Classification and Process Flow Chart of Garment Washing

 

Q: What is Garment Washing?

A: The technology that is used to modify the outlook, appearance, comfortability, and fashion of the garments is called garment washing.

Q: What is the Classification of Garments Washing?

A: There are mainly two types of garment washing. 

1. Wet Process/ Chemical Process
2. Dry / Mechanical Process

1. Wet Process/ Chemical Process:

• Normal wash/ Garment wash/Rinse wash
• Pigment wash
• Caustic wash
• Enzyme wash
• Stonewash
• Enzyme stone wash 
• Tinting (Tie) & Over Dyeing (Dip)
• Super whitewash
• Bleach wash
• Acid wash
• Silicon wash
• Soft wash

2. Dry Process / Mechanical Process:

• Sandblasting
• Hand scraping
• Overall wrinkles
• Permanent wrinkle
• Broken and tagging
• Grading and destroy
• PP spraying and pp sponging etc.

Normal Wash/ Rinse Wash/ Garment Wash: 

Normal wash is required for the following reasons: 

• To remove dust and impurities from the garments.
• To remove size materials present in the fabric
• To increase the soft feeling, so that to wear the garments after purchasing
• To get washing standard goods

Pigment Wash:

Pigment wash is applied on pigment dyed or printed garments. Pigment wash is used for the following reasons: 

• To get fading affected loom on garments  
• For soft feeling to wear the garments 
• To acquire buyer washing standard.
• To increase the color fastness and rubbing

Caustic Wash: 

Caustic wash generally applied on reactive dye, sulphur dye, direct dye or printed garments.

Caustic wash is used for the following reasons:

• To get fading affect and seam abrasion affect on seam area.
• To remove sizing material or starch from the garments 
• To improve the rubbing fastness and color fastness
• To improve the hairiness quality of the garments
• To acquire the buyer required standard sample

Enzyme Wash:

After unloading garments from the washing machine, they are sent to hydroextractor machine to remove excess water from the dye garments. Enzyme wash is used for the following reasons:

• Simple handling process and minimum problem
• Better feel to touch and increase luster
• It can be applied on cellulosic material and its blend
• It allows more loading of the garments than other washing process
• It is environment friendly process
• Less damage to seam edges occur after applying this process
• Use of softener can be minimized or avoided.

Stone Wash

Stone washing is a process use to give worn-in or worn-out effect on garments. It also increase the softness and flexibility of the stiff and rigid garments such as denim and canvas etc. Stone Wash is used for the following reasons: 

• To create irregular fading
• To remove dust, oil or impurities from the garments.
• To improve the softness of the fabric
• To acquire the buyer washing requirement

Enzyme Stone Wash 

Stones are used with enzymes during washing, to get a fading loom on the garment surface. The fabric comes in contact with stones during washing and the color fades by the rubbing action.

Tinting & Over Dyeing

After denim pant is faded, the pants have dyed with very light color. This dyeing process is called tinting / overdyeing. This process is only applied in garments, not in fabric or yarn. Tinting is required for the following reasons: 

• To create new fashions
• To provide the garments better appearance
• For inventing a new process.

Super White Wash

Super white wash is applied on the garments made from grey fabric. The garments after washing looks very white. This wash is carried out to increase the whiteness effect on the white fabric. Main chemical used in this wash is optical brightening agent. This wash is required for the following reasons: 

• To increase the whiteness of the garments
• To get the buyer washing requirement
• To get soft feeling during wear
• To remove sizing material from the garments.

Bleach Wash

Bleach wash is applied by using strong oxidative bleaching agent. A bleach is a chemical that remove color or whitens. Most commonly used chemicals are sodium hypochlorite, calcium hypochlorite, hydrogen peroxide and potassium permanganate.Garments made from indigo, vat, reactive and direct dyed fabric can be bleach wash. It is a discoloration process by oxidation. All types of garments can be washed: woven or knit garments

Acid Wash

Acid wash is done by tumbling the garments by pumic stones presoaked in a solution of sodium hypochlorite or potassium permanganete for localized bleaching resulting in a non-uniform sharp blue contrast. Following are the reasons for the use of acid wash:

• To remove the color only from the garment surface and create a frosted appearance.
• The color contrast of the fabric in this wash can be increased by optical brightening.
• Less Water Consumption compared to other washing processes.

Silicon Wash

Silicon wash can be applied on all types of fabric such as twil, denim, woven, canvas or knit etc.

• It gives durable softness
• It helps to anti-pilling effects dimensional stability and tear resistance.
• It helps to cut and sewn fabric more easily 
• It also improves wear and easy care properties

Soft Wash

This wash is used to increase the softness of all types of garments. It also improves the suitability to wear.

Sand Blasting

Sandblasting is based on blasting on abrasive material on granular, powdered form through a nozzle at very high speed and pressure onto specific area of the garments surface to be treated to get the desired look.

Method of Sand Blasting

• Sand Blasting
• Machine Sanding
• Hand Sanding or Hand Brushing

The advantages of Sand Blasting Process is as follows:

• Sandblasting process is quite easy
• Less machinery required such a compressor, a blasting pot and a nozzle.
• Sandblasting have wide applications
• This process is used for every material for the purpose of cleaning

Q: What are the Purposes of Garment Washing?

• To increase the softness of the garment, sizing material need to remove from the fabric. Drape ability also increased
• To develop unique appearances
• To create new fashion
• Special type of finishes are also possible such as wrinkle, wrinkle-free, flame-retardant, water proof breathable, flame retardant finish etc.
• To satisfy the customer

Q: What are the Garment Washing Processes?

A: 

1. Garments can be inverted to minimize unwanted abrasion streaks.
2. Load machine with garments
3. Add alpha amylase enzyme and detergent for desizing
4. Drain
5. Rinse
6. Add water into the machine and heat temperature up to 60 C. The range of liquor ratio varies from 10:1 to 20:1. Different types of synthetic detergent can be used. Also add soda ash and caustic soda amount ranging from 0.5-2gm/L. Some chemical suppliers offer special products to increase the rate of washing.
7. Wash action 20-60 minutes depending upon desired results.
8. Drain and rinse
9. Apply softener
10. Tumble dry
11. Invert garments
12. Press if required

Q: What are the Garment Washing Machine Types?

A: 

• Front loading washing machine
• Side loading washing machine
• Top loading washing machine
• Stone washing machine
• Semi-automatic washing machine

Q: What are the Advantages of Garment Washing?

A: 

1. Different outlooks (Fading effects) of garments could be produced by other washing techniques
2. Washed garments could be worn directly after purchase from the store
3. Shrinkage occurs in the garments during washing, there is no possibility of further shrinkage
4. The softness feeling of garments could be further increased

Q: What are the Disadvantages of Garment Washing?

A; 

1. Garment shade changes due to shrinkage of the fabric. The amount of shrinkage determines the size change of the fabric
2. Size material and finishing partly removed: Different types of washing are done by different types of chemicals and processes which are responsible for the removal of size material and finishing of the fabric
3. Color is Partially removed: Unfixed dye may remain on garments after dyeing. This unfixed dye will be subsequently removed by washing. Thus some color also may be partially removed

Q: What are the Washing Chemical List?

A: 

• Enzyme
• Detergent
• Acetic acid
• Antistatic
• Bleaching powder
• Sodium hyposulphite
• Caustic soda
• Soda ash
• Sodium bicarbonate
• Potassium permanganate
• Cationic/nonionic flax softener
• Microemulsion silicon
• Salt
• Buffer
• Hydrogen peroxide
• Stabilizer
• Fixing agent
• Catalyzer
• Optical brightening agent
• Resin
• Sodium metabisulphite 
• Detergent

Q: What are the Machines used in Garment Washing?

A: 

1. Garments Washing Machine
2. Hydro-extracting Machine
3. Garments Drying Machine
4. Sand Blasting Machine
5. Boiler for Stream Generation
6. Waste Water Treatment Plant

Q: What is the maximum capacity of the Washing Machine?

A: Approximately 450 lbs

Q: What is the spin speed (RPM) of a Hydro-extractor?

A: It usually is 900-1000

Q: What is the Inner Basket Speed?

A: It is about 35-40

Q: What is the purpose of Normal Wash?

A: 

1. To remove starch from garments
2. To control the shrinkage of garments
3. To increase the softness of the garments 

Q: What is Pigments Wash?

A: Those garments are made from pigment dyed and washed then it is called pigment wash. It is the same as a normal wash

Q: What is the result of Pigment Wash?

A: A light fading effect is produced in the garments 

Q: What is Bleach Wash?

A: It is nothing but light bleaching of garments

Q: What is the after-effect of Bleach Wash?

A: Partial color fading is produced like pigment wash

Q: What is Stone Wash?

A: When washing is done with stone then it is called Stone Wash

Q: What is the Size and Shape of Stone?

A: Size: Normally 2-2.5 inch diameter, Shape: Somewhat like round

Q: What is the other name of this type of Stone?

A: The other name is ' Natural Volcanic Pumice'

Q: From where do we get these Stones?

A: We (Bangladesh) normally import it from Malaysia and Indonesia

Q: What types of Garments are washed with Stone?

A: Normally those garments are made from heavy fabrics like jeans, denim, etc.

Q: What is the After-effect of Stone Wash?

A: Irregular Color Fading is Produced

Q: What is Acid Wash?

A; Acid wash is a kind of stone wash, but it consists of 2 steps; the first step is to wash without water, and the second step with water

Q: What type of acid is used in Acid Wash?

A: Normally Phosphoric acid

Q: Is stone used in Acid Wash?

A: Yes, it is a kind of stone wash

Q: What is Enzyme Wash?

A: When the enzyme is used in washing then it is called enzyme wash

Q: What type of enzyme is used in Enzyme Washing?

A: Normally cellulose enzyme is used

Q: What is the function of Enzyme in Washing?

A: It hydrolyses the projecting hairy cotton fibers and removes the color

Q: Why stone is used in Enzyme Wash?

A: Because enzyme wash is more costly than stone wash. So to reduce the cost, stone is used with enzyme wash.

Q: What is Caustic Wash?

A: When garments are washed with caustic soda then it is called Caustic Wash

Q: What type of garments are washed with Caustic Wash?

A: No, because scouring action is done in the caustic wash that will help to fade the color of the printing

Q: Where Whitening is used?

 

A: It is used for denim garments where warp yarn is colored and weft yarn is white. The white portion is done more by using whitening powder in the rinsing process

Q: What is garment dyeing?

 

A: When garments are made from grey fabric, and then the garments are dyed in the required color and shade called garments dyeing

Q: What are the advantages of garment dyeing?

A: 

1. Comparatively lower cost of production 
2. Less time is required
3. No possibility of shade variation

Q: What Precaution is to be taken before garment sewing in case of garment dyeing?

A: The sewing thread used for making the garments should be the same fiber as the garment fabric, otherwise color differences may occur between garment fabric and sewing thread.

Q: What is Garments Wash Over-Dye?

A: When garments are washed first, and then it is dyed called garments wash over-dye. In the case of denim garments, the stone wash is done first and then it is dyed as a result the fading areas absorb the dye and create a shade of a different look.

Flow Chart of Denim/Jeans Washing

1. Batching
2. Loading 
3. Desizing
4. Enzyme with Stone Wash
5. Enzyme Killing
6. Decolorization (Bleach/Acid Wash)
7. Neutralization of Chlorine/ Neutralization of MnO2
8. Neutralization with Acetic Acid
9. Finishing/Softening
10. Drying

Flow Chart of Normal Washing

1. Batching
2. Loading
3. Desizing (if necessary)
4. Washing
5. Finishing /Softening
6. Hydro extraction
7. Drying

Flow Chart of Pigment Washing

1. Batching 
2. Loading
3. Desizing (if necessary)
4. Pigment Wash
5. Neutralization (if alkali is used)
6. Finishing /Softening
7. Drying

Flow Chart of Silicon Washing

1. Batching 
2. Loading
3. Desizing (if necessary)
4. Silicon wash
5. Finishing/Softening
6. Drying

Flow Chart of Caustic Washing

1. Batching
2. Loading
3. Desizing (if necessary)
4.  Caustic wash
5. Neutralization
6. Finishing/ Softening
7. Drying

Flow Chart of Bleach Washing

1. Batching
2. Loading
3. Desizing (if necessary)
4. Bleaching
5. Neutralization of chlorine
6. Neutralization with acetic acid
7. Finishing/Softening
8. Drying

Flow Chart of Stone Washing

1. Batching
2. Loading
3. Desizing (if necessary)
4. Stone wash with bleach wash
5. Neutralization with Chlorine
6. Neutralization with Acetic Acid
7. Finishing /Softening
8. Drying

Flow Chart of Acid Stone Washing

1. Batching
2. Loading
3. Desizing (if necessary)
4. Conditioning of the Garments
5.  Stone Preparation
6. Acid wash
7. Neutralization of by-product
8. Neutralization
9. Finishing/Softening

FAQ for Garment Washing

What is garments washing?

A: The technology that is used to modify the outlook, appearance, comfortability, and fashion of the garments is called garment washing.

What are the types of garments washing?

A: There are mainly two types of garment washing. Wet Process/ Chemical Process Dry / Mechanical Process 1. Wet Process/ Chemical Process: Normal wash/ Garment wash/Rinse wash Pigment wash Caustic wash Enzyme wash Stonewash Enzyme stone wash Tinting (Tie) & Over Dyeing (Dip) Super whitewash Bleach wash Acid wash Silicon wash Soft wash 2. Dry Process / Mechanical Process: Sandblasting Hand scraping Overall wrinkles Permanent wrinkle Broken and tagging Grading and destroy PP spraying and pp sponging etc.

What is garment washing and finishing?

A: The technology that is used to modify the outlook, appearance, comfortability, and fashion of the garments is called garment washing. By finishing process faded/old look, color or tinted affect is created in the garment

What are the objects of garments washing?

To increase the softness of the garment, sizing material need to remove from the fabric. Drape ability also increased To develop unique appearances To create new fashion Special type of finishes are also possible such as wrinkle, wrinkle-free, flame-retardant, water proof breathable, flame retardant finish etc. To satisfy the customer

What is washing process?

A: The technology that is used to modify the outlook, appearance, comfortability, and fashion of the garments is called garment washing.

What are the benefits of garment wash?

A:Different outlooks (Fading effects) of garments could be produced by other washing techniques Washed garments could be worn directly after purchase from the store Shrinkage occurs in the garments during washing, there is no possibility of further shrinkage The softness feeling of garments could be further increased.

What are the three methods of washing?

A: There are mainly two types of garment washing. Wet Process/ Chemical Process Dry / Mechanical Process 1. Wet Process/ Chemical Process: Normal wash/ Garment wash/Rinse wash Pigment wash Caustic wash Enzyme wash Stonewash Enzyme stone wash Tinting (Tie) & Over Dyeing (Dip) Super whitewash Bleach wash Acid wash Silicon wash Soft wash 2. Dry Process / Mechanical Process: Sandblasting Hand scraping Overall wrinkles Permanent wrinkle Broken and tagging Grading and destroy PP spraying and pp sponging etc.

What is dry process in garment washing?

A:Sandblasting Hand scraping Overall wrinkles Permanent wrinkle Broken and tagging Grading and destroy PP spraying and pp sponging etc.

Which technique is used in washing?

A:Centrifugation method to squeeze out water from wet cloth.