DRY PROCESS

The process which is apply at the condition dry of garments is called dry
process. Actually this process is done at unwashed condition.Dryprocess is
the ornaments of denim garments. Without dry process denim garments
doesn’t look nice. This process is actually apply on denim garments. Now a
days some dry process are applied on twill garments also. This process is
maximum time we done by manual.

 Hand Sand.
 Sand Blast.
 Whisker.
 Laser Whisker.
 Destroy.
 PP Spray
 Tagging.
 Grinding.
 Crinkle.
 3-D Crinkle.
 PP Rubbing.
 Resin spray.
 Heat Pressing.
 Pocket Marking.
 Seam Marking.
 Center Crease.
 Crease Mark Over all.
 Bleach Spot/PP Spot.
 Hand Sand

Hand Sand is very important dry process now a days. This process is
done at dry condition. for remove the color from specific area.
Maximum garments we have to do this process because sand
blasting is now banned. This process is done by manually with
abrasive paper on specific area. At first we have to marking the
garments then put on dummy and scrapped. After this process
quality checked done and go for first wash. This process will nicely
visible after complete wash.

Material needed for hand sand process.

 Water paper.
 Hand Sand Dummy.
 Foam (5mm)
 Chalk for marking.
Process:

Marking the garments according to standard----------------put into the

hand sand dummy---------------then scrapping the garments by water
paper------------------check the quality.

Sand Blasting

This is the process that also applied for removing the color. This process is done
by air flow gun with the help of sand. The high pressure sand is applied on the
garments specific area and color will reduce. But this process has some
disadvantages ,so that tis process is banned now. This process this done at dry
condition of garments.

Material needed for sand blasting process.

 Sand blasting Machine.

 Sand without containing Iron.
 Pattern Board.
 Air pressure.
  N95 mask and ear plug for Safety Equipment.
 Marking Chalk.

Process:

Marking the garments according to standard--------------------keep the garments on

the machine surface----------------then spray the sand on the garments according to
marking---------------quality check.

Difference Between Sand Blast And

Hand Sand Process

Sand Blasting
 This process is done by gun with the help of air flow.
 Total indigo is out, so slap is down.
 Metal can be found sometimes.
 Effect is on top of surface.
 Less yarn character.
 Process is faster.
 Environmental hazardous.
 Health hazardous.
 Production high.
 Evenness on surface.
 Easy to control.

Hand Sand
 This process is done by manually with the help of abrasive paper.
 Inside indigo stay, so that slap is increase.
 No possibilities to found metal.
 Effect is in depth of surface.
 More yarn character.
 Process is lengthy.
 Environmental hazardous.
 Also health hazardous.
 Production low.
 Sometimes unevenness.
 Difficult to control.

Whisker

Whisker is most important dry process for denim garments. Whisker

is done making a pattern and put in the garments then remove color
from pattern area. After wash we can see the pattern mark. It is one
kind of design on the garments. Whisker are two types depends on
process.
  Manual Whisker:
 Laser Whisker:

Manual Whisker
This whisker is done by manual with the help of pattern. On denim
garments we have done it by abrasive paper. This whisker absorb the
color homogenously.

Material needed for manual whisker.

 Pattern board.
 Water paper.
 Marking Chalk.
 Foam.
Process:

Put the whisker pattern into the garments---------------then rub the pattern
area according to standard intensity by water paper------------quality check.
 Laser Whisker

This whisker is done by laser machine. First time we have to make a design in
the Photoshop illustrator then it insert into laser machine and fix the intensity
and impose on the garments according to marking and burn the indigo. After
wash the burned indigo will remove and whisker will see. This whisker
production is more but the tint absorb is very uneven.

Process:

Making the design by photoshop illustrator-------------------------put the

garments on the machine surface--------------------set the intensity of burn-------
-then burn the garments-----------check the quality of intensity.

Equipment and materials:

 Laser machine
 Leather hand Gloves and goggles for safety.
 Destroy

Destroy is a process which is done by pen grinding machine.Frist we have to

mark the garments then slightly attached this machine with the garments then
slowly remove the cellulose. After wash we can get a good destroy look of
garments. This process we can done by another method.

Materials need for destroy:

 Destruction Machine.
 Marking Chalk.
 Pattern Board.
 Hand gloves for safety.

Process:

Marking the destruction place as per standard-------------------destruct the

garments--------------check the quality.

PP Spray

Means potassium permanganate spray on the garments at specific area. We

sprayed these chemicals to reduce the color from garments.Frist we have to
put the garments into dummy then take air. Then we spray pp with the help of
 pp gun by air pressure. This spray is done on the scrapping area and after
neutralize we got a white look on the spray area.

Materials:

 Spray gun.
 PP solution.
 Air pressure
 Organic Mask for safety.

Process:

Put the garments into dummy--------------then spray the pp solution by pp gun ------
--------quality check.

Tagging

Tagging is the process which is done at unwashed condition of garments. After

wash we will get it effect. Maximum time we will do it at edge area by folding
the garments. This process can be done by the tag gun, plastic staple machine
or manually. Sometimes this process damages the garments by creating hole.
Materials needed for tagging:

 Tag gun
 Tag Pin
 Chalk
 Hand gloves.

Process:

Marking the garments-------------------Fold the garments as per standard--------------

--Then tag the garments--------------------quality check.

Grinding
Grinding is the process by which we will get the used effect of garments. This
process is completely done at edges area. If the garments has two time wash
that time we will wash it after first wash to avoid the damages of garments.
Materials needed for grinding:

 Grinding machine.
 Hand Gloves for safety.
Process:

Running the machine-------------------touching the edge of garments

according to standard----------------quality check.

Crinkle
Crinkle is the process by this we squeeze the garments at front and back knee
area. This process is done by crinkle machine or by manual clipping of specific
area. First time we have to spray the resin on the marked area then clipping
the garments and put into curing oven at 150c at a specific time. Another
process is after resin spray, squeeze by machine.
Material needed for crinkle:

 Crinkle machine
 Resin
 White fabric

Process:

Heating the machine--------------Apply the resin on the garments surface-------------

put in the garments in the machine handle------------squeeze the garments------------
keep it up to retention time---------------quality check.

3-D Crinkle

This is the 3d effect of crinkle. This effect is found by the special treatments of
garments. First we have to spray resin on the 3d area then making 3d with
help of pattern then it put into oven for curing after curing, washed this
garments to get white effect on top.
Material need for 3D crinkle:

 3D Machine.
 Resin
 White fabric

Process:

Apply the resin at 3D place------------put in the dummy----------make 3D crinkle as

per standard---------pre cure the garments at 90c---------------taken out the
garments from machine ----------------put into curing oven for full cure-------quality
check.

PP Rubbing

Sometime, according to development requirements we used pp rubbing

process to get the effect, By this process we get more high-low effect. There is
a deference between spray and rubbing. For spray we will not get more high—
low on the area but for rubbing, we will get it. But this process is difficult to
handle.
 Material Needed for PP Rubbing:

 PP Solution.
 Phosphoric Acid.
 Sponge.
 Dummy.
 Hanger for hanging.
 Hand gloves for safety.

Process:

Put the garments into the Dummy-------------------Rubbing PP solution by sponge----

---------Dry the garments by hanging----------neutralization-------------Quality check.

Resin Spray

Resin spray ,we will do it for making coating on the garments. When we need
the garments very smooth and hard then we used this process. This process is
done by spraying resin on the full of garments then put into oven for curing
the garments. After curing we will get coating garments.
Equipment’s and materials:

 Spray gun.
 Resin.
 Catalyst.

Process:

Put the garments into dummy----------------spray resin-----------------curing in

oven--------------check the quality.

Heat Pressing

Heat pressing is used to get permanents pleats of garments. First we spray

resin on specific area of garments then pressing by heat press the n we will get
a permanent pleated.
Equipment’s and Material Needed:

 Resin
 White fabric
 Heat Press machine
 Steam Connection.

Process:

Keep the garments on the pressing machine---------------------------Apply resin on

the required area----------------Make the crinkle on resin area-----------press the
garments with steam----------------check the quality.

Pocket Marking

Pocket mark is done by scrapping to the inside lining visible. This process we
can follow when you wear the garments. It means that you used this garments
so many time and for that reasons we can see pocket lining mark but this is
happened by hand sand.
Process:

Marking the garments-----------------Rub the pocket seam by water

paper------------Wash-----------------Quality Check.

Seam Marking

Side seam hand sand is done to get the seam marking at side seam point. This
effect we found after wash complete a marking is come at side seam and
looking nice.

Process:

Marking the garments-----------------Rub the side seam by water paper-

-----------Wash-----------------Quality Check.
 Center Crease

Center crease is the dry process which shows the crease mark at middle side
of front and back. This process is done by putting a pattern inside the
garments then making crease by abrasive paper. After wash we can see this
special mark.

Material Needed:

 Water paper.
 Pattern Board.
Process:
Put the pattern in the garments leg-------------------Rub vertically to the
pattern------------------wash----------------------Quality check.

Pigment Spray

Pigment spray is the process by which we will get uneven color look at
garments surface. First we completed the wash process the we spray the
pigment on the garments surface. We make the pigment solution by pigment
dye ,binder and liquid. After spray the garments will sent to oven for curing.
After oven this color will fix and we get a good look.

Material And Equipment’s:

 Spray gun.
 Pigment solution
 Oven.
 Hand gloves For safety.
 Color.

Process:
Make the pigment solution-------------------Spray or drop the solution on the
garments---------------oven for curing----------quality check.

Crimping
Fabric is crimped then ironed to create permanent crease mark.Before ironing
we used resin at crimping area.After ironing ,it send to oven for curing.After
finished curing rub the crimping area by water paper.When we need the
crease mark at different point of garments,apply this process.

Materials and Equipments:

 Water paper
 Resin
 Oven
 Gloves for safety.
 White fabric
Process:

Marking the crimping area----------------apply resin on required area--------------

---ironing or making crease--------------curing at oven------------rub with water
paper--------check quality.

Towel Bleach

It is one kind of bleaching process that give us the uneven look on the
garments. In this process first we take some small piece of towel then dipping
in bleaching solution then dry this piece slightly. After that we put into
machine and give the original garments which need to be uneven wash then
complete the process.
 Materials and equipments:

 Towel Pieces
 Bleach solution
 Washing machine
 Neutralization agent.

Process:

Cut the towel as small pieces ----------------------Dipping into bleach solution------

-----------Taken from solution and dry little----------tumbling in another machine
------------neutralization---------quality check.

PP Spot/Bleach Spot
This process is done by making pp solution or bleach solution then make some
spot on the garments according to requirement. After neutralize this garments
we will get the nice spot. But there is a difference between pp spot and bleach
spot. By pp spot we get white look spot and bleach we get slight yellowish
spot.
Materials and Equipment’s:

 PP or bleach solution.
 Dropper
 Neutralization agent
 Hand Gloves.

Process:

Marking the garments---------------Drop the solution of pp or bleach--

-----------neutralization----------------quality check.

Resin spot
Resin spot is the process by which we will get the spot or design. First we
make resin solution by resin and binder mixing with water at required level.
Then the solution is apply according to the design or spot. After making spot
we sent to the garments to oven for curing .after curing we will start washing
process. This process is done at unwashed condition because the design is
made by raw denim color for resin effect, the color will not cut.
 Materials and equipments:

 Resin
 Catalyst
 Curing oven
 Gloves for safety

Process:

Marking the garments----------Make spot of resin----------curing at

oven-----------washing----------check quality
 Resin application and problem

Resin is liquid form of polymer. Resin is the chemicals by which we

make the crinkle and 3d crinkle in washing plant. We also used this
chemical to hard the fabric, weight giving agent and for create
coating on the fabric. Most of used this chemicals to make the
permanent palette by 3d crinkle or crinkle. Based on used resin is
two types.

Pre catalyst Resin

The resin which we can apply directly on the fabric or garments. No
need to mix binder or catalyst. In this resin catalyst is mixed at
previous time. After applied it works on fabric cellulose and making
bond by curing reaction. This reaction is happened at 150c in the
oven.

Post catalyst Resin

The resin which we can not apply directly is called post catalyst resin.
Before applying we have to mix binder and catalyst. Then we apply
this resin on the garments or fabric. Some times we used the resin
to making coat and increase the weight of the fabric, This
application is done at washing machine.

Resin is used as various agent in textile section. It is used for

crinkle,3D crinkle, resin spot on the garments, making surface
coating on garments ,increase the hardness of fabric. Resin is react
with fiber and making bond with cellulose at high temperature. Then
permanent pleat is formed.

Application of Resin
Resin is directly used on the garments then curing. Resin application
is very critical because of its nature. If the application is more that
time we have to face very big problem. So we should apply resin at
optimum level. Resin should be apply according to fabric strength
and construction. Resin should be formaldehyde free.

Problems that’s Happened for Resin Application

 If the resin application is more on specific area that garments will

tear.
 If we use more than one time tear may come.
 If oven time is more tear may come.
 If oven temperature is excessively high tear may come.
 If we used more resin, garments will hard more.
 For resin garments will be unwanted spotted.
 For resin sometimes pocket may damage.
 Solution of Resin Problem

 To avoid tearing, use optimum resin.

 Frist time select the right percentage of resin to avoid two
times.
 Fixed the oven time and maintain properly.
 Oven temperature control properly.
 Resin percentage should be optimum to avoid hardness of
garments.
 Make the resin solution at specific area and apply properly to
avoid resin spot.
 Caring about the pocket that any resin drop may not on the
pocket.