denim Manufacturing and Limitation of Woven Denim
  6. Application of Recycled Denim
  7. Innovation in Spinning Technologies for Denim Wear
  8. Denim Washing | Types of Denim Washing | Process of Denim Washing
  9. Different Types of Dry Process for Denim Wash
  10. Denim Wet Processing: Importance of Blanket Wash
  11. Bleach Wash of Woven Denims: Analysis of before and after Wash Properties
  12. Performance Analysis of Denim Garments by Bleach Wash
  13. Latest Dry Washing Techniques in Denim Garments
  14. Different Types of Denim Fabric Used in Apparel Manufacturing
  15. Different Types of Jeans for Men's and Women's
  16. Denim Garment Finishing Treatments: Types and Process
  17. Enzyme Wash Process of Denim Mens Long Pant in Medium Shade
  18. Acid Wash Procedure on Denim Jeans
  19. Stone Wash on Denim Garments
 
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Mazharul Islam Kiron is a textile consultant and researcher on online business promotion. He is working with one European textile machinery company as a country agent. He is also a contributor of Wikipedia.


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